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544J Loader Operation and Test) (Serial No. 611800-

TECHNICAL MANUAL 544J Loader Operation and Test (S.N. 611800— ) TM10229 17MAR09 (ENGLISH)

For complete service information also see: 544J Loader Repair Manual (S.N. 611800— ) . . . . . . . . . . . . . . . . . . . . . . . . . . . TM10244 544J Loader Operator’s Manual (S.N. 611800— ) . . . . . . . . . . . . . . . . . . . . . . . . . . . OMT229869 Alternators and Starting Motors . . . . . . . . . . CTM77 POWERTECH 4.5 L and 6.8 L Diesel Engines—Base Engine . . . . . . . . . . . . . . . . . CTM104 TeamMate IV 1200 and 1400 Series Inboard Planetary Axles . . . . . . . . . . . . . . . . CTM442 POWERTECH E 4.5 & 6.8L Diesel Engines—Level 16 Electronic Fuel System with Denso HPCR . . . . . . . . . . . . . . . . . . . . . CTM502 Super Caddy Oil Cleanup Procedure . . . . . . CTM310 JDLink / ZXLink Machine Monitoring System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CTM10006

Worldwide Construction And Forestry Division LITHO IN U.S.A

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

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Introduction

Technical Information Feedback Form We need your help to continually improve our technical publications. Please copy this page and FAX or mail your comments, ideas and improvements. SEND TO:

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TX,TM,FAX –19–03JUL01–1/1

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Introduction

TM10229 (17MAR09)

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Contents 9000

SECTION 9000—General Information Group 01—Safety Information SECTION 9001—Diagnostic Trouble Codes (DTC) Group 10—CAN Monitor Unit (CMU) Diagnostic Trouble Codes Group 20—Engine Control Unit (ECU) Diagnostic Trouble Codes Group 30—Transmission Control Unit (TCU) Diagnostic Trouble Codes Group 40—Flex Load Controller (FLC) Diagnostic Trouble Codes Group 50—Sealed Switch Module (SSM) Diagnostic Trouble Codes

9001

9005

SECTION 9005—Operational Checkout Procedure Group 10—Operational Checkout Procedure

9010

SECTION 9010—Engine Group 05—Theory of Operation Group 15—Diagnostic Information Group 25—Tests

9015

SECTION 9015—Electrical System Group 05—System Information Group 10—System Diagrams Group 15—Sub-System Diagnostics Group 20—References

9020

SECTION 9020—Power Train Group 05—Theory of Operation Group 15—Diagnostic Information Group 20—Adjustments Group 25—Tests

9025

SECTION 9025—Hydraulic System Group 05—Theory of Operation Group 15—Diagnostic Information Group 20—Adjustments Group 25—Test

9031

SECTION 9031—Heating And Air Conditioning Group 05—Theory Of Operation Group 15—Diagnostic Information Group 25—Tests

INDX

All information, illustrations and specifications in this manual are based on the latest information available at the time of publication. The right is reserved to make changes at any time without notice. COPYRIGHT  2009 DEERE & COMPANY Moline, Illinois All rights reserved A John Deere ILLUSTRUCTION Manual Previous Editions Copyright  2007, 2008

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Contents 9000

9001

9005

9010

9015

9020

9025

9031

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9000

Section 9000

General Information Contents Page

Group 01—Safety Information Recognize Safety Information . . . . . . . . . . . .9000-01-1 Follow Safety Instructions . . . . . . . . . . . . . . .9000-01-1 Operate Only If Qualified. . . . . . . . . . . . . . . .9000-01-2 Wear Protective Equipment . . . . . . . . . . . . . .9000-01-2 Avoid Unauthorized Machine Modifications . . . . . . . . . . . . . . . . . . . . . . .9000-01-2 Add Cab Guarding For Special Uses . . . . . .9000-01-3 Inspect Machine . . . . . . . . . . . . . . . . . . . . . .9000-01-3 Stay Clear of Moving Parts . . . . . . . . . . . . . .9000-01-3 Avoid High-Pressure Fluids . . . . . . . . . . . . . .9000-01-4 Avoid High-Pressure Oils . . . . . . . . . . . . . . .9000-01-4 Beware of Exhaust Fumes . . . . . . . . . . . . . .9000-01-5 Prevent Fires. . . . . . . . . . . . . . . . . . . . . . . . .9000-01-5 Prevent Battery Explosions . . . . . . . . . . . . . .9000-01-5 Handle Chemical Products Safely . . . . . . . . .9000-01-6 Dispose of Waste Properly . . . . . . . . . . . . . .9000-01-6 Prepare for Emergencies. . . . . . . . . . . . . . . .9000-01-6 Use Steps and Handholds Correctly . . . . . . .9000-01-7 Start Only From Operator’s Seat . . . . . . . . . .9000-01-7 Use and Maintain Seat Belt. . . . . . . . . . . . . .9000-01-7 Prevent Unintended Machine Movement . . . .9000-01-8 Avoid Work Site Hazards . . . . . . . . . . . . . . .9000-01-9 Use Special Care When Operating Loader . . . . . . . . . . . . . . . . . . . . . . . . . . .9000-01-10 Keep Riders Off Machine . . . . . . . . . . . . . .9000-01-10 Avoid Backover Accidents . . . . . . . . . . . . . .9000-01-11 Avoid Machine Tip Over . . . . . . . . . . . . . . .9000-01-11 Operating on Slopes . . . . . . . . . . . . . . . . . .9000-01-12 Operating or Traveling On Public Roads . . .9000-01-12 Inspect and Maintain ROPS . . . . . . . . . . . .9000-01-13 Add and Operate Attachments Safely . . . . .9000-01-13 Prevent Unintended Detonation of Explosive Devices . . . . . . . . . . . . . . . . . . . . . . . . . .9000-01-13 Park And Prepare For Service Safely . . . . .9000-01-14 Service Cooling System Safely . . . . . . . . . .9000-01-14 Remove Paint Before Welding or Heating . . . . . . . . . . . . . . . . . . . . . . . . . .9000-01-15 Make Welding Repairs Safely . . . . . . . . . . .9000-01-16 Drive Metal Pins Safely . . . . . . . . . . . . . . . .9000-01-16

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Group 01

Safety Information 9000 01 1

Follow the precautions and safe operating practices highlighted by this symbol.

T133555

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.

–UN–28AUG00

Recognize Safety Information

T133588

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.

–19–28AUG00

A signal word — DANGER, WARNING, or CAUTION — is used with the safety alert symbol. DANGER identifies the most serious hazards.

TX03679,00016CC –19–03NOV08–1/1

T133556

Read the safety messages in this manual and on the machine. Follow these warnings and instructions carefully. Review them frequently. Keep safety signs in good condition. Replace missing or damaged safety signs. Replacement safety signs are available from your authorized John Deere dealer.

–UN–24AUG00

Follow Safety Instructions

Be sure all operators of this machine understand every safety message. Replace operator’s manual and safety labels immediately if missing or damaged.

TX03679,00016F9 –19–18OCT07–1/1

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Safety Information

Operate Only If Qualified Do not operate this machine unless you have read the operator’s manual carefully and you have been qualified by supervised training and instruction.

machine functions with the machine in an open area before starting to work. Know and observe all safety rules that may apply to your work situation and your work site.

Familiarize yourself with the job site and your surroundings before operating. Try all controls and

TX03679,00016FA –19–03NOV08–1/1

Wear Protective Equipment Guard against injury from flying pieces of metal or debris; wear goggles or safety glasses.

–UN–23AUG88

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

TS206

9000 01 2

TX03679,00016D0 –19–03NOV08–1/1

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 failures 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 John Deere dealer before making machine modifications that change the intended use, weight or balance of the machine, or that alter machine controls, performance or reliability.

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Safety Information 9000 01 3

Use load-clamping grapples to keep bulky loads from falling and add special screens or guarding when objects may be directed toward the cab. Contact your authorized John Deere dealer for information on devices intended to protect the operator from falling or flying objects in special work situations.

T141893

Special work situations or machine attachments may create an environment with falling or flying objects. Loading logs, using fork attachments, or operating in waste management applications requires special work tools. Added cab guarding to protect the operator may also be required.

–UN–04MAY01

Add Cab Guarding For Special Uses

TX03679,00017C6 –19–18OCT07–1/1

Inspect Machine

T6607AQ

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.

–UN–18OCT88

Inspect machine carefully each day by walking around it before starting.

TX03679,0001734 –19–03NOV08–1/1

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.

T133592

Entanglements in moving parts can cause serious injury.

–UN–12SEP01

Stay Clear of Moving Parts

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Safety Information

Avoid High-Pressure Fluids

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

X9811

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

–UN–08DEC08

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

DX,FLUID –19–03MAR93–1/1

Avoid High-Pressure Oils

T133509

If hydraulic oil penetrates your skin, see a doctor immediately. Injected oil must be removed surgically within hours or gangrene may result. Contact a knowledgeable medical source or the Deere & Company Medical Department in Moline, Illinois, U.S.A.

–UN–20SEP00

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.

–UN–17MAR06

This machine uses a high-pressure hydraulic system. Escaping oil under pressure can penetrate the skin causing serious injury.

T133840

9000 01 4

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Safety Information 9000 01 5

If you must operate in an enclosed space, provide adequate ventilation. Use an exhaust pipe extension to remove the exhaust fumes or open doors and windows to bring outside air into the area.

T133546

Prevent asphyxiation. Engine exhaust fumes can cause sickness or death.

–UN–24AUG00

Beware of Exhaust Fumes

TX03679,00016D4 –19–03NOV08–1/1

T133552 T133554

Keep A Fire Extinguisher Available: Always keep a multipurpose fire extinguisher on or near the machine. Know how to use extinguisher properly.

–UN–07SEP00

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.

T133553

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.

–UN–07SEP00

Handle Fuel Safely: Store flammable fluids away from fire hazards. Never refuel machine while smoking or when near sparks or flame.

–UN–14SEP00

Prevent Fires

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Prevent Battery Explosions

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

TS204

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

–UN–23AUG88

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

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Safety Information

If uncertain about safe handling or use of these chemical products, contact your authorized dealer for a Material Safety Data Sheet (MSDS) or go to internet website http://www.jdmsds.com. The MSDS describes physical and health hazards, safe use procedures, and emergency response techniques for chemical substances. Follow MSDS recommendations to handle chemical products safely.

T133580

Exposure to hazardous chemicals can cause serious injury. Under certain conditions, lubricants, coolants, paints and adhesives used with this machine may be hazardous.

–UN–25AUG00

Handle Chemical Products Safely

TX03679,00016D7 –19–03JAN07–1/1

Never pour waste onto the ground, down a drain, or into any water source.

T133567

Improper disposal of waste can threaten the environment. Fuel, oils, coolants, filters and batteries used with this machine may be harmful if not disposed of properly.

–UN–25AUG00

Dispose of Waste Properly

Air conditioning refrigerants can damage the atmosphere. Government regulations may require using a certified service center to recover and recycle used refrigerants. If uncertain about the safe disposal of waste, contact your local environmental or recycling center or your dealer for more information.

TX03679,0001733 –19–03NOV08–1/1

Prepare for Emergencies Be prepared if an emergency occurs or a fire starts.

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

–UN–23AUG88

Keep a first aid kit and fire extinguisher handy.

TS291

9000 01 6

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Safety Information 9000 01 7

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.

T133468

Prevent falls by facing the machine when getting on and off. Maintain 3-point contact with steps and handrails. Never use machine controls as handholds.

–UN–30AUG00

Use Steps and Handholds Correctly

TX03679,00016F2 –19–15MAR07–1/1

Never attempt to start engine from the ground. Do not attempt to start engine by shorting across the starter solenoid terminals.

T133715

Avoid unexpected machine movement. Start engine only while sitting in operator’s seat. Ensure all controls and working tools are in proper position for a parked machine.

–UN–07SEP00

Start Only From Operator’s Seat

TX03679,0001799 –19–03JAN07–1/1

Examine seat belt frequently. Be sure webbing is not cut or torn. Replace seat belt immediately if any part is damaged or does not function properly.

T133716

Use seat belt when operating machine. Remember to fasten seat belt when loading and unloading from trucks and during other uses.

–19–14SEP00

Use and Maintain Seat Belt

The complete seat belt assembly should be replaced every 3 years, regardless of appearance.

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Safety Information

Prevent Unintended Machine Movement

Lower all equipment to the ground during work interruptions. Lock transmission control in neutral, engage park brake and stop engine before allowing anyone to approach the machine. Follow these same precautions before standing up, leaving the operator’s seat, or exiting the machine.

–UN–15MAY01

When coworkers are present, disable hydraulics.

T142001

9000 01 8

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Safety Information 9000 01 9

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. 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.

T141894 –UN–24APR01

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.

T141670

Avoid contact with gas lines, buried cables and water lines. Call utility line location services to identify all underground utilities before starting work.

–UN–15JUN01

Avoid Work Site Hazards

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 seatbelt.

T141672

Avoid working under over-hanging embankments or stockpiles that could collapse under or on machine.

–UN–04MAY01

Operate only on solid footing with strength sufficient to support machine. Be especially alert working near embankments or excavations.

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Safety Information

Ensure that objects in the bucket are secure. Do not attempt to lift or carry objects that are too big or too long to fit inside the bucket unless secured with an adequate chain or other device. Keep bystanders away from raised loads. Be careful when lifting objects. Never attempt to lift objects too heavy for your machine. Assure machine stability and hydraulic capability with a test lift before attempting other maneuvers. Use an adequate chain or sling and proper rigging techniques to attach and stabilize loads. Never lift an object above or near another person.

T141957 –UN–07MAY01

Operate carefully with raised loads. Raising the load reduces machine stability, especially on side slopes or an unstable surface. Drive and turn slowly with a raised load.

T141902

Never use the loader to lift people. Do not allow anyone to ride in the bucket or use the bucket as a work platform.

–UN–15MAY01

Use Special Care When Operating Loader

TX03768,0000B70 –19–14MAY01–1/1

Keep Riders Off Machine

Riders are subject to injury. They may fall from machine, be caught between machine parts, or be struck by foreign objects. Riders may obstruct operator’s view or impair his ability to operate machine safely.

–UN–04MAY01

Only allow operator on machine.

T141671

9000 01 10

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Safety Information 9000 01 11

Be certain reverse warning alarm is working properly.

T141673

Before moving machine, be sure 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.

–UN–04MAY01

Avoid Backover Accidents

Use a signal person when backing if view is obstructed or when in close quarters. Keep signal person in view at all times. Use prearranged hand signals to communicate.

TX03679,000179C –19–20APR01–1/1

Be careful on slopes. Avoid sharp turns. Balance loads so weight is evenly distributed and load is stable. Carry tools and loads close to the ground to aid visibility and lower center of gravity. Use extra care on soft, rocky or frozen ground. Know the capacity of the machine. Do not overload. Be careful with heavy loads. Using oversize buckets or lifting heavy objects reduces machine stability.

T133716 T141672

Ensure solid footing. Use extra care in soft ground conditions that may not uniformly support the wheels, especially when raising the boom. Do not operate close to banks or open excavations that may cave in and cause machine to tip or fall.

–UN–04MAY01

Load and unload from trucks or trailers carefully. Be sure truck is wide enough and on a firm level surface. Use loading ramps and attach them properly to truck bed.

T141676

Do not jump if the machine tips. You will be unlikely to jump clear and the machine may crush you.

–UN–04MAY01

Use seat belt at all times.

–19–14SEP00

Avoid Machine Tip Over

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Safety Information

Select low gear speed before starting down slope. The grade of the slope will be limited by ground condition and load being handled. Use service brakes to control speed. Sudden brake application with a loaded bucket on downhill side could cause machine to tip forward.

T141681

Avoid side slope travel whenever possible. Drive up steep slope in forward and down in reverse.

–UN–30APR01

Operating on Slopes

TX03679,000179E –19–14MAY01–1/1

Machines that work near vehicle traffic or travel slower than normal highway speeds must have proper lighting and markings to assure they are visible to other drivers. Install additional lights, beacons, slow moving vehicle (SMV) emblems, or other devices and use as required to make the machine visible and identify it as a work machine. Check state and local regulations to assure compliance. Keep these devices clean and in working condition.

–UN–22MAY01

Operating or Traveling On Public Roads

T141891

9000 01 12

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Safety Information 9000 01 13

Inspect and Maintain ROPS A damaged roll-over protective structure (ROPS) should be replaced, not reused.

To maintain the ROPS:

The protection offered by ROPS will be impaired if ROPS is subjected to structural damage, is involved in an overturn incident, or is in any way altered by welding, bending, drilling, or cutting.

• 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.

If ROPS was loosened or removed for any reason, inspect it carefully before operating the machine again.

TX03679,000179F –19–07SEP06–1/1

Add and Operate Attachments Safely Always verify compatibility of attachments by contacting your authorized dealer. Adding unapproved attachments may affect machine stability or reliability, and may create a hazard for others near the machine. Ensure that a qualified person is involved in attachment installation. Add guards to machine if operator protection is required or recommended. Verify

that all connections are secure and attachment responds properly to controls. Carefully read attachment manual and follow all instructions and warnings. In an area free of bystanders and obstructions, carefully operate attachment to learn its characteristics and range of motion.

TX03679,00016F0 –19–24JAN07–1/1

TX1023216

Avoid serious injury or death from an explosion hazard. Deactivate all cellular or radio frequency devices on equipment stored or operating in an area, such as a blasting zone, where the use of radio transmitting devices are prohibited.

–UN–07MAY07

Prevent Unintended Detonation of Explosive Devices

VD76477,0001543 –19–08JAN08–1/1

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Safety Information

Park And Prepare For Service Safely

T133332

• Park machine on a level surface and lower equipment to the ground. • Engage park brake. • Stop engine and remove key. • Install articulation locking bar. • Attach a “Do Not Operate” tag in an obvious place in the operator’s station.

–19–14DEC01

Warn others of service work. Always park and prepare your machine for service or repair properly.

Understand service procedures before beginning repairs. Keep service area clean and dry. Use two people whenever the engine must be running for service work.

TS229

• Do not support machine with boom, bucket, or other hydraulically actuated equipment. • Do not support machine with cinder blocks or wooden pieces that may crumble or crush. • Do not support machine with a single jack or other devices that may slip out of place.

–UN–23AUG88

Securely support machine or attachment before working under it.

TX03679,00017A0 –19–18SEP01–1/1

Service Cooling System Safely

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.

–UN–23AUG88

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

TS281

9000 01 14

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Safety Information 9000 01 15

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

• Remove paint a minimum of 100 mm (4 in.) from area to be affected by heating. If paint cannot be removed, wear an approved respirator before heating or welding. • If you sand or grind paint, avoid breathing the dust. Wear an approved respirator. • If you use solvent or paint stripper, remove stripper with soap and water before welding. Remove solvent or paint stripper containers and other flammable material from area. Allow fumes to disperse at least 15 minutes before welding or heating.

TS220

Remove paint before heating:

–UN–23AUG88

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

Do not use a chlorinated solvent in areas where welding will take place. Do all work in an area that is well ventilated to carry toxic fumes and dust away. Dispose of paint and solvent properly.

DX,PAINT –19–24JUL02–1/1

TM10229 (17MAR09)

9000-01-15

544J Loader (S.N. 611800— ) 032409

PN=23

Safety Information

Avoid welding or heating near pressurized fluid lines. Flammable spray may result and cause severe burns if pressurized lines fail as a result of heating. Do not let heat go beyond work area to nearby pressurized lines.

T133547

IMPORTANT: Disable electrical power before welding. Turn off main battery switch or disconnect positive battery cable. Separate harness connectors to engine and vehicle microprocessors.

–UN–31AUG00

Make Welding Repairs Safely

Remove paint properly. Do not inhale paint dust or fumes. Use a qualified welding technician for structural repairs. Make sure there is good ventilation. Wear eye protection and protective equipment when welding.

TX03679,00016D5 –19–25APR08–1/1

Always wear protective goggles or safety glasses and other protective equipment before striking hardened parts. Hammering hardened metal parts such as pins and bucket teeth may dislodge chips at high velocity. Use a soft hammer or a brass bar between hammer and object to prevent chipping.

–UN–14SEP00

Drive Metal Pins Safely

T133738

9000 01 16

TX03679,0001745 –19–03JAN07–1/1

TM10229 (17MAR09)

9000-01-16

544J Loader (S.N. 611800— ) 032409

PN=24

Section 9001

Diagnostic Trouble Codes (DTC) Contents

9001

Page

Group 10—CAN Monitor Unit (CMU) Diagnostic Trouble Codes CAN Monitor Unit (CMU) Diagnostic Trouble Codes . . . . . . . . . . . . . . . . . . . . . .9001-10-1 000829.05 — Fuel Level Open or Short . . . .9001-10-1 Fuel Level Sensor Open or Short Diagnostic Procedure . . . . . . . . . . . . . . . . . . . . . . . . .9001-10-1 002000.09 — CAN Comm Lost For ECU . . .9001-10-3 CAN Comm Lost For ECU Diagnostic Procedure . . . . . . . . . . . . . . . . . . . . . . . . .9001-10-4 002003.09 — CAN Comm Lost For TCU . . .9001-10-6 CAN Comm Lost For TCU Diagnostic Procedure . . . . . . . . . . . . . . . . . . . . . . . . .9001-10-6 002033.09 — CAN Comm Lost For FLC . . . .9001-10-8 CAN Comm Lost For FLC Diagnostic Procedure . . . . . . . . . . . . . . . . . . . . . . . . .9001-10-8 002140.09 — CAN Comm Lost For SSM . . . . . . . . . . . . . . . . . . . . . . . . . . . .9001-10-10 CAN Comm Lost For SSM Diagnostic Procedure . . . . . . . . . . . . . . . . . . . . . . . .9001-10-10 002367.04 — Left Turn Switch Short to Ground . . . . . . . . . . . . . . . . . . . . . . . . . .9001-10-11 Left Turn Switch Short to Ground Diagnostic Procedure . . . . . . . . . . . . . . . . . . . . . . . .9001-10-12 002369.04 — Right Turn Switch Short to Ground . . . . . . . . . . . . . . . . . . . . . . . . . .9001-10-13 Right Turn Switch Short to Ground Diagnostic Procedure . . . . . . . . . . . . . . . . . . . . . . . .9001-10-13 524250.31 — Inspect Park Brake . . . . . . . .9001-10-15 Inspect Park Brake Diagnostic Procedure . . . . . . . . . . . . . . . . . . . . . . . .9001-10-15

000627.01 — ECU Unswitch Short to GND . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9001-20-7 Engine Control Unit (ECU) Unswitched Short to Ground Diagnostic Procedure. . . .9001-20-7 001253.13 — Injector Cal Required . . . . . . .9001-20-8 Injector Calibration Required Diagnostic Procedure . . . . . . . . . . . . . . . . . . . . . . . . .9001-20-8 002003.09 — CAN Comm Lost for TCU . . . .9001-20-9 CAN Communication Lost for TCU Diagnostic Procedure . . . . . . . . . . . . . . . . . . . . . . . . .9001-20-9 002033.09 — CAN Comm Lost for FLC . . .9001-20-11 CAN Communication Lost for FLC Diagnostic Procedure . . . . . . . . . . . . . . . . . . . . . . . .9001-20-11

Group 20—Engine Control Unit (ECU) Diagnostic Trouble Codes Engine Control Unit (ECU) Diagnostic Trouble Codes . . . . . . . . . . . . . . . . . . . . . .9001-20-1 000107.00 — Eng Air Filter Restricted . . . . .9001-20-2 Engine Air Filter Restricted Diagnostic Procedure . . . . . . . . . . . . . . . . . . . . . . . . .9001-20-2 000171.03 — Ambient Air Open Circuit. . . . .9001-20-3 Ambient Air Open Circuit Diagnostic Procedure . . . . . . . . . . . . . . . . . . . . . . . . .9001-20-3 000171.04 — Ambient Air Short to Gnd . . . .9001-20-5 Ambient Air Short to Ground Diagnostic Procedure . . . . . . . . . . . . . . . . . . . . . . . . .9001-20-5 TM10229 (17MAR09)

Group 30—Transmission Control Unit (TCU) Diagnostic Trouble Codes Transmission Control Unit (TCU) Diagnostic Trouble Codes . . . . . . . . . . . . . . . . . . . . . .9001-30-1 002023.09 — CAN Comm Lost for CMU. . . .9001-30-1 CAN Signal Missing from CMU Diagnostic Procedure . . . . . . . . . . . . . . . . . . . . . . . . .9001-30-2 002033.09 — CAN Comm Lost for FLC . . . .9001-30-4 CAN Signal Missing from FLC Diagnostic Procedure . . . . . . . . . . . . . . . . . . . . . . . . .9001-30-4 522344.00 — Converter Overtemp . . . . . . . .9001-30-6 Transmission Oil Temperature Too High Diagnostic Procedure. . . . . . . . . . . . . . . . .9001-30-6 522350.15 — Input Torque Overload . . . . . .9001-30-7 Input Torque Overload Diagnostic Procedure . . . . . . . . . . . . . . . . . . . . . . . . .9001-30-7 522364.07 — Trans Clutch Calibr Failed. . . .9001-30-8 Transmission Clutch Calibration Failed Diagnostic Procedure. . . . . . . . . . . . . . . . .9001-30-8 522364.13 — Trans Clutch Calibr Fault . . . .9001-30-9 Transmission Clutch Calibration Fault Diagnostic Procedure. . . . . . . . . . . . . . . .9001-30-10 522365.13 — Limp Home Mode . . . . . . . . .9001-30-10 Limp Home Mode Requested Diagnostic Procedure . . . . . . . . . . . . . . . . . . . . . . . .9001-30-10 522366.13 — Application Invalid . . . . . . . . .9001-30-11 Application Invalid Diagnostic Procedure . . .9001-30-11 522367.13 — TCU Configuration Invalid . . .9001-30-12 TCU Configuration Invalid Diagnostic Procedure . . . . . . . . . . . . . . . . . . . . . . . .9001-30-12

9001-1

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Contents

9001

Page

522368.02 — Memory Failure . . . . . . . . . . .9001-30-13 TCU Memory Failure Diagnostic Procedure . . . . . . . . . . . . . . . . . . . . . . . .9001-30-13 522369.03 — Remote Display Short to Power . . . . . . . . . . . . . . . . . . . . . . . . . . .9001-30-14 Remote Display Short to Power Diagnostic Procedure . . . . . . . . . . . . . . . . . . . . . . . .9001-30-14 522369.04 — Remote Display Short to Ground . . . . . . . . . . . . . . . . . . . . . . . . . .9001-30-16 Remote Display Short to Ground Diagnostic Procedure . . . . . . . . . . . . . . . . . . . . . . . .9001-30-16 522370.02 — TCU VP2 Short Circuit . . . . .9001-30-18 TCU Valve Power Supply 2 Short Circuit Diagnostic Procedure. . . . . . . . . . . . . . . .9001-30-18 522371.02 — TCU VP1 Short Circuit . . . . .9001-30-20 TCU Valve Power Supply 1 Short Circuit Diagnostic Procedure. . . . . . . . . . . . . . . .9001-30-20 522373.03 — Power Supply High Voltage . . . . . . . . . . . . . . . . . . . . . . . . . .9001-30-21 Power Supply High Voltage Diagnostic Procedure . . . . . . . . . . . . . . . . . . . . . . . .9001-30-21 522373.04 — Power Supply Low Voltage . . . . . . . . . . . . . . . . . . . . . . . . . .9001-30-22 Power Supply Low Voltage Diagnostic Procedure . . . . . . . . . . . . . . . . . . . . . . . .9001-30-22 522374.03 — Sensor Supply Short to Power . . . . . . . . . . . . . . . . . . . . . . . . . . .9001-30-24 Sensor Supply Short to Power Diagnostic Procedure . . . . . . . . . . . . . . . . . . . . . . . .9001-30-24 522374.04 — Sensor Supply Short to Gnd . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9001-30-25 Sensor Supply Short to Ground Diagnostic Procedure . . . . . . . . . . . . . . . . . . . . . . . .9001-30-25 522375.00 — Trans Oil Filter Restricted . . .9001-30-26 Transmission Oil Filter Restricted Diagnostic Procedure . . . . . . . . . . . . . . . . . . . . . . . .9001-30-27 522376.00 — Trans Oil Temp Max Value . . . . . . . . . . . . . . . . . . . . . . . . . . . .9001-30-28 Transmission Oil Temperature Maximum Value Diagnostic Procedure. . . . . . . . . . .9001-30-28 522379.03 — Park Brake Solenoid Short to Power . . . . . . . . . . . . . . . . . . . . . . . . .9001-30-29 Park Brake Solenoid Short to Power Diagnostic Procedure. . . . . . . . . . . . . . . .9001-30-30 522379.04 — Park Brake Solenoid Short to Gnd . . . . . . . . . . . . . . . . . . . . . . . . . . .9001-30-31 Park Brake Solenoid Short to Ground Diagnostic Procedure. . . . . . . . . . . . . . . .9001-30-32 522379.05 — Park Brake Solenoid Open Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . .9001-30-34 Park Brake Solenoid Open Circuit Diagnostic Procedure . . . . . . . . . . . . . . . . . . . . . . . .9001-30-35

522382.03 — Backup Alarm Short to Power . . . . . . . . . . . . . . . . . . . . . . . . . . .9001-30-36 Backup Alarm Short to Power Diagnostic Procedure . . . . . . . . . . . . . . . . . . . . . . . .9001-30-37 522382.04 — Backup Alarm Short to Gnd . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9001-30-40 Backup Alarm Short to Ground Diagnostic Procedure . . . . . . . . . . . . . . . . . . . . . . . .9001-30-40 522382.05 — Backup Alarm Open Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . .9001-30-43 Backup Alarm Open Circuit Diagnostic Procedure . . . . . . . . . . . . . . . . . . . . . . . .9001-30-43 522383.02 — Clutch KR Slippage . . . . . . . .9001-30-44 Clutch KR Slippage Diagnostic Procedure . . . . . . . . . . . . . . . . . . . . . . . .9001-30-45 522383.03 — Clutch Rev Sol Short to Power . . . . . . . . . . . . . . . . . . . . . . . . . . .9001-30-47 Clutch Reverse Solenoid Short to Power Diagnostic Procedure. . . . . . . . . . . . . . . .9001-30-47 522383.04 — Clutch Rev Sol Short to Gnd . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9001-30-49 Clutch Reverse Solenoid Short to Ground Diagnostic Procedure. . . . . . . . . . . . . . . .9001-30-50 522383.05 — Clutch Rev Sol Open Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . .9001-30-53 Clutch Reverse Solenoid Open Circuit Diagnostic Procedure. . . . . . . . . . . . . . . .9001-30-54 522386.02 — Clutch KV Slippage . . . . . . . .9001-30-55 Clutch KV Slippage Diagnostic Procedure . . . . . . . . . . . . . . . . . . . . . . . .9001-30-55 522386.03 — Clutch Fwd Sol Short to Power . . . . . . . . . . . . . . . . . . . . . . . . . . .9001-30-57 Clutch Forward Solenoid Short to Power Diagnostic Procedure. . . . . . . . . . . . . . . .9001-30-58 522386.04 — Clutch Fwd Sol Short to Gnd . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9001-30-60 Clutch Forward Solenoid Short to Ground Diagnostic Procedure. . . . . . . . . . . . . . . .9001-30-61 522386.05 — Clutch Fwd Sol Solenoid Open . . . . . . . . . . . . . . . . . . . . . . . . . . . .9001-30-64 Clutch Forward Solenoid Open Circuit Diagnostic Procedure. . . . . . . . . . . . . . . .9001-30-65 522389.02 — Clutch K4 Slippage . . . . . . . .9001-30-66 Clutch K4 Slippage Diagnostic Procedure . . . . . . . . . . . . . . . . . . . . . . . .9001-30-66 522389.03 — Clutch K4 Sol Short to Power . . . . . . . . . . . . . . . . . . . . . . . . . . .9001-30-68 Clutch K4 Control Solenoid Short to Power Diagnostic Procedure. . . . . . . . . . . . . . . .9001-30-69 522389.04 — Clutch K4 Sol Short to Gnd . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9001-30-71

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544J Loader (S.N. 611800— ) 032409

PN=2

Contents

Page

Clutch K4 Control Solenoid Short to Ground Diagnostic Procedure. . . . . . . . . . . . . . . .9001-30-72 522389.05 — Clutch K4 Sol Open Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . .9001-30-75 Clutch K4 Control Solenoid Open Circuit Diagnostic Procedure. . . . . . . . . . . . . . . .9001-30-76 522392.02 — Clutch K3 Slippage . . . . . . . .9001-30-77 Clutch K3 Slippage Diagnostic Procedure . . . . . . . . . . . . . . . . . . . . . . . .9001-30-77 522392.03 — Clutch K3 Sol Short to Power . . . . . . . . . . . . . . . . . . . . . . . . . . .9001-30-79 Clutch K3 Control Solenoid Short to Power Diagnostic Procedure. . . . . . . . . . . . . . . .9001-30-80 522392.04 — Clutch K3 Sol Short to Gnd . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9001-30-82 Clutch K3 Control Solenoid Short to Ground Diagnostic Procedure. . . . . . . . . . . . . . . .9001-30-83 522392.05 — Clutch K3 Sol Open Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . .9001-30-86 Clutch K3 Control Solenoid Open Circuit Diagnostic Procedure. . . . . . . . . . . . . . . .9001-30-87 522395.02 — Clutch K2 Slippage . . . . . . . .9001-30-88 Clutch K2 Slippage Diagnostic Procedure . . . . . . . . . . . . . . . . . . . . . . . .9001-30-88 522395.03 — Clutch K2 Sol Short to Power . . . . . . . . . . . . . . . . . . . . . . . . . . .9001-30-90 Transmission Clutch K2 Control Solenoid Short to Power Diagnostic Procedure . . .9001-30-91 522395.04 — Clutch K2 Sol Short to Gnd . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9001-30-93 Transmission Clutch K2 Control Solenoid Short to Ground Diagnostic Procedure. . .9001-30-94 522395.05 — Clutch K2 Sol Open Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . .9001-30-97 Transmission Clutch K2 Control Solenoid Open Circuit Diagnostic Procedure . . . . .9001-30-98 522399.02 — Clutch K1 Slippage . . . . . . . .9001-30-99 Transmission Clutch K1 Slippage Diagnostic Procedure . . . . . . . . . . . . . . . . . . . . . . . .9001-30-99 522399.03 — Clutch K1 Sol Short to Power . . . . . . . . . . . . . . . . . . . . . . . . . . 9001-30-101 Transmission Clutch K1 Control Solenoid Short to Power Diagnostic Procedure . . 9001-30-102 522399.04 — Clutch K1 Sol Short to Gnd . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9001-30-104 Transmission Clutch K1 Control Solenoid Short to Ground Diagnostic Procedure . . . . . . . . . . . . . . . . . . . . . . . 9001-30-105 522399.05 — Clutch K1 Sol Open Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . 9001-30-108 Transmission Clutch K1 Control Solenoid Open Circuit Diagnostic Procedure . . . . 9001-30-109

522401.02 — Trans Speed Sensor Fault . . . . . . . . . . . . . . . . . . . . . . . . . . . 9001-30-110 Transmission Output Speed Sensor Fault Diagnostic Procedure. . . . . . . . . . . . . . . 9001-30-110 522401.03 — Output Shaft Open or Short . . . . . . . . . . . . . . . . . . . . . . . . . . . 9001-30-111 Output Shaft Open or Short Diagnostic Procedure . . . . . . . . . . . . . . . . . . . . . . . 9001-30-112 522401.04 — Output Shaft Short to Gnd . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9001-30-115 Output Shaft Short to Ground Diagnostic Procedure . . . . . . . . . . . . . . . . . . . . . . . 9001-30-115 522401.12 — Output Shaft Fault. . . . . . . . 9001-30-117 Output Shaft Fault Diagnostic Procedure . . . . . . . . . . . . . . . . . . . . . . . 9001-30-117 522401.15 — Output Shaft Overspeed . . . 9001-30-118 Output Shaft Overspeed Diagnostic Procedure . . . . . . . . . . . . . . . . . . . . . . . 9001-30-118 522402.03 — Clutch Speed Open or Short . . . . . . . . . . . . . . . . . . . . . . . . . . . 9001-30-119 Clutch Speed Open or Short Diagnostic Procedure . . . . . . . . . . . . . . . . . . . . . . . 9001-30-119 522402.04 — Clutch Speed Short to Gnd . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9001-30-122 Clutch Speed Short to Ground Diagnostic Procedure . . . . . . . . . . . . . . . . . . . . . . . 9001-30-123 522402.12 — Clutch Speed Sensor Fault . . . . . . . . . . . . . . . . . . . . . . . . . . . 9001-30-124 Clutch Speed Sensor Fault Diagnostic Procedure . . . . . . . . . . . . . . . . . . . . . . . 9001-30-125 522403.03 — Conv Output Spd Open or Short . . . . . . . . . . . . . . . . . . . . . . . . . . . 9001-30-126 Converter Output Speed Open or Short Diagnostic Procedure. . . . . . . . . . . . . . . 9001-30-126 522403.04 — Conv Output Spd Short to Gnd . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9001-30-128 Converter Output Speed Short to Ground Diagnostic Procedure. . . . . . . . . . . . . . . 9001-30-129 522403.12 — Conv Output Spd Fault . . . . 9001-30-130 Converter Output Speed Fault Diagnostic Procedure . . . . . . . . . . . . . . . . . . . . . . . 9001-30-131 522404.03 — Conv Input Spd Open or Short . . . . . . . . . . . . . . . . . . . . . . . . . . . 9001-30-132 Converter Input Speed Open or Short Diagnostic Procedure. . . . . . . . . . . . . . . 9001-30-132 522404.04 — Conv Input Spd Short to Gnd . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9001-30-135 Torque Converter Input Speed Short to Ground Diagnostic Procedure . . . . . . . . 9001-30-136 522404.12 — Conv Input Spd Fault . . . . . 9001-30-138

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9001

Contents

9001

Page

Converter Input Speed Fault Diagnostic Procedure . . . . . . . . . . . . . . . . . . . . . . . 9001-30-139 522406.03 — Trans Oil Temp Open or Short . . . . . . . . . . . . . . . . . . . . . . . . . . . 9001-30-140 Transmission Oil Temperature Sensor Open or Short Diagnostic Procedure . . . 9001-30-140 522406.04 — Trans Oil Temp Short to Gnd . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9001-30-143 Transmission Oil Temperature Sensor Short to Ground Diagnostic Procedure . . . . . . . . . . . . . . . . . . . . . . . 9001-30-144 522407.03 — Clutch Cutoff Short to Power . . . . . . . . . . . . . . . . . . . . . . . . . . 9001-30-146 Clutch Cut-Off Sensor Short to Power Diagnostic Procedure. . . . . . . . . . . . . . . 9001-30-147 522407.04 — Clutch Cutoff Open or Short . . . . . . . . . . . . . . . . . . . . . . . . . . . 9001-30-148 Clutch Cut-Off Sensor Open or Short Diagnostic Procedure. . . . . . . . . . . . . . . 9001-30-148 522409.05 — 2nd FNR Open Circuit. . . . . 9001-30-149 2nd TCL Open Circuit Diagnostic Procedure (Pilot Control Joystick) . . . . . 9001-30-150 522409.12 — 2nd FNR Mult Inputs . . . . . . 9001-30-151 2nd TCL Missing Inputs Diagnostic Procedure . . . . . . . . . . . . . . . . . . . . . . . 9001-30-151 522411.05 — 1st FNR Open Circuit . . . . . 9001-30-153 1st TCL Open Circuit Diagnostic Procedure (Steering Column Shifter) . . . 9001-30-153 1st TCL Open Circuit Diagnostic Procedure (Pilot Control Joystick) . . . . . 9001-30-155 522411.12 — 1st FNR Mult Inputs . . . . . . 9001-30-156 1st TCL Multiple Inputs Diagnostic Procedure (Steering Column Shifter) . . . 9001-30-156 1st TCL Multiple Inputs Diagnostic Procedure (Pilot Control Joystick) . . . . . 9001-30-158 522412.12 — Gear Selection Error . . . . . . 9001-30-160 Gear Selection Error Diagnostic Procedure . . . . . . . . . . . . . . . . . . . . . . . 9001-30-160 522419.02 — Clutch Cutoff Disabled . . . . 9001-30-162 Clutch Cut-Off Disabled Diagnostic Procedure . . . . . . . . . . . . . . . . . . . . . . . 9001-30-163 522420.02 — Manual Downshift Disabled . . . . . . . . . . . . . . . . . . . . . . . . 9001-30-164 Manual Downshift Disabled Diagnostic Procedure . . . . . . . . . . . . . . . . . . . . . . . 9001-30-164 522421.02 — Auto To 1st Disabled. . . . . . 9001-30-165 Auto To 1st Disabled Diagnostic Procedure . . . . . . . . . . . . . . . . . . . . . . . 9001-30-165 524048.00 — Trans Output Torque Exceeded . . . . . . . . . . . . . . . . . . . . . . . 9001-30-166 Trans Output Torque Exceeded Diagnostic Procedure . . . . . . . . . . . . . . . . . . . . . . . 9001-30-166

524049.00 — Trans Input Torque Exceeded . . . . . . . . . . . . . . . . . . . . . . . 9001-30-166 Trans Input Torque Exceeded Diagnostic Procedure . . . . . . . . . . . . . . . . . . . . . . . 9001-30-167 524287.00 — Configure Machine Model . . . . . . . . . . . . . . . . . . . . . . . . . . 9001-30-167 Configure Machine Model Diagnostic Procedure . . . . . . . . . . . . . . . . . . . . . . . 9001-30-167

TM10229 (17MAR09)

Group 40—Flex Load Controller (FLC) Diagnostic Trouble Codes Flex Load Controller (FLC) Diagnostic Trouble Codes . . . . . . . . . . . . . . . . . . . . . .9001-40-1 000117.01 — Brake Pressure Low . . . . . . . .9001-40-1 Brake Pressure Low Diagnostic Procedure . . . . . . . . . . . . . . . . . . . . . . . . .9001-40-1 000167.16 — Alternator High Voltage . . . . . .9001-40-3 Alternator High Voltage Diagnostic Procedure . . . . . . . . . . . . . . . . . . . . . . . . .9001-40-3 000167.18 — Alternator Low Voltage . . . . . .9001-40-4 Alternator Low Voltage Diagnostic Procedure . . . . . . . . . . . . . . . . . . . . . . . . .9001-40-4 000168.16 — High Battery Voltage . . . . . . . .9001-40-5 High Battery Voltage Diagnostic Procedure . . . . . . . . . . . . . . . . . . . . . . . . .9001-40-5 000168.18 — Low Battery Voltage . . . . . . . .9001-40-6 Low Battery Voltage Diagnostic Procedure . . . . . . . . . . . . . . . . . . . . . . . . .9001-40-6 000444.05 — 12V Cntr Tap Open or Short . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9001-40-7 12 Volt Center Tap Open or Short Diagnostic Procedure . . . . . . . . . . . . . . . . . . . . . . . . .9001-40-7 000444.18 — Battery Voltage Imbalance . . .9001-40-9 Battery Voltage Imbalance Diagnostic Procedure . . . . . . . . . . . . . . . . . . . . . . . .9001-40-10 000544.19 — Refer Torq Mis-Match . . . . . .9001-40-11 Reference Torque MisMatch Diagnostic Procedure . . . . . . . . . . . . . . . . . . . . . . . .9001-40-11 000628.12 — Controller Not Programmed . . . . . . . . . . . . . . . . . . . . . .9001-40-11 Controller Not Programmed Diagnostic Procedure . . . . . . . . . . . . . . . . . . . . . . . .9001-40-12 000774.04 — JS Upshift Short to Gnd . . . .9001-40-12 Joystick Upshift Short to Ground Diagnostic Procedure . . . . . . . . . . . . . . . . . . . . . . . .9001-40-12 000774.10 — JS Upshift Button Stuck . . . .9001-40-14 Joystick Upshift Button Stuck Diagnostic Procedure . . . . . . . . . . . . . . . . . . . . . . . .9001-40-14 000775.04 — JS Downshift Short to Gnd . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9001-40-15

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Joystick Downshift Short to Ground Diagnostic Procedure. . . . . . . . . . . . . . . .9001-40-15 000775.10 — JS Downshift Button Stuck . . . . . . . . . . . . . . . . . . . . . . . . . . . .9001-40-17 Joystick Downshift Button Stuck Diagnostic Procedure . . . . . . . . . . . . . . . . . . . . . . . .9001-40-17 000785.03 — Pilot Solenoid Short to Power . . . . . . . . . . . . . . . . . . . . . . . . . . .9001-40-18 Pilot Solenoid Short to Power Diagnostic Procedure . . . . . . . . . . . . . . . . . . . . . . . .9001-40-18 000785.05 — Pilot Solenoid Open Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . .9001-40-20 Pilot Solenoid Open Circuit Diagnostic Procedure . . . . . . . . . . . . . . . . . . . . . . . .9001-40-20 000785.06 — Pilot Solenoid High Current . . . . . . . . . . . . . . . . . . . . . . . . . .9001-40-22 Pilot Solenoid High Current Diagnostic Procedure . . . . . . . . . . . . . . . . . . . . . . . .9001-40-22 000880.03 — Brake Lights Short to Power . . . . . . . . . . . . . . . . . . . . . . . . . . .9001-40-24 Brake Lights Short to Power Diagnostic Procedure . . . . . . . . . . . . . . . . . . . . . . . .9001-40-24 000880.05 — Brake Lights Open Circuit . . .9001-40-26 Brake Lights Open Circuit Diagnostic Procedure . . . . . . . . . . . . . . . . . . . . . . . .9001-40-27 000880.06 — Brake Lights High Current . . .9001-40-29 Brake Lights High Current Diagnostic Procedure . . . . . . . . . . . . . . . . . . . . . . . .9001-40-29 000977.03 — Rev Fan Solenoid Short to Power . . . . . . . . . . . . . . . . . . . . . . . . . . .9001-40-31 Reverse Fan Solenoid Short to Power Diagnostic Procedure. . . . . . . . . . . . . . . .9001-40-32 000977.05 — Rev Fan Sol Open Circuit . . .9001-40-34 Reverse Fan Solenoid Open Circuit Diagnostic Procedure. . . . . . . . . . . . . . . .9001-40-35 000977.06 — Rev Fan Sol High Current . . .9001-40-37 Reverse Fan Solenoid High Current Diagnostic Procedure. . . . . . . . . . . . . . . .9001-40-37 001045.04 — Brake Lt Sw Shorted to Gnd . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9001-40-39 Brake Light Switch Shorted to Ground Diagnostic Procedure. . . . . . . . . . . . . . . .9001-40-40 001069.02 — Tire Size Incorrect. . . . . . . . .9001-40-41 Tire Size Incorrect Diagnostic Procedure. . .9001-40-41 001071.31 — Fan Speed Sol Circuit Fault . . . . . . . . . . . . . . . . . . . . . . . . . . . .9001-40-42 Fan Speed Solenoid Circuit Fault Diagnostic Procedure . . . . . . . . . . . . . . . . . . . . . . . .9001-40-42 001075.00 — Fuel Pump On Too Long. . . .9001-40-46 Fuel Pump On Too Long Diagnostic Procedure . . . . . . . . . . . . . . . . . . . . . . . .9001-40-46 001079.04 — FLC Sensor 1 Voltage Low . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9001-40-46

FLC Sensor 1 Voltage Low Diagnostic Procedure . . . . . . . . . . . . . . . . . . . . . . . .9001-40-47 001080.04 — FLC Sensor 2 Voltage Low . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9001-40-48 FLC Sensor 2 Voltage Low Diagnostic Procedure . . . . . . . . . . . . . . . . . . . . . . . .9001-40-49 001638.00 — Hydraulic Oil High Temp . . . .9001-40-50 Hydraulic Oil High Temperature Diagnostic Procedure . . . . . . . . . . . . . . . . . . . . . . . .9001-40-50 001638.04 — Hyd Oil Temp Circuit Short to Gnd . . . . . . . . . . . . . . . . . . . . . . . . . . .9001-40-51 Hydraulic Oil Temperature Circuit Short to Ground Diagnostic Procedure . . . . . . . . .9001-40-51 001713.01 — Hyd Oil Filter Restricted . . . .9001-40-53 Hydraulic Oil Filter Restricted Diagnostic Procedure . . . . . . . . . . . . . . . . . . . . . . . .9001-40-53 001762.03 — Hyd Pressure Short to Power . . . . . . . . . . . . . . . . . . . . . . . . . . .9001-40-55 Hydraulic Pressure Short to Power Diagnostic Procedure . . . . . . . . . . . . . . . . . . . . . . . .9001-40-55 001762.04 — Hyd Pressure Open or Short . . . . . . . . . . . . . . . . . . . . . . . . . . . .9001-40-57 Hydraulic Pressure Open or Short Diagnostic Procedure . . . . . . . . . . . . . . . . . . . . . . . .9001-40-57 002000.09 — CAN Comm Lost for ECU . . .9001-40-60 CAN Communication Lost For ECU Diagnostic Procedure. . . . . . . . . . . . . . . .9001-40-60 002003.09 — CAN Comm Lost for TCU . . .9001-40-62 CAN Communication Lost for TCU Diagnostic Procedure . . . . . . . . . . . . . . . . . . . . . . . .9001-40-62 002023.09 — CAN Comm Lost for CMU. . .9001-40-64 CAN Communication Lost for CMU Diagnostic Procedure. . . . . . . . . . . . . . . .9001-40-64 002140.09 — CAN Comm Lost for SSM . . .9001-40-66 CAN Communication Lost for SSM Diagnostic Procedure . . . . . . . . . . . . . . . . . . . . . . . .9001-40-66 002350.05 — Drive Lamps Open or Short . . . . . . . . . . . . . . . . . . . . . . . . . . . .9001-40-67 Drive Lamps Open or Short Diagnostic Procedure . . . . . . . . . . . . . . . . . . . . . . . .9001-40-68 002350.06 — Drive Lamps High Current. . .9001-40-70 Drive Lamps High Current Diagnostic Procedure . . . . . . . . . . . . . . . . . . . . . . . .9001-40-71 002355.05 — Front Work Lts Open or Short . . . . . . . . . . . . . . . . . . . . . . . . . . . .9001-40-72 Auxiliary Lights Open or Short Diagnostic Procedure . . . . . . . . . . . . . . . . . . . . . . . .9001-40-73 002355.06 — Front Work Lts High Current . . . . . . . . . . . . . . . . . . . . . . . . . .9001-40-77 Auxiliary Lights High Current Diagnostic Procedure . . . . . . . . . . . . . . . . . . . . . . . .9001-40-77

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002356.05 — Front Work Lts Open or Short . . . . . . . . . . . . . . . . . . . . . . . . . . . .9001-40-80 Front Work Lights Open or Short Diagnostic Procedure . . . . . . . . . . . . . . . . . . . . . . . .9001-40-80 002356.06 — Front Work Lts High Current . . . . . . . . . . . . . . . . . . . . . . . . . .9001-40-84 Front Work Lights High Current Diagnostic Procedure . . . . . . . . . . . . . . . . . . . . . . . .9001-40-84 002362.05 — Rear Work Lts Open or Short . . . . . . . . . . . . . . . . . . . . . . . . . . . .9001-40-87 Rear Work Lights Open or Short Diagnostic Procedure . . . . . . . . . . . . . . . . . . . . . . . .9001-40-87 002362.06 — Rear Work Lts High Current . . . . . . . . . . . . . . . . . . . . . . . . . .9001-40-91 Rear Work Lights High Current Diagnostic Procedure . . . . . . . . . . . . . . . . . . . . . . . .9001-40-91 002368.03 — Left Turn Lts Circuit Short to Power . . . . . . . . . . . . . . . . . . . . . . . . . . .9001-40-94 Left Turn Lights Circuit Short to Power Diagnostic Procedure. . . . . . . . . . . . . . . .9001-40-94 002368.05 — Left Turn Lts Open Circuit . . .9001-40-98 Left Turn Lights Open Circuit Diagnostic Procedure . . . . . . . . . . . . . . . . . . . . . . . .9001-40-99 002368.06 — Left Turn Lts Circuit High Current . . . . . . . . . . . . . . . . . . . . . . . . . 9001-40-102 Left Turn Lights Circuit High Current Diagnostic Procedure. . . . . . . . . . . . . . . 9001-40-102 002370.03 — Right Turn Lts Short to Power . . . . . . . . . . . . . . . . . . . . . . . . . . 9001-40-106 Right Turn Lights Short to Power Diagnostic Procedure . . . . . . . . . . . . . . . . . . . . . . . 9001-40-107 002370.05 — Right Turn Lts Open Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . 9001-40-109 Right Turn Lights Open Circuit Diagnostic Procedure . . . . . . . . . . . . . . . . . . . . . . . 9001-40-110 002370.06 — Right Turn Lts High Current . . . . . . . . . . . . . . . . . . . . . . . . . 9001-40-112 Right Turn Lights High Current Diagnostic Procedure . . . . . . . . . . . . . . . . . . . . . . . 9001-40-112 002378.03 — Marker/Tail Lts Short to Power . . . . . . . . . . . . . . . . . . . . . . . . . . 9001-40-116 Marker/Tail Lights Short to Power Diagnostic Procedure . . . . . . . . . . . . . . . . . . . . . . . 9001-40-117 002378.05 — Marker/Tail Lts Open Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . 9001-40-121 Marker/Tail Lights Open Circuit Diagnostic Procedure . . . . . . . . . . . . . . . . . . . . . . . 9001-40-122 002378.06 — Marker/Tail Lts High Current . . . . . . . . . . . . . . . . . . . . . . . . . 9001-40-125 Marker/Tail Lights High Current Diagnostic Procedure . . . . . . . . . . . . . . . . . . . . . . . 9001-40-125 002386.06 — Beacon Light High Current . . . . . . . . . . . . . . . . . . . . . . . . . 9001-40-129

Beacon Light High Current diagnostic Procedure . . . . . . . . . . . . . . . . . . . . . . . 9001-40-130 002697.02 — JS Mag Out of Range . . . . . 9001-40-131 Joystick Magnitude Out of Range Diagnostic Procedure . . . . . . . . . . . . . . . . . . . . . . . 9001-40-131 002875.04 — 4-Way Flash Sw Short to Gnd . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9001-40-132 4-Way Flasher Switch Short to Ground Diagnostic Procedure. . . . . . . . . . . . . . . 9001-40-132 299261.02 — Machine Config Invalid . . . . 9001-40-133 Machine Configuration Invalid Diagnostic Procedure . . . . . . . . . . . . . . . . . . . . . . . 9001-40-134 522431.02 — Memory Test Failure . . . . . . 9001-40-134 Memory Test Failure Diagnostic Procedure . . . . . . . . . . . . . . . . . . . . . . . 9001-40-134 522432.05 — R Wiper H-Spd Open Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . 9001-40-135 Rear Wiper High-Speed Open Circuit Diagnostic Procedure. . . . . . . . . . . . . . . 9001-40-135 522432.06 — R Wiper H-Spd High Current . . . . . . . . . . . . . . . . . . . . . . . . . 9001-40-136 Rear Wiper High-Speed High Current Diagnostic Procedure. . . . . . . . . . . . . . . 9001-40-137 522433.05 — R Wiper L-Spd Open or Short . . . . . . . . . . . . . . . . . . . . . . . . . . . 9001-40-138 Rear Wiper Low-Speed Open or Short Diagnostic Procedure. . . . . . . . . . . . . . . 9001-40-139 522433.06 — R Wiper L-Spd High Current . . . . . . . . . . . . . . . . . . . . . . . . . 9001-40-141 Rear Wiper Low-Speed High Current Diagnostic Procedure. . . . . . . . . . . . . . . 9001-40-142 522434.05 — F Wiper L-Spd Open or Short . . . . . . . . . . . . . . . . . . . . . . . . . . . 9001-40-143 Front Wiper Low-Speed Open or Short Diagnostic Procedure. . . . . . . . . . . . . . . 9001-40-144 522434.06 — F Wiper L-Spd High Current . . . . . . . . . . . . . . . . . . . . . . . . . 9001-40-146 Front Wiper Low-Speed High Current Diagnostic Procedure. . . . . . . . . . . . . . . 9001-40-147 522435.05 — F Wiper H-Spd Open Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . 9001-40-148 Front Wiper High-Speed Open Circuit Diagnostic Procedure. . . . . . . . . . . . . . . 9001-40-149 522435.06 — F Wiper H-Spd High Current . . . . . . . . . . . . . . . . . . . . . . . . . 9001-40-150 Front Wiper High-Speed High Current Diagnostic Procedure. . . . . . . . . . . . . . . 9001-40-151 522436.03 — Bucket Pos Short to Power . . . . . . . . . . . . . . . . . . . . . . . . . . 9001-40-152 Bucket Position Short to Power Diagnostic Procedure . . . . . . . . . . . . . . . . . . . . . . . 9001-40-153

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522436.04 — Bucket Pos Open or Short . . . . . . . . . . . . . . . . . . . . . . . . . . . 9001-40-155 Bucket Position Open or Short Diagnostic Procedure . . . . . . . . . . . . . . . . . . . . . . . 9001-40-156 522437.04 — RTDig Switch 1 Short to Gnd . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9001-40-158 Return-to-dig Switch 1 Short to Ground Diagnostic Procedure. . . . . . . . . . . . . . . 9001-40-159 522438.03 — Pin Disc Sol Short to Power . . . . . . . . . . . . . . . . . . . . . . . . . . 9001-40-160 Pin Disconnect Solenoid Short to Power Diagnostic Procedure. . . . . . . . . . . . . . . 9001-40-161 522438.05 — Pin Disc Sol Open Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . 9001-40-163 Pin Disconnect Solenoid Open Circuit Diagnostic Procedure. . . . . . . . . . . . . . . 9001-40-164 522438.06 — Pin Disc Sol High Current . . . . . . . . . . . . . . . . . . . . . . . . . 9001-40-165 Pin Disconnect Solenoid High Current Diagnostic Procedure. . . . . . . . . . . . . . . 9001-40-166 522796.05 — R Washer Pump Open Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . 9001-40-168 Rear Washer Pump Open Circuit Diagnostic Procedure . . . . . . . . . . . . . . . . . . . . . . . 9001-40-169 522796.06 — R Washer Pump High Current . . . . . . . . . . . . . . . . . . . . . . . . . 9001-40-170 Rear Washer Pump High Current Diagnostic Procedure . . . . . . . . . . . . . . . . . . . . . . . 9001-40-170 522797.05 — F Washer Pump Open Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . 9001-40-172 Front Washer Pump Open Circuit Diagnostic Procedure . . . . . . . . . . . . . . . . . . . . . . . 9001-40-172 522797.06 — F Washer Pump High Current . . . . . . . . . . . . . . . . . . . . . . . . . 9001-40-173 Front Washer Pump High Current Diagnostic Procedure . . . . . . . . . . . . . . . . . . . . . . . 9001-40-174 523137.04 — Steering Press Sw Shrt to Gnd . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9001-40-175 Steering Pressure Switch Short to Ground Diagnostic Procedure. . . . . . . . . . . . . . . 9001-40-176 523214.05 — No Voltage to FLC on VP6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9001-40-177 No Voltage to FLC on VP6 Diagnostic Procedure . . . . . . . . . . . . . . . . . . . . . . . 9001-40-177 523215.05 — No Voltage to FLC on VP5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9001-40-178 No Voltage to FLC on VP5 Diagnostic Procedure . . . . . . . . . . . . . . . . . . . . . . . 9001-40-179 523216.05 — No Voltage to FLC on VP4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9001-40-180 No Voltage to FLC on VP4 Diagnostic Procedure . . . . . . . . . . . . . . . . . . . . . . . 9001-40-180

523217.05 — No Voltage to FLC on VP3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9001-40-182 No Voltage to FLC on VP3 Diagnostic Procedure . . . . . . . . . . . . . . . . . . . . . . . 9001-40-182 523218.05 — No Voltage to FLC on VP2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9001-40-183 No Voltage to FLC on VP2 Diagnostic Procedure . . . . . . . . . . . . . . . . . . . . . . . 9001-40-183 523219.05 — No Voltage to FLC on VP1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9001-40-185 No Voltage to FLC on VP1 Diagnostic Procedure . . . . . . . . . . . . . . . . . . . . . . . 9001-40-185 523436.17 — FLC Watchdog Timed Out . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9001-40-186 FLC Watchdog Timed Out Diagnostic Procedure . . . . . . . . . . . . . . . . . . . . . . . 9001-40-186 523577.03 — 2nd Steer Pump Short to Power . . . . . . . . . . . . . . . . . . . . . . . . . . 9001-40-187 Secondary Steering Pump Short to Power Diagnostic Procedure. . . . . . . . . . . . . . . 9001-40-187 523577.05 — 2nd Steer Pump Open Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . 9001-40-189 Secondary Steering Pump Open Circuit Diagnostic Procedure. . . . . . . . . . . . . . . 9001-40-190 523577.06 — 2nd Steer Pump High Current . . . . . . . . . . . . . . . . . . . . . . . . . 9001-40-192 Secondary Steer Pump High Current Diagnostic Procedure. . . . . . . . . . . . . . . 9001-40-192 523786.03 — Boom Position Short to Power . . . . . . . . . . . . . . . . . . . . . . . . . . 9001-40-194 Boom Position Short to Power Diagnostic Procedure . . . . . . . . . . . . . . . . . . . . . . . 9001-40-195 523786.04 — Boom Position Open or Short . . . . . . . . . . . . . . . . . . . . . . . . . . . 9001-40-196 Boom Position Open or Short Diagnostic Procedure . . . . . . . . . . . . . . . . . . . . . . . 9001-40-197 523837.01 — Brake Pressure Low-Rear . . . . . . . . . . . . . . . . . . . . . . . . 9001-40-199 Brake Pressure Low-Rear Diagnostic Procedure . . . . . . . . . . . . . . . . . . . . . . . 9001-40-200 523837.04 — Rr Brake Pressure Open or Short . . . . . . . . . . . . . . . . . . . . . . . . . . . 9001-40-200 Rear Brake Pressure Sensor Open or Short Diagnostic Procedure. . . . . . . . . . . . . . . 9001-40-200 523840.01 — Brake Pressure Low-Front . . . . . . . . . . . . . . . . . . . . . . . 9001-40-202 Brake Pressure Low-Front Diagnostic Procedure . . . . . . . . . . . . . . . . . . . . . . . 9001-40-202 523840.03 — Ft Brake Pressure Short to Power . . . . . . . . . . . . . . . . . . . . . . . . . . 9001-40-202

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Front Brake Pressure Sensor Short to Power Diagnostic Procedure. . . . . . . . . . . . . . . 9001-40-203 523840.04 — Ft Brake Pressure Open or Short . . . . . . . . . . . . . . . . . . . . . . . . . . . 9001-40-204 Front Brake Pressure Sensor Open or Short Diagnostic Procedure. . . . . . . . . . . . . . . 9001-40-204 523911.31 — Hyd Pwr Sol Circuit Fault . . . . . . . . . . . . . . . . . . . . . . . . . . . 9001-40-205 523948.03 — Ride Contrl Sol Short to Power . . . . . . . . . . . . . . . . . . . . . . . . . . 9001-40-206 Ride Control Solenoid Short to Power Diagnostic Procedure. . . . . . . . . . . . . . . 9001-40-206 523948.05 — Ride Contrl Sol Open Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . 9001-40-208 Ride Control Solenoid Open Circuit Diagnostic Procedure. . . . . . . . . . . . . . . 9001-40-208 523948.06 — Ride Contrl Sol High Current . . . . . . . . . . . . . . . . . . . . . . . . . 9001-40-209 Ride Control Solenoid High Current Diagnostic Procedure. . . . . . . . . . . . . . . 9001-40-210 524265.19 — Check Sum Error . . . . . . . . 9001-40-211 Check Sum Error Diagnostic Procedure . . . . . . . . . . . . . . . . . . . . . . . 9001-40-212

523526.10 — Reverse Fan Keypad Stuck . . . . . . . . . . . . . . . . . . . . . . . . . . . .9001-50-11 Reverse Fan Keypad Stuck Diagnostic Procedure . . . . . . . . . . . . . . . . . . . . . . . .9001-50-11 523527.10 — Pin Disconnect Keypad Stuck . . . . . . . . . . . . . . . . . . . . . . . . . . . .9001-50-12 Pin Disconnect Keypad Stuck Diagnostic Procedure . . . . . . . . . . . . . . . . . . . . . . . .9001-50-13 523528.10 — A/C Keypad Stuck. . . . . . . . .9001-50-14 A/C Keypad Stuck Diagnostic Procedure. . .9001-50-14 523529.10 — Work Lights Keypad Stuck . . . . . . . . . . . . . . . . . . . . . . . . . . . .9001-50-15 Work Lights Keypad Stuck Diagnostic Procedure . . . . . . . . . . . . . . . . . . . . . . . .9001-50-15 523530.10 — Beacon Light Keypad Stuck . . . . . . . . . . . . . . . . . . . . . . . . . . . .9001-50-16 Beacon Light Keypad Stuck Diagnostic Procedure . . . . . . . . . . . . . . . . . . . . . . . .9001-50-16 523532.10 — Spin Control Keypad Stuck . . . . . . . . . . . . . . . . . . . . . . . . . . . .9001-50-17 Spin Control Keypad Stuck Diagnostic Procedure . . . . . . . . . . . . . . . . . . . . . . . .9001-50-17 523533.10 — Clutch Cut-Off Keypad Stuck . . . . . . . . . . . . . . . . . . . . . . . . . . . .9001-50-18 Clutch Cut-Off Keypad Stuck Diagnostic Procedure . . . . . . . . . . . . . . . . . . . . . . . .9001-50-19 523534.10 — Pilot Enable Keypad Stuck . . . . . . . . . . . . . . . . . . . . . . . . . . . .9001-50-20 Pilot Enable Keypad Stuck Diagnostic Procedure . . . . . . . . . . . . . . . . . . . . . . . .9001-50-20 523535.10 — Ride Control Keypad Stuck . . . . . . . . . . . . . . . . . . . . . . . . . . . .9001-50-21 Ride Control Keypad Stuck Diagnostic Procedure . . . . . . . . . . . . . . . . . . . . . . . .9001-50-21 523536.10 — Auto Transmission Keypad Stuck . . . . . . . . . . . . . . . . . . . . . . . . . . . .9001-50-22 Auto Transmission Keypad Stuck Diagnostic Procedure . . . . . . . . . . . . . . . . . . . . . . . .9001-50-22 523537.10 — Drive Lights Keypad Stuck . . . . . . . . . . . . . . . . . . . . . . . . . . . .9001-50-23 Drive Lights Keypad Stuck Diagnostic Procedure . . . . . . . . . . . . . . . . . . . . . . . .9001-50-23 523538.10 — Keypad Not Used . . . . . . . . .9001-50-24 Keypad Not Used Diagnostic Procedure . . .9001-50-25 523607.10 — Return to Dig Keypad Stuck . . . . . . . . . . . . . . . . . . . . . . . . . . . .9001-50-26 Return-to-Dig Keypad Stuck Diagnostic Procedure . . . . . . . . . . . . . . . . . . . . . . . .9001-50-26 523608.10 — BHKO Keypad Stuck. . . . . . .9001-50-27 Boom Height Kickout Keypad Stuck Diagnostic Procedure. . . . . . . . . . . . . . . .9001-50-27

Group 50—Sealed Switch Module (SSM) Diagnostic Trouble Codes Sealed Switch Module (SSM) Diagnostic Trouble Codes . . . . . . . . . . . . . . . . . . . . . .9001-50-1 000628.12 — Controller Not Programmed. . .9001-50-1 Controller Not Programmed Diagnostic Procedure . . . . . . . . . . . . . . . . . . . . . . . . .9001-50-2 000629.12 — SSM Watchdog Time Out . . . .9001-50-2 SSM Watchdog Time Out Diagnostic Procedure . . . . . . . . . . . . . . . . . . . . . . . . .9001-50-2 000639.12 — SSM Lost Message . . . . . . . . .9001-50-3 SSM Lost Message Diagnostic Procedure. . .9001-50-3 000639.19 — SSM Lost CAN Communications . . . . . . . . . . . . . . . . . . . .9001-50-4 SSM Lost CAN Communications Diagnostic Procedure . . . . . . . . . . . . . . . . . . . . . . . . .9001-50-5 002033.09 — SSM Lost Communications . . .9001-50-6 SSM Lost Communications Diagnostic Procedure . . . . . . . . . . . . . . . . . . . . . . . . .9001-50-6 523523.10 — Rear Wiper Keypad Stuck . . . .9001-50-8 Rear Wiper Keypad Stuck Diagnostic Procedure . . . . . . . . . . . . . . . . . . . . . . . . .9001-50-8 523524.10 — Front Wiper Keypad Stuck . . .9001-50-9 Front Wiper Keypad Stuck Diagnostic Procedure . . . . . . . . . . . . . . . . . . . . . . . . .9001-50-9 523525.10 — Front Washer Keypad Stuck . . . . . . . . . . . . . . . . . . . . . . . . . . . .9001-50-10 Front Washer Keypad Stuck Diagnostic Procedure . . . . . . . . . . . . . . . . . . . . . . . .9001-50-10 TM10229 (17MAR09)

9001-8

Continued on next page

544J Loader (S.N. 611800— ) 032409

PN=8

Contents

Page

523609.10 — RTCarry Keypad Stuck . . . . .9001-50-28 Return-to-Carry Keypad Stuck Diagnostic Procedure . . . . . . . . . . . . . . . . . . . . . . . .9001-50-28 523610.10 — Rear Washer Keypad Stuck . . . . . . . . . . . . . . . . . . . . . . . . . . . .9001-50-29 Rear Washer Keypad Stuck Diagnostic Procedure . . . . . . . . . . . . . . . . . . . . . . . .9001-50-29

TM10229 (17MAR09)

9001-9

9001

544J Loader (S.N. 611800— ) 032409

PN=9

Contents

9001

TM10229 (17MAR09)

9001-10

544J Loader (S.N. 611800— ) 032409

PN=10

Group 10

CAN Monitor Unit (CMU) Diagnostic Trouble Codes CAN Monitor Unit (CMU) Diagnostic Trouble Codes The diagnostic trouble code number is indicated by a Suspect Parameter Number (SPN) and a Failure Mode Indicator (FMI) number. In the example 000829.05, 829 is the SPN and 05 is the FMI number.

9001 10 1

To view diagnostic trouble codes, use one of the following methods: • Service ADVISOR system. See Reading Diagnostic Trouble Codes with Service ADVISOR Diagnostic Application. (Group 9015-20.) • CAN Monitor Unit (CMU). See CAN Monitor Unit (CMU) Menu Structure—Service Mode. (Group 9015-20.) Note: For in-depth diagnostics on all CMU diagnostic trouble codes, see specific code diagnostic procedure. (Group 9001-10.)

Service ADVISOR is a trademark of Deere & Company

AA95137,00008F4 –19–09APR07–1/1

000829.05 — Fuel Level Open or Short

Fuel level sensor circuit is open or short to power.

AA95137,00008F5 –19–06JUN07–1/1

Fuel Level Sensor Open or Short Diagnostic Procedure Alarm Level: No Warning Lamp

– – –1/1

TM10229 (17MAR09)

9001-10-1

544J Loader (S.N. 611800— ) 032409

PN=27

CAN Monitor Unit (CMU) Diagnostic Trouble Codes 1 Component Check

Turn key switch OFF.

YES: Go to Open Circuit Check.

Disconnect fuel level sensor (B17). See Engine Harness (W6) Component Location. (Group 9015-10.) Measure resistance across sensor pins.

9001 10 2

NO: Fuel level sensor (B17) malfunction. Replace sensor.

Specification Fuel Level Sensor (B17)—Resistance ......................... 168—192 ohms at 100% fill (full) 91—109 ohms at 50% fill 4—16 ohms at 0% fill (empty) Is resistance within specifications? – – –1/1

2 Open Circuit Check

Turn key switch OFF.

YES: Go to Short Circuit Check.

Disconnect fuel level sensor (B17) and CAN monitor unit (CMU) connector (X48). See Engine Harness (W6) Component Location and see Front Console Harness (W4) Component Location. (Group 9015-10.)

NO: Go to next step in this check.

Check circuit Y02 YEL for continuity between pin B on fuel level sensor (B17) connector and pin N on CMU connector (X48). Check circuit R02 BLK for continuity between pin A on fuel level sensor (B17) connector and pin F on CMU connector (X48). Is continuity indicated?

Key switch OFF and fuel level sensor (B17) disconnected.

YES: Go to next step in this check.

Disconnect connector (X4). See Engine Harness (W6) Component Location. (Group 9015-10.) Check circuit Y02 YEL for continuity between pin B on fuel level sensor (B17) connector and pin 32 on engine harness side of connector (X4). Check circuit R02 BLK for continuity between pin A on fuel level sensor (B17) connector and pin 21 on engine harness side of connector (X4).

NO: Open circuit in engine harness (W6). Repair circuit without continuity or replace engine harness. See Engine Harness (W6) Wiring Diagram. (Group 9015-10.)

Is continuity indicated?

Key switch OFF. Disconnect connector (X30) and CMU connector (X48). See Front Console Harness (W4) Component Location. (Group 9015-10.) Check circuit Y02 YEL for continuity between pin N on CMU connector (X48) and pin 31 on front console harness side of connector (X30). See Load Center Harness (W3) Wiring Diagram and see Front Console Harness (W4) Wiring Diagram. (Group 9015-10.) Check circuit R02 BLK for continuity between pin F on CMU connector (X48) and pin 7 on front console harness side of connector (X30).

YES: Open circuit in load center harness (W3). Repair circuit without continuity or replace load center harness. NO: Open circuit in front console harness (W4). Repair circuit without continuity or replace front console harness.

Is continuity indicated?

– – –1/1

TM10229 (17MAR09)

9001-10-2

544J Loader (S.N. 611800— ) 032409

PN=28

CAN Monitor Unit (CMU) Diagnostic Trouble Codes 3 Short Circuit Check

Turn key switch OFF.

YES: Go to next step in this check.

Disconnect fuel level sensor (B17). See Engine Harness (W6) Component Location. (Group 9015-10.)

NO: Go to Reprogram Controller.

Turn key switch ON.

9001 10 3

Check circuit Y02 YEL for voltage between pin B on fuel level sensor (B17) connector and machine ground. Is system voltage present (approximately 24 volts)?

Turn key switch OFF.

YES: Circuit Y02 YEL is short to power in front console harness (W4). Repair circuit Y02 YEL or replace harness.

Disconnect connector (X30). See Front Console Harness (W4) Component Location. (Group 9015-10.) Turn key switch ON.

NO: Go to next step in this check.

Check circuit Y02 YEL for voltage between pin 31 on front console harness side of connector (X30) and machine ground. See Front Console Harness (W4) Wiring Diagram. (Group 9015-10.) Is system voltage present (approximately 24 volts)?

Turn key switch OFF.

YES: Circuit Y02 YEL is short to power in load center harness (W3). Repair circuit Y02 YEL or replace harness.

Disconnect connector (X4). See Load Center Harness (W3) Component Location. (Group 9015-10.) Turn key switch ON. Check circuit Y02 YEL for voltage between pin 32 on load center harness side of connector (X4) and machine ground. See Load Center Harness (W3) Wiring Diagram. (Group 9015-10.)

NO: Circuit Y02 YEL is short to power in engine harness (W6). Repair circuit Y02 YEL or replace harness.

Is system voltage present (approximately 24 volts)?

– – –1/1

4 Reprogram Controller

Reprogram CAN monitor unit (CMU).

YES: Replace controller.

Check for active codes.

NO: Checks complete.

Is CMU code 000829.05 present? – – –1/1

002000.09 — CAN Comm Lost For ECU

The CAN monitor unit (CMU) is not receiving a CAN signal from the engine control unit (ECU).

AA95137,00008F6 –19–24MAY07–1/1

TM10229 (17MAR09)

9001-10-3

544J Loader (S.N. 611800— ) 032409

PN=29

CAN Monitor Unit (CMU) Diagnostic Trouble Codes CAN Comm Lost For ECU Diagnostic Procedure Alarm Level: 9001 10 4

No Warning Lamp

– – –1/1

1 Controller Sensors Check

Turn key switch ON.

YES: Go to Reprogram CAN Monitor Unit.

View engine control unit (ECU) monitored sensor outputs by accessing the Diagnostics / Engine Sensors / Display All menu on the CAN monitor unit (CMU). See CAN Monitor Unit (CMU) Menu Structure—Service Mode. (Group 9015-20.)

NO: Go to Fuse Check.

Does the monitor show a reading for all sensors?

– – –1/1

2 Fuse Check

Turn key switch OFF.

YES: Go to Circuit Check.

Remove fuses (F3 and F10). See Fuse and Relay Specifications. (Group 9015-10.) Check continuity of fuses (F3 and F10). Is continuity indicated?

NO: Replace fuse(s) without continuity. See Fuse and Relay Specifications. (Group 9015-10.)

– – –1/1

TM10229 (17MAR09)

9001-10-4

544J Loader (S.N. 611800— ) 032409

PN=30

CAN Monitor Unit (CMU) Diagnostic Trouble Codes 3 Circuit Check

Turn key switch OFF.

YES: Go to next step in this check.

Disconnect ECU connector (X24). See Load Center Harness (W3) Component Location. (Group 9015-10.) Turn key switch ON. Check circuit P10 RED for voltage between pin E3 on ECU connector (X24) and machine ground. See Load Center Harness (W3) Wiring Diagram. (Group 9015-10.)

NO: Open circuit in load center harness (W3). Repair circuit without voltage or replace harness.

Check circuit P03 RED for voltage between pin B1 on ECU connector (X24) and machine ground. Check circuit P03 RED for voltage between pin B2 on ECU connector (X24) and machine ground. Is system voltage (approximately 24 volts) present?

Turn key switch OFF.

YES: Go to CAN Circuit Check.

ECU connector (X24) disconnected. Check circuit G11 BLK for ground at pins C2 and C3 on ECU connector (X24). See Load Center Harness (W3) Wiring Diagram. (Group 9015-10.) Is ground present?

NO: Circuit G11 BLK open circuit in load center harness (W3). Repair circuit G11 BLK or replace harness.

– – –1/1

4 CAN Circuit Check

Perform CAN Circuit Test. (Group 9015-20.)

YES: Go to Reprogram Engine Control Unit.

Does CAN circuit test good? NO: Repair CAN circuit.

– – –1/1

5 Reprogram Engine Control Unit

Reprogram engine control unit (ECU).

YES: Replace ECU.

Check for active codes.

NO: Checks complete.

Is CMU code 002000.09 present? – – –1/1

6 Reprogram CAN Monitor Unit

Reprogram CAN monitor unit (CMU).

YES: Replace CMU.

Check for active codes.

NO: Checks complete.

Is CMU code 002000.09 present? – – –1/1

TM10229 (17MAR09)

9001-10-5

544J Loader (S.N. 611800— ) 032409

PN=31

9001 10 5

CAN Monitor Unit (CMU) Diagnostic Trouble Codes

002003.09 — CAN Comm Lost For TCU

9001 10 6

The CAN monitor unit (CMU) is not receiving a CAN signal from transmission control unit (TCU).

AA95137,00008F7 –19–06JUN07–1/1

CAN Comm Lost For TCU Diagnostic Procedure Alarm Level: No Warning Lamp

– – –1/1

1 Controller Sensors Check

Turn key switch ON.

YES: Go to Reprogram CAN Monitor Unit.

View transmission control unit (TCU) monitored sensor outputs by accessing the Diagnostics / Transmission / Display All menu on the CAN monitor unit (CMU). See CAN Monitor Unit (CMU) Menu Structure—Service Mode. (Group 9015-20.)

NO: Go to Fuse Check.

Does the monitor show reading for all sensors?

– – –1/1

2 Fuse Check

Turn key switch OFF.

YES: Go to Circuit Check.

Remove fuses (F18 and F28). See Fuse and Relay Specifications. (Group 9015-10.) Check continuity of fuses (F18 and F28).

NO: Replace fuse(s) without continuity.

Is continuity indicated?

– – –1/1

TM10229 (17MAR09)

9001-10-6

544J Loader (S.N. 611800— ) 032409

PN=32

CAN Monitor Unit (CMU) Diagnostic Trouble Codes 3 Circuit Check

Turn key switch OFF.

YES: Go to next step in this check.

Disconnect TCU connector (X23). See Load Center Harness (W3) Component Location. (Group 9015-10.) Turn keys switch ON. Check circuit P18 RED for voltage between pin 23 on TCU connector (X23) and machine ground. See Load Center Harness (W3) Wiring Diagram. (Group 9015-10.)

NO: Open circuit in load center harness (W3). Repair circuit without voltage or replace harness.

Check circuit P28 RED for voltage between pin 45 on TCU connector (X23) and machine ground. Check circuit P28 RED for voltage between pin 68 on TCU connector (X23) and machine ground. Is system voltage (approximately 24 volts) present?

Turn key switch OFF.

YES: Go to CAN Circuit Check.

TCU connector (X23) disconnected. Check circuit G01 BLK for ground at pins 1 and 2 on TCU connector (X23). See Load Center Harness (W3) Wiring Diagram. (Group 9015-10.) Is ground present?

NO: Circuit G01 BLK open circuit in load center harness (W3). Repair circuit G01 BLK or replace harness.

– – –1/1

4 CAN Circuit Check

Perform CAN Circuit Test. (Group 9015-20.) Does CAN circuit test good?

YES: Go to Reprogram Transmission Control Unit. NO: Repair CAN circuit. – – –1/1

5 Reprogram Transmission Control Unit

Reprogram transmission control unit (TCU).

YES: Replace TCU.

Check active codes.

NO: Checks complete.

Is CMU code 002003.09 present? – – –1/1

6 Reprogram CAN Monitor Unit

Reprogram CAN monitor unit (CMU).

YES: Replace CMU.

Check active codes.

NO: Checks complete.

Is CMU code 002003.09 present? – – –1/1

TM10229 (17MAR09)

9001-10-7

544J Loader (S.N. 611800— ) 032409

PN=33

9001 10 7

CAN Monitor Unit (CMU) Diagnostic Trouble Codes

002033.09 — CAN Comm Lost For FLC

9001 10 8

The CAN monitor unit (CMU) is not receiving a CAN signal from flex load controller (FLC).

AA95137,00008F8 –19–05JUN07–1/1

CAN Comm Lost For FLC Diagnostic Procedure Alarm Level: No Warning Lamp

– – –1/1

1 Controller Sensors Check

Turn key switch ON.

YES: Go to Reprogram CAN Monitor Unit.

View flex load controller (FLC) monitored sensor outputs by accessing the Diagnostics / Hydraulic / Display All menu on the CAN monitor unit (CMU). See CAN Monitor Unit (CMU) Menu Structure—Service Mode. (Group 9015-20.)

NO: Go to Fuse Check.

Does the monitor show a reading for all sensors?

– – –1/1

2 Fuse Check

Turn key switch OFF.

YES: Go to Circuit Check.

Remove fuses (F15 and F21). See Fuse and Relay Specifications. (Group 9015-10.) Check continuity of fuses (F15 and F21).

NO: Replace fuse(s) without continuity.

Is continuity indicated?

– – –1/1

TM10229 (17MAR09)

9001-10-8

544J Loader (S.N. 611800— ) 032409

PN=34

CAN Monitor Unit (CMU) Diagnostic Trouble Codes 3 Circuit Check

Turn key switch OFF.

YES: Go to next step in this check.

Disconnect FLC connector (X41). See Load Center Harness (W3) Component Location. (Group 9015-10.)

NO: Open circuit in load center harness. Repair circuit without voltage or replace harness.

Turn key switch ON. Check circuit P21 RED for voltage between pin L1 on FLC connector (X41) and machine ground. See Load Center Harness (W3) Wiring Diagram. (Group 9015-10.) Check circuit P15 RED for voltage between pin M1 on FLC connector (X41) and machine ground. Is system voltage (approximately 24 volts) present?

Turn key switch OFF.

YES: Go to CAN Circuit Check.

FLC connector (X41) disconnected. Check for ground at pins M2 and L2 (circuit G01 BLK) on FLC connector (X41). See Load Center Harness (W3) Wiring Diagram. (Group 9015-10.) Is ground present?

NO: Circuit G01 BLK open circuit in load center harness (W3). Repair circuit G01 BLK or replace harness.

– – –1/1

4 CAN Circuit Check

Perform CAN Circuit Test. (Group 9015-20.)

YES: Go to Reprogram Flex Load Controller.

Does CAN circuit test good? NO: Repair CAN circuit.

– – –1/1

5 Reprogram Flex Load Controller

Reprogram flex load controller (FLC).

YES: Replace FLC.

Check for active codes.

NO: Checks complete.

Is CMU code 002033.09 present? – – –1/1

6 Reprogram CAN Monitor Unit

Reprogram CAN monitor unit (CMU).

YES: Replace CMU.

Check for active codes.

NO: Checks complete.

Is CMU code 002033.09 present? – – –1/1

TM10229 (17MAR09)

9001-10-9

544J Loader (S.N. 611800— ) 032409

PN=35

9001 10 9

CAN Monitor Unit (CMU) Diagnostic Trouble Codes

002140.09 — CAN Comm Lost For SSM

9001 10 10

The CAN monitor unit (CMU) is not receiving a CAN signal from the sealed switch module (SSM).

AA95137,00008FA –19–24MAY07–1/1

CAN Comm Lost For SSM Diagnostic Procedure Alarm Level: No Warning Lamp

– – –1/1

1 Button Check

Turn key switch ON. Access the sealed switch module (SSM) test by accessing the Diagnostics / Switch Module menu on the CAN monitor unit (CMU). See CAN Monitor Unit (CMU) Menu Structure—Service Mode. (Group 9015-20.)

YES: CMU is communicating with the SSM. Go to Reprogram CAN Monitor Unit. NO: Go to Fuse Check.

Push the buttons on the SSM. Do the corresponding squares on the CMU window come on when the buttons are pushed?

– – –1/1

2 Fuse Check

Turn key switch OFF.

YES: Go to Circuit Check.

Remove fuse (F13). See Fuse and Relay Specifications. (Group 9015-10.) NO: Replace fuse (F13). Check continuity of fuse (F13). Is continuity indicated?

– – –1/1

TM10229 (17MAR09)

9001-10-10

544J Loader (S.N. 611800— ) 032409

PN=36

CAN Monitor Unit (CMU) Diagnostic Trouble Codes 3 Circuit Check

Turn key switch OFF.

YES: Go to next step in this check.

Disconnect SSM connector (X53). See Load Center Harness (W3) Component Location. (Group 9015-10.)

NO: Circuit P13 open circuit on load center harness (W3). Repair circuit P13 RED or replace harness.

Turn key switch ON. Check circuit P13 RED for voltage between pin 1 on SSM connector (X53) and machine ground. See Load Center Harness (W3) Wiring Diagram. (Group 9015-10.)

9001 10 11

Is system voltage (approximately 24 volts) present?

Turn key switch OFF.

YES: Go to CAN Circuit Check.

SSM connector (X53) disconnected. Check circuit G01 BLK for ground at pin 2 on SSM connector (X53). See Load Center Harness (W3) Wiring Diagram. (Group 9015-10.) Is ground present?

NO: Circuit G01 BLK open circuit in load center harness (W3). Repair circuit G01 BLK or replace harness.

– – –1/1

4 CAN Circuit Check

Perform CAN Circuit Test. (Group 9015-20.)

YES: Go to Reprogram Sealed Switch Module.

Does CAN circuit test good? NO: Repair CAN circuit.

– – –1/1

5 Reprogram Sealed Switch Module

Reprogram sealed switch module (SSM).

YES: Replace controller.

Check for active codes.

NO: Checks complete.

IS CMU code 002140.09 present? – – –1/1

6 Reprogram CAN Monitor Unit

Reprogram CAN monitor unit (CMU).

YES: Replace controller.

Check for active codes.

NO: Checks complete.

Is CMU code 002140.09 present? – – –1/1

002367.04 — Left Turn Switch Short to Ground

Left turn input signal is short to ground.

AA95137,00008FB –19–09APR07–1/1

TM10229 (17MAR09)

9001-10-11

544J Loader (S.N. 611800— ) 032409

PN=37

CAN Monitor Unit (CMU) Diagnostic Trouble Codes Left Turn Switch Short to Ground Diagnostic Procedure Alarm Level: 9001 10 12

No Warning Lamp

– – –1/1

1 Component Check

Turn key switch OFF.

YES: Go to Short Circuit Check.

Disconnect turn switch (S25) connector. See Front Console Harness (W4) Component Location. (Group 9015-10.) Put turn switch (S25) in the LEFT turn position.

NO: Turn switch (S25) malfunction. Replace switch.

Check for continuity between pins E and F on switch. Is continuity indicated?

– – –1/1

2 Short Circuit Check

Turn key switch OFF.

YES: Go to next step in this check.

Disconnect turn switch (S25) connector. See Front Console Harness (W4) Component Location. (Group 9015-10.)

NO: Go to Reprogram Controller.

Check circuit L07 BRN for ground at pin E on turn switch (S25) connector. See Front Console Harness (W4) Wiring Diagram. (Group 9015-10.) Is ground present?

Key switch OFF and turn switch (S25) disconnected. Disconnect CMU connector (X48). See Front Console Harness (W4) Component Location. (Group 9015-10.) Check circuit L07 BRN for ground at pin E on turn switch (S25) connector. See Front Console Harness (W4) Wiring Diagram. (Group 9015-10.)

YES: Circuit L07 BRN short to ground on front console harness (W4). Repair circuit L07 BRN or replace harness. NO: Go to Continuity Check.

Is ground present?

– – –1/1

TM10229 (17MAR09)

9001-10-12

544J Loader (S.N. 611800— ) 032409

PN=38

CAN Monitor Unit (CMU) Diagnostic Trouble Codes 3 Continuity Check

Turn manual battery disconnect (S2) OFF. Disconnect turn switch (S25) and CMU connector (X48). See Front Console Harness (W4) Component Location. (Group 9015-10.) Check continuity between pin R (circuit L07 BRN) on CMU connector (X48) and all other pins on CMU connector (X48). See Front Console Harness (W4) Wiring Diagram. (Group 9015-10.)

YES: Circuit L07 BRN is short to circuit with continuity indicated on front frame harness (W4). Repair circuit L07 BRN or replace harness. NO: Go to Reprogram Controller.

Is continuity indicated?

– – –1/1

4 Reprogram Controller

Reprogram CAN monitor unit (CMU).

YES: Replace controller.

Check for active codes.

NO: Checks complete.

Is CMU code 002367.04 present? – – –1/1

002369.04 — Right Turn Switch Short to Ground

The right turn input signal is short to ground.

AA95137,00008FC –19–09APR07–1/1

Right Turn Switch Short to Ground Diagnostic Procedure Alarm Level: No Warning Lamp

– – –1/1

TM10229 (17MAR09)

9001-10-13

544J Loader (S.N. 611800— ) 032409

PN=39

9001 10 13

CAN Monitor Unit (CMU) Diagnostic Trouble Codes 1 Component Check

Turn key switch OFF.

YES: Go to Short Circuit Check.

Disconnect turn switch (S25) connector. See Front Console Harness (W4) Component Location. (Group 9015-10.) Put turn switch (S25) in the RIGHT turn position.

9001 10 14

NO: Turn switch (S25) malfunction. Replace switch.

Check for continuity between pins D and F on switch. Is continuity indicated?

– – –1/1

2 Short Circuit Check

Turn key switch OFF.

YES: Go to next step in this check.

Disconnect turn switch (S25) connector. See Front Console Harness (W4) Component Location. (Group 9015-10.)

NO: Go to Reprogram Controller.

Check circuit L10 BRN for ground at pin D on turn switch (S25) connector. Is ground present?

Key switch OFF and turn switch (S25) disconnected. Disconnect CMU connector (X48). See Front Console Harness (W4) Component Location. (Group 9015-10.) Check circuit L10 BRN for ground at pin D on turn switch (S25) connector. See Front Console Harness (W4) Wiring Diagram. (Group 9015-10.)

YES: Circuit L10 BRN is short to ground on front frame harness (W4). Repair circuit L10 BRN or replace harness. NO: Go to Continuity Check.

Is ground present?

– – –1/1

3 Continuity Check

Turn manual battery disconnect (S2) OFF. Turn switch (S25) disconnected and CMU connector (X48) disconnected. Check continuity between pin S (circuit L10 BRN) on CMU connector (X48) and all other pins on CMU connector (X48). Is continuity indicated?

YES: Circuit L10 BRN is short to circuit with continuity indicated on front frame harness (W4). Repair circuit L10 BRN or replace harness. See Front Console Harness (W4) Wiring Diagram. (Group 9015-10.) NO: Go to Reprogram Controller.

– – –1/1

4 Reprogram Controller

Reprogram CAN monitor unit (CMU).

YES: Replace controller.

Check for active codes.

NO: Checks complete.

Is CMU code 002369.04 present? – – –1/1

TM10229 (17MAR09)

9001-10-14

544J Loader (S.N. 611800— ) 032409

PN=40

CAN Monitor Unit (CMU) Diagnostic Trouble Codes

524250.31 — Inspect Park Brake

The CAN monitor unit (CMU) indicates that the park brake has been applied and the machine speed was 15.5 miles an hour or more.

9001 10 15

CAUTION: The park brake should be checked before operation of vehicle due to possible park brake damage. CMU code 524250.31 will stay active and park brake indicator light will flash (regardless of park brake position) until code is cleared. For more information on the park brake operation, see Transmission Control Unit (TCU) Circuit Theory of Operation. (Group 9015-15.)

AA95137,0000938 –19–19APR07–1/1

Inspect Park Brake Diagnostic Procedure

– – –1/1

1 Component Check

Check operation of park brake. Perform Park Brake Check. See Operational Checkout. (Group 9005-10.)

YES: Checks complete. NO: See Diagnose Park Brake Malfunctions.

Does park brake test good?

– – –1/1

TM10229 (17MAR09)

9001-10-15

544J Loader (S.N. 611800— ) 032409

PN=41

CAN Monitor Unit (CMU) Diagnostic Trouble Codes

9001 10 16

TM10229 (17MAR09)

9001-10-16

544J Loader (S.N. 611800— ) 032409

PN=42

Group 20

Engine Control Unit (ECU) Diagnostic Trouble Codes Engine Control Unit (ECU) Diagnostic Trouble Codes The diagnostic trouble code number is indicated by a (SPN) Suspect Parameter Number and a (FMI) Failure Mode Indicator number. In the example 0000107.00, 107 is the SPN and 00 is the FMI number.

• See CAN Monitor Unit (CMU) Menu Structure— Service Mode. (Group 9015-20.) • See Reading Diagnostic Trouble Codes with Service ADVISOR Diagnostic Application. (Group 9015-20.)

Diagnostic trouble codes can be displayed using the CAN monitor unit (CMU) or by using Service ADVISOR.

Service ADVISOR is a trademark of Deere & Company

M44215

For in-depth diagnostics on machine specific ECU diagnostic trouble codes, see specific code diagnostic procedures in this group. Additional engine control unit DTC diagnostic procedures for John Deere PowerTech E engines are located in the component technical manual, PowerTech E 4.5 L & 6.8 L Diesel Engines with Level 16 Electronic Fuel Systems with High Pressure Common Rail (HPCR) Fuel System (Two-Valve Cylinder Head). (CTM502.)

–UN–07SEP88

AA95137,0000A2B –19–19SEP07–1/2

PowerTech E is a trademark of Deere & Company

TM10229 (17MAR09)

AA95137,0000A2B –19–19SEP07–2/2

9001-20-1

544J Loader (S.N. 611800— ) 032409

PN=43

9001 20 1

Engine Control Unit (ECU) Diagnostic Trouble Codes

000107.00 — Eng Air Filter Restricted

9001 20 2

Engine air filter is restricted.

AA95137,0000A2C –19–24MAY07–1/1

Engine Air Filter Restricted Diagnostic Procedure Alarm Level: Engine Air Filter Icon

– – –1/1

1 Component Check

Disconnect engine air filter restriction switch (B19) and remove from air filter housing. See Engine Harness (W6) Component Location. (Group 9015-10.)

YES: Replace air filter restriction switch.

Check for continuity across pins A and B.

NO: Go to Short Circuit Check.

Is continuity indicated? – – –1/1

2 Short Circuit Check

Disconnect air filter restriction switch (B19) and load center harness-to-engine harness connector (X4). See Engine Harness (W6) Component Location. (Group 9015-10.) Check circuit M06 PUR for ground at pin A on air filter restriction switch connector. See Engine Harness (W6) Wiring Diagram. (Group 9015-10.)

YES: Short to ground on engine harness (W6). Repair or replace harness. NO: Go to next step in this check.

Is ground present?

Load center harness-to-engine harness connector (X4) disconnected. Disconnect engine control unit connector (ECU) (X72). See Load Center Harness (W3) Component Location. (Group 9015-10.)

YES: Short to ground on load center harness (W3). Repair or replace harness.

Check circuit M06 PUR for ground at pin F2 on ECU connector (X72). See Load Center Harness (W3) Wiring Diagram. (Group 9015-10.)

NO: Go to Replace Air Filter.

Is ground present?

– – –1/1

TM10229 (17MAR09)

9001-20-2

544J Loader (S.N. 611800— ) 032409

PN=44

Engine Control Unit (ECU) Diagnostic Trouble Codes 3 Replace Air Filter

Replace engine air filter.

YES: Go to Reprogram Controller.

Is ECU code 000107.00 present after repair? NO: Checks complete.

– – –1/1

4 Reprogram Controller

Reprogram Engine Control Unit (ECU).

YES: Replace controller.

Check for active codes.

NO: Checks complete.

Is ECU code 000107.00 present? – – –1/1

000171.03 — Ambient Air Open Circuit

Ambient air temperature sensor circuit is open.

WS68074,0000B48 –19–15JUL08–1/1

Ambient Air Open Circuit Diagnostic Procedure Alarm Level: No Warning Lamp

– – –1/1

TM10229 (17MAR09)

9001-20-3

544J Loader (S.N. 611800— ) 032409

PN=45

9001 20 3

Engine Control Unit (ECU) Diagnostic Trouble Codes 1 Component Check

Turn key switch OFF.

YES: Go to Open Circuit Check.

Disconnect ambient air temperature sensor (B10). See Engine Harness (W6) Component Location. (Group 9015-10.)

NO: Replace ambient air temperature sensor.

Check resistance of sensor across pins A and B.

9001 20 4

Specification Ambient Air Temperature Sensor (B10)—Resistance ........................................................ 90—108 kohms at -40°C (-40°F) 26—31 kohms at -20°C (-4°F) 8.7—10.2 kohms at 0°C (32°F) 3.3—3.8 kohms at 20°C (68°F) 1.4—1.6 kohms at 40°C (104°F) 648—708 ohms at 60°C (140°F) 317—350 ohms at 80°C (176°F) 170—186 ohms at 100°C (212°F) 97—105 ohms at 120°C (248°F) Is sensor within specifications?

– – –1/1

2 Open Circuit Check

Turn key switch OFF.

YES: Go to Reprogram Controller.

Disconnect ambient air temperature sensor (B10) and flex load controller FLC connector (X72). See Engine Harness (W6) Component Location and See Load Center Harness (W3) Component Location. (Group 9015-10.)

NO: Go to next step in this check.

Check continuity of circuit X07 YEL between pin B4 on connector (X72) and pin A on sensor connector. See Engine Harness (W6) Wiring Diagram and See Load Center Harness (W3) Wiring Diagram. (Group 9015-10.) Check continuity of circuit R73 BLK between pin D2 on connector (X71) and pin B on sensor connector. Is continuity indicated?

Key switch OFF.

YES: Open circuit in load center harness (W3). Repair circuit(s) without continuity indicated or replace harness.

Ambient air temperature sensor (B10) disconnected. Disconnect load center harness-to-engine harness connector (X4). See Engine Harness (W6) Component Location. (Group 9015-10.) Check continuity of circuit X07 YEL between pin 36 on engine harness side of connector (X4) and pin A on sensor connector. See Engine Harness (W6) Wiring Diagram. (Group 9015-10.)

NO: Open circuit in engine harness (W6). Repair circuit(s) without continuity indicated or replace harness.

Check continuity of circuit R73 BLK between pin 13 on engine harness side of connector (X4) and pin B on sensor connector. Is continuity indicated? – – –1/1

3 Reprogram Controller

Reprogram Engine Control Unit (ECU).

YES: Replace controller.

Check for active codes.

NO: Checks complete.

Is ECU code 000171.03 present? – – –1/1

TM10229 (17MAR09)

9001-20-4

544J Loader (S.N. 611800— ) 032409

PN=46

Engine Control Unit (ECU) Diagnostic Trouble Codes

000171.04 — Ambient Air Short to Gnd

Ambient air temperature circuit is short to ground.

9001 20 5

AA95137,0000A2E –19–18SEP07–1/1

Ambient Air Short to Ground Diagnostic Procedure Alarm Level: No Warning Lamp

– – –1/1

1 Component Check

Turn key switch OFF.

YES: Go to Short Circuit Check.

Disconnect ambient air temperature sensor (B10). See Engine Harness (W6) Component Location. (Group 9015-10.)

NO: Replace ambient air temperature sensor.

Check resistance of sensor across pins A and B. Specification Ambient Air Temperature Sensor (B10)—Resistance ........................................................ 90—108 kohms at -40°C (-40°F) 26—31 kohms at -20°C (-4°F) 8.7—10.2 kohms at 0°C (32°F) 3.3—3.8 kohms at 20°C (68°F) 1.4—1.6 kohms at 40°C (104°F) 648—708 ohms at 60°C (140°F) 317—350 ohms at 80°C (176°F) 170—186 ohms at 100°C (212°F) 97—105 ohms at 120°C (248°F) Is sensor within specifications?

– – –1/1

TM10229 (17MAR09)

9001-20-5

544J Loader (S.N. 611800— ) 032409

PN=47

Engine Control Unit (ECU) Diagnostic Trouble Codes 2 Short Circuit Check

Turn key switch OFF.

YES: Go to next step in this check.

Disconnect ambient air temperature sensor (B10). See Engine Harness (W6) Component Location. (Group 9015-10.)

NO: Go to Continuity Check.

Check circuit X07 YEL for ground at pin A. See Engine Harness (W6) Wiring Diagram. (Group 9015-10.)

9001 20 6

Is ground present?

Key switch OFF.

YES: Short to ground on engine harness (W6). Repair or replace harness.

Ambient air temperature sensor (B10) disconnected. Disconnect load center harness-to-engine harness connector (X4). See Engine Harness (W6) Component Location. (Group 9015-10.)

NO: Go to next step in this check.

Check circuit X07 YEL for ground at pin 36 on engine harness side of connector (X4). See Engine Harness (W6) Wiring Diagram. (Group 9015-10.) Is ground present?

Key switch OFF.

YES: Go to Continuity Check.

Disconnect load center harness-to-engine harness connector (X4) and ECU connector (X72). See Load Center Harness (W3) Component Location. (Group 9015-10.) Check circuit X07 YEL for ground at pin 36 on ECU harness side of connector (X4). See Load Center Harness (W3) Wiring Diagram. (Group 9015-10.)

NO: Open circuit load center harness (W3). Repair or replace harness.

Is ground present?

– – –1/1

3 Continuity Check

Disconnect Ambient air temperature sensor (B10) and load center harness-to-engine harness connector (X4). See Engine Harness (W6) Component Location. (Group 9015-10.) Check continuity of circuit X07 YEL between pin 36 on engine harness side of connector (X4) and remaining pins on connector (X4). See Engine Harness (W6) Wiring Diagram. (Group 9015-10.)

YES: Go to next step in this check. NO: Short to ground on engine harness (W6). Repair or replace harness.

Is continuity indicated?

Load center harness-to-engine harness connector (X4) disconnected.

YES: Go to Reprogram Controller.

Disconnect FLC connector (X72). See Load Center Harness (W3) Component Location. (Group 9015-10.) Check continuity of circuit X07 YEL between pin 36 on ECU side of connector (X4) and remaining pins on ECU side of connector (X4). See Load Center Harness (W3) Wiring Diagram. (Group 9015-10.)

NO: Short to ground on load center harness (W3). Repair or replace harness.

Is continuity indicated?

– – –1/1

TM10229 (17MAR09)

9001-20-6

544J Loader (S.N. 611800— ) 032409

PN=48

Engine Control Unit (ECU) Diagnostic Trouble Codes 4 Reprogram Controller

Reprogram Engine Control Unit (ECU).

YES: Replace controller.

Check for active codes.

NO: Checks complete.

Is ECU code 000171.04 present? – – –1/1

000627.01 — ECU Unswitch Short to GND

Engine control unit (ECU) unswitched power circuit is short to ground.

AA95137,0000A2F –19–24MAY07–1/1

Engine Control Unit (ECU) Unswitched Short to Ground Diagnostic Procedure Alarm Level: No Warning Lamp

– – –1/1

1 Fuse Check

Turn key switch OFF.

YES: Go to Circuit Check.

Remove 10 amp fuse (F03) and check for continuity. See Fuse and Relay Specifications. (Group 9015-10.)

NO: Replace fuse.

Is continuity indicated? – – –1/1

2 Circuit Check

Turn key switch OFF. Disconnect engine control unit (ECU) connector X72. See Engine Harness (W6) Component Location. (Group 9015-10.) Check circuit P03 RED for ground at the pins L1, L4, M1, and M4. See Engine Harness (W6) Wiring Diagram. (Group 9015-10.)

YES: Short to ground on load center harness (W3). Repair circuit(s) that has ground present or replace harness. NO: Go to Pin-to-Pin Check.

Is ground present?

– – –1/1

TM10229 (17MAR09)

9001-20-7

544J Loader (S.N. 611800— ) 032409

PN=49

9001 20 7

Engine Control Unit (ECU) Diagnostic Trouble Codes 3 Pin-to-Pin Check

Turn key switch OFF. Disconnect engine control unit (ECU) connector (X72 and X71). See Engine Harness (W6) Component Location. (Group 9015-10.) Check circuit P03 RED for continuity at the pins L1, L4, M1, and M4 and remaining pins on connector (X72) and all pins on connector (X71).

9001 20 8

YES: Short to ground on load center harness (W3). Repair circuit(s) that has continuity indicated or replace harness. NO: Go to Reprogram Controller.

Disconnect. See Engine Harness (W6) Wiring Diagram. (Group 9015-10.) Is continuity indicated?

– – –1/1

4 Reprogram Controller

Reprogram engine control unit (ECU).

YES: Replace controller.

Check for active codes.

NO: Checks complete.

Is ECU code 000627.01 present? – – –1/1

001253.13 — Injector Cal Required

Injector calibration is required.

AA95137,0000A30 –19–24MAY07–1/1

Injector Calibration Required Diagnostic Procedure Alarm Level: No Warning Lamp

– – –1/1

1 Injector Calibration

Perform Electronic Injector Calibration. (CTM502.)

YES: Go to Reprogram Controller.

Is ECU code 001253.13 present? NO: Checks Complete.

– – –1/1

TM10229 (17MAR09)

9001-20-8

544J Loader (S.N. 611800— ) 032409

PN=50

Engine Control Unit (ECU) Diagnostic Trouble Codes 2 Reprogram Controller

Reprogram Engine Control Unit (ECU).

YES: Replace controller.

Check for active codes.

NO: Checks complete.

Is ECU code 001253.13 present? – – –1/1

002003.09 — CAN Comm Lost for TCU

The engine control unit (ECU) is missing the CAN message from the transmission control unit (TCU).

AA95137,0000A31 –19–24MAY07–1/1

CAN Communication Lost for TCU Diagnostic Procedure Alarm Level: No Warning Lamp

– – –1/1

1 Controller Sensors Check

Using the CAN monitor unit (H2), view the input readings from the transmission control unit. Enter the Main Menu / Diagnostics / Transmission Sensors / Display All. See CAN Monitor Unit (CMU) Menu Structure—Service Mode. (Group 9015-20.)

YES: Go to Reprogram Engine Control Unit NO: Go to Fuse Check.

Are transmission sensor values displayed in the CMU? – – –1/1

2 Fuse Check

Turn key switch OFF.

YES: Go to Circuit Check.

Check fuses (F18 or F28) for continuity. See Fuse and Relay Specifications. (Group 9015-10.)

NO: Replace fuse(s).

Is continuity indicated? – – –1/1

TM10229 (17MAR09)

9001-20-9

544J Loader (S.N. 611800— ) 032409

PN=51

9001 20 9

Engine Control Unit (ECU) Diagnostic Trouble Codes 3 Circuit Check

Turn key switch OFF.

YES: Go to next step in this check.

Disconnect TCU connector (X23). See Load Center Harness (W3) Component location. (Group 9015-10.)

NO: Open circuit on wire P28 or P18 on load center harness (W3). Repair or replace harness.

Turn key switch ON.

9001 20 10

Check for voltage at the following pins: • 45—wire P28 RED • 23—wire P18 RED • 68—wire P18 RED Is voltage present at all the pins?

Key switch OFF.

YES: Go to next step in this check.

TCU connector (X23) disconnected. See Load Center Harness (W3) Component location. (Group 9015-10.) Check for ground at the following pins:

NO: Open circuit on load center harness (W3). Repair or replace harness.

• L2—wire G11 BLK • L3—wire G11 BLK • M2—wire G11 BLK Is ground present at all the pins?

Perform CAN Circuit Test. (Group 9015-20.) Does the CAN circuit test good.

YES: Go to Reprogram Transmission Control Unit. NO: Repair wires or replace harness on CAN circuit.

– – –1/1

4 Reprogram Transmission Control Unit

Reprogram transmission control unit (TCU).

YES: Replace controller.

Check for active codes.

NO: Checks complete.

Is FLC code 002003.09 present? – – –1/1

5 Reprogram Engine Control Unit

Reprogram engine control unit (ECU).

YES: Replace controller.

Check for active codes.

NO: Checks complete.

Is ECU code 002003.09 present? – – –1/1

TM10229 (17MAR09)

9001-20-10

544J Loader (S.N. 611800— ) 032409

PN=52

Engine Control Unit (ECU) Diagnostic Trouble Codes

002033.09 — CAN Comm Lost for FLC

The engine control unit (ECU) is missing the CAN message from flex load controller (FLC).

9001 20 11

AA95137,0000A32 –19–24MAY07–1/1

CAN Communication Lost for FLC Diagnostic Procedure Alarm Level: No Warning Lamp

– – –1/1

1 Controller Sensors Check

Turn key switch ON.

YES: Go to Reprogram Engine Control Unit.

NO: Go to Fuse Check.

Does the monitor show a reading for all sensors?

– – –1/1

2 Fuse Check

Turn key switch OFF.

YES: Go to Circuit Check.

Remove fuse (F15) and fuse (F21). See Fuse and Relay Specifications. (Group 9015-10.) Check continuity of fuse (F15) and fuse (F21). Is continuity indicated in both fuses?

NO: Replace fuse(s) without continuity. See Fuse and Relay Specifications. (Group 9015-10.)

– – –1/1

TM10229 (17MAR09)

9001-20-11

544J Loader (S.N. 611800— ) 032409

PN=53

Engine Control Unit (ECU) Diagnostic Trouble Codes 3 Circuit Check

Turn key switch OFF.

YES: Go to next step in this check.

Disconnect FLC connector (X41). See Load Center Harness (W3) Component Location. (Group 9015-10.) Turn key switch ON.

9001 20 12

Check circuit P15 RED for voltage between pin M1 on FLC connector (X41) and machine ground. Check circuit P21 RED for voltage between pin L1 on FLC connector (X41) and machine ground.

NO: Open circuit in load center harness. Repair circuit with no voltage or replace load center harness. See Load Center Harness (W3) Wiring Diagram. (Group 9015-10.)

Is system voltage (approximately 24 volts) present?

Key switch OFF and FLC connector (X41) disconnected.

YES: Go to CAN Circuit Check.

Check circuit G01 BLK for ground at pins M2 and L2 on FLC connector (X41). NO: Open circuit in load center harness. Repair circuit G01 BLK or replace load center harness. See Load Center Harness (W3) Wiring Diagram. (Group 9015-10.)

Is ground present?

– – –1/1

4 CAN Circuit Check

Perform CAN Circuit Test. (Group 9015-20.)

YES: Go to Reprogram Flex Load Controller.

Does CAN circuit test good? NO: Repair CAN circuit.

– – –1/1

5 Reprogram Flex Load Controller

Reprogram flex load controller (FLC).

YES: Replace FLC.

Check for active codes.

NO: Checks complete.

Is TCU code 002033.09 present? – – –1/1

6 Reprogram Engine Control Unit

Reprogram transmission control unit (TCU).

YES: Replace ECU.

Check for active codes.

NO: Checks complete.

Is ECU code 002033.09 present? – – –1/1

TM10229 (17MAR09)

9001-20-12

544J Loader (S.N. 611800— ) 032409

PN=54

Group 30

Transmission Control Unit (TCU) Diagnostic Trouble Codes Transmission Control Unit (TCU) Diagnostic Trouble Codes The diagnostic trouble code number is indicated by a suspect parameter number (SPN) and a failure mode indicator (FMI) number. In the example 002023.09, 2023 is the SPN and 09 is the FMI number.

9001 30 1

To view diagnostic trouble codes, use one of the following methods: • Service ADVISOR system. See Reading Diagnostic Trouble Codes with Service ADVISOR Diagnostic Application. (Group 9015-20.) • CAN Monitor Unit (CMU). See CAN Monitor Unit (CMU) Menu Structure—Service Mode. (Group 9015-20.) Note: For in-depth diagnostics on all TCU diagnostic trouble codes, see specific code diagnostic procedure. (Group 9001-30.)

Service ADVISOR is a trademark of Deere & Company

TF44157,0000224 –19–14MAR08–1/1

002023.09 — CAN Comm Lost for CMU

The transmission control unit (TCU) is not receiving a CAN signal from the CAN monitor unit (CMU).

TF44157,0000225 –19–14MAR08–1/1

TM10229 (17MAR09)

9001-30-1

544J Loader (S.N. 611800— ) 032409

PN=55

Transmission Control Unit (TCU) Diagnostic Trouble Codes CAN Signal Missing from CMU Diagnostic Procedure Alarm Level: 9001 30 2

No Warning Lamp

– – –1/1

1 Code Check

Turn key switch ON.

YES: Go to Fuse Check.

Check for active flex load controller (FLC) codes.

NO: Go to Reprogram Transmission Control Unit.

Is FLC code 002023.09 present?

– – –1/1

2 Fuse Check

Turn key switch OFF.

YES: Go to Voltage Check.

Remove fuses (F13 and F34). See Fuse and Relay Specifications. (Group 9015-10.) Check continuity of fuses (F13 and F34).

NO: Replace fuse(s) without continuity.

Is continuity indicated in both fuses?

– – –1/1

TM10229 (17MAR09)

9001-30-2

544J Loader (S.N. 611800— ) 032409

PN=56

Transmission Control Unit (TCU) Diagnostic Trouble Codes 3 Voltage Check

Turn key switch OFF.

YES: Go to Ground Circuit Check.

Disconnect CMU connector (X48). See Front Console Harness (W4) Component Location. (Group 9015-10.)

NO: Go to next step in this check.

Turn key switch ON.

9001 30 3

Check circuit P13 RED for voltage between pin L on CMU connector (X48) and machine ground. See Front Console Harness (W4) Wiring Diagram. (Group 9015-10.) Check circuit P34 RED for voltage between pin A on CMU connector (X48) and machine ground. Is system voltage (approximately 24 volts) present?

Turn key switch OFF. Disconnect connector (X30). See Load Center Harness (W3) Component Location. (Group 9015-10.)

YES: Open circuit in front console harness. Repair circuit with no voltage or replace front console harness.

Turn key switch ON. Check circuit P13 RED for voltage between pin 18 on load center harness side connector (X30) and machine ground. See Load Center Harness (W3) Wiring Diagram. (Group 9015-10.)

NO: Open circuit in load center harness. Repair circuit with no voltage or replace load center harness.

Check circuit P34 RED for voltage between pin 16 on load center harness side connector (X30) and machine ground. Is system voltage (approximately 24 volts) present? – – –1/1

4 Ground Circuit Check

Turn key switch OFF.

YES: Go to CAN Circuit Check.

Disconnect CMU connector (X48). See Front Console Harness (W4) Component Location. (Group 9015-10.)

NO: Go to next step in this check.

Check circuit G01 BLK for ground at pin P of CMU connector (X48). See Front Console Harness (W4) Wiring Diagram. (Group 9015-10.) Is ground present?

Turn key switch OFF. Disconnect connector (X30). See Load Center Harness (W3) Component Location. (Group 9015-10.) Check circuit G01 BLK for ground at pin 10 on the load center harness side of connector (X30). See Load Center Harness (W3) Wiring Diagram. (Group 9015-10.) Is ground present?

YES: Open circuit in front console harness. Repair circuit G01 BLK or replace front console harness. NO: Open circuit in load center harness. Repair circuit G01 BLK or replace load center harness. – – –1/1

5 CAN Circuit Check

Perform CAN Circuit Test. (Group 9015-20.)

YES: Go to Reprogram CAN Monitor Unit.

Does CAN circuit test good? NO: Repair CAN circuit.

– – –1/1

TM10229 (17MAR09)

9001-30-3

544J Loader (S.N. 611800— ) 032409

PN=57

Transmission Control Unit (TCU) Diagnostic Trouble Codes 6 Reprogram CAN Monitor Unit

Reprogram CAN monitor unit (CMU).

YES: Replace CMU.

Check codes.

NO: Checks complete.

Is TCU code 002023.09 active? 9001 30 4

– – –1/1

002033.09 — CAN Comm Lost for FLC

The transmission control unit (TCU) is not receiving a CAN signal from the flex load controller (FLC).

TF44157,0000226 –19–14MAR08–1/1

CAN Signal Missing from FLC Diagnostic Procedure Alarm Level: No Warning Lamp

– – –1/1

1 Controller Sensors Check

Turn key switch ON.

YES: Go to Circuit Check.

NO: Go to Fuse Check.

Does the monitor show a reading for all sensors?

– – –1/1

TM10229 (17MAR09)

9001-30-4

544J Loader (S.N. 611800— ) 032409

PN=58

Transmission Control Unit (TCU) Diagnostic Trouble Codes 2 Fuse Check

Turn key switch OFF.

YES: Go to Circuit Check.

Remove fuses (F15 and F21). See Fuse and Relay Specifications. (Group 9015-10.) NO: Replace fuse(s) without continuity.

Check continuity of fuses (F15 and F21).

9001 30 5

Is continuity indicated in both fuses?

– – –1/1

3 Circuit Check

Turn key switch OFF.

YES: Go to next step in this check.

Disconnect FLC connector (X41). See Load Center Harness (W3) Component Location. (Group 9015-10.) Turn key switch ON. Check circuit P15 RED for voltage between pin M1 on FLC connector (X41) and machine ground. See Load Center Harness (W3) Wiring Diagram. (Group 9015-10.)

NO: Open circuit in load center harness. Repair circuit with no voltage or replace load center harness.

Check circuit P21 RED for voltage between pin L1 on FLC connector (X41) and machine ground. Is system voltage (approximately 24 volts) present?

Key switch OFF and FLC connector (X41) disconnected.

YES: Go to CAN Circuit Check.

Check circuit G01 BLK for ground at pins M2 and L2 on FLC connector (X41). NO: Open circuit in load center harness. Repair circuit G01 BLK or replace load center harness.

Is ground present?

– – –1/1

4 CAN Circuit Check

Perform CAN Circuit Test. (Group 9015-20.)

YES: Checks complete.

Does CAN circuit test good?

NO: Repair CAN circuit.

– – –1/1

5 Program Flex Load Controller

Program flex load controller (FLC). Check for active codes.

YES: Replace controller. See Flex Load Controller (FLC) Remove and Install. (Group 9015-20.)

Is FLC code 002033.09 present? NO: Checks complete. – – –1/1

TM10229 (17MAR09)

9001-30-5

544J Loader (S.N. 611800— ) 032409

PN=59

Transmission Control Unit (TCU) Diagnostic Trouble Codes

522344.00 — Converter Overtemp

9001 30 6

Transmission control unit (TCU) measured a transmission oil temperature at the converter output that is over the allowed threshold.

TF44157,0000227 –19–14MAR08–1/1

Transmission Oil Temperature Too High Diagnostic Procedure Alarm Level: No Warning Lamp

– – –1/1

1 Oil Level and Type Check

Check transmission oil type and level. See Transmission, Hydraulic System, Park Brake, and Axle Oil and see Check Transmission Oil Level. (Operator’s Manual.)

YES: Go to Transmission Oil Cooler Check.

Is transmission oil at the correct level and type?

NO: If transmission oil is low, fill to correct level. See Transmission, Hydraulic System, Park Brake, and Axle Oil. (Operator’s Manual.) If transmission oil is incorrect type, drain and refill with correct oil type. See Transmission, Hydraulic System, Park Brake, and Axle Oil. (Operator’s Manual.)

– – –1/1

TM10229 (17MAR09)

9001-30-6

544J Loader (S.N. 611800— ) 032409

PN=60

Transmission Control Unit (TCU) Diagnostic Trouble Codes 2 Transmission Oil Cooler Check

Check transmission oil cooler for excessive debris buildup. See Power Train Component Location. (Group 9026-15.)

YES: Clean transmission oil cooler. See Transmission Oil Cooler, Hydraulic Oil Cooler, Air-to-Air Aftercooler, and Radiator External 9001 Cleaning Procedure. 30 (Operator’s Manual.) 7

Is there excessive debris on the oil cooler?

NO: Go to Component Check.

– – –1/1

3 Component Check

Disconnect transmission oil temperature sensor (B32). Measure resistance of sensor and compare to specification. See Electrical Component Specifications. (Group 9015-20.) Is resistance within specification?

YES: See Transmission System Diagnose Malfunctions. (Group 9026-25.) NO: Transmission oil temperature sensor (B32) malfunction. Replace sensor.

– – –1/1

522350.15 — Input Torque Overload

Transmission control unit (TCU) calculates a high input torque value.

TF44157,0000228 –19–14MAR08–1/1

Input Torque Overload Diagnostic Procedure Alarm Level: No Warning Lamp

– – –1/1

TM10229 (17MAR09)

9001-30-7

544J Loader (S.N. 611800— ) 032409

PN=61

Transmission Control Unit (TCU) Diagnostic Trouble Codes 1 Code Check

Check for ECU diagnostic trouble codes. See CAN Monitor Unit (CMU) Menu Structure—Service Mode. (Group 9015-20.)

YES: Correct problem causing engine derate condition. See ECU code 001569.31 for diagnostic procedure.

Is ECU code 001569.31 present? 9001 30 8

NO: Go to Component Check.

– – –1/1

2 Component Check

Turn key switch OFF.

YES: Replace controller, see Transmission Control Unit (TCU) Remove and Install. (Group 9015-20.)

Disconnect torque converter input speed sensor (B28). Check resistance across sensor pins A and B. Is resistance within specification? See Electrical Component Specifications. (Group 9015-20.)

NO: Torque converter input speed sensor (B28) malfunction. Replace sensor.

– – –1/1

522364.07 — Trans Clutch Calibr Failed

Clutch calibration values are out of range.

TF44157,0000229 –19–14MAR08–1/1

Transmission Clutch Calibration Failed Diagnostic Procedure Alarm Level: No Warning Lamp

– – –1/1

TM10229 (17MAR09)

9001-30-8

544J Loader (S.N. 611800— ) 032409

PN=62

Transmission Control Unit (TCU) Diagnostic Trouble Codes 1 Calibrate Transmission Control Unit (TCU) Control Clutch

Turn key switch ON.

YES: Checks complete.

Calibrate the electronic clutch solenoids. See Transmission Control Unit (TCU)— Electronic Clutch Calibration. (Group 9020-20.)

NO: Go to Component Check.

Is the transmission calibration successful? – – –1/1

2 Component Check

Perform Transmission Control Valve Solenoid Check. (Group 9015-20.)

YES: Go to Code Check.

Are all control solenoids within specification?

NO: Transmission control valve solenoid malfunction. Replace solenoid with resistance out of specification. See Transmission Control Valve Disassemble and Assemble. (Group 0360.)

– – –1/1

3 Code Check

Turn key switch ON. Check for active TCU clutch codes within the following range: 522383.02—522399.05. Are any TCU codes active within the range?

YES: Correct problem causing other TCU codes. See Diagnostic Trouble Codes (DTC) Quick Reference List. (Group 9015-10.) NO: Replace transmission control unit (TCU), see Transmission Control Unit (TCU) Remove and Install. (Group 9015-20.) – – –1/1

522364.13 — Trans Clutch Calibr Fault

Transmission control unit (TCU) is not able to read clutch adjustment parameters.

TF44157,000022A –19–14MAR08–1/1

TM10229 (17MAR09)

9001-30-9

544J Loader (S.N. 611800— ) 032409

PN=63

9001 30 9

Transmission Control Unit (TCU) Diagnostic Trouble Codes Transmission Clutch Calibration Fault Diagnostic Procedure Alarm Level: 9001 30 10

No Warning Lamp

– – –1/1

1 Reconfigure Transmission Control Unit (TCU)

TCU is brand new.

YES: Checks complete.

Re-configure TCU. See Electronic Controller Reconfiguration. (Group 9015-20.)

NO: Check for diagnostic trouble codes (DTC).

Perform Transmission Control Unit (TCU)—Electronic Clutch Calibration. (Group 9015-20.) Is transmission calibration successful?

If codes are present, correct problems causing other code(s). See Diagnostic Trouble Codes (DTC) Quick Reference List. (Group 9015-20.)

– – –1/1

522365.13 — Limp Home Mode

Another controller has requested limp home mode.

TF44157,000022B –19–14MAR08–1/1

Limp Home Mode Requested Diagnostic Procedure Alarm Level: Transmission Fault Indicator Light

– – –1/1

TM10229 (17MAR09)

9001-30-10

544J Loader (S.N. 611800— ) 032409

PN=64

Transmission Control Unit (TCU) Diagnostic Trouble Codes 1 Code Check

Turn key switch ON. Check for active diagnostic trouble codes. See CAN Monitor Unit (CMU) Menu Structure—Service Mode. (Group 9015-10.)

YES: Correct problems causing other codes. See Diagnostic Trouble Codes (DTC) Quick Reference List. (Group 9015-20.)

Are other diagnostic trouble codes present? NO: Go to CAN Circuit Check.

– – –1/1

2 CAN Circuit Check

Perform CAN Circuit Test. (Group 9015-20.) Does CAN circuit test good?

YES: Replace transmission control unit (TCU). See Transmission Control Unit (TCU) Remove and Install. (Group 9015-20.) NO: Repair CAN circuit.

– – –1/1

522366.13 — Application Invalid

An invalid machine setting is selected.

TF44157,000022C –19–14MAR08–1/1

Application Invalid Diagnostic Procedure Alarm Level: No Warning Lamp

– – –1/1

TM10229 (17MAR09)

9001-30-11

544J Loader (S.N. 611800— ) 032409

PN=65

9001 30 11

Transmission Control Unit (TCU) Diagnostic Trouble Codes 1 Code Check

9001 30 12

Reconfigure machine settings. Perform Electronic Controller Reconfiguration. (Group 9015-20.)

YES: Go to CAN Circuit Check.

Check for diagnostic trouble codes (DTC). See CAN Monitor Unit (CMU) Menu Structure—Service Mode. (Group 9015-20.)

NO: Checks complete.

Is TCU code 522366.13 present?

– – –1/1

2 CAN Circuit Check

Perform CAN Circuit Test. (Group 9015-20.) Does CAN circuit test good?

YES: Replace transmission control unit (TCU), see Transmission Control Unit (TCU) Remove and Install. (Group 9015-20.) NO: Repair CAN circuit.

– – –1/1

522367.13 — TCU Configuration Invalid

Transmission control unit (TCU) lost the correct configuration settings and cannot control the transmission.

TF44157,000022D –19–14MAR08–1/1

TCU Configuration Invalid Diagnostic Procedure Alarm Level: No Warning Lamp

– – –1/1

TM10229 (17MAR09)

9001-30-12

544J Loader (S.N. 611800— ) 032409

PN=66

Transmission Control Unit (TCU) Diagnostic Trouble Codes 1 Code Check

Reconfigure machine settings. Perform Electronic Controller Reconfiguration. (Group 9015-20.)

YES: Go to CAN Circuit Check.

Check for diagnostic trouble codes (DTC). See CAN Monitor Unit (CMU) Menu Structure—Service Mode. (Group 9015-20.)

NO: Checks complete. 9001 30 13

Is TCU code 522367.13 present?

– – –1/1

2 CAN Circuit Check

Perform CAN Circuit Test. (Group 9015-20.) Does CAN circuit test good?

YES: Replace transmission control unit (TCU). See Transmission Control Unit (TCU) Remove and Install. (Group 9015-20.) NO: Repair CAN circuit.

– – –1/1

522368.02 — Memory Failure

Transmission control unit (TCU) cannot read non-volatile memory.

TF44157,000022E –19–14MAR08–1/1

TCU Memory Failure Diagnostic Procedure Alarm Level: No Warning Lamp

– – –1/1

TM10229 (17MAR09)

9001-30-13

544J Loader (S.N. 611800— ) 032409

PN=67

Transmission Control Unit (TCU) Diagnostic Trouble Codes 1 Code Check

9001 30 14

Reconfigure machine settings. Perform Electronic Controller Reconfiguration. (Group 9015-20.)

YES: Go to CAN Circuit Check.

Check for diagnostic trouble codes (DTC). See CAN Monitor Unit (CMU) Menu Structure—Service Mode. (Group 9015-20.)

NO: Checks complete.

Is TCU code 522368.02 present?

– – –1/1

2 CAN Circuit Check

Perform CAN Circuit Test. (Group 9015-20.) Does CAN circuit test good?

YES: Replace transmission control unit (TCU). See Transmission Control Unit (TCU) Remove and Install. (Group 9015-20.) NO: Repair CAN circuit.

– – –1/1

522369.03 — Remote Display Short to Power

Transmission control unit (TCU) diagnostic and programming connector battery voltage cable is short to power.

TF44157,000022F –19–14MAR08–1/1

Remote Display Short to Power Diagnostic Procedure Alarm Level: No Warning Lamp

– – –1/1

TM10229 (17MAR09)

9001-30-14

544J Loader (S.N. 611800— ) 032409

PN=68

Transmission Control Unit (TCU) Diagnostic Trouble Codes 1 Code Check

Disconnect remote display (if equipped) from TCU diagnostic and programming connector (X2). See Load Center Harness (W3) Component Location. (Group 9015-10.)

YES: Go to Short Circuit Check—Power Circuit.

Check for active codes. See CAN Monitor Unit (CMU) Menu Structure—Service Mode. (Group 9015-20.)

NO: Remote display (if equipped) malfunction. Replace remote display.

Is TCU code 522369.03 present?

– – –1/1

2 Short Circuit Check— Power Circuit

Turn key switch OFF.

YES: Short circuit in load center harness. Repair circuit P28 RED or replace load center harness.

Disconnect remote display (if equipped) from TCU diagnostic and programming connector (X2). See Load Center Harness (W3) Component Location. (Group 9015-10.) Turn key switch ON.

NO: Go to Short Circuit Check—Signal Wires.

Check circuit P28 RED for voltage between pin A on connector (X2) and machine ground. See Load Center Harness (W3) Wiring Diagram. (Group 9015-10.) Is system voltage (approximately 24 volts) present?

– – –1/1

3 Short Circuit Check— Signal Wires

Turn key switch OFF.

YES: Short circuit in load center harness. Repair circuit with system voltage present or replace load center harness.

Disconnect remote display (if equipped) from TCU diagnostic and programming connector (X2). See Load Center Harness (W3) Component Location. (Group 9015-10.) Turn key switch ON.

NO: Go to Continuity Check.

Check circuit Z14 GRY for voltage between pin C on connector (X2) and machine ground. See Load Center Harness (W3) Wiring Diagram. (Group 9015-10.) Check circuit Z13 GRY for voltage between pin D on connector (X2) and machine ground. Check circuit Z12 GRY for voltage between pin E on connector (X2) and machine ground. Is system voltage (approximately 24 volts) present on any circuit?

– – –1/1

TM10229 (17MAR09)

9001-30-15

544J Loader (S.N. 611800— ) 032409

PN=69

9001 30 15

Transmission Control Unit (TCU) Diagnostic Trouble Codes 4 Continuity Check

Turn battery disconnect switch OFF. Disconnect remote display (if equipped) from TCU diagnostic and programming connector (X2) and disconnect TCU connector (X23). See Load Center Harness (W3) Component Location. (Group 9015-10.)

9001 30 16

Check circuit Z14 GRY for continuity between pin 18 on TCU connector (X23) and all other pins on connector (X23). See Load Center Harness (W3) Wiring Diagram. (Group 9015-10.) Check circuit Z13 GRY for continuity between pin 15 on TCU connector (X23) and all other pins on connector (X23).

YES: Short circuit in load center harness. Repair circuit with continuity indicated to another pin or replace load center harness. NO: Replace transmission control unit (TCU). See Transmission Control Unit (TCU) Remove and Install. (Group 9015-20.)

Check circuit Z12 GRY for continuity between pin 14 on TCU connector (X23) and all other pins on connector (X23). Is continuity indicated with any of the other pins?

– – –1/1

522369.04 — Remote Display Short to Ground

Transmission control unit (TCU) diagnostic and programming connector battery voltage cable is short to ground.

TF44157,0000230 –19–14MAR08–1/1

Remote Display Short to Ground Diagnostic Procedure Alarm Level: No Warning Lamp

– – –1/1

TM10229 (17MAR09)

9001-30-16

544J Loader (S.N. 611800— ) 032409

PN=70

Transmission Control Unit (TCU) Diagnostic Trouble Codes 1 Code Check

Disconnect remote display (if equipped) from TCU diagnostic and programming connector (X2). See Load Center Harness (W3) Component Location. (Group 9015-10.)

YES: Go to Short Circuit Check—Power Circuit.

Check for active codes. See CAN Monitor Unit (CMU) Menu Structure—Service Mode. (Group 9015-20.)

NO: Remote display (if equipped) malfunction. Replace remote display.

Is TCU code 522369.04 present?

– – –1/1

2 Short Circuit Check— Power Circuit

Turn key switch OFF. Disconnect remote display (if equipped) from TCU diagnostic and programming connector (X2). See Load Center Harness (W3) Component Location. (Group 9015-10.)

YES: Short to ground in load center harness. Repair circuit P28 RED or replace load center harness.

Check circuit P28 RED for ground at pin A on connector (X2). See Load Center Harness (W3) Wiring Diagram. (Group 9015-10.)

NO: Go to Short Circuit Check—Signal Wires.

Is ground present?

– – –1/1

3 Short Circuit Check— Signal Wires

Turn key switch OFF. Disconnect remote display (if equipped) from TCU diagnostic and programming connector (X2). See Load Center Harness (W3) Component Location. (Group 9015-10.) Check circuit Z14 GRY for ground at pin C on connector (X2).

YES: Short to ground in load center harness. Repair circuit with ground present or replace load center harness. See Load Center Harness (W3) Wiring Diagram. (Group 9015-10.)

Check circuit Z13 GRY for ground at pin D on connector (X2). Check circuit Z12 GRY for ground at pin E on connector (X2).

NO: Go to Open Circuit Check.

Is ground present on any circuit? – – –1/1

TM10229 (17MAR09)

9001-30-17

544J Loader (S.N. 611800— ) 032409

PN=71

9001 30 17

Transmission Control Unit (TCU) Diagnostic Trouble Codes 4 Open Circuit Check

Turn key switch OFF. Disconnect remote display (if equipped) from TCU diagnostic and programming connector (X2) and disconnect TCU connector (X23). See Load Center Harness (W3) Component Location. (Group 9015-10.)

9001 30 18

Check circuit Z14 GRY for continuity between pin C on connector (X2) and pin 14 on TCU connector (X23). See Load Center Harness (W3) Wiring Diagram. (Group 9015-10.) Check cricuit Z13 GRY for continuity between pin D on connector (X2) and pin 15 on TCU connector (X23).

YES: Replace transmission control unit (TCU), see Transmission Control Unit (TCU) Remove and Install. (Group 9015-20.) NO: Open circuit in load center harness. Repair circuit(s) without continuity indicated or replace load center harness.

Check cricuit Z12 GRY for continuity between pin E on connector (X2) and pin 18 on TCU connector (X23). Is continuity indicated for all circuits?

– – –1/1

522370.02 — TCU VP2 Short Circuit

Transmission control unit (TCU) valve power supply 2 has a short circuit to power or ground.

TF44157,0000231 –19–14MAR08–1/1

TCU Valve Power Supply 2 Short Circuit Diagnostic Procedure Alarm Level: No Warning Lamp

– – –1/1

TM10229 (17MAR09)

9001-30-18

544J Loader (S.N. 611800— ) 032409

PN=72

Transmission Control Unit (TCU) Diagnostic Trouble Codes 1 Component Check

Turn key switch OFF.

YES: Go to Short to Power Check.

Disconnect park brake release solenoid (Y19). See Loader Frame Harness (W2) Component Location. (Group 9015-10.) Measure resistance between pins 1 and 2 on park brake release solenoid (Y19). See Electrical Component Specifications. (Group 9015-20.)

NO: Park brake release solenoid (Y19) malfunction. Replace solenoid.

Is resistance within specification?

– – –1/1

2 Short to Power Check

Turn key switch OFF.

YES: Go to next step in this check.

Disconnect park brake release solenoid (Y19). See Loader Frame Harness (W2) Component Location. (Group 9015-10.)

NO: Go to Short to Ground Check.

Turn key switch ON. Check circuit P79 RED for voltage between pin 1 on park brake release solenoid (Y19) connector and ground. Is more than 4 volts present?

Turn key switch OFF. Disconnect loader frame harness-to-load center harness connector (X67). See Load Center Harness (W3) Component Location. (Group 9015-10.) Turn key switch ON. Check circuit P79 RED for voltage between pin 17 on load center harness side of connector (X67) and machine ground. Is more than 4 volts present?

YES: Circuit P79 RED is short to power in the load center harness. Repair circuit P79 RED or replace load center harness. See Load Center Harness (W3) Wiring Diagram. (Group 9015-10.) NO: Circuit P79 RED is short to power in the loader frame harness. Repair circuit P79 RED or replace loader frame harness. See Loader Frame Harness (W2) Wiring Diagram. (Group 9015-10.) – – –1/1

TM10229 (17MAR09)

9001-30-19

544J Loader (S.N. 611800— ) 032409

PN=73

9001 30 19

Transmission Control Unit (TCU) Diagnostic Trouble Codes 3 Short to Ground Check

Turn key switch OFF.

YES: Go to next step in this check.

Disconnect park brake release solenoid (Y19). See Loader Frame Harness (W2) Component Location. (Group 9015-10.) Check circuit P79 RED for ground at pin 1 on park brake release solenoid (Y19) connector.See Loader Frame Harness (W2) Wiring Diagram. (Group 9015-10.)

9001 30 20

Is ground present?

Turn key switch OFF. Disconnect loader frame harness-to-load center harness connector (X67). See Load Center Harness (W3) Component Location. (Group 9015-10.) Check circuit P79 RED for ground at pin 17 on load center harness side of connector (X67). See Load Center Harness (W3) Wiring Diagram. (Group 9015-10.)

NO: Replace transmission control unit (TCU), see Transmission Control Unit (TCU) Remove and Install. (Group 9015-20.)

YES: Circuit P79 RED is short to ground in the load center harness. Repair circuit P79 RED or replace load center harness. NO: Circuit P79 RED is short to ground in the loader frame harness. Repair circuit P79 RED or replace loader frame harness.

Is ground present?

– – –1/1

522371.02 — TCU VP1 Short Circuit

Transmission control unit (TCU) valve power supply 2 has a short circuit to power or ground.

TF44157,0000232 –19–14MAR08–1/1

TCU Valve Power Supply 1 Short Circuit Diagnostic Procedure Alarm Level: No Warning Lamp

– – –1/1

TM10229 (17MAR09)

9001-30-20

544J Loader (S.N. 611800— ) 032409

PN=74

Transmission Control Unit (TCU) Diagnostic Trouble Codes 1 Short Circuit Check

Check circuit P78 RED for a short to power or ground.

YES: Repair circuit P78 RED. Or replace load center or transmission harness.

Check for a short to power or ground at pin 7 on connector (X36). See Transmission Harness (W10) Component Location and see Transmission Harness (W10) Wiring Diagram. (Group 9015-10.)

NO: Replace controller, 9001 see Transmission Control 30 Unit (TCU) Remove and 21 Install. (Group 9015-20.)

Check for a short to power or ground at pin V on load center harness side of connector (X22). See Load Center Harness (W3) Component Location and see Load Center Harness (W3) Wiring Diagram. (Group 9015-10.) Check for a short to power or ground at pins 12 and 13 on transmission control unit (TCU) connector (X23). See Load Center Harness (W3) Component Location and see Load Center Harness (W3) Wiring Diagram. (Group 9015-10.)

Replace controller, see Electrical Component Specifications. (Group 9015-20.)

Is circuit P78 RED short to power or ground?

– – –1/1

522373.03 — Power Supply High Voltage

Transmission control unit (TCU) supply voltage is above 32.5 volts.

TF44157,0000233 –19–14MAR08–1/1

Power Supply High Voltage Diagnostic Procedure Alarm Level: No Warning Lamp

– – –1/1

TM10229 (17MAR09)

9001-30-21

544J Loader (S.N. 611800— ) 032409

PN=75

Transmission Control Unit (TCU) Diagnostic Trouble Codes 1 Voltage Check

Turn key switch OFF.

YES: Go to Alternator Check.

Disconnect TCU connector (X23). See Load Center Harness (W3) Component Location. (Group 9015-10.)

NO: Go to Reprogram Controller.

Turn key switch ON.

9001 30 22

Check circuit P18 RED for voltage between pin 23 on connector (X23) and machine ground. See Load Center Harness (W3) Wiring Diagram. (Group 9015-10.) Check circuit P28 RED for voltage between pin 45 on connector (X23) and machine ground. Is voltage on either circuit approximately 32.5 volts? – – –1/1

2 Alternator Check

Check alternator for correct output. Perform Alternator Test. (Group 9015-20.)

YES: Checks complete.

Are alternator and charging circuit operating properly?

NO: Repair alternator or charging circuit. See Starting and Charging Circuit Theory of Operation. (Group 9015-15.)

– – –1/1

522373.04 — Power Supply Low Voltage

Transmission control unit (TCU) supply voltage is below 18 volts.

TF44157,0000234 –19–14MAR08–1/1

Power Supply Low Voltage Diagnostic Procedure Alarm Level: No Warning Lamp

– – –1/1

TM10229 (17MAR09)

9001-30-22

544J Loader (S.N. 611800— ) 032409

PN=76

Transmission Control Unit (TCU) Diagnostic Trouble Codes 1 Fuse Check

Turn key switch OFF.

YES: Go to Battery Check.

Remove fuse (F18) and fuse (F28). See Fuse and Relay Specifications. (Group 9015-10.)

NO: Replace fuse(s) without continuity.

Check fuse (F18) and fuse (F28) for continuity.

9001 30 23

Is continuity indicated in both fuses?

– – –1/1

2 Battery Check

Turn key switch OFF.

YES: Go to Open Circuit Check.

Check battery voltage. NO: Check batteries. See Check Battery Electrolyte Level and Terminals. (Operator’s Manual.)

Is voltage approximately 24 volts?

Charge, repair or replace batteries as necessary. See Using Battery Charger and see Replacing Batteries. (Operator’s Manual.) – – –1/1

3 Open Circuit Check

Turn key switch OFF.

YES: Go to next step in this check.

Remove TCU connector (X23), VEC connector (X13), and VEC connector (X17). See Load Center Harness (W3) Component Location. (Group 9015-10.) Check circuit P18 RED for continuity between pin 23 on connector (X23) and pin C on connector (X13). See Load Center Harness (W3) Wiring Diagram. (Group 9015-10.)

NO: Open circuit in load center harness. Repair circuit(s) without continuity or replace load center harness.

Check circuit P28 RED for continuity between pin 43 on connector (X23) and pin A on connector (X17). Is continuity indicated in both circuits?

Key switch OFF and TCU connector (X23) disconnected. Check circuit G01 BLK for ground at pins 1 and 2 of connector (X23). See Load Center Harness (W3) Wiring Diagram. (Group 9015-10.) Is ground present?

YES: Replace controller, see Transmission Control Unit (TCU) Remove and Install. (Group 9015-20.) NO: Open circuit in load center harness. Repair circuit G01 BLK or replace load center harness.

– – –1/1

TM10229 (17MAR09)

9001-30-23

544J Loader (S.N. 611800— ) 032409

PN=77

Transmission Control Unit (TCU) Diagnostic Trouble Codes

522374.03 — Sensor Supply Short to Power

9001 30 24

Transmission control unit (TCU) measures more than 6 volts on the clutch cutoff sensor (B33) power circuit.

TF44157,0000235 –19–14MAR08–1/1

Sensor Supply Short to Power Diagnostic Procedure Alarm Level: No Warning Lamp

– – –1/1

1 Component Check

Turn key switch OFF.

YES: Go to Short Circuit Check.

Disconnect clutch cut-off sensor (B33). See Load Center Harness (W3) Component Location. (Group 9015-10.)

NO: Replace clutch cut-off sensor (B33).

Measure resistance of sensor across pins A and B. Measure resistance of sensor across pins A and C. See Electrical Component Specifications. (Group 9015-20.) Is resistance within specification?

– – –1/1

2 Short Circuit Check

Turn key switch OFF. Disconnect clutch cut-off sensor (B33). See Load Center Harness (W3) Component Location. (Group 9015-10.)

YES: Short circuit in load center harness. Repair circuit P77 RED or replace load center harness.

Turn key switch ON. Check circuit P77 RED for voltage between pin A of clutch cut-off sensor (B33) connector and machine ground. See Load Center Harness (W3) Wiring Diagram. (Group 9015-10.)

NO: Go to Continuity Check.

Is system voltage (approximately 24 volts) present?

– – –1/1

TM10229 (17MAR09)

9001-30-24

544J Loader (S.N. 611800— ) 032409

PN=78

Transmission Control Unit (TCU) Diagnostic Trouble Codes 3 Continuity Check

Turn battery disconnect switch OFF. Disconnect clutch cut-off sensor (B33) and disconnect TCU connector (X23). See Load Center Harness (W3) Component Location. (Group 9015-10.) Check circuit P77 RED for continuity between pin 37 on TCU connector (X23) and all other pins on connector (X23). Is continuity indicated with any of the other pins?

YES: Short circuit in load center harness. Repair circuit P77 RED or replace load center harness. 9001 NO: Replace controller, 30 see Transmission Control 25 Unit (TCU) Remove and Install. (Group 9015-20.)

– – –1/1

522374.04 — Sensor Supply Short to Gnd

Transmission control unit (TCU) measures less than 4 volts on the clutch cutoff sensor (B33) power circuit.

TF44157,0000236 –19–14MAR08–1/1

Sensor Supply Short to Ground Diagnostic Procedure Alarm Level: No Warning Lamp

– – –1/1

1 Component Check

Turn key switch OFF.

YES: Go to Open Circuit Check.

Disconnect clutch cut-off sensor (B33). See Load Center Harness (W3) Component Location. (Group 9015-10.)

NO: Replace clutch cut-off sensor (B33).

Measure resistance of sensor across pins A and B. See Load Center Harness (W3) Wiring Diagram. (Group 9015-10.) Measure resistance of sensor across pins A and C. See Electrical Component Specifications. (Group 9015-20.) Is resistance within specification?

– – –1/1

TM10229 (17MAR09)

9001-30-25

544J Loader (S.N. 611800— ) 032409

PN=79

Transmission Control Unit (TCU) Diagnostic Trouble Codes 2 Open Circuit Check

Turn key switch OFF.

YES: Go to Short Circuit Check.

Disconnect clutch cut-off sensor (B33) and TCU connector (X23). See Load Center Harness (W3) Component Location. (Group 9015-10.) Check circuit P77 RED for continuity between pin A on clutch cut-off sensor (B33) connector and pin 37 on TCU connector (X23). See Load Center Harness (W3) Wiring Diagram. (Group 9015-10.)

9001 30 26

NO: Open circuit in load center harness. Repair circuit(s) without continuity indicated or replace load center harness.

Check circuit R77 BLK for continuity between pin C on clutch cut-off sensor (B33) connector and pin 24 on TCU connector (X23). Is continuity indicated on both circuits? – – –1/1

3 Short Circuit Check

Turn key switch OFF.

YES: Short circuit in load center harness. Repair circuit P77 RED or replace load center harness.

Disconnect clutch cut-off sensor (B33). See Load Center Harness (W3) Component Location. (Group 9015-10.) Check circuit P77 RED for ground at pin A on clutch cut-off sensor (B33) connector. See Load Center Harness (W3) Wiring Diagram. (Group 9015-10.)

NO: Go to Continuity Check.

Is ground present?

– – –1/1

4 Continuity Check

YES: Short circuit in load center harness. Repair circuit P77 RED or replace load center harness. NO: Replace controller, see Transmission Control Unit (TCU) Remove and Install. (Group 9015-20.)

– – –1/1

522375.00 — Trans Oil Filter Restricted

Transmission control unit (TCU) detects transmission oil filter is restricted.

TF44157,0000237 –19–14MAR08–1/1

TM10229 (17MAR09)

9001-30-26

544J Loader (S.N. 611800— ) 032409

PN=80

Transmission Control Unit (TCU) Diagnostic Trouble Codes Transmission Oil Filter Restricted Diagnostic Procedure Alarm Level: Transmission Oil Filter Restricted Icon

9001 30 27

– – –1/1

1 Transmission Oil Filter Check

Turn key switch OFF.

YES: Replace transmission oil filter. See Replace Transmission Oil Filter. (Operator’s Manual.)

Remove transmission oil filter. See Power Train Component Location. (Group 9020-15.) Check filter for clogging or restrictions.

NO: Go to Open Circuit Check.

Is transmission oil filter clogged or restricted?

– – –1/1

2 Open Circuit Check

Turn key switch OFF.

YES: Go to Component Check.

Disconnect transmission oil filter restriction switch (B20). See Transmission Harness (W10) Component Location. (Group 9015-10.)

NO: Go to next step in this check.

Disconnect TCU connector (X23). See Load Center Harness (W3) Component Location. (Group 9015-10.) Check circuit R06 BLK for continuity between pin B on transmission oil filter restriction switch (B20) connector and pin 46 on TCU connector (X43). See Transmission Harness (W10) Wiring Diagram and see Load Center Harness (W3) Wiring Diagram. (Group 9015-10.) Check circuit N03 YEL for continuity between pin A on transmission oil filter restriction switch (B20) connector and pin 17 on TCU connector (X43). Is continuity indicated in both circuits?

Key switch OFF and TCU connector (X23) disconnected. Disconnect load center harness-to-transmission harness connector (X22). See Load Center Harness (W3) Component Location. (Group 9015-10.) Check circuit R06 BLK for continuity between pin M on load center harness side of connector (X22) and pin 46 on TCU connector (X23). See Load Center Harness (W3) Wiring Diagram. (Group 9015-10.) Check circuit N03 YEL for continuity between pin T on load center harness side of connector (X22) and pin 17 on TCU connector (X23).

YES: Open circuit in transmission harness. Repair circuit without continuity indicated or replace transmission harness. NO: Open circuit in load center harness. Repair circuit without continuity indicated or replace load center harness.

Is continuity indicated in both circuits? – – –1/1

TM10229 (17MAR09)

9001-30-27

544J Loader (S.N. 611800— ) 032409

PN=81

Transmission Control Unit (TCU) Diagnostic Trouble Codes 3 Component Check

Turn key switch ON. Remove transmission oil filter restriction switch (B20) from machine. See Transmission Harness (W10) Component Location. (Group 9015-10.) Check for active codes.

9001 30 28

Is TCU code 522375.00 present?

YES: Transmission oil filter restriction switch (B20) malfunction. Replace switch. Is TCU code 522375.00 still present? Replace controller, see Transmission Control Unit (TCU) Remove and Install. (Group 9015-20.) NO: Checks complete. – – –1/1

522376.00 — Trans Oil Temp Max Value

Transmission oil temperature in the oil sump exceeds 110°C (230°F).

TF44157,0000238 –19–14MAR08–1/1

Transmission Oil Temperature Maximum Value Diagnostic Procedure Alarm Level: No Warning Lamp

– – –1/1

TM10229 (17MAR09)

9001-30-28

544J Loader (S.N. 611800— ) 032409

PN=82

Transmission Control Unit (TCU) Diagnostic Trouble Codes 1 Oil Type and Level Check

Turn key switch OFF.

YES: Go to Component Check.

Check transmission oil type and level. See Check Transmission Oil Level. (Operator’s Manual.) Is transmission oil at correct level and type?

NO: If transmission oil is not correct level, fill transmission oil. See Check Transmission Oil Level. (Operator’s Manual.) NO: If transmission oil is not correct type, drain and refill with correct oil. See Change Transmission Oil. (Operator’s Manual.)

– – –1/1

2 Component Check

Turn key switch OFF.

YES: See Transmission System Diagnose Malfunctions. (Group 9020-15.)

Disconnect transmission harness-to-transmission control valve harness connector (X36). See Transmission Harness (W10) Component Location. (Group 9015-10.) Check resistance of transmission oil temperature sensor (B32) at pins 8 and 9 on transmission control valve harness side of connector (X36). See Electrical Component Specifications. (Group 9015-20.)

NO: Transmission oil temperature sensor (B32) malfunction. Replace sensor.

Is resistance within specification?

– – –1/1

522379.03 — Park Brake Solenoid Short to Power

Park brake solenoid circuit is short to power.

TF44157,0000239 –19–14MAR08–1/1

TM10229 (17MAR09)

9001-30-29

544J Loader (S.N. 611800— ) 032409

PN=83

9001 30 29

Transmission Control Unit (TCU) Diagnostic Trouble Codes Park Brake Solenoid Short to Power Diagnostic Procedure Alarm Level: 9001 30 30

No Warning Lamp

– – –1/1

1 Component Check

Turn key switch OFF.

YES: Go to Short Circuit Check.

NO: Park brake release solenoid (Y19) malfunction. Replace solenoid.

Is resistance within specification?

– – –1/1

2 Short Circuit Check

Turn key switch OFF.

YES: Go to next step in this check.

Disconnect park brake release solenoid (Y19). See Loader Frame Harness (W2) Component Location. (Group 9015-10.)

NO: Go to Continuity Check.

Turn key switch ON. Check circuit T09 BLU for voltage between pin 2 on park brake release solenoid (Y19) connector and machine ground. See Loader Frame Harness (W2) Wiring Diagram. (Group 9015-10.) Check circuit P79 RED for voltage between pin 1 on park brake release solenoid (Y19) connector and machine ground. Is more than 4 volts present in either circuit?

Turn key switch OFF. Disconnect load center harness-to-loader frame harness connector (X67). See Load Center Harness (W3) Component Location. (Group 9015-10.) Turn key switch ON. Check circuit T09 BLU for voltage between pin 16 on load center harness side of connector (X67) and machine ground. See Load Center Harness (W3) Wiring Diagram. (Group 9015-10.) Check circuit P79 RED for voltage between pin 17 on load center harness side of connector (X67) and machine ground.

YES: Short to power in load center harness. Repair circuit(s) with more than 4 volts or replace load center harness. NO: Short to power in loader frame harness. Repair circuit(s) with more than 4 volts or replace loader frame harness.

Is more than 4 volts present in either circuit? – – –1/1

TM10229 (17MAR09)

9001-30-30

544J Loader (S.N. 611800— ) 032409

PN=84

Transmission Control Unit (TCU) Diagnostic Trouble Codes 3 Continuity Check

Turn battery disconnect OFF. Disconnect park brake release solenoid (Y19) and load center-to-loader frame harness connector (X67). See Loader Frame Harness (W2) Component Location. (Group 9015-10.) Check for continuity between pin 16 (circuit T09 BLU ) on loader frame harness side of connector (X67) and all other pins on connector (X67). See Loader Frame Harness (W2) Wiring Diagram. (Group 9015-10.)

YES: Short circuit in loader frame harness. Repair circuit(s) with continuity indicated to another pin or replace loader frame harness. NO: Go to next step in this check.

Check for continuity between pin 17 (circuit P79 RED) on loader frame harness side of connector (X67) and all other pins on connector (X67). Is continuity indicated with any other pins?

Battery disconnect OFF. Load center-to-loader frame harness connector (X67) disconnected. Disconnect transmission control unit (TCU) connector (X23). See Load Center Harness (W3) Component Location. (Group 9015-10.) Check for continuity between pin 16 (circuit T09 BLU) on load center harness side of connector (X67) and all other pins on connector (X67). See Load Center Harness (W3) Wiring Diagram. (Group 9015-10.)

YES: Short circuit in load center harness. Repair circuit(s) with continuity indicated to another pin or replace load center harness. NO: Go to next step in this check.

Check for continuity between pin 17 (circuit P79 RED) on load center harness side of connector (X67) and all other pins on connector (X67). Is continuity indicated with any other pins?

Battery disconnect OFF. Load center-to-loader frame harness connector (X67) disconnected and TCU connector (X23) disconnected. Check for continuity between pin 33 (circuit T09 BLU) on connector (X23) and all other pins on connector (X23). See Load Center Harness (W3) Wiring Diagram. (Group 9015-10.) Check for continuity between pins 8 and 53 (circuit P79 RED) on connector (X23) and all other pins on connector (X23).

YES: Short circuit in load center harness. Repair circuit(s) with continuity indicated to another pin or replace load center harness. NO: Replace controller, see Transmission Control Unit (TCU) Remove and Install. (Group 9015-20.)

Is continuity indicated with any other pins?

– – –1/1

522379.04 — Park Brake Solenoid Short to Gnd

Transmission park brake release solenoid circuit is short to ground.

TF44157,000023A –19–14MAR08–1/1

TM10229 (17MAR09)

9001-30-31

544J Loader (S.N. 611800— ) 032409

PN=85

9001 30 31

Transmission Control Unit (TCU) Diagnostic Trouble Codes Park Brake Solenoid Short to Ground Diagnostic Procedure Alarm Level: 9001 30 32

No Warning Lamp

– – –1/1

1 Component Check

Turn key switch OFF.

YES: Go to Short Circuit Check.

NO: Park brake release solenoid (Y19) malfunction. Replace solenoid.

Is resistance within specifications?

– – –1/1

TM10229 (17MAR09)

9001-30-32

544J Loader (S.N. 611800— ) 032409

PN=86

Transmission Control Unit (TCU) Diagnostic Trouble Codes 2 Short Circuit Check

Turn key switch OFF.

YES: Go to next step in this check.

Disconnect park brake release solenoid (Y19). See Loader Frame Harness (W2) Component Location. (Group 9015-10.)

NO: Go to Continuity Check.

Check circuit T09 BLU for ground at pin 2 on park brake release solenoid (Y19) connector. See Loader Frame Harness (W2) Wiring Diagram. (Group 9015-10.)

9001 30 33

Check circuit P79 RED for ground at pin 1 on park brake release solenoid (Y19) connector. Is ground present in either circuit?

Key switch OFF and park brake release solenoid (Y19) disconnected.

YES: Go to next step in this check.

Disconnect TCU connector (X23). See Load Center Harness (W3) Component Location. (Group 9015-10.)

NO: Go to Continuity Check.

Check circuit T09 BLU for ground at pin 33 on TCU connector (X23). See Load Center Harness (W3) Wiring Diagram. (Group 9015-10.) Check circuit P79 RED for ground at pin 8 on TCU connector (X23). Is ground present in either circuit?

Key switch OFF, park brake release solenoid (Y19) and TCU connector (X23) disconnected. Disconnect load center harness-to-loader frame harness connector (X67). See Load Center Harness (W3) Component Location. (Group 9015-10.) Check circuit T09 BLU for ground at pin 16 on load center harness side of connector (X67). See Load Center Harness (W3) Wiring Diagram. (Group 9015-10.) Check circuit P79 RED for ground at pin 17 on load center harness side of connector (X67).

YES: Short to ground in load center harness. Repair circuit(s) with ground present or replace load center harness. NO: Short to ground in loader frame harness. Repair circuit(s) with ground present or replace loader frame harness.

Is ground present in either circuit? – – –1/1

TM10229 (17MAR09)

9001-30-33

544J Loader (S.N. 611800— ) 032409

PN=87

Transmission Control Unit (TCU) Diagnostic Trouble Codes 3 Continuity Check

Turn battery disconnect OFF. Disconnect park brake release solenoid (Y19) and load center-to-loader frame harness connector (X67). See Loader Frame Harness (W2) Component Location. (Group 9015-10.)

9001 30 34

Check for continuity between pin 16 (circuit T09 BLU ) on loader frame harness side of connector (X67) and all other pins on connector (X67). See Loader Frame Harness (W2) Wiring Diagram. (Group 9015-10.)

YES: Short circuit in loader frame harness. Repair circuit(s) with continuity indicated to another pin or replace loader frame harness. NO: Go to next step in this check.

Check for continuity between pin 17 (circuit P79 RED) on loader frame harness side of connector (X67) and all other pins on connector (X67). Is continuity indicated between either circuit and any of the other pins?

YES: Short circuit in load center harness. Repair circuit(s) with continuity indicated to another pin or replace load center harness. NO: Go to next step in this check.

Check for continuity between pin 17 (circuit P79 RED) on load center harness side of connector (X67) and all other pins on connector (X67). Is continuity indicated between either circuit and any of the other pins?

Is continuity indicated between either circuit and any of the other pins?

– – –1/1

522379.05 — Park Brake Solenoid Open Circuit

Transmission park brake release solenoid circuit is open.

TF44157,000023B –19–14MAR08–1/1

TM10229 (17MAR09)

9001-30-34

544J Loader (S.N. 611800— ) 032409

PN=88

Transmission Control Unit (TCU) Diagnostic Trouble Codes Park Brake Solenoid Open Circuit Diagnostic Procedure Alarm Level: No Warning Lamp

9001 30 35

– – –1/1

1 Component Check

Turn key switch OFF.

YES: Go to Open Circuit Check.

NO: Park brake release solenoid (Y19) malfunction. Replace solenoid.

Is resistance within specification?

– – –1/1

TM10229 (17MAR09)

9001-30-35

544J Loader (S.N. 611800— ) 032409

PN=89

Transmission Control Unit (TCU) Diagnostic Trouble Codes 2 Open Circuit Check

Turn key switch OFF. Disconnect park brake release solenoid (Y19) and TCU connector (X23). See Loader Frame Harness (W2) Component Location and see Load Center Harness (W3) Component Location. (Group 9015-10.)

9001 30 36

YES: Replace controller, see Transmission Control Unit (TCU) Remove and Install. (Group 9015-20.) NO: Go to next step in this check.

Check circuit T09 BLU for continuity between pin 2 on park brake release solenoid (Y19) connector and pin 33 on TCU connector (X23). Check circuit P79 RED for continuity between pin 1 on park brake release solenoid (Y19) connector and pins 8 and 53 on TCU connector (X23). Is continuity indicated in both circuits?

Key switch OFF and TCU connector (X23) disconnected. Disconnect load center harness-to-loader frame harness connector (X67). See Load Center Harness (W3) Component Location. (Group 9015-10.) Check circuit T09 BLU for continuity between pin 33 on TCU connector (X23) and pin 16 on load center harness side of connector (X67). Check circuit P79 RED for continuity between pins 53 and 8 on TCU connector (X23) and pin 17 on load center harness side of connector (X67). Is continuity indicated in both circuits?

YES: Open circuit in loader frame harness. Repair circuit(s) without continuity indicated or replace loader frame harness. See Loader Frame Harness (W2) Wiring Diagram. (Group 9015-10.) NO: Open circuit in load center harness. Repair circuit(s) without continuity indicated or replace load center harness. See Load Center Harness (W3) Wiring Diagram. (Group 9015-10.)

– – –1/1

522382.03 — Backup Alarm Short to Power

Transmission backup alarm circuit is short to power.

TF44157,000023C –19–14MAR08–1/1

TM10229 (17MAR09)

9001-30-36

544J Loader (S.N. 611800— ) 032409

PN=90

Transmission Control Unit (TCU) Diagnostic Trouble Codes Backup Alarm Short to Power Diagnostic Procedure Alarm Level: No Warning Lamp

9001 30 37

– – –1/1

1 Component Check

Turn key switch OFF.

YES: Go to Short Circuit Check.

Remove wire P32 RED from backup alarm and apply 24 volts. See Rear Frame Harness (W13) Component Location. (Group 9015-10.) Remove wire M28 PUR from backup alarm and apply ground.

NO: Backup alarm malfunction. Replace backup alarm.

Does alarm sound?

– – –1/1

TM10229 (17MAR09)

9001-30-37

544J Loader (S.N. 611800— ) 032409

PN=91

Transmission Control Unit (TCU) Diagnostic Trouble Codes 2 Short Circuit Check

Turn key switch OFF.

YES: Go to next step in this check.

Disconnect wires from backup alarm (H3). See Rear Frame Harness (W13) Component Location. (Group 9015-10.)

NO: Go to Continuity Check.

Turn key switch ON.

9001 30 38

Check circuit M28 PUR for voltage between backup alarm ring terminal and machine ground. See Rear Frame Harness (W13) Wiring Diagram. (Group 9015-10.) Is system voltage (approximately 24 volts) present?

Turn key switch OFF.

YES: Go to next step in this check.

Disconnect engine frame harness-to-rear frame harness connector (X39). See Engine Frame Harness (W5) Component Location. (Group 9015-10.) Turn key switch ON. Check circuit M28 PUR for voltage between pin 5 on engine frame harness side of connector (X39) and machine ground. See Engine Frame Harness (W5) Wiring Diagram. (Group 9015-10.)

NO: Short to power in rear frame harness. Repair circuit M28 PUR or replace rear frame harness.

Is system voltage (approximately 24 volts) present?

Turn key switch OFF. Disconnect load center harness-to-engine frame harness connector (X3). See Load Center Harness (W3) Component Location. (Group 9015-10.)

YES: Short to power in load center harness. Repair circuit M28 PUR or replace load center harness.

Turn key switch ON. Check circuit M28 PUR for voltage between pin 14 on load center harness side of connector (X3) and machine ground. See Load Center Harness (W3) Wiring Diagram. (Group 9015-10.)

NO: Short to power in engine frame harness. Repair circuit M28 PUR or replace engine frame harness.

Is system voltage (approximately 24 volts) present?

– – –1/1

TM10229 (17MAR09)

9001-30-38

544J Loader (S.N. 611800— ) 032409

PN=92

Transmission Control Unit (TCU) Diagnostic Trouble Codes 3 Continuity Check

Turn battery disconnect switch OFF. Disconnect engine frame harness-to-rear frame harness connector (X39). See Rear Frame Harness (W13) Component Location. (Group 9015-10.) Check for continuity between pin 5 (circuit M28 PUR) on rear frame harness side of connector (X39) and all other pins on connector (X39). See Rear Frame Harness (W13) Wiring Diagram. (Group 9015-10.)

YES: Circuit M28 PUR is short to pin with continuity indicated in rear frame harness. Repair circuit M28 PUR or replace rear frame harness. NO: Go to next step in this check.

Is continuity indicated with any of the other pins?

Battery disconnect OFF. Engine frame harness-to-rear frame harness connector (X39) is disconnected. Disconnect load center harness-to-engine frame harness connector (X3). See Engine Frame Harness (W5) Component Location. (Group 9015-10.) Check for continuity between pin 14 (circuit M28 PUR) on engine frame harness side of connector (X3) and all other pins on connector (X3). See Engine Frame Harness (W5) Wiring Diagram. (Group 9015-10.)

YES: Circuit M28 PUR is short to pin with continuity indicated in engine frame harness. Repair circuit M28 PUR or replace engine frame harness. NO: Go to next step in this check.

Is continuity indicated with any of the other pins?

Battery disconnect OFF.

YES: Circuit M28 PUR is short to pin with continuity indicated in load center harness. Repair circuit M28 PUR or replace load center harness.

Load center harness-to-engine frame harness connector (X3) is disconnected. Disconnect TCU connector (X23). See Load Center Harness (W3) Component Location. (Group 9015-10.) Check for continuity between pin 14 (circuit M28 PUR) on load center harness side of connector (X3) and all other pins on connector (X3). See Load Center Harness (W3) Wiring Diagram. (Group 9015-10.)

NO: Go to next step in this check.

Is continuity indicated with any of the other pins?

Battery disconnect OFF. TCU connector (X23) is disconnected. Check for continuity between pin 7 on TCU connector (X23) and all other pins on connector (X23). See Load Center Harness (W3) Component Location. (Group 9015-10.) Is continuity indicated with any of the other pins?

YES: Circuit M28 PUR is short to pin with continuity indicated in load center harness. Repair circuit M28 PUR or replace load center harness. NO: Replace controller, see Transmission Control Unit (TCU) Remove and Install. (Group 9015-20.)

– – –1/1

TM10229 (17MAR09)

9001-30-39

544J Loader (S.N. 611800— ) 032409

PN=93

9001 30 39

Transmission Control Unit (TCU) Diagnostic Trouble Codes

522382.04 — Backup Alarm Short to Gnd

9001 30 40

Transmission backup alarm circuit is short to ground.

TF44157,000023D –19–14MAR08–1/1

Backup Alarm Short to Ground Diagnostic Procedure Alarm Level: No Warning Lamp

– – –1/1

1 Fuse Check

Turn key switch OFF.

YES: Go to Component Check.

Remove fuse (F32). See Fuse and Relay Specifications. (Group 9015-10.) NO: Fuse (F32) is blown. Replace fuse.

Check fuse (F32) for continuity. Is continuity indicated?

– – –1/1

2 Component Check

Turn key switch OFF.

YES: Go to Short Circuit Check.

Remove wire P32 RED from backup alarm and apply 24 volts. See Rear Frame Harness (W13) Component Location. (Group 9015-10.) Remove wire M28 PUR from backup alarm and apply ground.

NO: Backup alarm malfunction. Replace backup alarm.

Does alarm sound?

– – –1/1

TM10229 (17MAR09)

9001-30-40

544J Loader (S.N. 611800— ) 032409

PN=94

Transmission Control Unit (TCU) Diagnostic Trouble Codes 3 Short Circuit Check

Turn key switch OFF.

YES: Go to next step in this check.

Disconnect backup alarm (H3). See Rear Frame Harness (W13) Component Location. (Group 9015-10.)

NO: Go to Continuity Check.

Check circuit P32 RED for ground at ring terminal on backup alarm connection. See Rear Frame Harness (W13) Wiring Diagram. (Group 9015-10.)

9001 30 41

Check circuit M28 PUR for ground at ring terminal on backup alarm connection. Is ground present in either circuit?

Turn key switch OFF.

YES: Go to next step in this check.

Disconnect engine frame harness-to-rear frame harness connector (X39). See Engine Frame Harness (W5) Component Location. (Group 9015-10.) Check circuit M28 PUR for ground at pin 5 on engine frame harness side of connector (X39). See Engine Frame Harness (W5) Wiring Diagram. (Group 9015-10.)

NO: Short to ground in rear frame harness. Repair circuit(s) with ground present or replace rear frame harness.

Check circuit P32 RED for ground at pin 7 on engine frame harness side of connector (X39). Is ground present in either circuit?

Turn key switch OFF. Disconnect load center harness-to-engine frame harness connector (X3). See Load Center Harness (W3) Component Location. (Group 9015-10.) Check circuit M28 PUR for ground at pin 14 on load center harness side of connector (X3). See Load Center Harness (W3) Wiring Diagram. (Group 9015-10.) Check circuit P32 RED for ground at pin 26 on load center harness side of connector (X3).

YES: Short to ground in load center harness. Repair circuit(s) with ground present or replace load center harness. NO: Short to ground in engine frame harness. Repair circuit(s) with ground present or replace load center harness.

Is ground present in either circuit?

– – –1/1

TM10229 (17MAR09)

9001-30-41

544J Loader (S.N. 611800— ) 032409

PN=95

Transmission Control Unit (TCU) Diagnostic Trouble Codes 4 Continuity Check

9001 30 42

YES: Circuit M28 PUR is short to pin with continuity indicated in rear frame harness. Repair circuit M28 PUR or replace rear frame harness. NO: Go to next step in this check.

Is continuity indicated with any of the other pins?

YES: Circuit M28 PUR is short to pin with continuity indicated in engine frame harness. Repair circuit M28 PUR or replace engine frame harness. NO: Go to next step in this check.

Is continuity indicated with any of the other pins?

Battery disconnect OFF.

YES: Circuit M28 PUR is short to pin with continuity indicated in load center harness. Repair circuit M28 PUR or replace load center harness.

NO: Go to next step in this check.

Is continuity indicated with any of the other pins?

– – –1/1

TM10229 (17MAR09)

9001-30-42

544J Loader (S.N. 611800— ) 032409

PN=96

Transmission Control Unit (TCU) Diagnostic Trouble Codes

522382.05 — Backup Alarm Open Circuit

Transmission backup alarm circuit is open.

9001 30 43

TF44157,000023E –19–14MAR08–1/1

Backup Alarm Open Circuit Diagnostic Procedure Alarm Level: No Warning Lamp

– – –1/1

1 Fuse Check

Turn key switch OFF.

YES: Go to Component Check.

Remove fuse (F32). See Fuse and Relay Specifications. (Group 9015-10.) NO: Fuse (F32) is blown. Replace fuse.

Check fuse (F32) for continuity. Is continuity indicated?

– – –1/1

2 Component Check

Turn key switch OFF.

YES: Go to Open Circuit Check.

Remove wire P32 RED from backup alarm and apply 24 volts. See Rear Frame Harness (W13) Component Location. (Group 9015-10.) Remove wire M28 PUR from backup alarm and apply ground.

NO: Backup alarm malfunction. Replace backup alarm.

Does alarm sound?

– – –1/1

TM10229 (17MAR09)

9001-30-43

544J Loader (S.N. 611800— ) 032409

PN=97

Transmission Control Unit (TCU) Diagnostic Trouble Codes 3 Open Circuit Check

Turn key switch OFF. Disconnect backup alarm (H3), TCU connector (X23), and VEC connector (X17). See Rear Frame Harness (W13) Component Location and see Load Center Harness (W3) Component Location. (Group 9015-10.)

9001 30 44

Check circuit M28 PUR for continuity between ring terminal on backup alarm connector and pin 7 on TCU connector (X23).

YES: Replace controller, see Transmission Control Unit (TCU) Remove and Install. (Group 9015-20.) NO: Go to next step in this check.

Check circuit P32 RED for continuity between ring terminal on backup alarm connector and pin E on VEC connector (X17). Is continuity indicated in both circuits?

Key switch OFF, TCU connector (X23) and VEC connector (X17) disconnected. Disconnect engine frame harness-to-rear frame harness connector (X39). See Engine Frame Harness (W5) Component Location. (Group 9015-10.) Check circuit M28 PUR for continuity between pin 5 on engine frame harness side of connector (X39) and pin 7 on TCU connector (X23). Check circuit P32 RED for continuity between pin 7 on engine frame harness side of connector (X39) and pin E on VEC connector (X17).

NO: Go to next step in this check.

Is continuity indicated in both circuits?

Key switch OFF, TCU connector (X23) and VEC connector (X17) disconnected. Disconnect load center harness-to-engine frame harness connector (X3). See Load Center Harness (W3) Component Location. (Group 9015-10.) Check circuit M28 PUR for continuity between pin 14 on load center harness side of connector (X3) and pin 7 on TCU connector (X23). Check circuit P32 RED for continuity between pin 26 on load center harness side of connector (X3) and pin E on VEC connector (X17). Is continuity indicated in both circuits?

YES: Open circuit in rear frame harness. Repair circuit(s) without continuity indicated or replace rear frame harness. See Rear Frame Harness (W13) Wiring Diagram. (Group 9015-10.)

YES: Open circuit in engine frame harness. Repair circuit(s) without continuity indicated or replace engine frame harness. See Engine Frame Harness (W5) Wiring Diagram. (Group 9015-10.) NO: Open circuit in load center harness. Repair circuit(s) without continuity indicated or replace load center harness. See Load Center Harness (W3) Wiring Diagram. (Group 9015-10.) – – –1/1

522383.02 — Clutch KR Slippage

Transmission control unit (TCU) detects reverse clutch is slipping.

TF44157,000023F –19–14MAR08–1/1

TM10229 (17MAR09)

9001-30-44

544J Loader (S.N. 611800— ) 032409

PN=98

Transmission Control Unit (TCU) Diagnostic Trouble Codes Clutch KR Slippage Diagnostic Procedure Alarm Level: Transmission Fault Indicator Icon

9001 30 45

– – –1/1

1 Code Check

Check for active codes. Check for the following TCU codes: 522383.03—Clutch Rev Sol Short to Power, 522383.04—Clutch Rev Sol Short to Gnd, and 522383.05—Clutch Rev Sol Open Circuit.

YES: Correct problem causing other active TCU code. See Diagnostic Trouble Codes (DTC) Quick Reference List. (Group 9015-20.)

Are any of the three TCU codes above active? NO: Go to Power Train System Pressure Check.

– – –1/1

2 Power Train System Pressure Check

Check transmission system pressure. See Transmission System Pressure Test. (Group 9020-25.)

YES: Go to Clutch Pressure Check.

Is system pressure within specification?

NO: Go to Transmission System Diagnose Malfunctions. (Group 9020-15.)

– – –1/1

3 Clutch Pressure Check

Check reverse KR clutch pressure. Perform Transmission Clutch Pressure Test. (Group 9020-25.)

YES: Go to Control Valve Solenoid Check.

Is clutch pressure within specification?

NO: Repair transmission hydraulic problem. See Transmission Clutch Pressure Test. (Group 9020-25.) See Transmission System Diagnose Malfunctions. (Group 9020-15.)

– – –1/1

TM10229 (17MAR09)

9001-30-45

544J Loader (S.N. 611800— ) 032409

PN=99

Transmission Control Unit (TCU) Diagnostic Trouble Codes 4 Control Valve Solenoid Check

Turn key switch OFF. Disconnect transmission harness-to-transmission control valve harness connector (X36). See Transmission Harness (W10) Component Location. (Group 9015-10.) Check resistance between pins 2 and 7 on transmission control valve harness side of connector (X36). See Transmission Control Valve Solenoid Check. (Group 9015-20.)

9001 30 46

Is resistance within specification?

YES: Go to Clutch Internal Speed Sensor Check. NO: Transmission control solenoid 2 (Y2) malfunction. Replace solenoid. See Transmission Control Valve Disassemble and Assemble. (Group 0360.)

– – –1/1

5 Clutch Internal Speed Sensor Check

YES: Go to Transmission Output Speed Sensor Check. NO: Internal clutch speed sensor (B30) malfunction. Replace sensor.

Specification Internal Clutch Speed Sensor (B30)— Torque ................................................................................................................... 30 N•m 22 lb-ft Measure resistance between sensor pins A and B. See Electrical Component Specifications. (Group 9015-20.) Is resistance within specification?

– – –1/1

6 Transmission Output Speed Sensor Check

Turn key switch OFF. Disconnect transmission output speed sensor (B31). See Transmission Harness (W10) Component Location. (Group 9015-10.)

YES: Replace transmission output speed sensor (B31). NO: Replace controller, see Transmission Control Unit (TCU) Remove and Install. (Group 9015-20.)

Verify transmission output speed sensor (B31) is installed to correct torque specification to ensure correct gap distance. Specification Transmission Output Speed Sensor (B31)—Torque ....................................................................................................... 30 N•m 22 lb-ft Connect transmission output speed sensor (B31). Start engine and operate machine under load. Check for active codes. Is transmission control unit (TCU) code 522383.02 present?

– – –1/1

TM10229 (17MAR09)

9001-30-46

544J Loader (S.N. 611800— ) 032409

PN=100

Transmission Control Unit (TCU) Diagnostic Trouble Codes

522383.03 — Clutch Rev Sol Short to Power

Transmission KR clutch solenoid is short to power.

9001 30 47

TF44157,0000240 –19–14MAR08–1/1

Clutch Reverse Solenoid Short to Power Diagnostic Procedure Alarm Level: No Warning Lamp

– – –1/1

1 Component Check

Turn key switch OFF.

YES: Go to Short Circuit Check.

Disconnect transmission harness-to-transmission control valve harness connector (X36). See Transmission Harness (W10) Component Location. (Group 9015-10.) Check resistance between pins 2 and 7 on transmission control valve harness side of connector (X36). See Transmission Control Valve Solenoid Check. (Group 9015-20.) Is resistance within specification?

NO: Replace transmission control solenoid 2 (Y2). See Transmission Control Valve Disassemble and Assemble. (Group 0360.)

– – –1/1

TM10229 (17MAR09)

9001-30-47

544J Loader (S.N. 611800— ) 032409

PN=101

Transmission Control Unit (TCU) Diagnostic Trouble Codes 2 Short Circuit Check

Turn key switch OFF. Disconnect transmission harness-to-transmission control valve harness connector (X36). See Transmission Harness (W10) Component Location. (Group 9015-10.) Check circuit T04 BLU for resistance between pin 2 and all other pins on transmission control valve harness side of connector (X36).

9001 30 48

Is resistance with any wire less than 5 ohms?

YES: Circuit T04 BLU is short to wire with resistance less than 5 ohms. Repair wire T04 BLU or replace transmission control valve harness. For procedure to disassemble transmission control valve, see Transmission Control Valve Disassemble and Assemble. (Group 0360.) NO: Go to next step in this check.

Key switch ON and transmission harness-to-transmission control valve harness connector (X36) disconnected.

YES: Go to next step in this check.

Check circuit T04 BLU for voltage between pin 2 on transmission harness side of connector (X36) and machine ground. See Transmission Harness (W10) Wiring Diagram. (Group 9015-10.)

NO: Go to Continuity Check.

Is system voltage (approximately 24 volts) present?

Turn key switch OFF. Disconnect load center harness-to-transmission harness connector (X22). See Load Center Harness (W3) Component Location. (Group 9015-10.)

YES: Short to power in load center harness. Repair circuit T04 BLU or replace load center harness.

Turn key switch ON. Check circuit T04 BLU for voltage between pin L on load center harness side of connector (X22) and machine ground. See Load Center Harness (W3) Wiring Diagram. (Group 9015-10.)

NO: Short to power in transmission harness. Repair circuit T04 BLU or replace transmission harness.

Is system voltage (approximately 24 volts) present? – – –1/1

TM10229 (17MAR09)

9001-30-48

544J Loader (S.N. 611800— ) 032409

PN=102

Transmission Control Unit (TCU) Diagnostic Trouble Codes 3 Continuity Check

Turn battery disconnect OFF.

YES: Circuit T04 BLU is short to pin with continuity indicated in transmission harness. Repair circuit T04 BLU or replace transmission harness.

Disconnect transmission harness-to-transmission control valve harness connector (X36) and load center harness-to-transmission harness connector (X22). See Transmission Harness (W10) Component Location. (Group 9015-10.) Check continuity between pin L (circuit T04 BLU) on transmission harness side of connector (X22) and all other pins on connector (X22). See Transmission Harness (W10) Wiring Diagram. (Group 9015-10.)

NO: Go to next step in this check.

Is continuity indicated with any other pins?

Battery disconnect OFF. Load center harness-to-transmission harness connector (X22) is disconnected. Disconnect transmission control unit (TCU) connector (X23). See Load Center Harness (W3) Component Location. (Group 9015-10.) Check continuity between pin L (circuit T04 BLU) on load center harness side of connector (X22) and all other pins on connector (X22). See Load Center Harness (W3) Wiring Diagram. (Group 9015-10.)

YES: Circuit T04 BLU is short to pin with continuity indicated in load center harness. Repair circuit T04 BLU or replace load center harness. NO: Go to next step in this check.

Is continuity indicated with any other pins?

Battery disconnect OFF. Load center harness-to-transmission harness connector (X22) is disconnected and TCU connector (X23) is disconnected. Check continuity between pin 10 (circuit T04 BLU) on TCU connector (X23) and all other pins on connector (X23). See Load Center Harness (W3) Wiring Diagram. (Group 9015-10.) Is continuity indicated with any other pins?

YES: Circuit T04 BLU is short to pin with continuity indicated in load center harness. Repair circuit T04 BLU or replace load center harness. NO: Replace controller, see Transmission Control Unit (TCU) Remove and Install. (Group 9015-20.)

– – –1/1

522383.04 — Clutch Rev Sol Short to Gnd

Transmission KR clutch solenoid short to ground.

TF44157,0000241 –19–14MAR08–1/1

TM10229 (17MAR09)

9001-30-49

544J Loader (S.N. 611800— ) 032409

PN=103

9001 30 49

Transmission Control Unit (TCU) Diagnostic Trouble Codes Clutch Reverse Solenoid Short to Ground Diagnostic Procedure Alarm Level: 9001 30 50

No Warning Lamp

– – –1/1

1 Component Check

YES: Go to Short Circuit Check—Short to Solenoid Circuits. NO: Replace transmission control solenoid 2 (Y2). See Transmission Control Valve Disassemble and Assemble. (Group 0360.)

– – –1/1

TM10229 (17MAR09)

9001-30-50

544J Loader (S.N. 611800— ) 032409

PN=104

Transmission Control Unit (TCU) Diagnostic Trouble Codes 2 Short Circuit Check— Short to Solenoid Circuits

Turn key switch OFF. Disconnect transmission harness-to-transmission control valve harness connector (X36). See Transmission Harness (W10) Component Location. (Group 9015-10.) Check circuit T04 BLU for continuity between pin 2 on transmission control valve harness side of connector (X36) and pins 1, 3, 4, 5, and 6.

YES: Circuit T04 BLU is short to circuit with continuity indicated. Repair or replace transmission control valve harness. For procedure to disassemble transmission control valve, see Transmission Control Valve Disassemble and Assemble. (Group 0360.)

Is continuity indicated between pin 2 and any of the other pins?

NO: Go to next step in this check.

Key switch OFF and transmission harness-to-transmission control valve harness connector (X36) disconnected.

YES: Go to next step in this check.

Disconnect transmission control unit (TCU) connector (X23). See Load Center Harness (W3) Component Location. (Group 9015-10.)

NO: Go to Short Circuit Check—Short to Ground.

Check circuit T04 BLU for continuity between pin 2 on transmission harness side of connector (X36) and pins 1, 3, 4, 5, and 6. See Transmission Harness (W10) Wiring Diagram. (Group 9015-10.) Is continuity indicated between pin 2 and any of the other pins?

Key switch OFF and TCU connector (X23) disconnected. Disconnect load center harness-to-transmission harness connector (X22). See Load Center Harness (W3) Component Location. (Group 9015-10.) Check circuit T04 BLU for continuity between pin L on load center harness side of connector (X22) and pins C, D, E, F, and K. See Load Center Harness (W3) Wiring Diagram. (Group 9015-10.) Is continuity indicated between pin L and any of the other pins?

YES: Circuit T04 BLU is short in the load center harness. Repair circuit T04 BLU or replace load center harness. NO: Circuit T04 BLU is short in the transmission harness. Repair circuit T04 BLU or replace transmission harness.

– – –1/1

TM10229 (17MAR09)

9001-30-51

544J Loader (S.N. 611800— ) 032409

PN=105

9001 30 51

Transmission Control Unit (TCU) Diagnostic Trouble Codes 3 Short Circuit Check— Short to Ground

Turn key switch OFF. Disconnect transmission harness-to-transmission control valve harness connector (X36). See Transmission Harness (W10) Component Location. (Group 9015-10.) Check circuit T04 BLU for ground at pin 2 on transmission control valve harness side of connector (X36).

9001 30 52

Is ground present?

YES: Circuit T04 BLU is short to ground in the transmission control valve harness. Repair circuit T04 BLU or replace transmission control valve harness. For procedure to disassemble transmission control valve, see Transmission Control Valve Disassemble and Assemble. (Group 0360.) NO: Go to next step in this check.

Key switch OFF and transmission harness-to-transmission control valve harness connector (X36) disconnected.

YES: Go to next step in this check.

Disconnect TCU connector (X23). See Load Center Harness (W3) Component Location. (Group 9015-10.)

NO: Go to Continuity Check.

Check circuit T04 BLU for ground at pin L on transmission harness side of connector (X22). See Transmission Harness (W10) Wiring Diagram. (Group 9015-10.) Is ground present?

Key switch OFF and TCU connector (X23) disconnected. Disconnect load center harness-to-transmission harness connector (X22). See Load Center Harness (W3) Component Location. (Group 9015-10.) Check circuit T04 BLU for ground at pin 10 on TCU connector (X23). See Load Center Harness (W3) Wiring Diagram. (Group 9015-10.) Is ground present?

YES: Short to ground in load center harness. Repair circuit T04 BLU or replace load center harness. NO: Short to ground in transmission harness. Repair circuit T04 BLU or replace transmission harness.

– – –1/1

TM10229 (17MAR09)

9001-30-52

544J Loader (S.N. 611800— ) 032409

PN=106

Transmission Control Unit (TCU) Diagnostic Trouble Codes 4 Continuity Check

Turn battery disconnect OFF.

YES: Circuit T04 BLU is short to pin with continuity indicated in transmission harness. Repair circuit T04 BLU or replace transmission harness.

NO: Go to next step in this check.

Is continuity indicated with any other pins?

YES: Circuit T04 BLU is short to pin with continuity indicated in load center harness. Repair circuit T04 BLU or replace load center harness. NO: Go to next step in this check.

Is continuity indicated with any other pins?

– – –1/1

522383.05 — Clutch Rev Sol Open Circuit

Transmission KR clutch solenoid circuit is open.

TF44157,0000242 –19–14MAR08–1/1

TM10229 (17MAR09)

9001-30-53

544J Loader (S.N. 611800— ) 032409

PN=107

9001 30 53

Transmission Control Unit (TCU) Diagnostic Trouble Codes Clutch Reverse Solenoid Open Circuit Diagnostic Procedure Alarm Level: 9001 30 54

No Warning Lamp

– – –1/1

1 Component Check

Turn key switch OFF.

YES: Go to Open Circuit Check.

Disconnect transmission harness-to-transmission control valve harness connector (X36). See Transmission Harness (W10) Component Location. (Group 9015-10.)

NO: Go to next step in this check.

Check resistance between pins 2 and 7 on transmission control valve side of connector (X36). See Transmission Control Valve Solenoid Check. (Group 9015-20.) Is resistance within specification?

Turn key switch OFF. Disassemble transmission control valve to access control solenoid (Y2). See Transmission Control Valve Disassemble and Assemble. (Group 0360.)

YES: Open circuit in transmission control valve harness. Replace transmission control valve harness.

Disconnect transmission control solenoid (Y2). Check resistance at connector on transmission control solenoid (Y2). See Transmission Control Valve Solenoid Check. (Group 9015-20.)

NO: Transmission control solenoid (Y2) malfunction. Replace solenoid.

Is resistance within specification? – – –1/1

TM10229 (17MAR09)

9001-30-54

544J Loader (S.N. 611800— ) 032409

PN=108

Transmission Control Unit (TCU) Diagnostic Trouble Codes 2 Open Circuit Check

Turn key switch OFF.

YES: Replace controller, see Transmission Control Unit (TCU) Remove and Install. (Group 9015-20.)

Disconnect transmission harness-to-transmission control valve harness connector (X36) and TCU connector (X23). See Transmission Harness (W10) Component Location and see Load Center Harness (W3) Component Location. (Group 9015-10.)

NO: Go to next step in this check.

Check circuit T04 BLU for continuity between pin 2 on transmission harness side connector (X36) and pin 10 on TCU connector (X23). See Transmission Harness (W10) Wiring Diagram and see Load Center Harness (W3) Wiring Diagram. (Group 9015-10.) Is continuity indicated?

Key switch OFF and TCU connector (X23) disconnected.

YES: Open circuit in transmission harness. Repair circuit T04 BLU or replace transmission harness.

Disconnect load center harness-to-transmission harness connector (X22). See Load Center Harness (W3) Component Location. (Group 9015-10.) Check circuit T04 BLU for continuity between pin L on load center harness side of connector (X22) and pin 10 on TCU connector (X23). See Load Center Harness (W3) Wiring Diagram. (Group 9015-10.) Is continuity indicated?

NO: Open circuit in load center harness. Repair circuit T04 BLU or replace load center harness.

– – –1/1

522386.02 — Clutch KV Slippage

TCU detects forward clutch is slipping.

TF44157,0000243 –19–14MAR08–1/1

Clutch KV Slippage Diagnostic Procedure Alarm Level: Transmission Fault Indicator Icon

– – –1/1

TM10229 (17MAR09)

9001-30-55

544J Loader (S.N. 611800— ) 032409

PN=109

9001 30 55

Transmission Control Unit (TCU) Diagnostic Trouble Codes 1 Code Check

Check for active codes. Check for the following TCU codes: 522386.03—Clutch Fwd Sol Short to Power, 522386.04—Clutch Fwd Sol Short to Gnd, and 522386.05—Clutch Fwd Sol Solenoid Open.

9001 30 56

YES: Correct problem causing other active TCU code(s). See Diagnostic Trouble Codes (DTC) Quick Reference List. (Group 9015-20.)

Are any of the three TCU codes above active? NO: Go to Power Train System Pressure Check.

– – –1/1

2 Power Train System Pressure Check

Check transmission system pressure. See Transmission System Pressure Test. (Group 9020-25.)

YES: Go to Clutch Pressure Check.

Is system pressure within specification?

NO: See Transmission System Diagnose Malfunctions. (Group 9020-15.)

– – –1/1

3 Clutch Pressure Check

Check forward KV clutch pressure. Perform Transmission Clutch Pressure Test. (Group 9020-25.)

YES: Go to Control Valve Solenoid Check.

Is clutch pressure within specifications?

NO: Repair transmission hydraulic problem. See Transmission Clutch Pressure Test. (Group 9020-25.) See Transmission System Diagnose Malfunctions. (Group 9020-15.)

– – –1/1

4 Control Valve Solenoid Check

Turn key switch OFF Disconnect transmission harness-to-transmission control valve harness connector (X36). See Transmission Harness (W10) Component Location. (Group 9015-10.) Check resistance between pins 5 and 7 on transmission control valve harness side of connector (X36). See Transmission Control Valve Solenoid Check. (Group 9015-20.) Is resistance within specification?

YES: Go to Clutch Internal Speed Sensor Check. NO: Transmission control solenoid 5 (Y5) malfunction. Replace solenoid. See Transmission Control Valve Disassemble and Assemble. (Group 0360.)

– – –1/1

TM10229 (17MAR09)

9001-30-56

544J Loader (S.N. 611800— ) 032409

PN=110

Transmission Control Unit (TCU) Diagnostic Trouble Codes 5 Clutch Internal Speed Sensor Check

Turn key switch OFF.

YES: Go to Transmission Output Speed Sensor Check.

Disconnect internal clutch speed sensor (B30). See Transmission Harness (W10) Component Location. (Group 9015-10.) Verify internal clutch speed sensor (B30) is installed to correct torque specification to ensure correct gap distance. Specification Internal Clutch Speed Sensor (B30)— Torque ................................................................................................................... 30 N•m 22 lb-ft

NO: Clutch internal speed sensor (B30) malfunction. 9001 Replace sensor. 30 57

Measure resistance between sensor pins A and B. See Electrical Component Specifications. (Group 9015-20.) Is resistance within specification?

– – –1/1

6 Transmission Output Speed Sensor Check

Turn key switch OFF. Disconnect transmission output speed sensor (B31). See Transmission Harness (W10) Component Location. (Group 9015-10.)

YES: Replace transmission output speed sensor (B31). NO: Replace controller, see Transmission Control Unit (TCU) Remove and Install. (Group 9015-20.)

– – –1/1

522386.03 — Clutch Fwd Sol Short to Power

Transmission KV forward clutch solenoid is short to power.

TF44157,0000244 –19–14MAR08–1/1

TM10229 (17MAR09)

9001-30-57

544J Loader (S.N. 611800— ) 032409

PN=111

Transmission Control Unit (TCU) Diagnostic Trouble Codes Clutch Forward Solenoid Short to Power Diagnostic Procedure Alarm Level: 9001 30 58

No Warning Lamp

– – –1/1

1 Component Check

Turn key switch OFF.

YES: Go to Short Circuit Check.

Disconnect transmission harness-to-transmission control valve harness connector (X36). See Transmission Harness (W10) Component Location. (Group 9015-10.) Check resistance between pins 5 and 7 on transmission control valve side of connector (X36). See Transmission Control Valve Solenoid Check. (Group 9015-20.) Is resistance within specification?

NO: Replace transmission control solenoid 5 (Y5). See Transmission Control Valve Disassemble and Assemble. (Group 0360.)

– – –1/1

TM10229 (17MAR09)

9001-30-58

544J Loader (S.N. 611800— ) 032409

PN=112

Transmission Control Unit (TCU) Diagnostic Trouble Codes 2 Short Circuit Check

Turn key switch OFF. Disconnect transmission harness-to-transmission control valve harness connector (X36). See Transmission Harness (W10) Component Location. (Group 9015-10.) Check circuit T07 BLU for resistance between pin 5 and all other pins on transmission control valve harness side of connector (X36). Is resistance with any wire less than 5 ohms?

YES: Circuit T07 BLU is short to wire with resistance less than 5 ohms. Repair circuit T07 BLU or replace transmission control valve 9001 harness. 30 59 See Transmission Control Valve Disassemble and Assemble. (Group 0360.) NO: Go to next step in this check.

Key switch ON and transmission harness-to-transmission control valve harness connector (X36) disconnected.

YES: Go to next step in this check.

Check circuit T07 BLU for voltage between pin 5 on transmission harness side of connector (X36) and machine ground. See Transmission Harness (W10) Wiring Diagram. (Group 9015-10.)

NO: Go to Continuity Check.

Is system voltage (approximately 24 volts) present?

Turn key switch OFF. Disconnect load center harness-to-transmission harness connector (X22). See Load Center Harness (W3) Component Location. (Group 9015-10.)

YES: Short to power in load center harness. Repair circuit T07 BLU or replace load center harness.

Turn key switch ON. Check circuit T07 BLU for voltage between pin D on load center harness side of connector (X22) and machine ground. See Load Center Harness (W3) Wiring Diagram. (Group 9015-10.)

NO: Short to power in transmission harness. Repair circuit T07 BLU or replace transmission harness.

Is system voltage (approximately 24 volts) present?

– – –1/1

TM10229 (17MAR09)

9001-30-59

544J Loader (S.N. 611800— ) 032409

PN=113

Transmission Control Unit (TCU) Diagnostic Trouble Codes 3 Continuity Check

Turn battery disconnect OFF.

YES: Circuit T07 BLU is short to pin with continuity indicated in transmission harness. Repair circuit T07 BLU or replace transmission harness.

Check continuity between pin D (circuit T07 BLU) on transmission harness side of connector (X22) and all other pins on connector (X22). See Transmission Harness (W10) Wiring Diagram. (Group 9015-10.)

NO: Go to next step in this check.

Is continuity indicated with any other pins?

Battery disconnect OFF. Load center harness-to-transmission harness connector (X22) is disconnected. Disconnect transmission control unit (TCU) connector (X23). See Load Center Harness (W3) Component Location. (Group 9015-10.) Check continuity between pin D (circuit T07 BLU) on load center harness side of connector (X22) and all other pins on connector (X22). See Load Center Harness (W3) Wiring Diagram. (Group 9015-10.)

YES: Circuit T07 BLU is short to pin with continuity indicated in load center harness. Repair circuit T07 BLU or replace load center harness. NO: Go to next step in this check.

Is continuity indicated with any other pins?

Battery disconnect OFF. Load center harness-to-transmission harness connector (X22) is disconnected and TCU connector (X23) is disconnected. Check continuity between pin 9 (circuit T07 BLU) on TCU connector (X23) and all other pins on connector (X23). See Load Center Harness (W3) Wiring Diagram. (Group 9015-10.) Is continuity indicated with any other pins?

YES: Circuit T07 BLU is short to pin with continuity indicated in load center harness. Repair circuit T07 BLU or replace load center harness. NO: Replace controller, see Transmission Control Unit (TCU) Remove and Install. (Group 9015-20.)

– – –1/1

522386.04 — Clutch Fwd Sol Short to Gnd

Transmission KV clutch solenoid is short to ground.

TF44157,0000245 –19–14MAR08–1/1

TM10229 (17MAR09)

9001-30-60

544J Loader (S.N. 611800— ) 032409

PN=114

Transmission Control Unit (TCU) Diagnostic Trouble Codes Clutch Forward Solenoid Short to Ground Diagnostic Procedure Alarm Level: No Warning Lamp

9001 30 61

– – –1/1

1 Component Check

Turn key switch OFF. Disconnect transmission harness-to-transmission control valve harness connector (X36). See Transmission Harness (W10) Component Location. (Group 9015-10.) Check resistance between pins 5 and 7 on transmission control valve side of connector (X36). See Transmission Control Valve Solenoid Check. (Group 9015-20.) Is resistance within specification?

YES: Go to Short Circuit Check—Short to Solenoid Circuits. NO: Replace transmission control solenoid 5 (Y5). See Transmission Control Valve Disassemble and Assemble. (Group 0360.)

– – –1/1

TM10229 (17MAR09)

9001-30-61

544J Loader (S.N. 611800— ) 032409

PN=115

Transmission Control Unit (TCU) Diagnostic Trouble Codes 2 Short Circuit Check— Short to Solenoid Circuits

Turn key switch OFF. Disconnect transmission harness-to-transmission control valve harness connector (X36). See Transmission Harness (W10) Component Location. (Group 9015-10.) Check circuit T07 BLU for continuity between pin 5 on transmission control valve harness side of connector (X36) and pins 1, 2, 3, 4, and 6.

9001 30 62

YES: Circuit T07 BLU is short to circuit with continuity indicated. Repair or replace transmission control valve harness. See Transmission Control Valve Disassemble and Assemble. (Group 0360.)

Is continuity indicated between pin 5 and any of the other pins?

NO: Go to next step in this check.

Key switch OFF and transmission harness-to-transmission control valve harness connector (X36) disconnected.

YES: Go to next step in this check.

Disconnect transmission control unit (TCU) connector (X23). See Load Center Harness (W3) Component Location. (Group 9015-10.)

NO: Go to Short Circuit Check—Short to Ground.

Check circuit T07 BLU for continuity between pin 5 on transmission harness side of connector (X36) and pins 1, 2, 3, 4, and 6. See Transmission Harness (W10) Wiring Diagram. (Group 9015-10.) Is continuity indicated between pin 5 and any of the other pins?

Key switch OFF and TCU connector (X23) disconnected. Disconnect load center harness-to-transmission harness connector (X22). See Load Center Harness (W3) Component Location. (Group 9015-10.) Check circuit T07 BLU for continuity between pin D on load center harness side of connector (X22) and pins C, E, F, K, and L. See Load Center Harness (W3) Wiring Diagram. (Group 9015-10.) Is continuity indicated between pin D and any of the other pins?

YES: Circuit T07 BLU is short in the load center harness. Repair circuit T07 BLU or replace load center harness. NO: Circuit T07 BLU is short in the transmission harness. Repair circuit T07 BLU or replace transmission harness.

– – –1/1

TM10229 (17MAR09)

9001-30-62

544J Loader (S.N. 611800— ) 032409

PN=116

Transmission Control Unit (TCU) Diagnostic Trouble Codes 3 Short Circuit Check— Short to Ground

Turn key switch OFF. Disconnect transmission harness-to-transmission control valve harness connector (X36). See Transmission Harness (W10) Component Location. (Group 9015-10.) Check circuit T07 BLU for ground at pin 5 on transmission control valve harness side of connector (X36). Is ground present?

YES: Circuit T07 BLU is short to ground in the transmission control valve harness. Repair circuit T07 BLU or replace transmission control valve 9001 harness. 30 63 See Transmission Control Valve Disassemble and Assemble. (Group 0360.) NO: Go to next step in this check.

Key switch OFF and transmission harness-to-transmission control valve harness connector (X36) disconnected.

YES: Go to next step in this check.

Disconnect TCU connector (X23). See Load Center Harness (W3) Component Location. (Group 9015-10.)

NO: Go to Continuity Check.

Check circuit T07 BLU for ground at pin 5 on transmission harness side of connector (X36). See Transmission Harness (W10) Wiring Diagram. (Group 9015-10.) Is ground present?

Key switch OFF and TCU connector (X23) disconnected. Disconnect load center harness-to-transmission harness connector (X22). See Load Center Harness (W3) Component Location. (Group 9015-10.) Check circuit T07 BLU for ground at pin 9 on TCU connector (X23). See Load Center Harness (W3) Wiring Diagram. (Group 9015-10.) Is ground present?

YES: Short to ground in load center harness. Repair circuit T07 BLU or replace load center harness. NO: Short to ground in transmission harness. Repair circuit T07 BLU or replace transmission harness.

– – –1/1

TM10229 (17MAR09)

9001-30-63

544J Loader (S.N. 611800— ) 032409

PN=117

Transmission Control Unit (TCU) Diagnostic Trouble Codes 4 Continuity Check

Turn battery disconnect OFF.

YES: Circuit T07 BLU is short to pin with continuity indicated in transmission harness. Repair circuit T07 BLU or replace transmission harness.

Check continuity between pin D (circuit T07 BLU) on transmission harness side of connector (X22) and all other pins on connector (X22). See Transmission Harness (W10) Wiring Diagram. (Group 9015-10.)

NO: Go to next step in this check.

Is continuity indicated with any other pins?

Battery disconnect OFF. Load center harness-to-transmission harness connector (X22) is disconnected. Disconnect transmission control unit (TCU) connector (X23). See Load Center Harness (W3) Component Location. (Group 9015-10.) Check continuity between pin D (circuit T07 BLU) on load center harness side of connector (X22) and all other pins on connector (X22). See Load Center Harness (W3) Wiring Diagram. (Group 9015-10.)

YES: Circuit T07 BLU is short to pin with continuity indicated in load center harness. Repair circuit T07 BLU or replace load center harness. NO: Go to next step in this check.

Is continuity indicated with any other pins?

– – –1/1

522386.05 — Clutch Fwd Sol Solenoid Open

Transmission KV clutch solenoid circuit is open.

TF44157,0000246 –19–14MAR08–1/1

TM10229 (17MAR09)

9001-30-64

544J Loader (S.N. 611800— ) 032409

PN=118

Transmission Control Unit (TCU) Diagnostic Trouble Codes Clutch Forward Solenoid Open Circuit Diagnostic Procedure Alarm Level: No Warning Lamp

9001 30 65

– – –1/1

1 Component Check

Turn key switch OFF.

YES: Go to Open Circuit Check.

Disconnect transmission harness-to-transmission control valve harness connector (X36). See Transmission Harness (W10) Component Location. (Group 9015-10.)

NO: Go to next step in this check.

Check resistance between pins 5 and 7 on transmission control valve side of connector (X36). See Transmission Control Valve Solenoid Check. (Group 9015-20.) Is resistance within specification?

Turn key switch OFF.

YES: Open circuit in transmission control valve harness. Replace transmission control valve harness.

Disassemble transmission control valve to access control solenoid (Y5). See Transmission Control Valve Disassemble and Assemble. (Group 0360.) Disconnect transmission control solenoid (Y5). Check resistance at connector on transmission control solenoid (Y5). See Electrical Component Specifications. (Group 9015-20.)

NO: Transmission control solenoid (Y5) malfunction. Replace solenoid.

Is resistance within specification? – – –1/1

TM10229 (17MAR09)

9001-30-65

544J Loader (S.N. 611800— ) 032409

PN=119

Transmission Control Unit (TCU) Diagnostic Trouble Codes 2 Open Circuit Check

Turn key switch OFF.

YES: Replace controller, see Transmission Control Unit (TCU) Remove and Install. (Group 9015-20.)

Check circuit T07 BLU for continuity between pin 5 on transmission harness side connector (X36) and pin 9 on TCU connector (X23). See Transmission Harness (W10) Wiring Diagram and see Load Center Harness (W3) Wiring Diagram. (Group 9015-10.)

NO: Go to next step in this check.

Is continuity indicated?

Key switch OFF and TCU connector (X23) disconnected. Disconnect load center harness-to-transmission harness connector (X22). See Load Center Harness (W3) Component Location. (Group 9015-10.) Check circuit T07 BLU for continuity between pin D on load center harness side of connector (X22) and pin 9 on TCU connector (X23). See Load Center Harness (W3) Wiring Diagram. (Group 9015-10.) Is continuity indicated?

YES: Open circuit in transmission harness. Repair circuit T07 BLU or replace transmission harness. NO: Open circuit in load center harness. Repair circuit T07 BLU or replace load center harness.

– – –1/1

522389.02 — Clutch K4 Slippage

TCU detects transmission control clutch K4 is slipping.

TF44157,0000247 –19–14MAR08–1/1

Clutch K4 Slippage Diagnostic Procedure Alarm Level: Transmission Fault Indicator Icon

– – –1/1

TM10229 (17MAR09)

9001-30-66

544J Loader (S.N. 611800— ) 032409

PN=120

Transmission Control Unit (TCU) Diagnostic Trouble Codes 1 Code Check

Check for active codes. Check for the following TCU codes: 522389.03—Clutch K4 Sol Short to Power, 522389.04—Clutch K4 Sol Short to Gnd, and 522389.05—Clutch K4 Sol Open Circuit. Are any of the three TCU codes above active?

YES: Correct problem causing other active TCU code(s). See Diagnostic Trouble Codes (DTC) Quick Reference List. (Group 9015-20.) NO: Go to Power Train System Pressure Check.

– – –1/1

2 Power Train System Pressure Check

Check transmission system pressure. See Transmission System Pressure Test. (Group 9020-25.)

YES: Go to Clutch Pressure Check.

Is system pressure within specification?

NO: See Transmission System Diagnose Malfunctions. (Group 9020-15.)

– – –1/1

3 Clutch Pressure Check

Check transmission clutch K4 pressure. Perform Transmission Clutch Pressure Test. (Group 9020-25.)

YES: Go to Control Valve Solenoid Check.

Is clutch pressure within specification?

NO: Repair transmission hydraulic problem. See Transmission Clutch Pressure Test. (Group 9020-25.) See Transmission System Diagnose Malfunctions. (Group 9020-15.)

– – –1/1

4 Control Valve Solenoid Check

Check transmission control solenoid 1 (Y1). Disconnect transmission harness-to-transmission control valve harness connector (X36). See Transmission Harness (W10) Component Location. (Group 9015-10.) Check resistance of solenoid between pins 1 and 7 on transmission control valve harness side of connector (X36). See Transmission Control Valve Solenoid Check. (Group 9015-20.) Is resistance within specification?

YES: Go to Clutch Internal Speed Sensor Check. NO: Transmission control solenoid 1 (Y1) malfunction. Replace solenoid. See Transmission Control Valve Disassemble and Assemble. (Group 0360.)

– – –1/1

TM10229 (17MAR09)

9001-30-67

544J Loader (S.N. 611800— ) 032409

PN=121

9001 30 67

Transmission Control Unit (TCU) Diagnostic Trouble Codes 5 Clutch Internal Speed Sensor Check

Turn key switch OFF.

YES: Go to Transmission Output Speed Sensor Check.

Disconnect internal clutch speed sensor (B30). See Transmission Harness (W10) Component Location. (Group 9015-10.)

NO: Internal clutch speed sensor (B30) malfunction. Replace sensor.

Verify internal clutch speed sensor (B30) is installed to correct torque specification to ensure correct gap distance.

9001 30 68

– – –1/1

6 Transmission Output Speed Sensor Check

Turn key switch OFF. Disconnect transmission output speed sensor (B31). See Transmission Harness (W10) Component Location. (Group 9015-10.)

YES: Replace transmission output speed sensor (B31). NO: Replace controller, see Transmission Control Unit (TCU) Remove and Install. (Group 9015-20.)

Verify transmission output speed sensor (B31) is installed to correct torque specification to ensure correct gap distance. Specification Internal Clutch Speed Sensor (B30)— Torque ................................................................................................................... 30 N•m 22 lb-ft Connect transmission output speed sensor (B31). Start engine and operate machine under load. Check for active codes. Is transmission control unit (TCU) code 522389.02 present?

– – –1/1

522389.03 — Clutch K4 Sol Short to Power

Transmission clutch K4 control solenoid (Y1) is short to power.

TF44157,0000248 –19–14MAR08–1/1

TM10229 (17MAR09)

9001-30-68

544J Loader (S.N. 611800— ) 032409

PN=122

Transmission Control Unit (TCU) Diagnostic Trouble Codes Clutch K4 Control Solenoid Short to Power Diagnostic Procedure Alarm Level: No Warning Lamp

9001 30 69

– – –1/1

1 Component Check

Turn key switch OFF.

YES: Go to Short Circuit Check.

Disconnect transmission harness-to-transmission control valve harness connector (X36). See Transmission Harness (W10) Component Location. (Group 9015-10.) Check resistance between pins 1 and 7 on transmission control valve side of connector (X36). See Transmission Control Valve Solenoid Check. (Group 9015-20.) Is resistance within specification?

NO: Replace transmission control solenoid 1 (Y1). See Transmission Control Valve Disassemble and Assemble. (Group 0360.)

– – –1/1

TM10229 (17MAR09)

9001-30-69

544J Loader (S.N. 611800— ) 032409

PN=123

Transmission Control Unit (TCU) Diagnostic Trouble Codes 2 Short Circuit Check

Turn key switch OFF. Disconnect transmission harness-to-transmission control valve harness connector (X36). See Transmission Harness (W10) Component Location. (Group 9015-10.) Check circuit T03 BLU for resistance between pin 1 and all other pins on transmission control valve harness side of connector (X36).

9001 30 70

Is resistance with any wire less than 5 ohms?

YES: Circuit T03 BLU is short to wire with resistance less than 5 ohms. Repair wire T03 BLU or replace transmission control valve harness. See Transmission Control Valve Disassemble and Assemble. (Group 0360.) NO: Go to next step in this check.

Key switch ON.

YES: Go to next step in this check.

Transmission harness-to-transmission control valve harness connector (X36) is disconnected.

NO: Go to Continuity Check.

Check circuit T03 BLU for voltage between pin 1 on transmission harness side of connector (X36) and machine ground. See Transmission Harness (W10) Wiring Diagram. (Group 9015-10.) Is system voltage (approximately 24 volts) present?

Turn key switch OFF. Disconnect load center harness-to-transmission harness connector (X22). See Load Center Harness (W3) Component Location. (Group 9015-10.)

YES: Short to power in load center harness. Repair circuit T03 BLU or replace load center harness.

Turn key switch ON. Check circuit T03 BLU for voltage between pin K on load center harness side of connector (X22) and machine ground. See Load Center Harness (W3) Wiring Diagram. (Group 9015-10.)

NO: Short to power in transmission harness. Repair circuit T03 BLU or replace transmission harness.

Is system voltage (approximately 24 volts) present? – – –1/1

TM10229 (17MAR09)

9001-30-70

544J Loader (S.N. 611800— ) 032409

PN=124

Transmission Control Unit (TCU) Diagnostic Trouble Codes 3 Continuity Check

Turn battery disconnect OFF.

YES: Circuit T03 BLU is short to pin with continuity indicated in transmission harness. Repair circuit T03 BLU or replace transmission harness.

Disconnect transmission harness-to-transmission control valve harness connector (X36) and load center harness-to-transmission harness connector (X22). See Transmission Harness (W10) Component Location. (Group 9015-10.) Check continuity between pin K (circuit T03 BLU) on transmission harness side of connector (X22) and all other pins on connector (X22). See Transmission Harness (W10) Wiring Diagram. (Group 9015-10.)

NO: Go to next step in this check.

Is continuity indicated with any other pins?

Battery disconnect OFF. Load center harness-to-transmission harness connector (X22) is disconnected. Disconnect transmission control unit (TCU) connector (X23). See Load Center Harness (W3) Component Location. (Group 9015-10.) Check continuity between pin K (circuit T03 BLU) on load center harness side of connector (X22) and all other pins on connector (X22). See Load Center Harness (W3) Wiring Diagram. (Group 9015-10.)

YES: Circuit T03 BLU is short to pin with continuity indicated in load center harness. Repair circuit T03 BLU or replace load center harness. NO: Go to next step in this check.

Is continuity indicated with any other pins?

Battery disconnect OFF. Load center harness-to-transmission harness connector (X22) is disconnected and TCU connector (X23) is disconnected. Check continuity between pin 56 (circuit T03 BLU) on TCU connector (X23) and all other pins on connector (X23). See Load Center Harness (W3) Wiring Diagram. (Group 9015-10.) Is continuity indicated with any other pins?

YES: Circuit T03 BLU is short to pin with continuity indicated in load center harness. Repair circuit T03 BLU or replace load center harness. NO: Replace controller, see Transmission Control Unit (TCU) Remove and Install. (Group 9015-20.)

– – –1/1

522389.04 — Clutch K4 Sol Short to Gnd

Transmission clutch K4 control solenoid (Y1) short to ground.

TF44157,0000249 –19–14MAR08–1/1

TM10229 (17MAR09)

9001-30-71

544J Loader (S.N. 611800— ) 032409

PN=125

9001 30 71

Transmission Control Unit (TCU) Diagnostic Trouble Codes Clutch K4 Control Solenoid Short to Ground Diagnostic Procedure Alarm Level: 9001 30 72

No Warning Lamp

– – –1/1

1 Component Check

Turn key switch OFF. Disconnect transmission harness-to-transmission control valve harness connector (X36). See Transmission Harness (W10) Component Location. (Group 9015-10.) Check resistance between pins 1 and 7 on transmission control valve side of connector (X36). See Transmission Control Valve Solenoid Check. (Group 9015-20.) Is resistance within specification?

YES: Go to Short Circuit Check—Short to Solenoid Circuits. NO: Replace transmission control solenoid 1 (Y1). See Transmission Control Valve Disassemble and Assemble. (Group 0360.)

– – –1/1

TM10229 (17MAR09)

9001-30-72

544J Loader (S.N. 611800— ) 032409

PN=126

Transmission Control Unit (TCU) Diagnostic Trouble Codes 2 Short Circuit Check— Short to Solenoid Circuits

Turn key switch OFF. Disconnect transmission harness-to-transmission control valve harness connector (X36). See Transmission Harness (W10) Component Location. (Group 9015-10.) Check circuit T03 BLU for continuity between pin 1 on transmission control valve harness side of connector (X36) and pins 2, 3, 4, 5, and 6. Is continuity indicated between pin 1 and any of the other pins?

YES: Circuit T03 BLU is short to circuit with continuity indicated. Repair or replace transmission control valve harness.

9001 30 See Transmission Control 73 Valve Disassemble and Assemble. (Group 0360.) NO: Go to next step in this check.

Key switch OFF and transmission harness-to-transmission control valve harness connector (X36) disconnected.

YES: Go to next step in this check.

Disconnect transmission control unit (TCU) connector (X23). See Load Center Harness (W3) Component Location. (Group 9015-10.)

NO: Go to Short Circuit Check—Short to Ground.

Check circuit T03 BLU for continuity between pin 1 on transmission harness side of connector (X36) and pins 2, 3, 4, 5, and 6. See Transmission Harness (W10) Wiring Diagram. (Group 9015-10.) Is continuity indicated between pin 1 and any of the other pins?

Key switch OFF and TCU connector (X23) disconnected. Disconnect load center harness-to-transmission harness connector (X22). See Load Center Harness (W3) Component Location. (Group 9015-10.) Check circuit T03 BLU for continuity between pin K on load center harness side of connector (X22) and pins C, D, E, F, and L. See Load Center Harness (W3) Wiring Diagram. (Group 9015-10.) Is continuity indicated between pin K and any of the other pins?

YES: Circuit T03 BLU is short in the load center harness. Repair circuit T03 BLU or replace load center harness. NO: Circuit T03 BLU is short in the transmission harness. Repair circuit T03 BLU or replace transmission harness.

– – –1/1

TM10229 (17MAR09)

9001-30-73

544J Loader (S.N. 611800— ) 032409

PN=127

Transmission Control Unit (TCU) Diagnostic Trouble Codes 3 Short Circuit Check— Short to Ground

Turn key switch OFF. Disconnect transmission harness-to-transmission control valve harness connector (X36). See Transmission Harness (W10) Component Location. (Group 9015-10.) Check circuit T03 BLU for ground at pin 1 on transmission control valve harness side of connector (X36).

9001 30 74

Is ground present?

YES: Circuit T03 BLU is short to ground in the transmission control valve harness. Repair circuit T03 BLU or replace transmission control valve harness. See Transmission Control Valve Disassemble and Assemble. (Group 0360.) NO: Go to next step in this check.

Key switch OFF.

YES: Go to next step in this check.

Transmission harness-to-transmission control valve harness connector (X36) is disconnected.

NO: Go to Continuity Check.

Disconnect TCU connector (X23). See Load Center Harness (W3) Component Location. (Group 9015-10.) Check circuit T03 BLU for ground at pin 1 on transmission harness side of connector (X36). See Transmission Harness (W10) Wiring Diagram. (Group 9015-10.) Is ground present?

Key switch OFF. TCU connector (X23) is disconnected. Disconnect load center harness-to-transmission harness connector (X22). See Load Center Harness (W3) Component Location. (Group 9015-10.) Check circuit T03 BLU for ground at pin 56 on TCU connector (X23). See Load Center Harness (W3) Wiring Diagram. (Group 9015-10.) Is ground present?

YES: Short to ground in load center harness. Repair circuit T03 BLU or replace load center harness. NO: Short to ground in transmission harness. Repair circuit T03 BLU or replace transmission harness. – – –1/1

TM10229 (17MAR09)

9001-30-74

544J Loader (S.N. 611800— ) 032409

PN=128

Transmission Control Unit (TCU) Diagnostic Trouble Codes 4 Continuity Check

Turn battery disconnect OFF.

YES: Circuit T03 BLU is short to pin with continuity indicated in transmission harness. Repair circuit T03 BLU or replace transmission harness.

Disconnect transmission harness-to-transmission control valve harness connector (X36) and load center harness-to-transmission harness connector (X22). See Transmission Harness (W10) Component Location. (Group 9015-10.) Check continuity between pin K (circuit T03 BLU) on transmission harness side of connector (X22) and all other pins on connector (X22). See Transmission Harness (W10) Wiring Diagram. (Group 9015-10.)

NO: Go to next step in this check.

Is continuity indicated with any other pins?

Battery disconnect OFF. Load center harness-to-transmission harness connector (X22) is disconnected. Disconnect transmission control unit (TCU) connector (X23). See Load Center Harness (W3) Component Location. (Group 9015-10.) Check continuity between pin K (circuit T03 BLU) on load center harness side of connector (X22) and all other pins on connector (X22). See Load Center Harness (W3) Wiring Diagram. (Group 9015-10.)

YES: Circuit T03 BLU is short to pin with continuity indicated in load center harness. Repair circuit T03 BLU or replace load center harness. NO: Go to next step in this check.

Is continuity indicated with any other pins?

– – –1/1

522389.05 — Clutch K4 Sol Open Circuit

Transmission clutch K4 control solenoid (Y1) circuit is open.

TF44157,000024A –19–14MAR08–1/1

TM10229 (17MAR09)

9001-30-75

544J Loader (S.N. 611800— ) 032409

PN=129

9001 30 75

Transmission Control Unit (TCU) Diagnostic Trouble Codes Clutch K4 Control Solenoid Open Circuit Diagnostic Procedure Alarm Level: 9001 30 76

No Warning Lamp

– – –1/1

1 Component Check

Turn key switch OFF.

YES: Go to Open Circuit Check.

Disconnect transmission harness-to-transmission control valve harness connector (X36). See Transmission Harness (W10) Component Location. (Group 9015-10.)

NO: Go to next step in this check.

Check resistance between pins 1 and 7 on transmission control valve side of connector (X36). See Transmission Control Valve Solenoid Check. (Group 9015-20.) Is resistance within specification?

Turn key switch OFF. Disassemble transmission control valve to access control solenoid (Y1). See Transmission Control Valve Disassemble and Assemble. (Group 0360.)

YES: Open circuit in transmission control valve harness. Replace transmission control valve harness.

Disconnect transmission control solenoid (Y1). Check resistance at connector on transmission control solenoid (Y1). See Transmission Control Valve Solenoid Check. (Group 9015-20.)

NO: Transmission control solenoid (Y1) malfunction. Replace solenoid.

Is resistance within specification? – – –1/1

TM10229 (17MAR09)

9001-30-76

544J Loader (S.N. 611800— ) 032409

PN=130

Transmission Control Unit (TCU) Diagnostic Trouble Codes 2 Open Circuit Check

Turn key switch OFF. Disconnect transmission harness-to-transmission control valve harness connector (X36). See Transmission Harness (W10) Component Location. (Group 9015-10.)

YES: Replace controller, see Transmission Control Unit (TCU) Remove and Install. (Group 9015-20.)

Disconnect transmission control unit (TCU) connector (X23). See Load Center Harness (W3) Component Location. (Group 9015-10.)

NO: Go to next step in this check.

Check circuit T03 BLU for continuity between pin 1 on transmission harness side connector (X36) and pin 56 on TCU connector (X23). See Transmission Harness (W10) Wiring Diagram and see Load Center Harness (W3) Wiring Diagram. (Group 9015-10.) Is continuity indicated?

Key switch OFF.

YES: Open circuit in transmission harness. Repair circuit T03 BLU or replace transmission harness.

TCU connector (X23) is disconnected. Disconnect load center harness-to-transmission harness connector (X22). See Load Center Harness (W3) Component Location. (Group 9015-10.) Check circuit T03 BLU for continuity between pin K on load center harness side of connector (X22) and pin 56 on TCU connector (X23). See Load Center Harness (W3) Wiring Diagram. (Group 9015-10.)

NO: Open circuit in load center harness. Repair circuit T03 BLU or replace load center harness.

Is continuity indicated?

– – –1/1

522392.02 — Clutch K3 Slippage

TCU detects transmission control clutch K3 is slipping.

TF44157,000024B –19–14MAR08–1/1

Clutch K3 Slippage Diagnostic Procedure

– – –1/1

TM10229 (17MAR09)

9001-30-77

544J Loader (S.N. 611800— ) 032409

PN=131

9001 30 77

Transmission Control Unit (TCU) Diagnostic Trouble Codes 1 Code Check

Check for active codes. Check for the following TCU codes: 522392.03—Clutch K3 Sol Short to Power, 522392.04—Clutch K3 Sol Short to Gnd, and 522392.05—Clutch K3 Sol Open Circuit. Are any of the three TCU codes above active?

9001 30 78

YES: Correct problem causing other active TCU code(s). See Diagnostic Trouble Codes (DTC) Quick Reference List. (Group 9015-20.) NO: Go to Power Train System Pressure Check.

– – –1/1

2 Power Train System Pressure Check

Check transmission system pressure. See Transmission System Pressure Test. (Group 9020-25.)

YES: Go to Clutch Pressure Check.

Is system pressure within specification?

NO: See Transmission System Diagnose Malfunctions. (Group 9020-15.)

– – –1/1

3 Clutch Pressure Check

Check transmission clutch K3 pressure. Perform Transmission Clutch Pressure Test. (Group 9020-25.)

YES: Go to Control Valve Solenoid Check.

Is clutch pressure within specification?

NO: Repair transmission hydraulic problem. See Transmission Clutch Pressure Test. (Group 9020-25.) See Transmission System Diagnose Malfunctions. (Group 9020-15.)

– – –1/1

4 Control Valve Solenoid Check

Check transmission control solenoid 4 (Y4). Disconnect transmission harness-to-transmission control valve harness connector (X36). See Transmission Harness (W10) Component Location. (Group 9015-10.) Measure resistance of solenoid between pins 4 and 7 on transmission control valve harness side of connector (X36). See Transmission Control Valve Solenoid Check. (Group 9015-20.) Is resistance within specification?

YES: Go to Clutch Internal Speed Sensor Check. NO: Transmission control solenoid 4 (Y4) malfunction. Replace solenoid. See Transmission Control Valve Disassemble and Assemble. (Group 0360.)

– – –1/1

TM10229 (17MAR09)

9001-30-78

544J Loader (S.N. 611800— ) 032409

PN=132

Transmission Control Unit (TCU) Diagnostic Trouble Codes 5 Clutch Internal Speed Sensor Check

Turn key switch OFF.

YES: Go to Transmission Output Speed Sensor Check.

NO: Internal clutch speed sensor (B30) malfunction. 9001 Replace sensor. 30 79

Measure resistance between sensor pins A and B. See Electrical Component Specifications. (Group 9015-20.) Is resistance within specification?

– – –1/1

6 Transmission Output Speed Sensor Check

Turn key switch OFF. Disconnect transmission output speed sensor (B31). See Transmission Harness (W10) Component Location. (Group 9015-10.)

YES: Replace transmission output speed sensor (B31). NO: Replace controller, see Transmission Control Unit (TCU) Remove and Install. (Group 9015-20.)

Verify internal clutch speed sensor (B31) is installed to correct torque specification to ensure correct gap distance. Specification Transmission Output Speed Sensor (B31)—Torque ....................................................................................................... 30 N•m 22 lb-ft Connect transmission output speed sensor (B31). Start engine and operate machine under load. Check for active codes. Is transmission control unit (TCU) code 522392.02 present?

– – –1/1

522392.03 — Clutch K3 Sol Short to Power

Transmission clutch K3 control solenoid (Y4) circuit is short to power.

TF44157,000024C –19–14MAR08–1/1

TM10229 (17MAR09)

9001-30-79

544J Loader (S.N. 611800— ) 032409

PN=133

Transmission Control Unit (TCU) Diagnostic Trouble Codes Clutch K3 Control Solenoid Short to Power Diagnostic Procedure Alarm Level: 9001 30 80

No Warning Lamp

– – –1/1

1 Component Check

Turn key switch OFF.

YES: Go to Short Circuit Check.

Disconnect transmission harness-to-transmission control valve harness connector (X36). See Transmission Harness (W10) Component Location. (Group 9015-10.) Check resistance between pins 4 and 7 on transmission control valve side of connector (X36). See Transmission Control Valve Solenoid Check. (Group 9015-20.) Is resistance within specification?

NO: Replace transmission control solenoid 4 (Y4). See Transmission Control Valve Disassemble and Assemble. (Group 0360.)

– – –1/1

TM10229 (17MAR09)

9001-30-80

544J Loader (S.N. 611800— ) 032409

PN=134

Transmission Control Unit (TCU) Diagnostic Trouble Codes 2 Short Circuit Check

Turn key switch OFF. Disconnect transmission harness-to-transmission control valve harness connector (X36). See Transmission Harness (W10) Component Location. (Group 9015-10.) Check circuit T06 BLU for resistance between pin 4 and all other pins on transmission control valve harness side of connector (X36). Is resistance with any wire less than 5 ohms?

YES: Circuit T06 BLU is short to wire with resistance less than 5 ohms. Repair circuit T06 BLU or replace transmission control valve 9001 harness. 30 81 For procedure to disassemble transmission control valve, see Transmission Control Valve Disassemble and Assemble. (Group 0360.) NO: Go to next step in this check.

Key switch ON.

YES: Go to next step in this check.

Transmission harness-to-transmission control valve harness connector (X36) is disconnected.

NO: Go to Continuity Check.

Check circuit T06 BLU for voltage between pin 4 on transmission harness side of connector (X36) and machine ground. See Transmission Harness (W10) Wiring Diagram. (Group 9015-10.) Is system voltage (approximately 24 volts) present?

Turn key switch OFF. Disconnect load center harness-to-transmission harness connector (X22). See Load Center Harness (W3) Component Location. (Group 9015-10.)

YES: Short to power in load center harness. Repair circuit T06 BLU or replace load center harness.

Turn key switch ON. Check circuit T06 BLU for voltage between pin E on load center harness side of connector (X22) and machine ground. See Load Center Harness (W3) Wiring Diagram. (Group 9015-10.)

NO: Short to power in transmission harness. Repair circuit T06 BLU or replace transmission harness.

Is system voltage (approximately 24 volts) present?

– – –1/1

TM10229 (17MAR09)

9001-30-81

544J Loader (S.N. 611800— ) 032409

PN=135

Transmission Control Unit (TCU) Diagnostic Trouble Codes 3 Continuity Check

Turn battery disconnect OFF.

YES: Circuit T06 BLU is short to pin with continuity indicated in transmission harness. Repair circuit T06 BLU or replace transmission harness.

Check continuity between pin E (circuit T06 BLU) on transmission harness side of connector (X22) and all other pins on connector (X22). See Transmission Harness (W10) Wiring Diagram. (Group 9015-10.)

NO: Go to next step in this check.

Is continuity indicated with any other pins?

Battery disconnect OFF. Load center harness-to-transmission harness connector (X22) is disconnected. Disconnect transmission control unit (TCU) connector (X23). See Load Center Harness (W3) Component Location. (Group 9015-10.) Check continuity between pin E (circuit T06 BLU) on load center harness side of connector (X22) and all other pins on connector (X22). See Load Center Harness (W3) Wiring Diagram. (Group 9015-10.)

YES: Circuit T06 BLU is short to pin with continuity indicated in load center harness. Repair circuit T06 BLU or replace load center harness. NO: Go to next step in this check.

Is continuity indicated with any other pins?

Battery disconnect OFF. Load center harness-to-transmission harness connector (X22) is disconnected and TCU connector (X23) is disconnected. Check continuity between pin 55 (circuit T06 BLU) on TCU connector (X23) and all other pins on connector (X23). See Load Center Harness (W3) Wiring Diagram. (Group 9015-10.) Is continuity indicated with any other pins?

YES: Circuit T06 BLU is short to pin with continuity indicated in load center harness. Repair circuit T06 BLU or replace load center harness. NO: Replace controller, see Transmission Control Unit (TCU) Remove and Install. (Group 9015-20.)

– – –1/1

522392.04 — Clutch K3 Sol Short to Gnd

Transmission clutch K3 control solenoid (Y4) circuit is short to ground.

TF44157,000024D –19–14MAR08–1/1

TM10229 (17MAR09)

9001-30-82

544J Loader (S.N. 611800— ) 032409

PN=136

Transmission Control Unit (TCU) Diagnostic Trouble Codes Clutch K3 Control Solenoid Short to Ground Diagnostic Procedure Alarm Level: No Warning Lamp

9001 30 83

– – –1/1

1 Component Check

Turn key switch OFF. Disconnect transmission harness-to-transmission control valve harness connector (X36). See Transmission Harness (W10) Component Location. (Group 9015-10.) Check resistance between pins 4 and 7 on transmission control valve side of connector (X36). See Transmission Control Valve Solenoid Check. (Group 9015-20.) Is resistance within specification?

YES: Go to Short Circuit Check—Short to Solenoid Circuits. NO: Replace transmission control solenoid 4 (Y4). See Transmission Control Valve Disassemble and Assemble. (Group 0360.)

– – –1/1

TM10229 (17MAR09)

9001-30-83

544J Loader (S.N. 611800— ) 032409

PN=137

Transmission Control Unit (TCU) Diagnostic Trouble Codes 2 Short Circuit Check— Short to Solenoid Circuits

Turn key switch OFF. Disconnect transmission harness-to-transmission control valve harness connector (X36). See Transmission Harness (W10) Component Location. (Group 9015-10.) Check circuit T06 BLU for continuity between pin 4 on transmission control valve harness side of connector (X36) and pins 1, 2, 3, 5, and 6.

9001 30 84

YES: Circuit T06 BLU is short to circuit with continuity indicated. Repair or replace transmission control valve harness. See Transmission Control Valve Disassemble and Assemble. (Group 0360.)

Is continuity indicated between pin 4 and any of the other pins?

NO: Go to next step in this check.

Key switch OFF and transmission harness-to-transmission control valve harness connector (X36) disconnected.

YES: Go to next step in this check.

Disconnect transmission control unit (TCU) connector (X23). See Load Center Harness (W3) Component Location. (Group 9015-10.)

NO: Go to Short Circuit Check—Short to Ground.

Check circuit T06 BLU for continuity between pin 4 on transmission harness side of connector (X36) and pins 1, 2, 3, 5, and 6. See Transmission Harness (W10) Wiring Diagram. (Group 9015-10.) Is continuity indicated between pin 4 and any of the other pins?

Key switch OFF and TCU connector (X23) disconnected. Disconnect load center harness-to-transmission harness connector (X22). See Load Center Harness (W3) Component Location. (Group 9015-10.) Check circuit T06 BLU for continuity between pin E on load center harness side of connector (X22) and pins C, D, F, K, and L. See Load Center Harness (W3) Wiring Diagram. (Group 9015-10.) Is continuity indicated between pin E and any of the other pins?

YES: Circuit T06 BLU is short in the load center harness. Repair circuit T06 BLU or replace load center harness. NO: Circuit T06 BLU is short in the transmission harness. Repair circuit T06 BLU or replace transmission harness.

– – –1/1

TM10229 (17MAR09)

9001-30-84

544J Loader (S.N. 611800— ) 032409

PN=138

Transmission Control Unit (TCU) Diagnostic Trouble Codes 3 Short Circuit Check— Short to Ground

Turn key switch OFF. Disconnect transmission harness-to-transmission control valve harness connector (X36). See Transmission Harness (W10) Component Location. (Group 9015-10.) Check circuit T06 BLU for ground at pin 4 on transmission control valve harness side of connector (X36). Is ground present?

YES: Circuit T06 BLU is short to ground in the transmission control valve harness. Repair circuit T06 BLU or replace transmission control valve 9001 harness. 30 85 For procedure to disassemble transmission control valve, see Transmission Control Valve Disassemble and Assemble. (Group 0360.) NO: Go to next step in this check.

Key switch OFF.

YES: Go to next step in this check.

Transmission harness-to-transmission control valve harness connector (X36) is disconnected.

NO: Go to Continuity Check.

Disconnect TCU connector (X23). See Load Center Harness (W3) Component Location. (Group 9015-10.) Check circuit T06 BLU for ground at pin 4 on transmission harness side of connector (X36). See Transmission Harness (W10) Wiring Diagram. (Group 9015-10.) Is ground present?

Key switch OFF and TCU connector (X23) disconnected. Disconnect load center harness-to-transmission harness connector (X22). See Load Center Harness (W3) Component Location. (Group 9015-10.) Check circuit T06 BLU for ground at pin 55 on TCU connector (X23). See Load Center Harness (W3) Wiring Diagram. (Group 9015-10.) Is ground present?

YES: Short to ground in load center harness. Repair circuit T06 BLU or replace load center harness. NO: Short to ground in transmission harness. Repair circuit T06 BLU or replace transmission harness.

– – –1/1

TM10229 (17MAR09)

9001-30-85

544J Loader (S.N. 611800— ) 032409

PN=139

Transmission Control Unit (TCU) Diagnostic Trouble Codes 4 Continuity Check

Turn battery disconnect OFF.

YES: Circuit T06 BLU is short to pin with continuity indicated in transmission harness. Repair circuit T06 BLU or replace transmission harness.

Check continuity between pin E (circuit T06 BLU) on transmission harness side of connector (X22) and all other pins on connector (X22). See Transmission Harness (W10) Wiring Diagram. (Group 9015-10.)

NO: Go to next step in this check.

Is continuity indicated with any other pins?

Battery disconnect OFF. Load center harness-to-transmission harness connector (X22) is disconnected. Disconnect transmission control unit (TCU) connector (X23). See Load Center Harness (W3) Component Location. (Group 9015-10.) Check continuity between pin E (circuit T06 BLU) on load center harness side of connector (X22) and all other pins on connector (X22). See Load Center Harness (W3) Wiring Diagram. (Group 9015-10.)

YES: Circuit T06 BLU is short to pin with continuity indicated in load center harness. Repair circuit T06 BLU or replace load center harness. NO: Go to next step in this check.

Is continuity indicated with any other pins?

Battery disconnect OFF. Load center harness-to-transmission harness connector (X22) is disconnected and TCU connector (X23) is disconnected. Check continuity between pin 55 (circuit T06 BLU) on TCU connector (X23) and all other pins on connector (X23). See Load Center Harness (W3) Wiring Diagram. (Group 9015-10.) Is continuity indicated with any other pins?

– – –1/1

522392.05 — Clutch K3 Sol Open Circuit

Transmission clutch K3 control solenoid (Y4) circuit is open.

TF44157,000024E –19–14MAR08–1/1

TM10229 (17MAR09)

9001-30-86

544J Loader (S.N. 611800— ) 032409

PN=140

Transmission Control Unit (TCU) Diagnostic Trouble Codes Clutch K3 Control Solenoid Open Circuit Diagnostic Procedure Alarm Level: No Warning Lamp

9001 30 87

– – –1/1

1 Component Check

Turn key switch OFF.

YES: Go to Open Circuit Check.

Disconnect transmission harness-to-transmission control valve harness connector (X36). See Transmission Harness (W10) Component Location. (Group 9015-10.)

NO: Go to next step in this check.

Check resistance between pins 4 and 7 on transmission control valve side of connector (X36). See Transmission Control Valve Solenoid Check. (Group 9015-20.) Is resistance within specification?

Turn key switch OFF. Disassemble transmission control valve to access control solenoid (Y4). See Transmission Control Valve Disassemble and Assemble. (Group 0360.) Disconnect transmission control solenoid (Y4). Check resistance at connector on transmission control solenoid (Y4). Is resistance within specification?

YES: Open circuit in transmission control valve harness. Replace transmission control valve harness. See Transmission Control Valve Disassemble and Assemble. (Group 0360.) NO: Transmission control solenoid (Y4) malfunction. Replace solenoid. – – –1/1

TM10229 (17MAR09)

9001-30-87

544J Loader (S.N. 611800— ) 032409

PN=141

Transmission Control Unit (TCU) Diagnostic Trouble Codes 2 Open Circuit Check

Turn key switch OFF.

YES: Replace controller, see Transmission Control Unit (TCU) Remove and Install. (Group 9015-20.)

NO: Go to next step in this check.

Check circuit T06 BLU for continuity between pin 4 on transmission harness side connector (X36) and pin 55 on TCU connector (X23). See Transmission Harness (W10) Wiring Diagram. (Group 9015-10.) Is continuity indicated?

Key switch OFF and TCU connector (X23) disconnected.

YES: Open circuit in transmission harness. Repair circuit T06 BLU or replace transmission harness.

Disconnect load center harness-to-transmission harness connector (X22). See Load Center Harness (W3) Component Location. (Group 9015-10.) Check circuit T06 BLU for continuity between pin E on load center harness side of connector (X22) and pin 55 on TCU connector (X23). See Load Center Harness (W3) Wiring Diagram. (Group 9015-10.) Is continuity indicated?

NO: Open circuit in load center harness. Repair circuit T06 BLU or replace load center harness.

– – –1/1

522395.02 — Clutch K2 Slippage

Transmission control unit (TCU) detects transmission control clutch K2 is slipping.

TF44157,000024F –19–14MAR08–1/1

Clutch K2 Slippage Diagnostic Procedure

– – –1/1

TM10229 (17MAR09)

9001-30-88

544J Loader (S.N. 611800— ) 032409

PN=142

Transmission Control Unit (TCU) Diagnostic Trouble Codes 1 Code Check

Check for active codes. Check for the following TCU codes: 522395.03—Clutch K2 Sol Short to Power, 522395.04—Clutch K2 Sol Short to Gnd, and 522395.05—Clutch K2 Sol Open Circuit. Are any of the three TCU codes above active?

YES: Correct problem causing other active TCU code(s). See Diagnostic Trouble Codes (DTC) Quick Reference List. (Group 9015-20.) NO: Go to Power Train System Pressure Check.

– – –1/1

2 Power Train System Pressure Check

Check transmission system pressure. See Transmission System Pressure Test. (Group 9020-25.)

YES: Go to Clutch Pressure Check.

Is system pressure within specification?

NO: Go to Transmission System Diagnose Malfunctions. (Group 9020-15.)

– – –1/1

3 Clutch Pressure Check

Check transmission clutch K2 pressure. Perform Transmission Clutch Pressure Test. (Group 9020-25.)

YES: Go to Control Valve Solenoid Check.

Is clutch pressure within specification?

NO: Repair transmission hydraulic problem. See Transmission Clutch Pressure Test. (Group 9020-25.) See Transmission System Diagnose Malfunctions. (Group 9020-15.)

– – –1/1

4 Control Valve Solenoid Check

Check transmission control solenoid 6 (Y6). Disconnect transmission harness-to-transmission control valve harness connector (X36). Check resistance of solenoid between pins 6 and 7 on transmission control valve harness side of connector (X36). Perform Transmission Control Valve Solenoid Check. (Group 9015-20.) Is resistance within specification?

YES: Go to Clutch Internal Speed Sensor Check. NO: Transmission control solenoid 6 (Y6) malfunction. Replace solenoid. See Transmission Control Valve Disassemble and Assemble. (Group 0360.)

– – –1/1

TM10229 (17MAR09)

9001-30-89

544J Loader (S.N. 611800— ) 032409

PN=143

9001 30 89

Transmission Control Unit (TCU) Diagnostic Trouble Codes 5 Clutch Internal Speed Sensor Check

Turn key switch OFF.

YES: Go to Transmission Output Speed Sensor Check.

Disconnect internal clutch speed sensor (B30). See Transmission Harness (W10) Component Location. (Group 9015-10.)

NO: Internal clutch speed sensor (B30) malfunction. Replace sensor.

Verify internal clutch speed sensor (B30) is installed to correct torque specification to ensure correct gap distance.

9001 30 90

– – –1/1

6 Transmission Output Speed Sensor Check

Turn key switch OFF. Disconnect transmission output speed sensor (B31). See Transmission Harness (W10) Component Location. (Group 9015-10.)

YES: Replace transmission output speed sensor (B31). NO: Replace controller, see Transmission Control Unit (TCU) Remove and Install. (Group 9015-20.)

– – –1/1

522395.03 — Clutch K2 Sol Short to Power

Transmission clutch K2 control solenoid circuit is short to power.

TF44157,0000250 –19–14MAR08–1/1

TM10229 (17MAR09)

9001-30-90

544J Loader (S.N. 611800— ) 032409

PN=144

Transmission Control Unit (TCU) Diagnostic Trouble Codes Transmission Clutch K2 Control Solenoid Short to Power Diagnostic Procedure Alarm Level: No Warning Lamp

9001 30 91

– – –1/1

1 Component Check

Turn key switch OFF.

YES: Go to Short Circuit Check.

Disconnect transmission harness-to-transmission control valve harness connector (X36). See Transmission Harness (W10) Component Location. (Group 9015-10.) Check resistance between pins 6 and 7 on transmission control valve side of connector (X36). See Transmission Control Valve Solenoid Check. (Group 9015-20.) Is resistance within specification?

NO: Replace transmission control solenoid 6 (Y6). See Transmission Control Valve Disassemble and Assemble. (Group 0360.)

– – –1/1

TM10229 (17MAR09)

9001-30-91

544J Loader (S.N. 611800— ) 032409

PN=145

Transmission Control Unit (TCU) Diagnostic Trouble Codes 2 Short Circuit Check

Turn key switch OFF. Disconnect transmission harness-to-transmission control valve harness connector (X36). See Transmission Harness (W10) Component Location. (Group 9015-10.) Check circuit T08 BLU for resistance between pin 6 and all other pins on transmission control valve harness side of connector (X36).

9001 30 92

Is resistance with any wire less than 5 ohms?

YES: Circuit T08 BLU is short to wire with resistance less than 5 ohms. Repair wire T08 BLU or replace transmission control valve harness. For procedure to disassemble transmission control valve, see Transmission Control Valve Disassemble and Assemble. (Group 0360.) NO: Go to next step in this check.

Key switch ON and transmission harness-to-transmission control valve harness connector (X36) disconnected.

YES: Go to next step in this check.

Check circuit T08 BLU for voltage between pin 6 on transmission harness side of connector (X36) and machine ground. See Transmission Harness (W10) Wiring Diagram. (Group 9015-10.)

NO: Go to Continuity Check.

Is system voltage (approximately 24 volts) present?

Turn key switch OFF. Disconnect load center harness-to-transmission harness connector (X22). See Load Center Harness (W3) Component Location. (Group 9015-10.)

YES: Short to power in load center harness. Repair circuit T08 BLU or replace load center harness.

Turn key switch ON. Check circuit T08 BLU for voltage between pin C on load center harness side of connector (X22) and machine ground. See Load Center Harness (W3) Wiring Diagram. (Group 9015-10.)

NO: Short to power in transmission harness. Repair circuit T08 BLU or replace transmission harness.

Is system voltage (approximately 24 volts) present? – – –1/1

TM10229 (17MAR09)

9001-30-92

544J Loader (S.N. 611800— ) 032409

PN=146

Transmission Control Unit (TCU) Diagnostic Trouble Codes 3 Continuity Check

Turn battery disconnect OFF.

YES: Circuit T08 BLU is short to pin with continuity indicated in transmission harness. Repair circuit T08 BLU or replace transmission harness.

Disconnect transmission harness-to-transmission control valve harness connector (X36) and load center harness-to-transmission harness connector (X22). See Transmission Harness (W10) Component Location. (Group 9015-10.) Check continuity between pin C (circuit T08 BLU) on transmission harness side of connector (X22) and all other pins on connector (X22). See Transmission Harness (W10) Wiring Diagram. (Group 9015-10.)

NO: Go to next step in this check.

Is continuity indicated with any other pins?

Battery disconnect OFF. Load center harness-to-transmission harness connector (X22) is disconnected. Disconnect transmission control unit (TCU) connector (X23). See Load Center Harness (W3) Component Location. (Group 9015-10.) Check continuity between pin C (circuit T08 BLU) on load center harness side of connector (X22) and all other pins on connector (X22). See Load Center Harness (W3) Wiring Diagram. (Group 9015-10.)

YES: Circuit T08 BLU is short to pin with continuity indicated in load center harness. Repair circuit T08 BLU or replace load center harness. NO: Go to next step in this check.

Is continuity indicated with any other pins?

Battery disconnect OFF. Load center harness-to-transmission harness connector (X22) is disconnected and TCU connector (X23) is disconnected. Check continuity between pin 51 (circuit T08 BLU) on TCU connector (X23) and all other pins on connector (X23). See Load Center Harness (W3) Wiring Diagram. (Group 9015-10.) Is continuity indicated with any other pins?

YES: Circuit T08 BLU is short to pin with continuity indicated in load center harness. Repair circuit T08 BLU or replace load center harness. NO: Replace controller, see Transmission Control Unit (TCU) Remove and Install. (Group 9015-20.)

– – –1/1

522395.04 — Clutch K2 Sol Short to Gnd

Transmission clutch K2 control solenoid circuit is short to ground.

TF44157,0000251 –19–14MAR08–1/1

TM10229 (17MAR09)

9001-30-93

544J Loader (S.N. 611800— ) 032409

PN=147

9001 30 93

Transmission Control Unit (TCU) Diagnostic Trouble Codes Transmission Clutch K2 Control Solenoid Short to Ground Diagnostic Procedure Alarm Level: 9001 30 94

No Warning Lamp

– – –1/1

1 Component Check

Turn key switch OFF. Disconnect transmission harness-to-transmission control valve harness connector (X36). See Transmission Harness (W10) Component Location. (Group 9015-10.) Check resistance between pins 6 and 7 on transmission control valve side of connector (X36). See Transmission Control Valve Solenoid Check. (Group 9015-20.) Is resistance within specification?

YES: Go to Short Circuit Check—Short to Solenoid Circuits. NO: Replace transmission control solenoid 6 (Y6). See Transmission Control Valve Disassemble and Assemble. (Group 0360.)

– – –1/1

TM10229 (17MAR09)

9001-30-94

544J Loader (S.N. 611800— ) 032409

PN=148

Transmission Control Unit (TCU) Diagnostic Trouble Codes 2 Short Circuit Check— Short to Solenoid Circuits

Turn key switch OFF. Disconnect transmission harness-to-transmission control valve harness connector (X36). See Transmission Harness (W10) Component Location. (Group 9015-10.) Check circuit T08 BLU for continuity between pin 6 on transmission control valve harness side of connector (X36) and pins 1, 2, 3, 4, and 5.

YES: Circuit T08 BLU is short to circuit with continuity indicated. Repair or replace transmission control valve harness. For procedure to disassemble transmission control valve, see Transmission Control Valve Disassemble and Assemble. (Group 0360.)

Is continuity indicated with any of the pins?

NO: Go to next step in this check.

Key switch OFF.

YES: Go to next step in this check.

Transmission harness-to-transmission control valve harness connector (X36) is disconnected.

NO: Go to Short Circuit Check—Short to Ground.

Disconnect transmission control unit (TCU) connector (X23). See Load Center Harness (W3) Component Location. (Group 9015-10.) Check circuit T08 BLU for continuity between pin 6 on transmission harness side of connector (X36) and pins 1, 2, 3, 4, and 5. See Transmission Harness (W10) Wiring Diagram. (Group 9015-10.) Is continuity indicated with any of the pins?

Key switch OFF. TCU connector (X23) is disconnected. Disconnect load center harness-to-transmission harness connector (X22). See Load Center Harness (W3) Component Location. (Group 9015-10.) Check circuit T08 BLU for continuity between pin C on load center harness side of connector (X22) and pins D, E, F, K, and L. See Load Center Harness (W3) Wiring Diagram. (Group 9015-10.)

YES: Circuit T08 BLU is short in the load center harness. Repair circuit T08 BLU or replace load center harness. NO: Circuit T08 BLU is short in the transmission harness. Repair circuit T08 BLU or replace transmission harness.

Is continuity indicated with any of the pins?

– – –1/1

TM10229 (17MAR09)

9001-30-95

544J Loader (S.N. 611800— ) 032409

PN=149

9001 30 95

Transmission Control Unit (TCU) Diagnostic Trouble Codes 3 Short Circuit Check— Short to Ground

Turn key switch OFF. Disconnect transmission harness-to-transmission control valve harness connector (X36). See Transmission Harness (W10) Component Location. (Group 9015-10.) Check circuit T08 BLU for ground at pin 6 on transmission control valve harness side of connector (X36).

9001 30 96

Is ground present?

YES: Circuit T08 BLU is short to ground in the transmission control valve harness. Repair circuit T08 BLU or replace transmission control valve harness. For procedure to disassemble transmission control valve, see Transmission Control Valve Disassemble and Assemble. (Group 0360.) NO: Go to next step in this check.

Key switch OFF.

YES: Go to next step in this check.

Transmission harness-to-transmission control valve harness connector (X36) is disconnected.

NO: Go to Continuity Check.

Disconnect TCU connector (X23). See Load Center Harness (W3) Component Location. (Group 9015-10.) Check circuit T08 BLU for ground at pin 6 on transmission harness side of connector (X36). See Transmission Harness (W10) Wiring Diagram. (Group 9015-10.) Is ground present?

Key switch OFF and TCU connector (X23) disconnected. Disconnect load center harness-to-transmission harness connector (X22). See Load Center Harness (W3) Component Location. (Group 9015-10.) Check circuit T08 BLU for ground at pin 51 on TCU connector (X23). See Load Center Harness (W3) Wiring Diagram. (Group 9015-10.) Is ground present?

YES: Short to ground in load center harness. Repair circuit T08 BLU or replace load center harness. NO: Short to ground in transmission harness. Repair circuit T08 BLU or replace transmission harness.

– – –1/1

TM10229 (17MAR09)

9001-30-96

544J Loader (S.N. 611800— ) 032409

PN=150

Transmission Control Unit (TCU) Diagnostic Trouble Codes 4 Continuity Check

Turn battery disconnect OFF.

YES: Circuit T08 BLU is short to pin with continuity indicated in transmission harness. Repair circuit T08 BLU or replace transmission harness.

Disconnect transmission harness-to-transmission control valve harness connector (X36) and load center harness-to-transmission harness connector (X22). See Transmission Harness (W10) Component Location. (Group 9015-10.) Check continuity between pin C (circuit T08 BLU) on transmission harness side of connector (X22) and all other pins on connector (X22). See Transmission Harness (W10) Wiring Diagram. (Group 9015-10.)

NO: Go to next step in this check.

Is continuity indicated with any other pins?

Battery disconnect OFF. Load center harness-to-transmission harness connector (X22) is disconnected. Disconnect transmission control unit (TCU) connector (X23). See Load Center Harness (W3) Component Location. (Group 9015-10.) Check continuity between pin C (circuit T08 BLU) on load center harness side of connector (X22) and all other pins on connector (X22). See Load Center Harness (W3) Wiring Diagram. (Group 9015-10.)

YES: Circuit T08 BLU is short to pin with continuity indicated in load center harness. Repair circuit T08 BLU or replace load center harness. NO: Go to next step in this check.

Is continuity indicated with any other pins?

Battery disconnect OFF. Load center harness-to-transmission harness connector (X22) is disconnected and TCU connector (X23) is disconnected. Check continuity between pin 51 (circuit T08 BLU) on TCU connector (X23) and all other pins on connector (X23). See Load Center Harness (W3) Wiring Diagram. (Group 9015-10.) Is continuity indicated with any other pins?

– – –1/1

522395.05 — Clutch K2 Sol Open Circuit

Transmission clutch K2 control solenoid (Y6) circuit is open.

TF44157,0000252 –19–14MAR08–1/1

TM10229 (17MAR09)

9001-30-97

544J Loader (S.N. 611800— ) 032409

PN=151

9001 30 97

Transmission Control Unit (TCU) Diagnostic Trouble Codes Transmission Clutch K2 Control Solenoid Open Circuit Diagnostic Procedure Alarm Level: 9001 30 98

No Warning Lamp

– – –1/1

1 Component Check

Turn key switch OFF.

YES: Go to Open Circuit Check.

Disconnect transmission harness-to-transmission control valve harness connector (X36). See Transmission Harness (W10) Component Location. (Group 9015-10.)

NO: Go to next step in this check.

Check resistance between pins 6 and 7 on transmission control valve side of connector (X36). See Transmission Control Valve Solenoid Check. (Group 9015-20.) Is resistance within specification?

Turn key switch OFF. Disassemble transmission control valve to access control solenoid (Y6). See Transmission Control Valve Disassemble and Assemble. (Group 0360.)

YES: Open circuit in transmission control valve harness. Replace transmission control valve harness.

Disconnect transmission control solenoid (Y6). Check resistance at connector on transmission control solenoid (Y6). See Transmission Control Valve Solenoid Check. (Group 9015-20.)

NO: Transmission control solenoid (Y6) malfunction. Replace solenoid.

Is resistance within specification? – – –1/1

TM10229 (17MAR09)

9001-30-98

544J Loader (S.N. 611800— ) 032409

PN=152

Transmission Control Unit (TCU) Diagnostic Trouble Codes 2 Open Circuit Check

Turn key switch OFF. Disconnect transmission harness-to-transmission control valve harness connector (X36) and TCU connector (X23). See Transmission Harness (W10) Component Location and see Load Center Harness (W3) Component Location. (Group 9015-10.) Check circuit T08 BLU for continuity between pin 6 on transmission harness side connector (X36) and pin 51 on TCU connector (X23).

YES: Replace controller, see Transmission Control Unit (TCU) Remove and Install. (Group 9015-20.) NO: Go to next step in this check.

Is continuity indicated?

YES: Open circuit in transmission harness. Repair circuit T08 BLU or replace transmission harness. See Transmission Harness (W10) Wiring Diagram. (Group 9015-10.)

Is continuity indicated? NO: Open circuit in load center harness. Repair circuit T08 BLU or replace load center harness. See Load Center Harness (W3) Wiring Diagram. (Group 9015-10.)

– – –1/1

522399.02 — Clutch K1 Slippage

TCU detects transmission clutch K1 is slipping.

TF44157,0000253 –19–14MAR08–1/1

Transmission Clutch K1 Slippage Diagnostic Procedure Alarm Level: Transmission Fault Indicator Icon

– – –1/1

TM10229 (17MAR09)

9001-30-99

544J Loader (S.N. 611800— ) 032409

PN=153

9001 30 99

Transmission Control Unit (TCU) Diagnostic Trouble Codes 1 Code Check

Check for active codes. Check for the following TCU codes: 522399.03—Clutch K1 Sol Short to Power, 522399.04—Clutch K1 Sol Short to Gnd, and 522399.05—Clutch K1 Sol Open Circuit. Are any of the three TCU codes above active?

9001 30 ,100

YES: Correct problem causing other active TCU code(s). See Diagnostic Trouble Codes (DTC) Quick Reference List. (Group 9015-20.) NO: Go to Power Train System Pressure Check.

– – –1/1

2 Power Train System Pressure Check

Check transmission system pressure. See Transmission System Pressure Test. (Group 9020-25.)

YES: Go to Clutch Pressure Check.

Is system pressure within specifications?

NO: Go to Transmission System Diagnose Malfunctions. (Group 9020-15.)

– – –1/1

3 Clutch Pressure Check

Check transmission clutch K1 pressure. Perform Transmission Clutch Pressure Test. (Group 9020-25.)

YES: Go to Control Valve Solenoid Check.

Is clutch pressure within specifications?

NO: Repair transmission hydraulic problem. See Transmission Clutch Pressure Test. (Group 9020-25.) See Transmission System Diagnose Malfunctions. (Group 9020-15.)

– – –1/1

4 Control Valve Solenoid Check

Check transmission control solenoid 3 (Y3). Disconnect transmission harness-to-transmission control valve harness connector (X36). See Transmission Harness (W10) Component Location. (Group 9015-10.) Check resistance of solenoid between pins 3 and 7 on transmission control valve harness side of connector (X36). See Transmission Control Valve Solenoid Check. (Group 9015-20.) Is resistance within specifications?

YES: Go to Clutch Internal Speed Sensor Check. NO: Transmission control solenoid 3 (Y3) malfunction. Replace solenoid. See Transmission Control Valve Disassemble and Assemble. (Group 0360.)

– – –1/1

TM10229 (17MAR09)

9001-30-100

544J Loader (S.N. 611800— ) 032409

PN=154

Transmission Control Unit (TCU) Diagnostic Trouble Codes 5 Clutch Internal Speed Sensor Check

Turn key switch OFF.

YES: Go to Transmission Output Speed Sensor Check.

NO: Internal clutch speed sensor (B30) malfunction. 9001 Replace sensor. 30 ,101

Measure resistance between sensor pins A and B. See Electrical Component Specifications. (Group 9015-20.) Is resistance within specification?

– – –1/1

6 Transmission Output Speed Sensor Check

Turn key switch OFF. Disconnect transmission output speed sensor (B31). See Transmission Harness (W10) Component Location. (Group 9015-10.)

YES: Replace transmission output speed sensor (B31). NO: Replace controller, see Transmission Control Unit (TCU) Remove and Install. (Group 9015-20.)

– – –1/1

522399.03 — Clutch K1 Sol Short to Power

Transmission clutch K1 control solenoid (Y3) circuit is short to power.

TF44157,0000254 –19–14MAR08–1/1

TM10229 (17MAR09)

9001-30-101

544J Loader (S.N. 611800— ) 032409

PN=155

Transmission Control Unit (TCU) Diagnostic Trouble Codes Transmission Clutch K1 Control Solenoid Short to Power Diagnostic Procedure Alarm Level: 9001 30 ,102

No Warning Lamp

– – –1/1

1 Component Check

Turn key switch OFF.

YES: Go to Short Circuit Check.

Disconnect transmission harness-to-transmission control valve harness connector (X36). See Transmission Harness (W10) Component Location. (Group 9015-10.) Check resistance between pins 3 and 7 on transmission control valve side of connector (X36). See Transmission Control Valve Solenoid Check. (Group 9015-20.) Is resistance within specification?

NO: Replace transmission control solenoid 3 (Y3). See Transmission Control Valve Disassemble and Assemble. (Group 0360.)

– – –1/1

TM10229 (17MAR09)

9001-30-102

544J Loader (S.N. 611800— ) 032409

PN=156

Transmission Control Unit (TCU) Diagnostic Trouble Codes 2 Short Circuit Check

Turn key switch OFF. Disconnect transmission harness-to-transmission control valve harness connector (X36). See Transmission Harness (W10) Component Location. (Group 9015-10.) Check circuit T05 BLU for resistance between pin 3 and all other pins on transmission control valve harness side of connector (X36). Is resistance with any wire less than 5 ohms?

YES: Circuit T05 BLU is short to wire with resistance less than 5 ohms. Repair wire T05 BLU or replace transmission control valve 9001 harness. 30 ,103 For procedure to disassemble transmission control valve, see Transmission Control Valve Disassemble and Assemble. (Group 0360.) NO: Go to next step in this check.

Key switch ON and transmission harness-to-transmission control valve harness connector (X36) disconnected.

YES: Go to next step in this check.

Check circuit T05 BLU for voltage between pin 3 on transmission harness side of connector (X36) and machine ground. See Transmission Harness (W10) Wiring Diagram. (Group 9015-10.)

NO: Go to Continuity Check.

Is system voltage (approximately 24 volts) present?

Turn key switch OFF. Disconnect load center harness-to-transmission harness connector (X22). See Load Center Harness (W3) Component Location. (Group 9015-10.)

YES: Short to power in load center harness. Repair circuit T05 BLU or replace load center harness.

Turn key switch ON. Check circuit T05 BLU for voltage between pin F on load center harness side of connector (X22) and machine ground. See Load Center Harness (W3) Wiring Diagram. (Group 9015-10.)

NO: Short to power in transmission harness. Repair circuit T05 BLU or replace transmission harness.

Is system voltage (approximately 24 volts) present? – – –1/1

TM10229 (17MAR09)

9001-30-103

544J Loader (S.N. 611800— ) 032409

PN=157

Transmission Control Unit (TCU) Diagnostic Trouble Codes 3 Continuity Check

Turn battery disconnect OFF.

YES: Circuit T05 BLU is short to pin with continuity indicated in transmission harness. Repair circuit T05 BLU or replace transmission harness.

Check continuity between pin F (circuit T05 BLU) on transmission harness side of connector (X22) and all other pins on connector (X22). See Transmission Harness (W10) Wiring Diagram. (Group 9015-10.)

NO: Go to next step in this check.

Is continuity indicated with any other pins?

Battery disconnect OFF. Load center harness-to-transmission harness connector (X22) is disconnected. Disconnect transmission control unit (TCU) connector (X23). See Load Center Harness (W3) Component Location. (Group 9015-10.) Check continuity between pin F (circuit T05 BLU) on load center harness side of connector (X22) and all other pins on connector (X22). See Load Center Harness (W3) Wiring Diagram. (Group 9015-10.)

YES: Circuit T05 BLU is short to pin with continuity indicated in load center harness. Repair circuit T05 BLU or replace load center harness. NO: Go to next step in this check.

Is continuity indicated with any other pins?

Battery disconnect OFF. Load center harness-to-transmission harness connector (X22) is disconnected and TCU connector (X23) is disconnected. Check continuity between pin 32 (circuit T05 BLU) on TCU connector (X23) and all other pins on connector (X23). See Load Center Harness (W3) Wiring Diagram. (Group 9015-10.) Is continuity indicated with any other pins?

YES: Circuit T05 BLU is short to pin with continuity indicated in load center harness. Repair circuit T05 BLU or replace load center harness. NO: Replace controller, see Transmission Control Unit (TCU) Remove and Install. (Group 9015-20.)

– – –1/1

522399.04 — Clutch K1 Sol Short to Gnd

Transmission clutch K1 control solenoid circuit is short to ground.

TF44157,0000255 –19–14MAR08–1/1

TM10229 (17MAR09)

9001-30-104

544J Loader (S.N. 611800— ) 032409

PN=158

Transmission Control Unit (TCU) Diagnostic Trouble Codes Transmission Clutch K1 Control Solenoid Short to Ground Diagnostic Procedure Alarm Level: No Warning Lamp

9001 30 ,105

– – –1/1

1 Component Check

Turn key switch OFF. Disconnect transmission harness-to-transmission control valve harness connector (X36). See Transmission Harness (W10) Component Location. (Group 9015-10.) Check resistance between pins 3 and 7 on transmission control valve side of connector (X36). See Transmission Control Valve Solenoid Check. (Group 9015-20.) Is resistance within specification?

YES: Go to Short Circuit Check—Short to Solenoid Circuits. NO: Replace transmission control solenoid 3 (Y3). See Transmission Control Valve Disassemble and Assemble. (Group 0360.)

– – –1/1

TM10229 (17MAR09)

9001-30-105

544J Loader (S.N. 611800— ) 032409

PN=159

Transmission Control Unit (TCU) Diagnostic Trouble Codes 2 Short Circuit Check— Short to Solenoid Circuits

Turn key switch OFF. Disconnect transmission harness-to-transmission control valve harness connector (X36). See Transmission Harness (W10) Component Location. (Group 9015-10.) Check circuit T05 BLU for continuity between pin 3 on transmission control valve harness side of connector (X36) and pins 1, 2, 4, 5, and 6.

9001 30 ,106

YES: Circuit T05 BLU is short to circuit with continuity indicated. Repair or replace transmission control valve harness. For procedure to disassemble transmission control valve, see Transmission Control Valve Disassemble and Assemble. (Group 0360.)

Is continuity indicated with any of the pins?

NO: Go to next step in this check.

Key switch OFF and

YES: Go to next step in this check.

Transmission harness-to-transmission control valve harness connector (X36) is disconnected.

NO: Go to Short Circuit Check—Short to Ground.

Disconnect transmission control unit (TCU) connector (X23). See Load Center Harness (W3) Component Location. (Group 9015-10.) Check circuit T05 BLU for continuity between pin 3 on transmission harness side of connector (X36) and pins 1, 2, 4, 5, and 6. See Transmission Harness (W10) Wiring Diagram. (Group 9015-10.) Is continuity indicated with any of the pins?

Key switch OFF. TCU connector (X23) is disconnected. Disconnect load center harness-to-transmission harness connector (X22). See Load Center Harness (W3) Component Location. (Group 9015-10.) Check circuit T05 BLU for continuity between pin F on load center harness side of connector (X22) and pins C, D, E, K, and L. See Load Center Harness (W3) Wiring Diagram. (Group 9015-10.)

YES: Circuit T05 BLU is short in the load center harness. Repair circuit T05 BLU or replace load center harness. NO: Circuit T05 BLU is short in the transmission harness. Repair circuit T05 BLU or replace transmission harness.

Is continuity indicated with any of the pins?

– – –1/1

TM10229 (17MAR09)

9001-30-106

544J Loader (S.N. 611800— ) 032409

PN=160

Transmission Control Unit (TCU) Diagnostic Trouble Codes 3 Short Circuit Check— Short to Ground

Turn key switch OFF. Disconnect transmission harness-to-transmission control valve harness connector (X36). See Transmission Harness (W10) Component Location. (Group 9015-10.) Check circuit T05 BLU for ground at pin 3 on transmission control valve harness side of connector (X36). Is ground present?

YES: Circuit T05 BLU is short to ground in the transmission control valve harness. Repair circuit T05 BLU or replace transmission control valve 9001 harness. 30 ,107 For procedure to disassemble transmission control valve, see Transmission Control Valve Disassemble and Assemble. (Group 0360.) NO: Go to next step in this check.

Key switch OFF.

YES: Go to next step in this check.

Transmission harness-to-transmission control valve harness connector (X36) is disconnected.

NO: Go to Continuity Check.

Disconnect TCU connector (X23). See Load Center Harness (W3) Component Location. (Group 9015-10.) Check circuit T05 BLU for ground at pin 3 on transmission harness side of connector (X36). See Transmission Harness (W10) Wiring Diagram. (Group 9015-10.) Is ground present?

Key switch OFF. TCU connector (X23) is disconnected. Disconnect load center harness-to-transmission harness connector (X22). See Load Center Harness (W3) Component Location. (Group 9015-10.) Check circuit T05 BLU for ground at pin 32 on TCU connector (X23). See Load Center Harness (W3) Wiring Diagram. (Group 9015-10.) Is ground present?

YES: Short to ground in load center harness. Repair circuit T05 BLU or replace load center harness. NO: Short to ground in transmission harness. Repair circuit T05 BLU or replace transmission harness.

– – –1/1

TM10229 (17MAR09)

9001-30-107

544J Loader (S.N. 611800— ) 032409

PN=161

Transmission Control Unit (TCU) Diagnostic Trouble Codes 4 Continuity Check

Turn battery disconnect OFF.

YES: Circuit T05 BLU is short to pin with continuity indicated in transmission harness. Repair circuit T05 BLU or replace transmission harness.

Check continuity between pin F (circuit T05 BLU) on transmission harness side of connector (X22) and all other pins on connector (X22). See Transmission Harness (W10) Wiring Diagram. (Group 9015-10.)

NO: Go to next step in this check.

Is continuity indicated with any other pins?

Battery disconnect OFF. Load center harness-to-transmission harness connector (X22) is disconnected. Disconnect transmission control unit (TCU) connector (X23). See Load Center Harness (W3) Component Location. (Group 9015-10.) Check continuity between pin F (circuit T05 BLU) on load center harness side of connector (X22) and all other pins on connector (X22). See Load Center Harness (W3) Wiring Diagram. (Group 9015-10.)

YES: Circuit T05 BLU is short to pin with continuity indicated in load center harness. Repair circuit T05 BLU or replace load center harness. NO: Go to next step in this check.

Is continuity indicated with any other pins?

– – –1/1

522399.05 — Clutch K1 Sol Open Circuit

Transmission clutch K1 control solenoid (Y3) circuit is open.

TF44157,0000256 –19–14MAR08–1/1

TM10229 (17MAR09)

9001-30-108

544J Loader (S.N. 611800— ) 032409

PN=162

Transmission Control Unit (TCU) Diagnostic Trouble Codes Transmission Clutch K1 Control Solenoid Open Circuit Diagnostic Procedure Alarm Level: No Warning Lamp

9001 30 ,109

– – –1/1

1 Component Check

Turn key switch OFF.

YES: Go to Open Circuit Check.

Disconnect transmission harness-to-transmission control valve harness connector (X36). See Transmission Harness (W10) Component Location. (Group 9015-10.)

NO: Go to next step in this check.

Check resistance between pins 3 and 7 on transmission control valve side of connector (X36). See Transmission Control Valve Solenoid Check. (Group 9015-20.) Is resistance within specification?

Turn key switch OFF. Disassemble transmission control valve to access control solenoid (Y3). See Transmission Control Valve Disassemble and Assemble. (Group 0360.)

YES: Open circuit in transmission control valve harness. Replace transmission control valve harness.

Disconnect transmission control solenoid (Y3). Check resistance at connector on transmission control solenoid (Y3). See Transmission Control Valve Solenoid Check. (Group 9015-20.)

NO: Transmission control solenoid (Y3) malfunction. Replace solenoid.

Is resistance within specification? – – –1/1

TM10229 (17MAR09)

9001-30-109

544J Loader (S.N. 611800— ) 032409

PN=163

Transmission Control Unit (TCU) Diagnostic Trouble Codes 2 Open Circuit Check

Turn key switch OFF. Disconnect transmission harness-to-transmission control valve harness connector (X36) and transmission control unit (TCU) connector (X23). See Transmission Harness (W10) Component Location and see Load Center Harness (W3) Component Location. (Group 9015-10.)

9001 30 ,110

YES: Replace controller, see Transmission Control Unit (TCU) Remove and Install. (Group 9015-20.) NO: Go to next step in this check.

Check circuit T05 BLU for continuity between pin 3 on transmission harness side connector (X36) and pin 32 on TCU connector (X23). See Transmission Harness (W10) Wiring Diagram and see Load Center Harness (W3) Wiring Diagram. (Group 9015-10.) Is continuity indicated?

Key switch OFF.

YES: Open circuit in transmission harness. Repair circuit T05 BLU or replace transmission harness.

TCU connector (X23) is disconnected. Disconnect load center harness-to-transmission harness connector (X22). See Load Center Harness (W3) Component Location. (Group 9015-10.) Check circuit T05 BLU for continuity between pin F on load center harness side of connector (X22) and pin 32 on TCU connector (X23). See Load Center Harness (W3) Wiring Diagram. (Group 9015-10.)

NO: Open circuit in load center harness. Repair circuit T05 BLU or replace load center harness.

Is continuity indicated?

– – –1/1

522401.02 — Trans Speed Sensor Fault

The transmission control unit (TCU) detects output speed is zero and other speed sensor values are not zero.

TF44157,0000257 –19–14MAR08–1/1

Transmission Output Speed Sensor Fault Diagnostic Procedure Alarm Level: No Warning Lamp

– – –1/1

TM10229 (17MAR09)

9001-30-110

544J Loader (S.N. 611800— ) 032409

PN=164

Transmission Control Unit (TCU) Diagnostic Trouble Codes 1 Code Check

Turn key switch ON.

YES: Correct problem causing other code first. See Diagnostic Trouble Codes (DTC) Quick Reference List. (Group 9015-20.)

Check for TCU code 522401.03—Output Shaft Open or Short. Is TCU code 522401.03 present?

NO: Go to Component Check.

– – –1/1

2 Component Check

Turn key switch OFF. Disconnect transmission output speed sensor (B31). See Transmission Harness (W10) Component Location. (Group 9015-10.) Verify transmission output speed sensor (B31) is installed to correct torque specification to ensure correct gap distance. Specification Transmission Output Speed Sensor (B31)—Torque ....................................................................................................... 30 N•m 22 lb-ft

YES: Replace speed sensor (B31) and replace transmission control unit (TCU). See Transmission Control Unit (TCU) Remove and Install. (Group 9015-20.) NO: Checks complete.

Connect transmission output speed sensor (B31). Start engine and operate machine under load. Check for active codes. Is TCU code 522401.02 present?

– – –1/1

522401.03 — Output Shaft Open or Short

Transmission output speed sensor circuit is open or short to power.

TF44157,0000258 –19–14MAR08–1/1

TM10229 (17MAR09)

9001-30-111

544J Loader (S.N. 611800— ) 032409

PN=165

9001 30 ,111

Transmission Control Unit (TCU) Diagnostic Trouble Codes Output Shaft Open or Short Diagnostic Procedure Alarm Level: 9001 30 ,112

No Warning Lamp

– – –1/1

1 Short Circuit Check

Turn key switch OFF.

YES: Go to next step in this check.

Disconnect transmission output speed sensor (B31). See Transmission Harness (W10) Component Location. (Group 9015-10.)

NO: Go to Open Circuit Check.

Turn key switch ON. Check voltage of circuit M10 PUR between pin B on output shaft speed sensor (B31) connector and machine ground. See Transmission Harness (W10) Wiring Diagram. (Group 9015-10.) Is system voltage (approximately 24 volts) present?

Turn key switch OFF. Disconnect load center harness-to-transmission harness connector (X22). See Load Center Harness (W3) Component Location. (Group 9015-10.)

YES: Short circuit in load center harness. Repair circuit M10 PUR or replace load center harness.

Turn key switch ON. Check voltage of circuit M10 PUR between pin Q on load center harness side of connector (X22) and machine ground. See Load Center Harness (W3) Wiring Diagram. (Group 9015-10.)

NO: Short circuit in transmission harness. Repair circuit M10 PUR or replace transmission harness.

Is system voltage (approximately 24 volts) present?

– – –1/1

TM10229 (17MAR09)

9001-30-112

544J Loader (S.N. 611800— ) 032409

PN=166

Transmission Control Unit (TCU) Diagnostic Trouble Codes 2 Open Circuit Check

Turn key switch OFF.

YES: Go to Continuity Check.

Disconnect transmission output speed sensor (B31). See Transmission Harness (W10) Component Location. (Group 9015-10.)

NO: Go to next step in this check.

Disconnect transmission control unit (TCU) connector (X23) and vehicle electrical center (VEC) connector (X10). See Load Center Harness (W3) Component Location. (Group 9015-10.)

9001 30 ,113

Check circuit M10 PUR for continuity between pin B on transmission output speed sensor (B31) connector and pin 62 on TCU connector (X23). See Transmission Harness (W10) Wiring Diagram and see Load Center Harness (W3) Wiring Diagram. (Group 9015-10.) Check circuit R40 BLK for continuity between pin A on transmission output speed sensor (B31) connector and pin 4 on TCU connector (X23). Check circuit P40 RED for continuity between pin C on transmission output speed sensor (B31) connector and pin H on VEC connector (X10). Is continuity indicated?

Key switch OFF. TCU connector (X23) and VEC connector (X10) are disconnected. Disconnect load center harness-to-transmission harness connector (X22). See Load Center Harness (W3) Component Location. (Group 9015-10.) Check circuit M10 PUR for continuity between pin Q on load center harness side of connector (X22) and pin 62 on TCU connector (X23). See Load Center Harness (W3) Wiring Diagram. (Group 9015-10.) Check circuit R40 BLK for continuity between pin A on load center harness side of connector (X22) and pin 4 on TCU connector (X23).

YES: Open circuit in transmission harness. Repair circuit(s) without continuity indicated or replace transmission harness. NO: Open circuit in load center harness. Repair circuit(s) without continuity indicated or replace load center harness.

Check circuit P40 RED for continuity between pin U on load center harness side of connector (X22) and pin H on VEC connector (X10). Is continuity indicated?

– – –1/1

TM10229 (17MAR09)

9001-30-113

544J Loader (S.N. 611800— ) 032409

PN=167

Transmission Control Unit (TCU) Diagnostic Trouble Codes 3 Continuity Check

Turn key switch OFF. Disconnect transmission output speed sensor (B31) and load center harness-to-transmission harness connector (X22). See Transmission Harness (W10) Component Location. (Group 9015-10.)

9001 30 ,114

Check for continuity between pin Q (circuit M10 PUR) on transmission harness side of connector (X22) and all other pins on connector (X22). See Transmission Harness (W10) Wiring Diagram. (Group 9015-10.)

YES: Circuit M10 PUR is short to wire with continuity indicated in transmission harness. Repair circuit M10 PUR or replace transmission harness. NO: Go to next step in this check.

Is continuity indicated with any other pins?

Key switch OFF.

YES: Circuit M10 PUR is short to wire with continuity indicated in load center harness. Repair circuit M10 PUR or replace load center harness.

Load center harness-to-transmission harness connector (X22) is disconnected. Disconnect TCU connector (X23). See Load Center Harness (W3) Component Location. (Group 9015-10.) Check continuity between pin Q (circuit M10 PUR) on load center harness side of connector (X22) and all other pins on connector (X22). See Load Center Harness (W3) Wiring Diagram. (Group 9015-10.)

NO: Go to next step in this check.

Is continuity indicated with any other pins?

Key switch OFF. Load center harness-to-transmission harness connector (X22) and TCU connector (X23) are disconnected. Check continuity between pin 62 (circuit M10 PUR) on TCU connector (X23) and all other pins on connector (X23). See Load Center Harness (W3) Wiring Diagram. (Group 9015-10.)

YES: Circuit M10 PUR is short to wire with continuity indicated in load center harness. Repair circuit M10 PUR or replace load center harness. NO: Go to Component Check.

Is continuity indicated with any other pins?

– – –1/1

4 Component Check

Turn key switch OFF. Verify transmission output speed sensor (B31) is installed to correct torque specification in order to ensure correct gap distance. See Transmission Harness (W10) Component Location. (Group 9015-10.) Specification Transmission Output Speed Sensor (B31)—Torque ....................................................................................................... 30 N•m 22 lb-ft

YES: Replace speed sensor (B31) and replace transmission control unit (TCU). See Transmission Control Unit (TCU) Remove and Install. (Group 9015-20.) NO: Checks complete.

Start engine and operate machine under load. Check for active codes. Is TCU code 522401.03 present?

– – –1/1

TM10229 (17MAR09)

9001-30-114

544J Loader (S.N. 611800— ) 032409

PN=168

Transmission Control Unit (TCU) Diagnostic Trouble Codes

522401.04 — Output Shaft Short to Gnd

Transmission output speed sensor circuit is short to ground.

9001 30 ,115

TF44157,0000259 –19–14MAR08–1/1

Output Shaft Short to Ground Diagnostic Procedure Alarm Level: No Warning Lamp

– – –1/1

1 Short Circuit Check

Turn key switch OFF.

YES: Go to next step in this check.

Disconnect transmission output speed sensor (B31) and transmission control unit (TCU) connector (X23). See Transmission Harness (W10) Component Location and see Load Center Harness (W3) Component Location. (Group 9015-10.)

NO: Go to Continuity Check.

Check circuit M10 PUR for ground at pin 62 on TCU connector (X23). Is ground present?

YES: Short circuit in load center harness. Repair circuit M10 PUR or replace load center harness. See Load Center Harness (W3) Wiring Diagram. (Group 9015-10.) NO: Short circuit in transmission harness. Repair circuit M10 PUR or replace transmission harness. See Transmission Harness (W10) Wiring Diagram. (Group 9015-10.)

– – –1/1

TM10229 (17MAR09)

9001-30-115

544J Loader (S.N. 611800— ) 032409

PN=169

Transmission Control Unit (TCU) Diagnostic Trouble Codes 2 Continuity Check

9001 30 ,116

YES: Circuit M10 PUR is short to wire with continuity indicated in transmission harness. Repair circuit M10 PUR or replace transmission harness. NO: Go to next step in this check.

Is continuity indicated with any other pins?

Key switch OFF.

YES: Circuit M10 PUR is short to wire with continuity indicated in load center harness. Repair circuit M10 PUR or replace load center harness.

NO: Go to next step in this check.

Is continuity indicated with any other pins?

YES: Circuit M10 PUR is short to wire with continuity indicated in load center harness. Repair circuit M10 PUR or replace load center harness. NO: Go to Component Check.

Is continuity indicated with any other pins?

– – –1/1

3 Component Check

YES: Replace speed sensor (B31) and replace transmission control unit (TCU). See Transmission Control Unit (TCU) Remove and Install. (Group 9015-20.) NO: Checks complete.

Start engine and operate machine under load. Check for active codes. Is TCU code 522401.04 present?

– – –1/1

TM10229 (17MAR09)

9001-30-116

544J Loader (S.N. 611800— ) 032409

PN=170

Transmission Control Unit (TCU) Diagnostic Trouble Codes

522401.12 — Output Shaft Fault

Transmission output speed sensor signal fault

9001 30 ,117

TF44157,000025A –19–14MAR08–1/1

Output Shaft Fault Diagnostic Procedure Alarm Level: No Warning Lamp

– – –1/1

1 Code Check

Turn key switch ON. Check for transmission control unit (TCU) codes: 522401.03—Output Shaft Open or Short and 522401.04—Output Shaft Short to Gnd Are either of the TCU codes above active?

YES: Correct problem causing other TCU codes. See Diagnostic Trouble Codes (DTC) Quick Reference List. (Group 9015-10.) NO: Go to Component Check.

– – –1/1

TM10229 (17MAR09)

9001-30-117

544J Loader (S.N. 611800— ) 032409

PN=171

Transmission Control Unit (TCU) Diagnostic Trouble Codes 2 Component Check

9001 30 ,118

Specification Transmission Output Speed Sensor (B31)—Torque ....................................................................................................... 30 N•m 22 lb-ft

YES: Replace speed sensor (B31) and replace transmission control unit (TCU). See Transmission Control Unit (TCU) Remove and Install. (Group 9015-20.) NO: Checks complete.

Start engine and operate machine under load. Check for active codes. Is TCU code 522401.04 present?

– – –1/1

522401.15 — Output Shaft Overspeed

Transmission control unit (TCU) detects output speed is too high.

TF44157,000025B –19–14MAR08–1/1

Output Shaft Overspeed Diagnostic Procedure

– – –1/1

TM10229 (17MAR09)

9001-30-118

544J Loader (S.N. 611800— ) 032409

PN=172

Transmission Control Unit (TCU) Diagnostic Trouble Codes 1 Component Check

Turn key switch OFF. Verify transmission output speed sensor (B31) is installed to correct torque specification in order to ensure correct gap distance. Specification Transmission Output Speed Sensor (B31)—Torque ....................................................................................................... 30 N•m 22 lb-ft

YES: Transmission output speed sensor (B31) malfunction. Replace sensor. See Transmission Harness (W10) Component Location. 9001 (Group 9015-10.) 30 ,119 NO: Checks complete.

Start engine and operate machine under load. Check for active codes. Is TCU code 522401.04 present?

– – –1/1

522402.03 — Clutch Speed Open or Short

Clutch internal speed sensor circuit is open or short to power.

TF44157,000025C –19–14MAR08–1/1

Clutch Speed Open or Short Diagnostic Procedure Alarm Level: No Warning Lamp

– – –1/1

TM10229 (17MAR09)

9001-30-119

544J Loader (S.N. 611800— ) 032409

PN=173

Transmission Control Unit (TCU) Diagnostic Trouble Codes 1 Component Check

Turn key switch OFF.

YES: Go to Open Circuit Check.

9001 30 ,120

Specification Internal Clutch Speed Sensor (B30)— Torque ................................................................................................................... 30 N•m 22 lb-ft

NO: Internal clutch speed sensor (B30) malfunction. Replace sensor. See Transmission Harness (W10) Component Location. (Group 9015-10.)

Measure resistance between sensor pins A and B. See Electrical Component Specifications. (Group 9015-20.) Is resistance within specification?

– – –1/1

2 Open Circuit Check

Turn key switch OFF.

YES: Go to Short Circuit Check.

Disconnect internal clutch speed sensor (B30) connector. See Transmission Harness (W10) Component Location. (Group 9015-10.)

NO: Go to next step in this check.

Disconnect transmission control unit (TCU) connector (X23). See Load Center Harness (W3) Component Location. (Group 9015-10.) Check circuit M09 PUR for continuity between pin A on internal clutch speed sensor (B30) connector and pin 42 on TCU connector (X23). See Transmission Harness (W10) Wiring Diagram and see Load Center Harness (W3) Wiring Diagram. (Group 9015-10.) Check circuit R09 BLK for continuity between pin B on internal clutch speed sensor (B30) connector and pin 3 on TCU connector (X23). Is continuity indicated?

Key switch OFF and TCU connector (X23) disconnected. Disconnect load center harness-to-transmission harness connector (X22). See Load Center Harness (W3) Component Location. (Group 9015-10.) Check circuit M09 PUR for continuity between pin P on load center harness side of connector (X22) and pin 42 on TCU connector (X23). See Load Center Harness (W3) Wiring Diagram. (Group 9015-10.) Check circuit R09 BLK for continuity between pin J on load center harness side of connector (X22) and pin 3 on TCU connector (X23). Is continuity indicated?

TM10229 (17MAR09)

9001-30-120

544J Loader (S.N. 611800— ) 032409

PN=174

Transmission Control Unit (TCU) Diagnostic Trouble Codes 3 Short Circuit Check

Turn key switch OFF.

YES: Go to next step in this check.

Disconnect internal clutch speed sensor (B30). See Transmission Harness (W10) Component Location. (Group 9015-10.)

NO: Go to Continuity Check.

Turn key switch ON.

9001 30 ,121

Check circuit M09 PUR for voltage between pin A on internal clutch speed sensor (B30) connector and machine ground. See Transmission Harness (W10) Wiring Diagram. (Group 9015-10.) Is system voltage (approximately 24 volts) present?

Turn key switch OFF. Disconnect load center harness-to-transmission harness connector (X22). See Load Center Harness (W3) Component Location. (Group 9015-10.)

YES: Short to power in load center harness. Repair circuit M09 PUR or replace load center harness.

Turn key switch ON. Check circuit M09 PUR for voltage between pin P on load center harness side of connector (X22) and machine ground. See Load Center Harness (W3) Wiring Diagram. (Group 9015-10.)

NO: Short to power in transmission harness. Repair circuit M09 PUR or replace transmission harness.

Is system voltage (approximately 24 volts) present?

– – –1/1

TM10229 (17MAR09)

9001-30-121

544J Loader (S.N. 611800— ) 032409

PN=175

Transmission Control Unit (TCU) Diagnostic Trouble Codes 4 Continuity Check

Turn key switch OFF. Disconnect internal clutch speed sensor (B30) and load center harness-to-transmission harness connector (X22). See Transmission Harness (W10) Component Location. (Group 9015-10.)

9001 30 ,122

Check for continuity between pin P (circuit M09 PUR) on transmission harness side of connector (X22) and all other pins on connector (X22). See Transmission Harness (W10) Wiring Diagram. (Group 9015-10.)

YES: Short circuit in transmission harness. Repair circuit with continuity indicated to another pin or replace transmission harness. NO: Go to next step in this check.

Check for continuity between pin J (circuit R09 BLK) on transmission harness side of connector (X22) and all other pins on connector (X22). Is continuity indicated with any other pins?

Key switch OFF.

YES: Short circuit in load center harness. Repair circuit(s) with continuity indicated to another pin or replace load center harness.

Load center harness-to-transmission harness connector (X22) is disconnected. Disconnect TCU connector (X23). See Load Center Harness (W3) Component Location. (Group 9015-10.) Check continuity between pin P (circuit M09 PUR) on load center harness side of connector (X22) and all other pins on connector (X22). See Load Center Harness (W3) Wiring Diagram. (Group 9015-10.)

NO: Go to next step in this check.

Check continuity between pin J (circuit R09 BLK) on load center harness side of connector (X22) and all other pins on connector (X22). Is continuity indicated with any other pins?

Key switch OFF. Load center harness-to-transmission harness connector (X22) and TCU connector (X23) are disconnected. Check continuity between pin 42 (circuit M09 PUR) on TCU connector (X23) and all other pins on connector (X23). See Load Center Harness (W3) Wiring Diagram. (Group 9015-10.) Check continuity between pin 3 (circuit R09 BLK) on TCU connector (X23) and all other pins on connector (X23).

Is continuity indicated with any other pins?

– – –1/1

522402.04 — Clutch Speed Short to Gnd

Clutch internal speed sensor circuit is short to ground.

TF44157,000025D –19–14MAR08–1/1

TM10229 (17MAR09)

9001-30-122

544J Loader (S.N. 611800— ) 032409

PN=176

Transmission Control Unit (TCU) Diagnostic Trouble Codes Clutch Speed Short to Ground Diagnostic Procedure Alarm Level: No Warning Lamp

9001 30 ,123

– – –1/1

1 Component Check

Turn key switch OFF.

YES: Go to Short Circuit Check.

Disconnect internal clutch speed sensor (B30). See Transmission Harness (W10) Component Location. (Group 9015-10.) Verify internal clutch speed sensor (B30) is installed to correct torque specification in order to ensure correct gap distance. Specification Internal Clutch Speed Sensor (B30)— Torque ................................................................................................................... 30 N•m 22 lb-ft

NO: Internal clutch speed sensor (B30) malfunction. Replace sensor. See Transmission Harness (W10) Component Location. (Group 9015-10.)

Measure resistance between sensor pins A and B. See Electrical Component Specifications. (Group 9015-20.) Is resistance within specification?

– – –1/1

2 Short Circuit Check

Turn key switch OFF.

YES: Go to next step in this check.

Disconnect internal clutch speed sensor (B30) and transmission control unit (TCU) connector (X23). See Transmission Harness (W10) Component Location and see Load Center Harness (W3) Component Location. (Group 9015-10.)

NO: Go to Continuity Check.

Check circuit M09 PUR for ground at pin A on internal clutch speed sensor (B30) connector. See Transmission Harness (W10) Wiring Diagram. (Group 9015-10.) Is ground present?

Key switch OFF and TCU connector (X23) disconnected. Disconnect load center harness-to-transmission harness connector (X22). See Load Center Harness (W3) Component Location. (Group 9015-10.) Check circuit M09 PUR for ground at pin 42 on TCU connector (X23). See Load Center Harness (W3) Wiring Diagram. (Group 9015-10.) Is ground present?

YES: Short to ground in load center harness. Repair circuit M09 PUR or replace load center harness. NO: Short to ground in transmission harness. Repair circuit M09 PUR or replace transmission harness. – – –1/1

TM10229 (17MAR09)

9001-30-123

544J Loader (S.N. 611800— ) 032409

PN=177

Transmission Control Unit (TCU) Diagnostic Trouble Codes 3 Continuity Check

Turn key switch OFF. Disconnect internal clutch speed sensor (B30) and load center harness-to-transmission harness connector (X22). See Transmission Harness (W10) Component Location. (Group 9015-10.)

9001 30 ,124

YES: Short circuit in transmission harness. Repair circuit with continuity indicated to another pin or replace transmission harness. NO: Go to next step in this check.

Check for continuity between pin J (circuit R09 BLK) on transmission harness side of connector (X22) and all other pins on connector (X22). Is continuity indicated with any other pins?

Key switch OFF.

YES: Short circuit in load center harness. Repair circuit(s) with continuity indicated to another pin or replace load center harness.

Load center harness-to-transmission harness connector (X22) is disconnected. Disconnect TCU connector (X23). See Load Center Harness (W3) Component Location. (Group 9015-10.) Check continuity between pin P (circuit M09 PUR) on load center harness side of connector (X22) and all other pins on connector (X22). See Load Center Harness (W3) Wiring Diagram. (Group 9015-10.)

NO: Go to next step in this check.

Check continuity between pin J (circuit R09 BLK) on load center harness side of connector (X22) and all other pins on connector (X22). Is continuity indicated with any other pins?

Is continuity indicated with any other pins?

– – –1/1

522402.12 — Clutch Speed Sensor Fault

Internal clutch speed sensor signal fault.

TF44157,000025E –19–14MAR08–1/1

TM10229 (17MAR09)

9001-30-124

544J Loader (S.N. 611800— ) 032409

PN=178

Transmission Control Unit (TCU) Diagnostic Trouble Codes Clutch Speed Sensor Fault Diagnostic Procedure Alarm Level: No Warning Lamp

9001 30 ,125

– – –1/1

1 Code Check

Turn key switch ON. Check for transmission control unit (TCU) codes: 522402.03—Clutch Speed Open or Short and 522402.04—Clutch Speed Short to Gnd. Are either of the TCU codes above active?

YES: Correct problem causing other TCU codes. See Diagnostic Trouble Codes (DTC) Quick Reference List. (Group 9015-10.) NO: Go to Component Check.

– – –1/1

2 Component Check

Turn key switch OFF. Disconnect internal clutch speed sensor (B30). See Transmission Harness (W10) Component Location. (Group 9015-10.) Verify internal clutch speed sensor (B30) is installed to correct torque specification in order to ensure correct gap distance. Specification Internal Clutch Speed Sensor (B30)— Torque ................................................................................................................... 30 N•m 22 lb-ft

YES: Replace controller, see Transmission Control Unit (TCU) Remove and Install. (Group 9015-20.) NO: Internal clutch speed sensor (B30) malfunction. Replace sensor. See Transmission Harness (W10) Component Location. (Group 9015-10.)

Measure resistance between sensor pins A and B. See Electrical Component Specifications. (Group 9015-20.) Is resistance within specification?

– – –1/1

TM10229 (17MAR09)

9001-30-125

544J Loader (S.N. 611800— ) 032409

PN=179

Transmission Control Unit (TCU) Diagnostic Trouble Codes

522403.03 — Conv Output Spd Open or Short

9001 30 ,126

Torque converter output speed sensor circuit is open or short to power.

TF44157,000025F –19–14MAR08–1/1

Converter Output Speed Open or Short Diagnostic Procedure Alarm Level: No Warning Lamp

– – –1/1

1 Component Check

Turn key switch OFF.

YES: Go to Open Circuit Check.

Disconnect torque converter output speed sensor (B29). See Transmission Harness (W10) Component Location. (Group 9015-10.) Verify torque converter output speed sensor (B29) is installed to correct torque specification in order to ensure correct gap distance. Specification Torque Converter Output Speed Sensor (B29)—Torque ....................................................................................................... 30 N•m 22 lb-ft

NO: Torque converter output speed sensor (B29) malfunction. Replace sensor. See Transmission Harness (W10) Component Location. (Group 9015-10.)

Measure resistance between pins A and B on torque converter output speed sensor (B29). See Electrical Component Specifications. (Group 9015-20.) Is resistance within specification?

– – –1/1

TM10229 (17MAR09)

9001-30-126

544J Loader (S.N. 611800— ) 032409

PN=180

Transmission Control Unit (TCU) Diagnostic Trouble Codes 2 Open Circuit Check

Turn key switch OFF.

YES: Go to Short Circuit Check.

Disconnect torque converter output speed sensor (B29) and transmission control unit (TCU) connector (X23). See Transmission Harness (W10) Component Location. (Group 9015-10.)

NO: Go to next step in this check. 9001 30 ,127

Check circuit M08 PUR for continuity between pin A on torque converter output speed sensor (B29) connector and pin 41 on TCU connector (X23). See Transmission Harness (W10) Wiring Diagram and see Load Center Harness (W3) Wiring Diagram. (Group 9015-10.) Is continuity indicated?

Key switch OFF. TCU connector (X23) is disconnected. Disconnect load center harness-to-transmission harness connector (X22). See Load Center Harness (W3) Component Location. (Group 9015-10.) Check circuit M08 PUR for continuity between pin O on load center harness side of connector (X22) and pin 41 on TCU connector (X23). See Load Center Harness (W3) Wiring Diagram. (Group 9015-10.)

YES: Open circuit in transmission harness. Repair circuit M08 PUR or replace transmission harness. NO: Open circuit in load center harness. Repair circuit M08 PUR or replace load center harness.

Is continuity indicated?

– – –1/1

3 Short Circuit Check

Turn key switch OFF.

YES: Go to next step in this check.

Disconnect torque converter output speed sensor (B29). See Transmission Harness (W10) Component Location. (Group 9015-10.)

NO: Go to Continuity Check.

Turn key switch ON. Check circuit M08 PUR for voltage between pin A on torque converter output speed sensor (B29) connector and machine ground. See Transmission Harness (W10) Wiring Diagram. (Group 9015-10.) Is system voltage (approximately 24 volts) present?

Turn key switch OFF. Disconnect load center harness-to-transmission harness connector (X22). See Load Center Harness (W3) Component Location. (Group 9015-10.)

YES: Short to power in load center harness. Repair circuit M08 PUR or replace load center harness.

Turn key switch ON. Check circuit M08 PUR for voltage between pin O on load center harness side of connector (X22) and machine ground. See Load Center Harness (W3) Wiring Diagram. (Group 9015-10.)

NO: Short to power in transmission harness. Repair circuit M08 PUR or replace transmission harness.

Is system voltage (approximately 24 volts) present?

– – –1/1

TM10229 (17MAR09)

9001-30-127

544J Loader (S.N. 611800— ) 032409

PN=181

Transmission Control Unit (TCU) Diagnostic Trouble Codes 4 Continuity Check

Turn key switch OFF.

YES: Short circuit in transmission harness. Repair circuit with continuity indicated to another pin or replace transmission harness.

Disconnect torque converter output speed sensor (B29) and load center harness-to-transmission harness connector (X22). See Transmission Harness (W10) Component Location. (Group 9015-10.) 9001 30 ,128

Check for continuity between pin O (circuit M08 PUR) on transmission harness side of connector (X22) and all other pins on connector (X22). See Transmission Harness (W10) Wiring Diagram. (Group 9015-10.)

NO: Go to next step in this check.

Check for continuity between pin H (circuit R09 BLK) on transmission harness side of connector (X22) and all other pins on connector (X22). Is continuity indicated with any other pins?

Key switch OFF.

YES: Short circuit in load center harness. Repair circuit(s) with continuity indicated to another pin or replace load center harness.

Load center harness-to-transmission harness connector (X22) is disconnected. Disconnect TCU connector (X23). See Load Center Harness (W3) Component Location. (Group 9015-10.) Check continuity between pin O (circuit M08 PUR) on load center harness side of connector (X22) and all other pins on connector (X22). See Load Center Harness (W3) Wiring Diagram. (Group 9015-10.)

NO: Go to next step in this check.

Check continuity between pin H (circuit R09 BLK) on load center harness side of connector (X22) and all other pins on connector (X22). Is continuity indicated with any other pins?

Key switch OFF. Load center harness-to-transmission harness connector (X22) and TCU connector (X23) are disconnected. Check continuity between pin 41 (circuit M08 PUR) on TCU connector (X23) and all other pins on connector (X23). See Load Center Harness (W3) Wiring Diagram. (Group 9015-10.) Check continuity between pin 3 (circuit R09 BLK) on TCU connector (X23) and all other pins on connector (X23).

Is continuity indicated with any other pins?

– – –1/1

522403.04 — Conv Output Spd Short to Gnd

Torque converter output speed sensor circuit is short to ground.

TF44157,0000260 –19–14MAR08–1/1

TM10229 (17MAR09)

9001-30-128

544J Loader (S.N. 611800— ) 032409

PN=182

Transmission Control Unit (TCU) Diagnostic Trouble Codes Converter Output Speed Short to Ground Diagnostic Procedure Alarm Level: No Warning Lamp

9001 30 ,129

– – –1/1

1 Component Check

Turn key switch OFF.

YES: Go to Short Circuit Check.

NO: Torque converter output speed sensor (B29) malfunction. Replace sensor. See Transmission Harness (W10) Component Location. (Group 9015-10.)

Measure resistance between pins A and B on torque converter output speed sensor (B29). See Electrical Component Specifications. (Group 9015-20.) Is resistance within specification?

– – –1/1

2 Short Circuit Check

Turn key switch OFF.

YES: Go to next step in this check.

Disconnect torque converter output speed sensor (B29) and transmission control unit (TCU) connector (X23). See Transmission Harness (W10) Component Location and see Load Center Harness (W3) Component Location. (Group 9015-10.)

NO: Go to Continuity Check.

Check circuit M08 PUR for ground at pin A on torque converter output speed sensor (B29) connector. See Transmission Harness (W10) Wiring Diagram. (Group 9015-10.) Is ground present?

Key switch OFF and TCU connector (X23) disconnected. Disconnect load center harness-to-transmission harness connector (X22). See Load Center Harness (W3) Component Location. (Group 9015-10.) Check circuit M08 PUR for ground at pin 41 on TCU connector (X23). See Load Center Harness (W3) Wiring Diagram. (Group 9015-10.) Is ground present?

YES: Short to ground in load center harness. Repair circuit M08 PUR or replace load center harness. NO: Short to ground in transmission harness. Repair circuit M08 PUR or replace transmission harness. – – –1/1

TM10229 (17MAR09)

9001-30-129

544J Loader (S.N. 611800— ) 032409

PN=183

Transmission Control Unit (TCU) Diagnostic Trouble Codes 3 Continuity Check

Turn key switch OFF.

YES: Short circuit in transmission harness. Repair circuit with continuity indicated to another pin or replace transmission harness.

Disconnect torque converter output speed sensor (B29) and load center harness-to-transmission harness connector (X22). See Transmission Harness (W10) Component Location. (Group 9015-10.) 9001 30 ,130

NO: Go to next step in this check.

Check for continuity between pin H (circuit R09 BLK) on transmission harness side of connector (X22) and all other pins on connector (X22). Is continuity indicated with any other pins?

Key switch OFF.

YES: Short circuit in load center harness. Repair circuit(s) with continuity indicated to another pin or replace load center harness.

Load center harness-to-transmission harness connector (X22) is disconnected. Disconnect TCU connector (X23). See Load Center Harness (W3) Component Location. (Group 9015-10.) Check continuity between pin O (circuit M08 PUR) on load center harness side of connector (X22) and all other pins on connector (X22). See Load Center Harness (W3) Wiring Diagram. (Group 9015-10.)

NO: Go to next step in this check.

Check continuity between pin H (circuit R09 BLK) on load center harness side of connector (X22) and all other pins on connector (X22). Is continuity indicated with any other pins?

Is continuity indicated with any other pins?

– – –1/1

522403.12 — Conv Output Spd Fault

Torque converter output speed sensor signal does not match other speed sensors.

TF44157,0000261 –19–14MAR08–1/1

TM10229 (17MAR09)

9001-30-130

544J Loader (S.N. 611800— ) 032409

PN=184

Transmission Control Unit (TCU) Diagnostic Trouble Codes Converter Output Speed Fault Diagnostic Procedure Alarm Level: No Warning Lamp

9001 30 ,131

– – –1/1

1 Code Check

Turn key switch ON. Check for transmission control unit (TCU) codes: 522403.03—Conv Output Spd Open or Short and 522403.04—Conv Output Spd Short to Gnd. Are either of the TCU codes above active?

YES: Correct problem causing other TCU codes. See Diagnostic Trouble Codes (DTC) Quick Reference List. (Group 9015-10.) NO: Go to Component Check.

– – –1/1

2 Component Check

Turn key switch OFF. Disconnect torque converter output speed sensor (B29). See Transmission Harness (W10) Component Location. (Group 9015-10.) Verify torque converter output speed sensor (B29) is installed to correct torque specification in order to ensure correct gap distance. Specification Torque Converter Output Speed Sensor (B29)—Torque ....................................................................................................... 30 N•m 22 lb-ft

YES: Replace controller, see Transmission Control Unit (TCU) Remove and Install. (Group 9015-20.) NO: Torque converter output speed sensor (B29) malfunction. Replace sensor. See Transmission Harness (W10) Component Location. (Group 9015-10.)

Measure resistance between pins A and B on torque converter output speed sensor (B29). See Electrical Component Specifications. (Group 9015-20.) Is resistance within specification?

– – –1/1

TM10229 (17MAR09)

9001-30-131

544J Loader (S.N. 611800— ) 032409

PN=185

Transmission Control Unit (TCU) Diagnostic Trouble Codes

522404.03 — Conv Input Spd Open or Short

9001 30 ,132

Torque converter input speed sensor circuit is open or short to power.

TF44157,0000262 –19–14MAR08–1/1

Converter Input Speed Open or Short Diagnostic Procedure Alarm Level: No Warning Lamp

– – –1/1

1 Component Check

Turn key switch OFF.

YES: Go to Open Circuit Check.

Disconnect torque converter input speed sensor (B28). See Transmission Harness (W10) Component Location. (Group 9015-10.) Verify torque converter input speed sensor (B28) is installed to correct torque specification in order to ensure correct gap distance. Specification Torque Converter Input Speed Sensor (B28)—Torque ....................................................................................................... 30 N•m 22 lb-ft

NO: Torque converter input speed sensor (B28) malfunction. Replace sensor. See Transmission Harness (W10) Component Location. (Group 9015-10.)

Measure resistance between pins A and B on torque converter input speed sensor (B28). See Electrical Component Specifications. (Group 9015-20.) Is resistance within specification?

– – –1/1

TM10229 (17MAR09)

9001-30-132

544J Loader (S.N. 611800— ) 032409

PN=186

Transmission Control Unit (TCU) Diagnostic Trouble Codes 2 Open Circuit Check

Turn key switch OFF.

YES: Go to Short Circuit Check.

Disconnect torque converter input speed sensor (B28). See Transmission Harness (W10) Component Location. (Group 9015-10.)

NO: Go to next step in this check.

Transmission control unit (TCU) connector (X23). See Load Center Harness (W3) Component Location. (Group 9015-10.)

9001 30 ,133

Check circuit M07 PUR for continuity between pin A on torque converter input speed sensor (B28) connector and pin 19 on TCU connector (X23). See Transmission Harness (W10) Wiring Diagram and see Load Center Harness (W3) Wiring Diagram. (Group 9015-10.) Check circuit R09 BLK for continuity between pin B on torque converter input speed sensor (B28) connector and pin 3 on TCU connector (X23). Is continuity indicated?

Key switch OFF. TCU connector (X23) is disconnected. Disconnect load center harness-to-transmission harness connector (X22). See Load Center Harness (W3) Component Location. (Group 9015-10.) Check circuit M07 PUR for continuity between pin N on load center harness side of connector (X22) and pin 19 on TCU connector (X23). See Load Center Harness (W3) Wiring Diagram. (Group 9015-10.)

YES: Open circuit in transmission harness. Repair circuit M07 PUR or replace transmission harness. NO: Open circuit in load center harness. Repair circuit M07 PUR or replace load center harness.

Check circuit R09 BLK for continuity between pin G on load center harness side of connector (X22) and pin 3 on TCU connector (X23) Is continuity indicated?

– – –1/1

TM10229 (17MAR09)

9001-30-133

544J Loader (S.N. 611800— ) 032409

PN=187

Transmission Control Unit (TCU) Diagnostic Trouble Codes 3 Short Circuit Check

Turn key switch OFF.

YES: Go to next step in this check.

Disconnect torque converter input speed sensor (B28). See Transmission Harness (W10) Component Location. (Group 9015-10.)

NO: Go to Continuity Check.

Turn key switch ON.

9001 30 ,134

Check circuit M07 PUR for voltage between pin A on torque converter input speed sensor (B28) connector and machine ground. Is system voltage (approximately 24 volts) present?

Turn key switch OFF. Disconnect load center harness-to-transmission harness connector (X22). See Load Center Harness (W3) Component Location. (Group 9015-10.) Turn key switch ON. Check circuit M07 PUR for voltage between pin N on load center harness side of connector (X22) and machine ground. Is system voltage (approximately 24 volts) present?

YES: Short to power in load center harness. Repair circuit M07 PUR or replace load center harness. See Load Center Harness (W3) Wiring Diagram. (Group 9015-10.) NO: Short to power in transmission harness. Repair circuit M07 PUR or replace transmission harness. See Transmission Harness (W10) Wiring Diagram. (Group 9015-10.)

– – –1/1

TM10229 (17MAR09)

9001-30-134

544J Loader (S.N. 611800— ) 032409

PN=188

Transmission Control Unit (TCU) Diagnostic Trouble Codes 4 Continuity Check

Turn key switch OFF.

YES: Short circuit in transmission harness. Repair circuit with continuity indicated to another pin or replace transmission harness.

Disconnect torque converter input speed sensor (B28) and load center harness-to-transmission harness connector (X22). See Transmission Harness (W10) Component Location. (Group 9015-10.) Check for continuity between pin N (circuit M07 PUR) on transmission harness side of connector (X22) and all other pins on connector (X22). See Transmission Harness (W10) Wiring Diagram. (Group 9015-10.)

NO: Go to next step in this check.

Check for continuity between pin G (circuit R09 BLK) on transmission harness side of connector (X22) and all other pins on connector (X22). Is continuity indicated with any other pins?

Key switch OFF.

YES: Short circuit in load center harness. Repair circuit(s) with continuity indicated to another pin or replace load center harness.

Load center harness-to-transmission harness connector (X22) is disconnected. Disconnect TCU connector (X23). See Load Center Harness (W3) Component Location. (Group 9015-10.) Check continuity between pin N (circuit M07 PUR) on load center harness side of connector (X22) and all other pins on connector (X22). See Load Center Harness (W3) Wiring Diagram. (Group 9015-10.)

NO: Go to next step in this check.

Check continuity between pin G(circuit R09 BLK) on load center harness side of connector (X22) and all other pins on connector (X22). Is continuity indicated with any other pins?

Key switch OFF. Load center harness-to-transmission harness connector (X22) and TCU connector (X23) are disconnected. Check continuity between pin 19 (circuit M07 PUR) on TCU connector (X23) and all other pins on connector (X23). See Load Center Harness (W3) Wiring Diagram. (Group 9015-10.) Check continuity between pin 3 (circuit R09 BLK) on TCU connector (X23) and all other pins on connector (X23).

Is continuity indicated with any other pins?

– – –1/1

522404.04 — Conv Input Spd Short to Gnd

Torque converter input speed sensor circuit is short to ground.

TF44157,0000263 –19–14MAR08–1/1

TM10229 (17MAR09)

9001-30-135

544J Loader (S.N. 611800— ) 032409

PN=189

9001 30 ,135

Transmission Control Unit (TCU) Diagnostic Trouble Codes Torque Converter Input Speed Short to Ground Diagnostic Procedure Alarm Level: 9001 30 ,136

No Warning Lamp

– – –1/1

1 Component Check

Turn key switch OFF.

YES: Go to Short Circuit Check.

NO: Torque converter input speed sensor (B28) malfunction. Replace sensor. See Transmission Harness (W10) Component Location. (Group 9015-10.)

Measure resistance between pins A and B on torque converter input speed sensor (B28). See Electrical Component Specifications. (Group 9015-20.) Is resistance within specification?

– – –1/1

TM10229 (17MAR09)

9001-30-136

544J Loader (S.N. 611800— ) 032409

PN=190

Transmission Control Unit (TCU) Diagnostic Trouble Codes 2 Short Circuit Check

Turn key switch OFF.

YES: Go to next step in this check.

Disconnect torque converter input speed sensor (B28). See Transmission Harness (W10) Component Location. (Group 9015-10.)

NO: Go to Continuity Check.

Disconnect transmission control unit (TCU) connector (X23). See Load Center Harness (W3) Component Location. (Group 9015-10.)

9001 30 ,137

Check circuit M07 PUR for ground at pin A on torque converter input speed sensor (B28) connector. See Transmission Harness (W10) Wiring Diagram. (Group 9015-10.) Is ground present?

Key switch OFF and TCU connector (X23) disconnected. Disconnect load center harness-to-transmission harness connector (X22). See Load Center Harness (W3) Component Location. (Group 9015-10.) Check circuit M07 PUR for ground at pin 19 on TCU connector (X23). See Load Center Harness (W3) Wiring Diagram. (Group 9015-10.) Is ground present?

YES: Short to ground in load center harness. Repair circuit M07 PUR or replace load center harness. NO: Short to ground in transmission harness. Repair circuit M07 PUR or replace transmission harness.

– – –1/1

TM10229 (17MAR09)

9001-30-137

544J Loader (S.N. 611800— ) 032409

PN=191

Transmission Control Unit (TCU) Diagnostic Trouble Codes 3 Continuity Check

Turn key switch OFF.

YES: Short circuit in transmission harness. Repair circuit with continuity indicated to another pin or replace transmission harness.

Disconnect torque converter input speed sensor (B28) and load center harness-to-transmission harness connector (X22). See Transmission Harness (W10) Component Location. (Group 9015-10.) 9001 30 ,138

Check for continuity between pin N (circuit M07 PUR) on transmission harness side of connector (X22) and all other pins on connector (X22). See Transmission Harness (W10) Wiring Diagram. (Group 9015-10.)

NO: Go to next step in this check.

Check for continuity between pin G (circuit R09 BLK) on transmission harness side of connector (X22) and all other pins on connector (X22). Is continuity indicated with any other pins?

Key switch OFF.

YES: Short circuit in load center harness. Repair circuit(s) with continuity indicated to another pin or replace load center harness.

Load center harness-to-transmission harness connector (X22) is disconnected. Disconnect TCU connector (X23). See Load Center Harness (W3) Component Location. (Group 9015-10.) Check continuity between pin N (circuit M07 PUR) on load center harness side of connector (X22) and all other pins on connector (X22). See Load Center Harness (W3) Wiring Diagram. (Group 9015-10.)

NO: Go to next step in this check.

Check continuity between pin G(circuit R09 BLK) on load center harness side of connector (X22) and all other pins on connector (X22). Is continuity indicated with any other pins?

Is continuity indicated with any other pins?

– – –1/1

522404.12 — Conv Input Spd Fault

Torque converter input speed sensor signal fault.

TF44157,0000264 –19–14MAR08–1/1

TM10229 (17MAR09)

9001-30-138

544J Loader (S.N. 611800— ) 032409

PN=192

Transmission Control Unit (TCU) Diagnostic Trouble Codes Converter Input Speed Fault Diagnostic Procedure Alarm Level: No Warning Lamp

9001 30 ,139

– – –1/1

1 Code Check

Turn key switch ON. Check for transmission control unit (TCU) codes: 522404.03—Conv Input Spd Open or Short and 522404.04—Conv Input Spd Short to Gnd. Are either of the TCU codes above active?

YES: Correct problem causing other TCU codes. See Diagnostic Trouble Codes (DTC) Quick Reference List. (Group 9015-10.) NO: Go to Component Check.

– – –1/1

2 Component Check

Turn key switch OFF. Disconnect torque converter input speed sensor (B28). See Transmission Harness (W10) Component Location. (Group 9015-10.) Verify torque converter input speed sensor (B28) is installed to correct torque specification in order to ensure correct gap distance. Specification Torque Converter Input Speed Sensor (B28)—Torque ....................................................................................................... 30 N•m 22 lb-ft

YES: Replace controller, see Transmission Control Unit (TCU) Remove and Install. (Group 9015-20.) NO: Torque converter input speed sensor (B28) malfunction. Replace sensor. See Transmission Harness (W10) Component Location. (Group 9015-10.)

Measure resistance between pins A and B on torque converter input speed sensor (B28). See Electrical Component Specifications. (Group 9015-20.) Is resistance within specification?

– – –1/1

TM10229 (17MAR09)

9001-30-139

544J Loader (S.N. 611800— ) 032409

PN=193

Transmission Control Unit (TCU) Diagnostic Trouble Codes

522406.03 — Trans Oil Temp Open or Short

9001 30 ,140

Transmission oil temperature sensor circuit is open or short to power.

TF44157,0000265 –19–14MAR08–1/1

Transmission Oil Temperature Sensor Open or Short Diagnostic Procedure Alarm Level: No Warning Lamp

– – –1/1

1 Component Check

Turn key switch OFF.

YES: Go to Open Circuit Check.

Disconnect transmission harness-to-transmission control valve harness connector (X36). See Transmission Harness (W10) Component Location. (Group 9015-10.)

NO: Go to next step in this check.

Check resistance of transmission oil temperature sensor between pins 8 and 9 on transmission control valve harness side of connector (X36). See Electrical Component Specifications. (Group 9015-20.) Is resistance within specification?

Key switch OFF. Disassemble transmission control valve to access transmission oil temperature sensor (B32). See Transmission Control Valve Disassemble and Assemble. (Group 0360.) Disconnect transmission oil temperature sensor (B32). Check resistance of transmission oil temperature sensor (B32). See Electrical Component Specifications. (Group 9015-20.) Is resistance within specification?

YES: Open circuit in transmission control valve harness. Repair circuit X06 YEL or replace transmission control valve harness. NO: Transmission oil temperature sensor (B32) malfunction. Replace sensor. – – –1/1

TM10229 (17MAR09)

9001-30-140

544J Loader (S.N. 611800— ) 032409

PN=194

Transmission Control Unit (TCU) Diagnostic Trouble Codes 2 Open Circuit Check

Turn key switch OFF.

YES: Go to Short Circuit Check.

Disconnect transmission harness-to-transmission control valve harness connector (X36). See Transmission Harness (W10) Component Location. (Group 9015-10.)

NO: Go to next step in this check.

Disconnect transmission control unit (TCU) connector (X23). See Load Center Harness (W3) Component Location. (Group 9015-10.)

9001 30 ,141

Check circuit X06 YEL for continuity between pin 8 on transmission harness side of connector (X36) and pin 39 on TCU connector (X23). See Transmission Harness (W10) Wiring Diagram and see Load Center Harness (W3) Wiring Diagram. (Group 9015-10.) Check circuit R06 BLK for continuity between pin 9 on transmission harness side of connector (X36) and pin 46 on TCU connector (X23). Is continuity indicated?

Key switch OFF. TCU connector (X23) is disconnected. Disconnect load center harness-to-transmission harness connector (X22). See Load Center Harness (W3) Component Location. (Group 9015-10.) Check circuit X06 YEL for continuity between pin B on load center harness side of connector (X22) and pin 29 on TCU connector (X23). See Load Center Harness (W3) Wiring Diagram. (Group 9015-10.) Check circuit R06 BLK for continuity between pin M on load center harness side of connector (X22) and pin 9 on TCU connector (X23).

Is continuity indicated?

– – –1/1

TM10229 (17MAR09)

9001-30-141

544J Loader (S.N. 611800— ) 032409

PN=195

Transmission Control Unit (TCU) Diagnostic Trouble Codes 3 Short Circuit Check

Turn key switch OFF. Disconnect transmission harness-to-transmission control valve harness connector (X36). See Transmission Harness (W10) Component Location. (Group 9015-10.) Check circuit X06 YEL for resistance between pin 8 and all other pins on transmission control valve harness side of connector (X36).

9001 30 ,142

YES: Short circuit to wire with resistance less than 5 ohms. Repair circuit X06 YEL or replace transmission control valve harness. NO: Go to next step in this check.

Is resistance with any wire less than 5 ohms?

Key switch OFF.

YES: Go to next step in this check.

Transmission harness-to-transmission control valve harness connector (X36) is disconnected.

NO: Go to Continuity Check.

Turn key switch ON. Check circuit X06 YEL for voltage between pin 8 on transmission harness side of connector (X36) and machine ground. See Transmission Harness (W10) Wiring Diagram. (Group 9015-10.) Is voltage more than approximately 5 volts?

Turn key switch OFF. Disconnect load center harness-to-transmission harness connector (X22). See Load Center Harness (W3) Component Location. (Group 9015-10.)

YES: Short to power in load center harness. Repair circuit X06 YEL or replace load center harness.

Turn key switch ON. Check circuit X06 YEL for voltage between pin B on load center harness side of connector (X22) and machine ground. See Load Center Harness (W3) Wiring Diagram. (Group 9015-10.)

NO: Short to power in transmission harness. Repair circuit X06 YEL or replace transmission harness.

Is voltage more than approximately 5 volts?

– – –1/1

TM10229 (17MAR09)

9001-30-142

544J Loader (S.N. 611800— ) 032409

PN=196

Transmission Control Unit (TCU) Diagnostic Trouble Codes 4 Continuity Check

Turn battery disconnect OFF.

YES: Short circuit in transmission harness. Repair circuit(s) with continuity indicated to another pin or replace transmission harness.

Disconnect transmission harness-to-transmission control valve harness connector (X36) and load center harness-to-transmission harness connector (X22). See Transmission Harness (W10) Component Location. (Group 9015-10.) Check for continuity between pin B (circuit X06 YEL) on transmission harness side of connector (X22) and all other pins on connector (X22). See Transmission Harness (W10) Wiring Diagram. (Group 9015-10.)

NO: Go to next step in this check.

Check for continuity between pin M (circuit R06 BLK) on transmission harness side of connector (X22) and all other pins on connector (X22). Is continuity indicated with any other pins?

Battery disconnect OFF.

YES: Short circuit in load center harness. Repair circuit(s) with continuity indicated to another pin or replace load center harness.

Load center harness-to-transmission harness connector (X22) is disconnected. Disconnect TCU connector (X23). See Load Center Harness (W3) Component Location. (Group 9015-10.) Check for continuity between pin B on (circuit X06 YEL) on load center harness side of connector (X22) and all other pins on connector (X22). See Load Center Harness (W3) Wiring Diagram. (Group 9015-10.)

NO: Go to next step in this check.

Check for continuity between pin M (circuit R06 BLK) on load center harness side of connector (X22) and all other pins on connector (X22). Is continuity indicated with any other pins?

Battery disconnect OFF. Load center harness-to-transmission harness connector (X22) and TCU connector (X23) are disconnected. Check for continuity between pin 39 on TCU connector (X23) and all other pins on connector (X23). See Load Center Harness (W3) Wiring Diagram. (Group 9015-10.) Check for continuity between pin 46 on TCU connector (X23) and all other pins on connector (X23).

– – –1/1

522406.04 — Trans Oil Temp Short to Gnd

Transmission oil temperature sensor circuit is short to ground.

TF44157,0000266 –19–14MAR08–1/1

TM10229 (17MAR09)

9001-30-143

544J Loader (S.N. 611800— ) 032409

PN=197

9001 30 ,143

Transmission Control Unit (TCU) Diagnostic Trouble Codes Transmission Oil Temperature Sensor Short to Ground Diagnostic Procedure Alarm Level: 9001 30 ,144

No Warning Lamp

– – –1/1

1 Component Check

Turn key switch OFF.

YES: Go to Short Circuit Check.

Disconnect transmission harness-to-transmission control valve harness connector (X36). See Transmission Harness (W10) Component Location. (Group 9015-10.)

NO: Go to next step in this check.

TM10229 (17MAR09)

9001-30-144

544J Loader (S.N. 611800— ) 032409

PN=198

Transmission Control Unit (TCU) Diagnostic Trouble Codes 2 Short Circuit Check

Turn key switch OFF. Disconnect transmission harness-to-transmission control valve harness connector (X36). See Transmission Harness (W10) Component Location. (Group 9015-10.) Check circuit X06 YEL for ground at pin 8 on transmission control valve harness side of connector (X36).

YES: Short to ground in transmission control valve harness. Repair circuit X06 YEL or replace transmission control valve harness. NO: Go to next step in this check.

Is ground present?

Key switch OFF.

YES: Go to next step in this check.

Transmission harness-to-transmission control valve harness connector (X36) is disconnected.

NO: Go to Continuity Check.

Disconnect transmission control unit (TCU) connector (X23). See Load Center Harness (W3) Component Location. (Group 9015-10.) Check circuit X06 YEL for ground at pin 8 on transmission harness side of connector (X36). See Transmission Harness (W10) Wiring Diagram. (Group 9015-10.) Is ground present?

Key switch OFF. TCU connector (X23) is disconnected. Disconnect load center harness-to-transmission harness connector (X22). See Load Center Harness (W3) Component Location. (Group 9015-10.) Check circuit X06 YEL for ground at pin 39 on TCU connector (X23). See Load Center Harness (W3) Wiring Diagram. (Group 9015-10.) Is ground present?

YES: Short to ground in load center harness. Repair circuit X06 YEL or replace load center harness. NO: Short to ground in transmission harness. Repair circuit X06 YEL or replace transmission harness.

– – –1/1

TM10229 (17MAR09)

9001-30-145

544J Loader (S.N. 611800— ) 032409

PN=199

9001 30 ,145

Transmission Control Unit (TCU) Diagnostic Trouble Codes 3 Continuity Check

Turn battery disconnect OFF.

YES: Short circuit in transmission harness. Repair circuit(s) with continuity indicated to another pin or replace transmission harness.

Check for continuity between pin B (circuit X06 YEL) on transmission harness side of connector (X22) and all other pins on connector (X22). See Transmission Harness (W10) Wiring Diagram. (Group 9015-10.)

NO: Go to next step in this check.

Check for continuity between pin M (circuit R06 BLK) on transmission harness side of connector (X22) and all other pins on connector (X22). Is continuity indicated with any other pins?

Battery disconnect OFF.

YES: Short circuit in load center harness. Repair circuit(s) with continuity indicated to another pin or replace load center harness.

Load center harness-to-transmission harness connector (X22) is disconnected. Disconnect TCU connector (X23). See Load Center Harness (W3) Component Location. (Group 9015-10.) Check for continuity between pin B on (circuit X06 YEL) on load center harness side of connector (X22) and all other pins on connector (X22). See Load Center Harness (W3) Wiring Diagram. (Group 9015-10.)

NO: Go to next step in this check.

Check for continuity between pin M (circuit R06 BLK) on load center harness side of connector (X22) and all other pins on connector (X22). Is continuity indicated with any other pins?

– – –1/1

522407.03 — Clutch Cutoff Short to Power

Clutch cut-off sensor circuit is short to power.

TF44157,0000267 –19–14MAR08–1/1

TM10229 (17MAR09)

9001-30-146

544J Loader (S.N. 611800— ) 032409

PN=200

Transmission Control Unit (TCU) Diagnostic Trouble Codes Clutch Cut-Off Sensor Short to Power Diagnostic Procedure Alarm Level: No Warning Lamp

9001 30 ,147

– – –1/1

1 Component Check

Turn key switch OFF.

YES: Go to Short Circuit Check—Power Circuit.

Disconnect clutch cut-off sensor (B33). See Load Center Harness (W3) Component Location. (Group 9015-10.) Check resistance of clutch cutoff sensor between pins A and B.

NO: Clutch cut-off sensor (B33) malfunction. Replace sensor.

Check resistance of clutch cutoff sensor between pins A and C. See Electrical Component Specifications. (Group 9015-20.) Is resistance within specification?

– – –1/1

2 Short Circuit Check— Power Circuit

Turn key switch OFF. Disconnect clutch cut-off sensor (B33). See Load Center Harness (W3) Component Location. (Group 9015-10.)

YES: Short circuit in load center harness. Repair circuit P77 RED or replace load center harness.

Turn key switch ON. Check circuit P77 RED for voltage between pin A on clutch cut-off sensor (B33) connector and machine ground. See Load Center Harness (W3) Wiring Diagram. (Group 9015-10.)

NO: Go to Short Circuit Check—Signal Wire.

Is system voltage (approximately 24 volts) present?

– – –1/1

3 Short Circuit Check— Signal Wire

Turn key switch OFF. Disconnect clutch cut-off sensor (B33). See Load Center Harness (W3) Component Location. (Group 9015-10.)

YES: Short circuit in load center harness. Repair circuit T20 BLU or replace load center harness.

Turn key switch ON. Check circuit T20 BLU for voltage between pin B on clutch cut-off sensor (B33) connector and machine ground. See Load Center Harness (W3) Wiring Diagram. (Group 9015-10.)

NO: Go to Continuity Check.

Is voltage more than 1 volt?

– – –1/1

TM10229 (17MAR09)

9001-30-147

544J Loader (S.N. 611800— ) 032409

PN=201

Transmission Control Unit (TCU) Diagnostic Trouble Codes 4

Continuity Check

Turn battery disconnect switch OFF. Disconnect clutch cut-off sensor (B33) and transmission control unit (TCU) connector (X23). See Load Center Harness (W3) Component Location. (Group 9015-10.) Check circuit T20 BLU for continuity between pin 38 on TCU connector (X23) and all other pins on TCU connector (X23). See Load Center Harness (W3) Wiring Diagram. (Group 9015-10.)

9001 30 ,148

Is continuity indicated?

YES: Short circuit to wire with continuity indicated in the load center harness. Repair circuit T20 BLU or replace load center harness. NO: Replace controller, see Transmission Control Unit (TCU) Remove and Install. (Group 9015-20.)

– – –1/1

522407.04 — Clutch Cutoff Open or Short

Clutch cut-off sensor circuit is open or short to ground.

TF44157,0000268 –19–14MAR08–1/1

Clutch Cut-Off Sensor Open or Short Diagnostic Procedure Alarm Level: No Warning Lamp

– – –1/1

1 Component Check

Turn key switch OFF.

YES: Go to Short Circuit Check.

Disconnect clutch cut-off sensor (B33). See Load Center Harness (W3) Component Location. (Group 9015-10.) Check resistance of clutch cutoff sensor between pins A and B. Check resistance of clutch cutoff sensor between pins A and C. See Electrical Component Specifications. (Group 9015-20.)

NO: Clutch cut-off sensor (B33) malfunction. Replace sensor. See Load Center Harness (W3) Component Location. (Group 9015-10.)

Is resistance within specification?

– – –1/1

TM10229 (17MAR09)

9001-30-148

544J Loader (S.N. 611800— ) 032409

PN=202

Transmission Control Unit (TCU) Diagnostic Trouble Codes 2 Short Circuit Check

Turn key switch OFF. Disconnect clutch cut-off sensor (B33) and transmission control unit (TCU) connector (X23). See Load Center Harness (W3) Component Location. (Group 9015-10.)

YES: Short to ground in load center harness. Repair circuit(s) with ground present.

Check circuit T20 BLU for ground at pin 38 on TCU connector (X23). See Load Center Harness (W3) Wiring Diagram. (Group 9015-10.)

NO: Go to Open Circuit Check.

Check circuit P77 RED for ground at pin 37 on TCU connector (X23). Is ground present in either circuit?

– – –1/1

3 Open Circuit Check

Turn key switch OFF.

YES: Go to Continuity Check.

Disconnect clutch cut-off sensor (B33) and transmission control unit (TCU) connector (X23). See Load Center Harness (W3) Component Location. (Group 9015-10.) Check circuit T20 BLU for continuity between pin B on clutch cut-off sensor (B33) connector and pin 38 on TCU connector (X23). See Load Center Harness (W3) Wiring Diagram. (Group 9015-10.)

NO: Open circuit in load center harness. Repair circuit(s) without continuity indicated or replace load center harness.

Check circuit P77 RED for continuity between pin A on clutch cut-off sensor (B33) connector and pin 37 on TCU connector (X23). Is continuity indicated in both circuits? – – –1/1

4 Continuity Check

Turn battery disconnect switch OFF. Disconnect clutch cut-off sensor (B33) and TCU connector (X23). See Load Center Harness (W3) Component Location. (Group 9015-10.) Check circuit T20 BLU for continuity between pin 38 on TCU connector (X23) and all other pins on connector (X23). See Load Center Harness (W3) Wiring Diagram. (Group 9015-10.) Check circuit P77 RED for continuity between pin 37 on TCU connector (X23) and all other pins on connector (X23).

Is continuity indicated with any other pins? – – –1/1

522409.05 — 2nd FNR Open Circuit

Secondary TCL circuit is open. NOTE: The TCL is referred to as the FNR.

TF44157,0000269 –19–14MAR08–1/1

TM10229 (17MAR09)

9001-30-149

544J Loader (S.N. 611800— ) 032409

PN=203

9001 30 ,149

Transmission Control Unit (TCU) Diagnostic Trouble Codes 2nd TCL Open Circuit Diagnostic Procedure (Pilot Control Joystick) Alarm Level: 9001 30 ,150

No Warning Lamp

– – –1/1

1 Component Check

Turn key switch OFF.

YES: Go to Open Circuit Check.

Disconnect joystick shifter (S9) connector (X27). See Load Center Harness (W3) Component Location. (Group 9015-10.) Check continuity of switch in all positions.

NO: Joystick shifter (S9) malfunction. Replace joystick shifter.

Joystick Shifter (S9) Continuity Table Switch Position

Continuity Between Pins

Forward (up)

4 and 5

Neutral (middle)

2 and 5

Reverse (down)

2 and 3

Is continuity indicated between specified pins in the three switch positions?

– – –1/1

2 Open Circuit Check

Turn key switch OFF. Disconnect joystick shifter (S9) connector (X27) and transmission control unit (TCU) connector (X23). See Load Center Harness (W3) Component Location. (Group 9015-10.) Check circuit T16 BLU for continuity between pin 5 on load center harness side of connector (X27) and pin 59 on TCU connector (X23). See Load Center Harness (W3) Wiring Diagram. (Group 9015-10.) Check circuit T22 BLU for continuity between pin 3 on load center harness side of connector (X27) and pin 66 on TCU connector (X23).

YES: Replace controller, see Transmission Control Unit (TCU) Remove and Install. (Group 9015-20.) NO: Open circuit in load center harness. Repair circuit(s) with no continuity indicated or replace load center harness.

Check circuit T23 BLU for continuity between pin 4 on load center harness side of connector (X27) and pin 29 on TCU connector (X23). Check circuit T24 BLU for continuity between pin 2 on load center harness side of connector (X27) and pin 35 on TCU connector (X23). Is continuity indicated in all circuits?

– – –1/1

TM10229 (17MAR09)

9001-30-150

544J Loader (S.N. 611800— ) 032409

PN=204

Transmission Control Unit (TCU) Diagnostic Trouble Codes

522409.12 — 2nd FNR Mult Inputs

Transmission control unit detects multiple inputs from the secondary TCL.

9001 30 ,151

NOTE: The TCL is referred to as the FNR.

TF44157,000026A –19–14MAR08–1/1

2nd TCL Missing Inputs Diagnostic Procedure Alarm Level: No Warning Lamp

– – –1/1

1 Code Check

Turn key switch ON. Check for active codes. Is TCU code 522411.05 present?

YES: Correct problem causing other TCU code first. See Diagnostic Trouble Codes (DTC) Quick Reference List. (Group 9015-20.) NO: Go to Component Check.

– – –1/1

TM10229 (17MAR09)

9001-30-151

544J Loader (S.N. 611800— ) 032409

PN=205

Transmission Control Unit (TCU) Diagnostic Trouble Codes 2 Component Check

Turn key switch OFF.

YES: Go to Short Circuit Check—Short to Power.

Disconnect joystick shifter (S9) connector (X27). See Load Center Harness (W3) Component Location. (Group 9015-10.) Check continuity of switch in all positions.

9001 30 ,152

NO: Joystick shifter (S9) malfunction. Replace joystick shifter.

Joystick Shifter (S9) Continuity Table Switch Position

Continuity Between Pins

Forward (up)

4 and 5

Neutral (middle)

2 and 5

Reverse (down)

2 and 3

Is continuity indicated between specified pins in the three switch positions?

– – –1/1

3 Short Circuit Check— Short to Power

Turn key switch OFF. Disconnect joystick shifter (S9) connector (X27). See Load Center Harness (W3) Component Location. (Group 9015-10.) Turn key switch ON. Check circuit T16 BLU for voltage between pin 5 on load center harness side of connector (X27) and machine ground. See Load Center Harness (W3) Wiring Diagram. (Group 9015-10.)

YES: Short to power in load center harness. Repair circuit(s) with system voltage present or replace load center harness. NO: Go to Short Circuit Check—TCL Circuits.

Check circuit T22 BLU for voltage between pin 3 on load center harness side of connector (X27) and machine ground. Check circuit T23 BLU for voltage between pin 4 on load center harness side of connector (X27) and machine ground. Check circuit T24 BLU for voltage between pin 2 on load center harness side of connector (X27) and machine ground. Is system voltage (approximately 24 volts) present?

– – –1/1

TM10229 (17MAR09)

9001-30-152

544J Loader (S.N. 611800— ) 032409

PN=206

Transmission Control Unit (TCU) Diagnostic Trouble Codes 4 Short Circuit Check— TCL Circuits

Turn key switch OFF. Disconnect joystick shifter (S9) connector (X27) and TCU connector (X23). See Load Center Harness (W3) Component Location. (Group 9015-10.) Check for continuity between pin 5 (T16 BLU) and pins 2, 3, and 4 on connector (X27). See Load Center Harness (W3) Wiring Diagram. (Group 9015-10.) Check for continuity between pin 3 (T22 BLU) and pins 2, 4, and 5 on connector (X27).

Check for continuity between pin 4 (T23 BLU) and pins 2, 3, and 5 on connector (X27). Check for continuity between pin 2 (T24 BLU) and pins 3, 4, and 5 on connector (X27). Is continuity indicated?

– – –1/1

522411.05 — 1st FNR Open Circuit

Primary TCL circuit is open. NOTE: The TCL is referred to as the FNR.

TF44157,000026B –19–14MAR08–1/1

1st TCL Open Circuit Diagnostic Procedure (Steering Column Shifter) Alarm Level: No Warning Lamp

– – –1/1

TM10229 (17MAR09)

9001-30-153

544J Loader (S.N. 611800— ) 032409

PN=207

9001 30 ,153

Transmission Control Unit (TCU) Diagnostic Trouble Codes 1 Component Check

Turn key switch OFF.

YES: Go to Open Circuit Check.

Disconnect column shifter (S10) connector (X50). See Front Console Harness (W4) Component Location. (Group 9015-10.) Check continuity of switch in all positions.

9001 30 ,154

NO: Column shifter (S10) malfunction. Replace switch.

Column Shifter (S10) Continuity Table Switch Position

Continuity Between Pins

Forward

A and B

Neutral

A and D

Reverse

A and C

Is continuity indicated between specified pins in the three switch positions?

– – –1/1

2 Open Circuit Check

Turn key switch OFF. Disconnect column shifter (S10) connector (X50) and transmission control unit (TCU) connector (X23). See Front Console Harness (W4) Component Location and see Load Center Harness (W3) Component Location. (Group 9015-10.) Check circuit T13 BLU for continuity between pin B on front console harness side of connector (X50) and pin 43 on TCU connector (X23). See Front Console Harness (W4) Wiring Diagram and see Load Center Harness (W3) Wiring Diagram. (Group 9015-10.)

YES: Replace controller, see Transmission Control Unit (TCU) Remove and Install. (Group 9015-20.) NO: Go to next step in this check.

Check circuit T14 BLU for continuity between pin C on front console harness side of connector (X50) and pin 64 on TCU connector (X23). Check circuit T15 BLU for continuity between pin D on front console harness side of connector (X50) and pin 67 on TCU connector (X23). Is continuity indicated in all circuits?

Key switch OFF and TCU connector (X23) disconnected. Disconnect load center harness-to-front console harness connector (X30). See Load Center Harness (W3) Component Location. (Group 9015-10.) Check circuit T13 BLU for continuity between pin 25 on load center harness side of connector (X30) and pin 43 on TCU connector (X23). See Load Center Harness (W3) Wiring Diagram. (Group 9015-10.) Check circuit T14 BLU for continuity between pin 26 on load center harness side of connector (X30) and pin 64 on TCU connector (X23). Check circuit T15 BLU for continuity between pin 8 on load center harness side of connector (X30) and pin 67 on TCU connector (X23).

YES: Open circuit in front console harness. Repair circuit(s) with no continuity indicated or replace front console harness. NO: Open circuit in load center harness. Repair circuit(s) with no continuity indicated or replace load center harness.

Is continuity indicated in all circuits?

– – –1/1

TM10229 (17MAR09)

9001-30-154

544J Loader (S.N. 611800— ) 032409

PN=208

Transmission Control Unit (TCU) Diagnostic Trouble Codes 1st TCL Open Circuit Diagnostic Procedure (Pilot Control Joystick) Alarm Level: No Warning Lamp

9001 30 ,155

– – –1/1

1 Component Check

Turn key switch OFF.

YES: Go to Open Circuit Check.

Disconnect joystick shifter (S9) connector (X27). See Load Center Harness (W3) Component Location. (Group 9015-10.) Check continuity of switch in all positions.

NO: Joystick shifter (S9) malfunction. Replace joystick shifter.

Joystick Shifter (S9) Continuity Table Switch Position

Continuity Between Pins

Forward (up)

4 and 5

Neutral (middle)

2 and 5

Reverse (down)

2 and 3

Is continuity indicated between specified pins in the three switch positions?

– – –1/1

2 Open Circuit Check

– – –1/1

TM10229 (17MAR09)

9001-30-155

544J Loader (S.N. 611800— ) 032409

PN=209

Transmission Control Unit (TCU) Diagnostic Trouble Codes

522411.12 — 1st FNR Mult Inputs

9001 30 ,156

Transmission control unit (TCU) detects multiple inputs from primary TCL. NOTE: The TCL is referred to as the FNR.

TF44157,000026C –19–14MAR08–1/1

1st TCL Multiple Inputs Diagnostic Procedure (Steering Column Shifter) Alarm Level: No Warning Lamp

– – –1/1

1 Code Check

Turn key switch ON. Check for active codes. Is TCU code 522411.05 present?

YES: Correct problem causing other TCU code first. See Diagnostic Trouble Codes (DTC) Quick Reference List. (Group 9015-20.) NO: Go to Component Check.

– – –1/1

TM10229 (17MAR09)

9001-30-156

544J Loader (S.N. 611800— ) 032409

PN=210

Transmission Control Unit (TCU) Diagnostic Trouble Codes 2 Component Check

Turn key switch OFF.

YES: Go to Short Circuit Check—Short to Power.

Disconnect column shifter (S10) connector (X50). See Front Console Harness (W4) Component Location. (Group 9015-10.) Check continuity of switch in all positions.

NO: Column shifter (S10) malfunction. Replace switch.

Column Shifter (S10) Continuity Table Switch Position

Continuity Between Pins

Forward

A and B

Neutral

A and D

Reverse

A and C

Is continuity indicated between specified pins in the three switch positions?

– – –1/1

3 Short Circuit Check— Short to Power

Turn key switch OFF.

YES: Go to next step in this check.

Disconnect column shifter (S10) connector (X50). See Front Console Harness (W4) Component Location. (Group 9015-10.)

NO: Go to Short Circuit Check—TCL Circuits.

Turn key switch ON. Check circuit T13 BLU for voltage between pin B on front console harness side of connector (X50) and machine ground. See Load Center Harness (W3) Wiring Diagram and see Front Console Harness (W4) Wiring Diagram. (Group 9015-10.) Check circuit T14 BLU for voltage between pin C on front console harness side of connector (X50) and machine ground. Check circuit T15 BLU for voltage between pin D on front console harness side of connector (X50) and machine ground. Is system voltage (approximately 24 volts) present?

Turn key switch OFF. Disconnect load center harness-to-front console harness connector (X30). See Load Center Harness (W3) Component Location. (Group 9015-10.) Turn key switch ON. Check circuit T13 BLU for voltage between pin 25 on load center harness side of connector (X30) and machine ground. See Front Console Harness (W4) Wiring Diagram. (Group 9015-10.) Check circuit T14 BLU for voltage between pin 26 on load center harness side of connector (X30) and machine ground.

YES: Short to power in load center harness. Repair circuit(s) with system voltage present or replace load center harness. NO: Short to power in front console harness. Repair circuit(s) with system voltage present or replace front console harness.

Check circuit T15 BLU for voltage between pin 8 on load center harness side of connector (X30) and machine ground. Is system voltage (approximately 24 volts) present?

– – –1/1

TM10229 (17MAR09)

9001-30-157

544J Loader (S.N. 611800— ) 032409

PN=211

9001 30 ,157

Transmission Control Unit (TCU) Diagnostic Trouble Codes 4 Short Circuit Check— TCL Circuits

Turn key switch OFF.

YES: Go to next step in this check.

Disconnect column shifter (S10) connector (X50) and TCU connector (X23). See Front Console Harness (W4) Component Location. (Group 9015-10.) Check for continuity between pin B (T13 BLU) and pins C and D on connector (X50). See Front Console Harness (W4) Wiring Diagram and see Load Center Harness (W3) Wiring Diagram. (Group 9015-10.)

9001 30 ,158

NO: Replace controller, see Transmission Control Unit (TCU) Remove and Install. (Group 9015-20.)

Check for continuity between pin C (T14 BLU) and pins B and D on connector (X50). Check for continuity between pin D (T15 BLU) and pins B and C on connector (X50). Is continuity indicated?

Key switch OFF and TCU connector (X23) disconnected. Disconnect load center harness-to-front console harness connector (X30). See Load Center Harness (W3) Component Location. (Group 9015-10.) Check for continuity between pin 26 (T13 BLU) and pins 8 and 25 on connector (X30). See Load Center Harness (W3) Wiring Diagram. (Group 9015-10.) Check for continuity between pin 25 (T14 BLU) and pins 8 and 26 on connector (X30). Check for continuity between pin 8 (T15 BLU) and pins 25 and 26 on connector (X30). Is continuity indicated?

YES: Short circuit in load center harness. Repair circuit(s) with continuity indicated to another pin or replace load center harness. NO: Short circuit in front console harness. Repair circuit(s) with continuity indicated to another pin or replace front console harness.

– – –1/1

1st TCL Multiple Inputs Diagnostic Procedure (Pilot Control Joystick) Alarm Level: No Warning Lamp

– – –1/1

1 Code Check

Turn key switch ON. Check for active codes. Is TCU code 522411.05 present?

YES: Correct problem causing other TCU code first. See Diagnostic Trouble Codes (DTC) Quick Reference List. (Group 9015-20.) NO: Go to Component Check.

– – –1/1

TM10229 (17MAR09)

9001-30-158

544J Loader (S.N. 611800— ) 032409

PN=212

Transmission Control Unit (TCU) Diagnostic Trouble Codes 2 Component Check

Turn key switch OFF.

YES: Go to Short Circuit Check—Short to Power.

Disconnect joystick shifter (S9) connector (X27). See Load Center Harness (W3) Component Location. (Group 9015-10.) Check continuity of switch in all positions.

NO: Joystick shifter (S9) malfunction. Replace joystick shifter.

Joystick Shifter (S9) Continuity Table Switch Position

Continuity Between Pins

Forward (up)

4 and 5

Neutral (middle)

2 and 5

Reverse (down)

2 and 3

Is continuity indicated between specified pins in the three switch positions?

– – –1/1

3 Short Circuit Check— Short to Power

YES: Short to power in load center harness. Repair circuit(s) with system voltage present or replace load center harness. NO: Go to Short Circuit Check—TCL Circuits.

– – –1/1

TM10229 (17MAR09)

9001-30-159

544J Loader (S.N. 611800— ) 032409

PN=213

9001 30 ,159

Transmission Control Unit (TCU) Diagnostic Trouble Codes 4 Short Circuit Check— TCL Circuits

9001 30 ,160

Check for continuity between pin 3 (T22 BLU) and pins 2, 4, and 5 on connector (X27).

Check for continuity between pin 4 (T23 BLU) and pins 2, 3, and 5 on connector (X27). Check for continuity between pin 2 (T24 BLU) and pins 3, 4, and 5 on connector (X27). Is continuity indicated?

– – –1/1

522412.12 — Gear Selection Error

Transmission control unit (TCU) detects wrong signal combination for gear range.

TF44157,000026D –19–14MAR08–1/1

Gear Selection Error Diagnostic Procedure Alarm Level: No Warning Lamp

– – –1/1

TM10229 (17MAR09)

9001-30-160

544J Loader (S.N. 611800— ) 032409

PN=214

Transmission Control Unit (TCU) Diagnostic Trouble Codes 1 Component Check

Turn key switch OFF.

YES: Go to Short Circuit Check—Short to Power.

Disconnect column shifter (S10) connector 2 (X51). See Front Console Harness (W4) Component Location. (Group 9015-10.) Check continuity of switch in all four switch positions. Gear Selector Continuity Table

NO: Column shifter (S10) malfunction. Replace column shifter. See Front 9001 Console Harness (W4) 30 Component Location. ,161 (Group 9015-10.)

Gear Selector Continuity Table Gear

Continuity between Pins

1st

A and C

2nd

None

3rd

A and B

4th

A, B and C

Is continuity indicated between the appropriate pins?

– – –1/1

2 Short Circuit Check— Short to Power

Turn key switch OFF.

YES: Go to next step in this check.

Disconnect column shifter (S10) connector 2 (X51). See Front Console Harness (W4) Component Location. (Group 9015-10.) Turn key switch ON.

NO: Go to Short Circuit Check—Gear Selector Circuits.

Check circuit T10 BLU for voltage between pin C on front console harness side of connector (X51) and machine ground. See Front Console Harness (W4) Wiring Diagram. (Group 9015-10.) Check circuit T11 BLU for voltage between pin B on front console harness side of connector (X51) and machine ground. Check circuit T12 BLU for voltage between pin A on front console harness side of connector (X51) and machine ground. Is system voltage (approximately 24 volts) present?

Turn key switch OFF. Disconnect load center harness-to-front console harness connector (X30). See Load Center Harness (W3) Component Location. (Group 9015-10.)

YES: Short circuit in load center harness. Repair circuit(s) with system voltage present or replace load center harness.

Turn key switch ON. Check circuit T10 BLU for voltage between pin 22 on load center harness side of connector (X30) and machine ground. See Load Center Harness (W3) Wiring Diagram. (Group 9015-10.)

NO: Short circuit in front console harness. Repair circuit(s) with system voltage present or replace front console harness.

Check circuit T11 BLU for voltage between pin 23 on load center harness side of connector (X30) and machine ground. Check circuit T12 BLU for voltage between pin 24 on load center harness side of connector (X30) and machine ground. Is system voltage (approximately 24 volts) present?

– – –1/1

TM10229 (17MAR09)

9001-30-161

544J Loader (S.N. 611800— ) 032409

PN=215

Transmission Control Unit (TCU) Diagnostic Trouble Codes 3 Short Circuit Check— Gear Selector Circuits

Turn key switch OFF.

YES: Go to next step in this check.

Disconnect column shifter (S10) connector 2 (X51). See Front Console Harness (W4) Component Location. (Group 9015-10.) Disconnect transmission control unit (TCU) connector (X23). See Load Center Harness (W3) Component Location. (Group 9015-10.)

9001 30 ,162

NO: Replace controller, see Transmission Control Unit (TCU) Remove and Install. (Group 9015-20.)

Check for continuity between pin C (T10 BLU) and pins A and B on connector (X51). See Front Console Harness (W4) Wiring Diagram. (Group 9015-10.) Check for continuity between pin B (T11 BLU) and pins A and C on connector (X51). Check for continuity between pin A (T12 BLU) and pins B and C on connector (X51). Is continuity indicated?

Key switch OFF and TCU connector (X23) disconnected. Disconnect load center harness-to-front console harness connector (X30). Check for continuity between pin 22 (T10 BLU) and pins 23 and 24 on load center harness side of connector (X30). See Load Center Harness (W3) Wiring Diagram. (Group 9015-10.) Check for continuity between pin 23 (T11 BLU) and pins 22 and 24 on load center harness side of connector (X30).

YES: Short circuit in load center harness. Repair circuit(s) with continuity indicated or replace load center harness. NO: Short circuit in front console harness. Repair circuit(s) with continuity indicated or replace front console harness.

Check for continuity between pin 24 (T12 BLU) and pins 22 and 23 on load center harness side of connector (X30). Is continuity indicated?

– – –1/1

522419.02 — Clutch Cutoff Disabled

CAN signal for clutch cut-off is defective.

TF44157,000026E –19–14MAR08–1/1

TM10229 (17MAR09)

9001-30-162

544J Loader (S.N. 611800— ) 032409

PN=216

Transmission Control Unit (TCU) Diagnostic Trouble Codes Clutch Cut-Off Disabled Diagnostic Procedure Alarm Level: No Warning Lamp

9001 30 ,163

– – –1/1

1 Code Check

Turn key switch ON.

YES: Correct problem causing FLC code(s). See Diagnostic Trouble Codes (DTC) Quick Reference List. (Group 9015-20.)

Check for active flex load controller (FLC) codes. Are any FLC codes present?

NO: Go to CAN Circuit Check.

– – –1/1

2 CAN Circuit Check

Perform CAN Circuit Test. (Group 9015-20.)

YES: Go to Component Check.

Does CAN circuit pass test? NO: Repair CAN circuit. See CAN Circuit Test for diagnostic procedure. (Group 9015-20.)

– – –1/1

3 Component Check

YES: SSM is functioning properly. Replace controller, see Transmission Control Unit (TCU) Remove and Install. (Group 9015-20.)

Push the buttons on the SSM. Do the corresponding squares on the CMU window turn white when the buttons are pushed?

NO: SSM malfunction. Replace SSM.

– – –1/1

TM10229 (17MAR09)

9001-30-163

544J Loader (S.N. 611800— ) 032409

PN=217

Transmission Control Unit (TCU) Diagnostic Trouble Codes

522420.02 — Manual Downshift Disabled

9001 30 ,164

CAN signal for manual downshift is defective.

TF44157,000026F –19–14MAR08–1/1

Manual Downshift Disabled Diagnostic Procedure

– – –1/1

1 Code Check

Turn key switch ON. Check for active CAN monitor unit (CMU) and flex load controller (FLC) codes. Are CMU or FLC codes present?

YES: Correct problem causing CMU and FLC codes. See Diagnostic Trouble Codes (DTC) Quick Reference List. (Group 9015-20.) NO: Go to CAN Circuit Check

– – –1/1

2 CAN Circuit Check

Perform CAN Circuit Test. (Group 9015-20.) Does CAN circuit pass test?

YES: Replace controller, see Transmission Control Unit (TCU) Remove and Install. (Group 9015-20.) NO: Repair CAN circuit. See CAN Circuit Test for diagnostic procedure. (Group 9015-20.)

– – –1/1

TM10229 (17MAR09)

9001-30-164

544J Loader (S.N. 611800— ) 032409

PN=218

Transmission Control Unit (TCU) Diagnostic Trouble Codes

522421.02 — Auto To 1st Disabled

CAN signal for automatic downshift is defective.

9001 30 ,165

TF44157,0000270 –19–14MAR08–1/1

Auto To 1st Disabled Diagnostic Procedure Alarm Level: No Warning Lamp

– – –1/1

1 Code Check

Turn key switch ON. Check for active CAN monitor unit (CMU) and flex load controller (FLC) codes. Are CMU or FLC codes present?

YES: Correct problem causing CMU and FLC codes. See Diagnostic Trouble Codes (DTC) Quick Reference List. (Group 9015-20.) NO: Go to CAN Circuit Check

– – –1/1

2 CAN Circuit Check

Perform CAN Circuit Test. (Group 9015-20.) Does CAN circuit pass test?

YES: Replace controller, see Transmission Control Unit (TCU) Remove and Install. (Group 9015-20.) NO: Repair CAN circuit. See CAN Circuit Test for diagnostic procedure. (Group 9015-20.)

– – –1/1

TM10229 (17MAR09)

9001-30-165

544J Loader (S.N. 611800— ) 032409

PN=219

Transmission Control Unit (TCU) Diagnostic Trouble Codes

524048.00 — Trans Output Torque Exceeded

9001 30 ,166

Transmission output torque is above normal operating range.

TF44157,0000271 –19–14MAR08–1/1

Trans Output Torque Exceeded Diagnostic Procedure Alarm Level: No Warning Lamp

– – –1/1

1 Code Check

Turn key switch ON. Check for active engine control unit (ECU) codes. Are any ECU codes present?

YES: Correct problem causing ECU code(s). See Diagnostic Trouble Codes (DTC) Quick Reference List. (Group 9015-10.) NO: Replace controller, see Transmission Control Unit (TCU) Remove and Install. (Group 9015-20.)

– – –1/1

524049.00 — Trans Input Torque Exceeded

Transmission input torque is above normal operating range.

TF44157,0000272 –19–14MAR08–1/1

TM10229 (17MAR09)

9001-30-166

544J Loader (S.N. 611800— ) 032409

PN=220

Transmission Control Unit (TCU) Diagnostic Trouble Codes Trans Input Torque Exceeded Diagnostic Procedure Alarm Level: No Warning Lamp

9001 30 ,167

– – –1/1

1 Code Check

Turn key switch ON. Check for active engine control unit (ECU) codes. Are any ECU codes present?

– – –1/1

524287.00 — Configure Machine Model

Machine is configured for the incorrect model.

TF44157,0000273 –19–14MAR08–1/1

Configure Machine Model Diagnostic Procedure Alarm Level: No Warning Lamp

– – –1/1

TM10229 (17MAR09)

9001-30-167

544J Loader (S.N. 611800— ) 032409

PN=221

Transmission Control Unit (TCU) Diagnostic Trouble Codes 1 Re-Configure Machine

9001 30 ,168

Turn key switch ON. Set machine configuration to correct model by accessing the Machine Config / Machine Model menu on the CAN monitor unit (CMU).

YES: Replace controller, see Transmission Control Unit (TCU) Remove and Install. (Group 9015-20.)

Check active codes.

NO: Checks complete.

Is code 524287.00 present?

– – –1/1

TM10229 (17MAR09)

9001-30-168

544J Loader (S.N. 611800— ) 032409

PN=222

Group 40

Flex Load Controller (FLC) Diagnostic Trouble Codes Flex Load Controller (FLC) Diagnostic Trouble Codes The diagnostic trouble code is indicated by a Suspect Parameter Number (SPN) and a Failure Mode Indicator (FMI) number. In the example 000117.01, 117 is the SPN and 01 is the FMI number.

• CAN Monitor Unit (CMU). See CAN Monitor Unit (CMU) Menu Structure—Service Mode. (Group 9015-20.) Note: For in-depth diagnostics on all FLC diagnostic trouble codes, see specific code diagnostic procedure in Group 9001-40.

To view diagnostic trouble codes, use one of the following methods: • Service ADVISOR system. See Service ADVISOR Diagnostic Application. (Group 9015-20.)

Service ADVISOR is a trademark of Deere & Company

TF44157,0000040 –19–13MAR08–1/1

000117.01 — Brake Pressure Low

Service brake pressure is too low.

TF44157,0000041 –19–13MAR08–1/1

Brake Pressure Low Diagnostic Procedure Alarm Level: Brake Lamp

– – –1/1

TM10229 (17MAR09)

9001-40-1

544J Loader (S.N. 611800— ) 032409

PN=223

9001 40 1

Flex Load Controller (FLC) Diagnostic Trouble Codes 1 Component Check

Check hydraulic brake system. See Brake Valve Pressure Test. (Group 9025-25.) Specification Front Brakes Applied—Pressure ............................... 3895—4380 kPa @ 875—925 rpm 38.9—43.8 bar @ 875—925 rpm 565—635 psi @ 875—925 rpm Front Brakes Released—Pressure ................................... 0—138 kPa @ 875—925 rpm 0—1.4 bar @ 875—925 rpm 0—20 psi @ 875—925 rpm

9001 40 2

YES: See Pump Load Sense Differential and Standby Pressure Test. (Group 9025-25.) NO: Go to Open Circuit Check.

Is reading within specification?

– – –1/1

2 Open Circuit Check

Turn key switch OFF.

YES: Go to next step in this check.

Disconnect brake pressure sensor (B27) and flex load controller (FLC) connector (X41). See Load Center Harness (W3) Component Location. (Group 9015-10.) Check circuit R69 BLK for continuity of between pin A on pressure sensor and pin K3 on FLC connector. See Load Center Harness (W3) Wiring Diagram. (Group 9015-10.)

NO: Open circuit on load center harness (W3). Repair circuit or replace harness.

Is continuity indicated?

Key switch OFF.

YES: Go to next step in this check.

Brake pressure sensor (B27) and FLC connector (X41) disconnected. Check circuit P69 BLK for continuity of between pin B on pressure sensor and pin K4 on FLC connector. See Load Center Harness (W3) Wiring Diagram. (Group 9015-10.)

NO: Open circuit on load center harness (W3). Repair circuit or replace harness.

Is continuity indicated?

Key switch OFF.

YES: Go to Reprogram Controller.

Brake pressure sensor (B27) and FLC connector (X41) disconnected. Check circuit N06 YEL for continuity of between pin C on pressure sensor and pin G1 on FLC connector. See Load Center Harness (W3) Wiring Diagram. (Group 9015-10.)

NO: Open circuit on load center harness (W3). Repair circuit or replace harness.

Is continuity indicated?

– – –1/1

3 Reprogram Controller

Reprogram flex load controller (FLC). See Electronic Controller Reconfiguration. (Group 9015-20.)

YES: Replace controller. NO: Checks complete.

Check for active codes. Is FLC code 000117.01 present? – – –1/1

TM10229 (17MAR09)

9001-40-2

544J Loader (S.N. 611800— ) 032409

PN=224

Flex Load Controller (FLC) Diagnostic Trouble Codes

000167.16 — Alternator High Voltage

Alternator voltage is above 32 volts (with engine running).

9001 40 3

TF44157,0000042 –19–13MAR08–1/1

Alternator High Voltage Diagnostic Procedure Alarm Level: No Warning Lamp

– – –1/1

1 Voltage Check

Turn key switch OFF.

YES: Go to Alternator Check.

Disconnect flex load controller (FLC) connector (X41). See Load Center Harness (W3) Component Location. (Group 9015-10.)

NO: Go to Reprogram Controller.

Turn key switch ON. Check circuit P15 RED for voltage at FLC connector (X41). See Load Center Harness (W3) Wiring Diagram. (Group 9015-10.) Is voltage 32 volts or above?

– – –1/1

2 Alternator Check

Perform Alternator Test. (Group 9015-20.)

YES: Go to Reprogram Controller.

Does alternator test good? NO: Replace alternator.

– – –1/1

3 Reprogram Controller

Reprogram flex load controller (FLC). See Electronic Controller Reconfiguration. (Group 9015-20.)

YES: Replace controller. NO: Checks complete.

Check for active codes. Is FLC code 000167.16 present? – – –1/1

TM10229 (17MAR09)

9001-40-3

544J Loader (S.N. 611800— ) 032409

PN=225

Flex Load Controller (FLC) Diagnostic Trouble Codes

000167.18 — Alternator Low Voltage

9001 40 4

Alternator voltage is below 24 volts (engine running).

TF44157,0000043 –19–13MAR08–1/1

Alternator Low Voltage Diagnostic Procedure Alarm Level: No Warning Lamp

– – –1/1

1 Voltage Check

Turn key switch OFF.

YES: Go to Alternator Check.

Disconnect flex load controller (FLC) connector (X41). See Load Center Harness (W3) Component Location. (Group 9015-10.)

NO: Go to Reprogram Controller.

Turn key switch ON. Check circuit P15 RED for voltage at FLC connector (X41). See Load Center Harness (W3) Wiring Diagram. (Group 9015-10.) Is voltage 24 volts or below?

– – –1/1

2 Alternator Check

Perform Alternator Test. (Group 9015-20.)

YES: Go to Battery Check.

Does alternator test good? NO: Replace alternator.

– – –1/1

3 Battery Check

Test batteries separately. See Handling Batteries Safely. (Operator’s Manual.)

YES: Go to Reprogram Controller.

Do the batteries test good? NO: Replace batteries.

– – –1/1

TM10229 (17MAR09)

9001-40-4

544J Loader (S.N. 611800— ) 032409

PN=226

Flex Load Controller (FLC) Diagnostic Trouble Codes 4 Reprogram Controller

Reprogram flex load controller (FLC). See Electronic Controller Reconfiguration. (Group 9015-20.)

YES: Replace controller. NO: Checks complete.

Check for active codes. Is FLC code 000167.18 present? – – –1/1

000168.16 — High Battery Voltage

Battery voltage is above 28 volts (engine off).

TF44157,0000044 –19–13MAR08–1/1

High Battery Voltage Diagnostic Procedure Alarm Level: No Warning Lamp

– – –1/1

1 Voltage Check

Turn key switch OFF.

YES: Go to Battery Check.

Disconnect flex load controller (FLC) connector (X41). See Load Center Harness (W3) Component Location. (Group 9015-10.)

NO: Go to Reprogram Controller.

Check circuit P15 RED for voltage at FLC connector (X41). See Load Center Harness (W3) Wiring Diagram. (Group 9015-10.) Is voltage 28 volts or above?

– – –1/1

2 Battery Check

Test batteries separately. See Handling Batteries Safely. (Operator’s Manual.)

YES: Go to Reprogram Controller.

Do the batteries test good? NO: Replace batteries.

– – –1/1

TM10229 (17MAR09)

9001-40-5

544J Loader (S.N. 611800— ) 032409

PN=227

9001 40 5

Flex Load Controller (FLC) Diagnostic Trouble Codes 3 Reprogram Controller

Reprogram flex load controller (FLC). See Electronic Controller Reconfiguration. (Group 9015-20.)

YES: Replace controller. NO: Checks complete.

Check for active codes. Is FLC code 000168.16 present?

9001 40 6

– – –1/1

000168.18 — Low Battery Voltage

Battery voltage is below 18 volts (engine off).

TF44157,0000045 –19–13MAR08–1/1

Low Battery Voltage Diagnostic Procedure Alarm Level: No Warning Lamp

– – –1/1

1 Voltage Check

Turn key switch OFF.

YES: Go to Battery Check.

Disconnect flex load controller (FLC) connector (X41). See Load Center Harness (W3) Component Location. (Group 9015-10.)

NO: Go to Reprogram Controller.

Check circuit P15 RED for voltage at FLC connector (X41). See Load Center Harness (W3) Wiring Diagram. (Group 9015-10.) Is voltage 18 volts or below?

– – –1/1

2 Battery Check

Test batteries separately. See Handling Batteries Safely. (Operator’s Manual.)

YES: Go to Fuse Check.

Do the batteries test good?

NO: Charge batteries individually or replace batteries if necessary. – – –1/1

TM10229 (17MAR09)

9001-40-6

544J Loader (S.N. 611800— ) 032409

PN=228

Flex Load Controller (FLC) Diagnostic Trouble Codes 3 Fuse Check

Turn key switch OFF.

YES: Go to Reprogram Controller.

Check continuity of fuses F15 and F21. See Fuse and Relay Specifications. (Group 9015-10.)

NO: Replace fuse(s).

Is continuity indicated? – – –1/1

4 Reprogram Controller

Reprogram flex load controller (FLC). See Electronic Controller Reconfiguration. (Group 9015-20.)

YES: Replace controller. NO: Checks complete.

Check for active codes. Is FLC code 000168.18 present? – – –1/1

000444.05 — 12V Cntr Tap Open or Short

12 volt center tap circuit is open or short to ground.

TF44157,0000046 –19–13MAR08–1/1

12 Volt Center Tap Open or Short Diagnostic Procedure Alarm Level: No Warning Lamp

– – –1/1

TM10229 (17MAR09)

9001-40-7

544J Loader (S.N. 611800— ) 032409

PN=229

9001 40 7

Flex Load Controller (FLC) Diagnostic Trouble Codes 1 Open Circuit Check

Turn key switch OFF.

YES: Go to Reprogram Controller.

Disconnect flex load controller (FLC) connector (X40). See Load Center Harness (W3) Component Location. (Group 9015-10.)

NO: Go to next step in this check.

Disconnect 12 volt center tap connector (X43). See Engine Frame Harness (W5) Component Location. (Group 9015-10.)

9001 40 8

Check circuit B05 RED for continuity between pin F1 on FLC connector (X40) and 12 volt center tap connector (X43). See Load Center Harness (W3) Wiring Diagram and see Engine Frame Harness (W5) Wiring Diagram. (Group 9015-10.) Is continuity indicated?

Key switch OFF.

YES: Go to next step in this check.

12 volt center tap connector (X43) disconnected. Disconnect engine frame harness-to-load center harness connector (X3). See Engine Frame Harness (W5) Component Location. (Group 9015-10.)

NO: Open circuit on engine frame harness (W5). Repair circuit or replace harness.

Check circuit B05 RED for continuity between pin 3 on engine frame harness side of connector (X3) and 12 volt center tap connector (X43). See Engine Frame Harness (W5) Wiring Diagram. (Group 9015-10.) Is continuity indicated?

Key switch OFF.

YES: Go to Short Circuit Check.

Engine frame harness-to-load center harness connector (X3) and FLC connector (X40) disconnected. Check circuit B05 RED for continuity between pin F1 on connector (X3) and pin 3 on load center harness side of connector (X3). See Engine Frame Harness (W5) Wiring Diagram. (Group 9015-10.)

NO: Open circuit on load center harness (W3). Repair circuit or replace harness.

Is continuity indicated?

– – –1/1

TM10229 (17MAR09)

9001-40-8

544J Loader (S.N. 611800— ) 032409

PN=230

Flex Load Controller (FLC) Diagnostic Trouble Codes 2 Short Circuit Check

Turn key switch OFF.

YES: Go to next step in this check.

Disconnect FLC connector (X40). See Load Center Harness (W3) Component Location. (Group 9015-10.)

NO: Go to Reprogram Controller.

Disconnect 12 volt center tap connector (X43). See Engine Frame Harness (W5) Component Location. (Group 9015-10.)

9001 40 9

Check circuit B05 RED for ground at connector (X43). See Engine Frame Harness (W5) Wiring Diagram. (Group 9015-10.) Is ground present?

Key switch OFF.

YES: Short to ground on load center harness (W3). Repair circuit or replace harness.

Disconnect engine frame harness-to-load center harness connector (X3). See Engine Frame Harness (W5) Component Location. (Group 9015-10.) Disconnected FLC connector (X40). See Load Center Harness (W3) Component Location. (Group 9015-10.) Check circuit B05 RED for ground at pin 3 on load center side of connector (X3). See Load Center Harness (W3) Wiring Diagram. (Group 9015-10.)

NO: Short to ground on engine frame harness (W5). Repair circuit or replace harness.

Is ground present?

– – –1/1

3 Reprogram Controller

Reprogram flex load controller (FLC). See Electronic Controller Reconfiguration. (Group 9015-20.)

YES: Replace controller. NO: Checks complete.

Check for active codes. Is FLC code 000444.05 present? – – –1/1

000444.18 — Battery Voltage Imbalance

Battery number 2 voltage is low.

TF44157,0000047 –19–13MAR08–1/1

TM10229 (17MAR09)

9001-40-9

544J Loader (S.N. 611800— ) 032409

PN=231

Flex Load Controller (FLC) Diagnostic Trouble Codes Battery Voltage Imbalance Diagnostic Procedure Alarm Level: 9001 40 10

No Warning Lamp

– – –1/1

1 Battery Check

Test batteries separately. See Handling Batteries Safely. (Operator’s Manual.)

YES: Go to Circuit Check.

Do the batteries test good? NO: Charge batteries individually or replace batteries if necessary. – – –1/1

2 Circuit Check

Turn key switch OFF.

YES: Go to next step in this check.

Disconnect 12 volt center tap connector (X43). See Engine Frame Harness (W5) Component Location. (Group 9015-10.) Check circuit B05 RED for voltage on battery side of connector (X43). See Engine Frame Harness (W5) Wiring Diagram. (Group 9015-10.)

NO: Connector or terminal malfunction. Repair or replace connector or terminal.

Is voltage approximately 12 volts?

Key switch OFF.

YES: Go to next step in this check.

12 volt center tap connector (X43) connected. See Engine Frame Harness (W5) Component Location. (Group 9015-10.) Disconnect engine frame harness-to-load center harness connector (X3). See Engine Frame Harness (W5) Component Location. (Group 9015-10.)

NO: Connector or circuit malfunction on engine frame harness (W5). Repair or replace connector or harness.

Check circuit B05 RED for voltage at pin 3 on connector (X3) on engine harness side of connector. See Engine Frame Harness (W5) Wiring Diagram. (Group 9015-10.) Is voltage approximately 12 volts?

Key switch OFF.

YES: Go to Reprogram Controller.

12 volt center tap connector (X43) connected. Connect engine frame harness-to-load center harness connector (X3). See Engine Frame Harness (W5) Component Location. (Group 9015-10.) Disconnect flex load controller (FLC) connector (X40). See Load Center Harness (W3) Component Location. (Group 9015-10.)

NO: Connector or circuit malfunction on load center harness (W3). Repair or replace connector or harness.

Check circuit B05 RED for voltage at pin F1 on FLC connector (X40). See Load Center Harness (W3) Wiring Diagram. (Group 9015-10.) Is voltage approximately 12 volts?

– – –1/1

TM10229 (17MAR09)

9001-40-10

544J Loader (S.N. 611800— ) 032409

PN=232

Flex Load Controller (FLC) Diagnostic Trouble Codes 3 Reprogram Controller

Reprogram flex load controller (FLC). See Electronic Controller Reconfiguration. (Group 9015-20.)

YES: Replace controller. NO: Checks complete.

Check for active codes. Is FLC code 000444.18 present? – – –1/1

000544.19 — Refer Torq Mis-Match

Engine control unit (ECU) and flex load controller (FLC) engine torque references do not match.

TF44157,0000048 –19–13MAR08–1/1

Reference Torque MisMatch Diagnostic Procedure Alarm Level: No Warning Lamp

– – –1/1

1 Reprogram Controller

Reprogram engine control unit (ECU).

YES: Replace controller.

Check for active codes.

NO: Checks complete.

Is FLC code 000544.19 present? – – –1/1

000628.12 — Controller Not Programmed

Flex load controller (FLC) is not programmed.

TF44157,0000049 –19–13MAR08–1/1

TM10229 (17MAR09)

9001-40-11

544J Loader (S.N. 611800— ) 032409

PN=233

9001 40 11

Flex Load Controller (FLC) Diagnostic Trouble Codes Controller Not Programmed Diagnostic Procedure Alarm Level: 9001 40 12

No Warning Lamp

– – –1/1

1 Reprogram Controller

Reprogram flex load controller (FLC). See Electronic Controller Reconfiguration. (Group 9015-20.)

YES: Replace controller. NO: Checks complete.

Check for active codes. Is FLC code 000628.12 present? – – –1/1

000774.04 — JS Upshift Short to Gnd

Joystick upshift button is short to ground.

TF44157,000004A –19–13MAR08–1/1

Joystick Upshift Short to Ground Diagnostic Procedure Alarm Level: No Warning Lamp

– – –1/1

TM10229 (17MAR09)

9001-40-12

544J Loader (S.N. 611800— ) 032409

PN=234

Flex Load Controller (FLC) Diagnostic Trouble Codes 1 Component Check

Turn key switch OFF.

YES: Replace joystick shifter (S9).

Disconnect joystick connector (X27). See Load Center Harness (W3) Component Location. (Group 9015-10.)

NO: Go to Short Circuit Check.

Check continuity at connector (X27) between pins 11 and 1, and pins 10 and 1 with buttons in neutral state.

9001 40 13

Is there continuity indicated in either positions?

– – –1/1

2 Short Circuit Check

Turn key switch OFF. Disconnect joystick connector (X27). See Load Center Harness (W3) Component Location. (Group 9015-10.)

YES: Short to ground on load center harness (W3). Repair circuit or replace harness.

Check circuit T10 BLU for ground at pin 10 on connector (X27). See Load Center Harness (W3) Wiring Diagram. (Group 9015-10.)

NO: Go to Continuity Check.

Is ground present?

– – –1/1

3 Continuity Check

Turn key switch OFF. Disconnect flex load controller (FLC) connectors (X40, X41, and X42) and joystick connector (X27). See Load Center Harness (W3) Component Location. (Group 9015-10.) Check for continuity between H1 (circuit T10 BLU) on FLC connector (X41) and remaining pins on connectors (X40, X41, and X42). See Load Center Harness (W3) Wiring Diagram. (Group 9015-10.)

YES: Circuit T10 BLU is short to pin that indicated continuity in load center harness (W3). Repair circuit T10 BLU or replace rear frame harness. NO: Go to Reprogram Controller.

Is continuity indicated between any pins?

– – –1/1

4 Reprogram Controller

Reprogram flex load controller (FLC). See Electronic Controller Reconfiguration. (Group 9015-20.)

YES: Replace controller. NO: Checks complete.

Check for active codes. Is FLC code 000774.04 present? – – –1/1

TM10229 (17MAR09)

9001-40-13

544J Loader (S.N. 611800— ) 032409

PN=235

Flex Load Controller (FLC) Diagnostic Trouble Codes

000774.10 — JS Upshift Button Stuck

9001 40 14

Joystick upshift button is stuck.

TF44157,000004B –19–13MAR08–1/1

Joystick Upshift Button Stuck Diagnostic Procedure Alarm Level: No Warning Lamp

– – –1/1

1 Component Check

Turn key switch OFF.

YES: Replace joystick shifter (S9).

Disconnect joystick connector (X27). See Load Center Harness (W3) Component Location. (Group 9015-10.)

NO: Go to Short Circuit Check.

Check continuity at connector (X27) between pins 11 and 1, and pins 10 and 1 with buttons in neutral state. Is there continuity indicated in either position?

– – –1/1

2 Short Circuit Check

Turn key switch OFF. Disconnect joystick connector (X27). See Load Center Harness (W3) Component Location. (Group 9015-10.)

YES: Circuit T10 BLU short to power on load center harness (W3). Repair circuit T10 BLU or replace harness.

Turn key switch ON. Check circuit T10 BLU for voltage at pin 10 on connector (X27). See Load Center Harness (W3) Wiring Diagram. (Group 9015-10.)

NO: Go to Continuity Check.

Is voltage present?

– – –1/1

TM10229 (17MAR09)

9001-40-14

544J Loader (S.N. 611800— ) 032409

PN=236

Flex Load Controller (FLC) Diagnostic Trouble Codes 3 Continuity Check

Turn key switch OFF. Disconnect flex load controller (FLC) connectors (X40, X41, and X42) and joystick connector (X27). See Load Center Harness (W3) Component Location. (Group 9015-10.) Check for continuity between pin B1 (circuit T10 BLU) on FLC connector (X41) and remaining pins on connectors (X40, X41, and X42). See Load Center Harness (W3) Wiring Diagram. (Group 9015-10.)

YES: Circuit T10 BLU is short to pin that indicated continuity in load center harness (W3). Repair circuit T10 BLU or replace harness. NO: Go to Reprogram Controller.

Is continuity indicated between any pins?

– – –1/1

4 Reprogram Controller

Reprogram flex load controller (FLC). See Electronic Controller Reconfiguration. (Group 9015-20.)

YES: Replace controller. NO: Checks complete.

Check for active codes. Is FLC code 000774.10 present? – – –1/1

000775.04 — JS Downshift Short to Gnd

Joystick downshift button is short to ground.

TF44157,000004C –19–13MAR08–1/1

Joystick Downshift Short to Ground Diagnostic Procedure Alarm Level: No Warning Lamp

– – –1/1

TM10229 (17MAR09)

9001-40-15

544J Loader (S.N. 611800— ) 032409

PN=237

9001 40 15

Flex Load Controller (FLC) Diagnostic Trouble Codes 1 Component Check

Turn key switch OFF.

YES: Replace joystick shifter (S9).

Disconnect joystick connector (X27). See Load Center Harness (W3) Component Location. (Group 9015-10.)

NO: Go to Short Circuit Check.

Check continuity at connector (X27) between pins 11 and 1, and pins 10 and 1 with buttons in neutral state.

9001 40 16

Is there continuity indicated in either position?

– – –1/1

2 Short Circuit Check

Turn key switch OFF. Disconnect joystick connector (X27). See Load Center Harness (W3) Component Location. (Group 9015-10.)

YES: Circuit T11 BLU short to power on load center harness (W3). Repair circuit T11 BLU or replace harness.

Turn key switch ON. Check circuit T11 BLU for voltage at pin 11 on connector (X27). See Load Center Harness (W3) Wiring Diagram. (Group 9015-10.)

NO: Go to Continuity Check.

Is voltage present?

– – –1/1

3 Continuity Check

Turn key switch OFF. Disconnect flex load controller (FLC) connector (X41) and joystick connector (X27). See Load Center Harness (W3) Component Location. (Group 9015-10.) Check continuity between pin H1 (circuit T11 BLU) on FLC connector (X41) and remaining pins on connector (X41). See Load Center Harness (W3) Wiring Diagram. (Group 9015-10.)

YES: Circuit T11 BLU is short to pin that indicated continuity in load center harness (W3). Repair circuit T11 BLU or replace rear frame harness. NO: Go to Reprogram Controller.

Is continuity indicated between any pins?

– – –1/1

4 Reprogram Controller

Reprogram flex load controller (FLC). See Electronic Controller Reconfiguration. (Group 9015-20.)

YES: Replace controller. NO: Checks complete.

Check for active codes. Is FLC code 000775.04 present? – – –1/1

TM10229 (17MAR09)

9001-40-16

544J Loader (S.N. 611800— ) 032409

PN=238

Flex Load Controller (FLC) Diagnostic Trouble Codes

000775.10 — JS Downshift Button Stuck

Joystick downshift button is stuck.

9001 40 17

TF44157,000004D –19–13MAR08–1/1

Joystick Downshift Button Stuck Diagnostic Procedure Alarm Level: No Warning Lamp

– – –1/1

1 Component Check

Turn key switch OFF.

YES: Replace joystick shifter (S9).

Disconnect joystick connector (X27). See Load Center Harness (W3) Component Location. (Group 9015-10.)

NO: Go to Short Circuit Check.

Check continuity at connector (X27) between pins 11 and 1, and pins 10 and 1 with buttons in neutral state. Is there continuity indicated in either position?

– – –1/1

2 Short Circuit Check

Turn key switch OFF. Disconnect joystick connector (X27). See Load Center Harness (W3) Component Location. (Group 9015-10.)

YES: Circuit T11 BLU short to power on load center harness (W3). Repair circuit T11 BLU or replace harness.

Turn key switch ON. Check circuit T11 BLU for voltage at pin 11 on connector (X27). See Load Center Harness (W3) Wiring Diagram. (Group 9015-10.)

NO: Go to Continuity Check.

Is voltage present?

– – –1/1

TM10229 (17MAR09)

9001-40-17

544J Loader (S.N. 611800— ) 032409

PN=239

Flex Load Controller (FLC) Diagnostic Trouble Codes 3 Continuity Check

Turn key switch OFF. Disconnect flex load controller (FLC) connectors (X40, X41, and X42) and joystick connector (X27). See Load Center Harness (W3) Component Location. (Group 9015-10.)

9001 40 18

Check for continuity between pin H1 (circuit T11 BLU) on FLC connector (X41) and remaining pins on connectors (X40, X41, and X42). See Load Center Harness (W3) Wiring Diagram. (Group 9015-10.)

YES: Circuit T11 BLU is short to pin that indicated continuity in load center harness (W3). Repair circuit T11 BLU or replace harness. NO: Go to Reprogram Controller.

Is continuity indicated between any pins?

– – –1/1

4 Reprogram Controller

Reprogram flex load controller (FLC). See Electronic Controller Reconfiguration. (Group 9015-20.)

YES: Replace controller. NO: Checks complete.

Check for active codes. Is FLC code 000775.10 present? – – –1/1

000785.03 — Pilot Solenoid Short to Power

Pilot enable solenoid circuit is short to power.

TF44157,000004E –19–13MAR08–1/1

Pilot Solenoid Short to Power Diagnostic Procedure Alarm Level: No Warning Lamp

– – –1/1

TM10229 (17MAR09)

9001-40-18

544J Loader (S.N. 611800— ) 032409

PN=240

Flex Load Controller (FLC) Diagnostic Trouble Codes 1 Component Check

Turn key switch OFF.

YES: Go to Short Circuit Check.

Disconnect pilot enable solenoid (Y14). See Engine Frame Harness (W5) Component Location. (Group 9015-10.)

NO: Replace solenoid.

Check resistance of solenoid across pins 1 and 2 on solenoid.

9001 40 19

Specification Pilot Enable Solenoid (Y14)—Resistance .......................................... 25.65—31.35 ohms Is solenoid within specification?

– – –1/1

2 Short Circuit Check

Turn key switch OFF.

YES: Go to next step in this check.

Disconnect pilot enable solenoid (Y14). See Engine Frame Harness (W5) Component Location. (Group 9015-10.)

NO: Go to Continuity Check.

Turn key switch ON. Turn pilot enable solenoid OFF. Check circuit H24 GRN for voltage at pin 2 on pilot enable solenoid (Y14) connector. See Engine Frame Harness (W5) Wiring Diagram. (Group 9015-10.) Is voltage present?

Turn key switch OFF. Disconnect load center harness-to-engine frame harness (X3). See Load Center Harness (W3) Component Location. (Group 9015-10.)

YES: Circuit H24 GRN short to power on load center harness (W3). Repair circuit H24 GRN or replace harness.

Turn key switch ON. Turn pilot enable solenoid OFF. Check circuit H24 GRN for voltage at pin 31 on load center side of connector (X3). See Load Center Harness (W3) Wiring Diagram and see Engine Frame Harness (W5) Wiring Diagram. (Group 9015-10.)

NO: Circuit H24 GRN short to power on engine frame harness (W5). Repair circuit H24 or replace harness.

Is voltage present?

– – –1/1

TM10229 (17MAR09)

9001-40-19

544J Loader (S.N. 611800— ) 032409

PN=241

Flex Load Controller (FLC) Diagnostic Trouble Codes 3 Continuity Check

Turn key switch OFF. Disconnect pilot enable solenoid (Y14) and load center harness-to-engine frame harness (X3). See Engine Frame Harness (W5) Component Location. (Group 9015-10.)

9001 40 20

Check for continuity between pin 31 (circuit H24 GRN) on engine frame side of connector (X3) and remaining pins on engine frame harness side of connector (X3). See Engine Frame Harness (W5) Wiring Diagram. (Group 9015-10.)

YES: Circuit H24 GRN is short to pin that indicated continuity on engine frame harness (W5). Repair circuit H24 GRN or replace harness. NO: Go to next step in this check.

Is continuity indicated between any pins?

Key switch OFF. Load center harness-to-engine frame harness (X3) and flex load controller (FLC) connectors (X40, X41, and X42) disconnected. Check for continuity between pin E1 (circuit H24 GRN) on flex load controller (FLC) connector (X41) and remaining pins on FLC connectors (X40, X41, and X42). See Load Center Harness (W3) Wiring Diagram. (Group 9015-10.)

YES: Circuit H24 GRN is short to pin that indicated continuity on load center harness (W3). Repair circuit H24 GRN or replace harness. NO: Go to Reprogram Controller.

Is continuity indicated between any pins? – – –1/1

4 Reprogram Controller

Reprogram flex load controller (FLC). See Electronic Controller Reconfiguration. (Group 9015-20.)

YES: Replace controller. NO: Checks complete.

Check for active codes. Is FLC code 000785.03 present? – – –1/1

000785.05 — Pilot Solenoid Open Circuit

Pilot enable solenoid circuit is open.

TF44157,000004F –19–13MAR08–1/1

Pilot Solenoid Open Circuit Diagnostic Procedure Alarm Level: No Warning Lamp

– – –1/1

TM10229 (17MAR09)

9001-40-20

544J Loader (S.N. 611800— ) 032409

PN=242

Flex Load Controller (FLC) Diagnostic Trouble Codes 1 Component Check

Turn key switch OFF.

YES: Go to Open Circuit Check.

Disconnect pilot enable solenoid (Y14). See Engine Frame Harness (W5) Component Location. (Group 9015-10.)

NO: Replace solenoid.

Check resistance of solenoid across pins 1 and 2 on solenoid.

9001 40 21

Specification Pilot Enable Solenoid (Y14)—Resistance .......................................... 25.65—31.35 ohms Is solenoid within specification?

– – –1/1

2 Open Circuit Check

Turn key switch OFF.

YES: Go to Reprogram Controller.

Disconnect pilot enable solenoid (Y14) and flex load controller (FLC) connector (X42). See Engine Frame Harness (W5) Component Location and see Load Center Harness (W3) Component Location. (Group 9015-10.) Check circuit H24 GRN for continuity between pin 2 on solenoid (Y14) and pin E1 on flex load controller (FLC) connector (X42). See Load Center Harness (W3) Wiring Diagram and See Engine Frame Harness (W5) Component Location. (Group 9015-10.) Check circuit G02 BLK for continuity between pin 1 on solenoid (Y14) and frame ground. See Load Center Harness (W3) Wiring Diagram and See Engine Frame Harness (W5) Component Location. (Group 9015-10.)

NO: If circuit G02 BLK does not indicate continuity there is an open on engine frame harness (W5). Repair circuit G02 BLK or replace harness. Go to next step in this check if circuit H24 GRN does not indicate continuity.

Is continuity indicated?

Key switch OFF. Pilot enable solenoid (Y14) disconnected. Disconnect load center harness-to-engine frame harness (X3). See Engine Frame Harness (W5) Component Location. (Group 9015-10.) Check circuit H24 GRN for continuity between pin 2 on solenoid (Y14) and pin 31 on engine frame side of connector (X3). See Engine Frame Harness (W5) Component Location. (Group 9015-10.)

YES: Circuit H24 GRN open on load center harness (W3). Repair circuit H24 GRN or replace harness. NO: Circuit H24 GRN open on engine frame harness (W5). Repair circuit H24 GRN or replace harness.

Is continuity indicated?

– – –1/1

3 Reprogram Controller

Reprogram flex load controller (FLC). See Electronic Controller Reconfiguration. (Group 9015-20.)

YES: Replace controller. NO: Checks complete.

Check for active codes. Is FLC code 000785.05 present? – – –1/1

TM10229 (17MAR09)

9001-40-21

544J Loader (S.N. 611800— ) 032409

PN=243

Flex Load Controller (FLC) Diagnostic Trouble Codes

000785.06 — Pilot Solenoid High Current

9001 40 22

Pilot enable solenoid circuit is short to ground.

TF44157,0000050 –19–13MAR08–1/1

Pilot Solenoid High Current Diagnostic Procedure Alarm Level: No Warning Lamp

– – –1/1

1 Component Check

Turn key switch OFF.

YES: Go to Short Circuit Check.

Disconnect pilot enable solenoid (Y14). See Engine Frame Harness (W5) Component Location. (Group 9015-10.)

NO: Replace solenoid.

Check resistance of solenoid across pins 1 and 2 on solenoid. Specification Pilot Enable Solenoid (Y14)—Resistance .......................................... 25.65—31.35 ohms Is solenoid within specification?

– – –1/1

TM10229 (17MAR09)

9001-40-22

544J Loader (S.N. 611800— ) 032409

PN=244

Flex Load Controller (FLC) Diagnostic Trouble Codes 2 Short Circuit Check

Turn key switch OFF.

YES: Go to next step in this check.

Disconnect pilot enable solenoid (Y14). See Engine Frame Harness (W5) Component Location. (Group 9015-10.)

NO: Go to Continuity Check.

Check circuit H24 GRN for ground at pin 2 on solenoid (Y14) connector. See Engine Frame Harness (W5) Component Location. (Group 9015-10.)

9001 40 23

Is ground present?

Key switch OFF. Pilot enable solenoid (Y14) disconnected. Disconnect load center harness-to-engine frame harness (X3). See Load Center Harness (W3) Component Location. (Group 9015-10.) Check circuit H24 GRN for ground at pin 31 on load center side of connector (X3). See Load Center Harness (W3) Wiring Diagram. (Group 9015-10.) Is ground present?

YES: Circuit H24 GRN short to ground on load center harness (W3). Repair circuit H24 GRN or replace harness. NO: Circuit H24 GRN short to ground on engine frame harness (W5). Repair circuit H24 GRN or replace harness. – – –1/1

3 Continuity Check

Turn key switch OFF. Disconnect pilot enable solenoid (Y14) and load center harness-to-engine frame harness (X3). See Engine Frame Harness (W5) Component Location and see Load Center Harness (W3) Component Location. (Group 9015-10.) Check for continuity between pin 31 (circuit H24 GRN) on engine frame side of connector (X3) and remaining pins on engine frame harness side of connector (X3). See Engine Frame Harness (W5) Wiring Diagram. (Group 9015-10.)

YES: Circuit H24 GRN is short to pin that indicated continuity on engine frame harness (W5). Repair circuit H24 GRN or replace harness. NO: Go to next step in this check.

Is continuity indicated between any pins?

YES: Circuit H24 GRN is short to pin that indicated continuity on load center harness (W3). Repair circuit H24 GRN or replace harness. NO: Go to Reprogram Controller.

Is continuity indicated between any pins? – – –1/1

4 Reprogram Controller

Reprogram flex load controller (FLC). See Electronic Controller Reconfiguration. (Group 9015-20.)

YES: Replace controller. NO: Checks complete.

Check for active codes. Is FLC code 000785.06 present? – – –1/1

TM10229 (17MAR09)

9001-40-23

544J Loader (S.N. 611800— ) 032409

PN=245

Flex Load Controller (FLC) Diagnostic Trouble Codes

000880.03 — Brake Lights Short to Power

9001 40 24

Left and right rear brake light circuit is short to power.

TF44157,0000051 –19–13MAR08–1/1

Brake Lights Short to Power Diagnostic Procedure Alarm Level: No Warning Lamp

– – –1/1

1 Component Check

Turn key switch OFF.

YES: Go to Short Circuit Check.

Remove brake light assembly (E16 or E17). See Rear Frame Harness (W13) Component Location. (Group 9015-10.)

NO: Replace brake light assembly.

Apply 24 volts to pin 3 on brake light assembly, and ground to pin 1. See Rear Frame Harness (W13) Wiring Diagram. (Group 9015-10.) Does brake light assembly illuminate?

– – –1/1

TM10229 (17MAR09)

9001-40-24

544J Loader (S.N. 611800— ) 032409

PN=246

Flex Load Controller (FLC) Diagnostic Trouble Codes 2 Short Circuit Check

Turn key switch OFF.

YES: Go to next step in this check.

Verify that rear brakes are not applied. Disconnect rear brake light (E16 or E17). See Rear Frame Harness (W13) Component Location. (Group 9015-10.)

NO: Go to Continuity Check. 9001 40 25

Turn key switch ON. Check circuit L04 BRN for voltage at pin 3 on brake light connector. See Rear Frame Harness (W13) Wiring Diagram. (Group 9015-10.) Is voltage present?

Turn key switch OFF.

YES: Go to next step in this check.

Verify that rear brakes are not applied. Disconnect rear frame harness-to-engine frame harness connector (X39). See Rear Frame Harness (W13) Component Location. (Group 9015-10.) Turn key switch ON.

NO: Circuit L04 BRN short to power on rear frame harness (W13). Repair circuit L04 BRN or replace harness.

Check circuit L04 BRN for voltage at pin 1 on engine frame harness side of connector (X39). See Rear Frame Harness (W13) Component Location. (Group 9015-10.) Is voltage present?

Turn key switch OFF. Verify that rear brakes are not applied. Disconnect load center harness-to-engine frame harness connector (X3). See Load Center Harness (W3) Component Location. (Group 9015-10.) Turn key switch ON. Check circuit L04 BRN for voltage at pin 8 on load center harness side of connector. See Load Center Harness (W3) Wiring Diagram. (Group 9015-10.)

YES: Circuit L04 BRN short to power on load center harness (W3). Repair circuit L04 BRN or replace harness. NO: Circuit L04 BRN short to power on engine frame harness (W5). Repair circuit L04 BRN or replace harness.

Is voltage present?

– – –1/1

TM10229 (17MAR09)

9001-40-25

544J Loader (S.N. 611800— ) 032409

PN=247

Flex Load Controller (FLC) Diagnostic Trouble Codes 3 Continuity Check

Turn key switch OFF. Disconnect connector (X39) and brake lights (E16 and E17). See Rear Frame Harness (W13) Component Location. (Group 9015-10.) Check continuity between pin 1 (circuit L04 BRN) on rear frame harness side of connector (X39) and all the pins on connector (X39). See Rear Frame Harness (W13) Wiring Diagram. (Group 9015-10.)

9001 40 26

YES: Circuit L04 BRN is short to pin that indicated continuity on rear frame harness (W13). Repair circuit L04 BRN or replace harness. NO: Go to next step in this check.

Is continuity indicated between any pins?

Key switch OFF.

YES: Circuit L04 BRN is short to pin that indicated continuity on engine frame harness (W5). Repair circuit L04 BRN or replace harness.

Connector (X39) disconnected. Disconnect load center harness-to-engine frame harness (X3). See Engine Frame Harness (W5) Component Location. (Group 9015-10.) Check continuity between pin 11 (circuit L04 BRN) on engine frame harness side of connector (X3) and all the pins on connector (X3). See Engine Frame Harness (W5) Wiring Diagram. (Group 9015-10.)

NO: Go to next step in this check.

Is continuity indicated between any pins?

Key switch OFF.

YES: Circuit L04 BRN is short to pin that indicated continuity on load center harness (W3). Repair circuit L04 BRN or replace harness.

Load center harness-to-engine frame harness (X3) disconnected. Disconnect flex load controller (FLC) connectors (X40, X41, and X42). See Load Center Harness (W3) Component Location. (Group 9015-10.) Check continuity between pin B4 (circuit L04 BRN) on FLC connector (X42) and all the pins on connectors (X40, X41, and X42). See Load Center Harness (W3) Wiring Diagram. (Group 9015-10.)

NO: Go to Reprogram Controller.

Is continuity indicated between any pins?

– – –1/1

4 Reprogram Controller

Reprogram flex load controller (FLC). See Electronic Controller Reconfiguration. (Group 9015-20.)

YES: Replace controller. NO: Checks complete.

Check for active codes. Is FLC code 000880.03 present? – – –1/1

000880.05 — Brake Lights Open Circuit

Left and right brake light circuit is open.

TF44157,0000052 –19–13MAR08–1/1

TM10229 (17MAR09)

9001-40-26

544J Loader (S.N. 611800— ) 032409

PN=248

Flex Load Controller (FLC) Diagnostic Trouble Codes Brake Lights Open Circuit Diagnostic Procedure Alarm Level: No Warning Lamp

9001 40 27

– – –1/1

1 Component Check

Turn key switch OFF.

YES: Go to Open Circuit Check.

Remove brake light assembly (E16 or E17). See Rear Frame Harness (W13) Component Location. (Group 9015-10.)

NO: Replace brake light assembly.

Apply 24 volts to pin 3 on brake light assembly, and ground to pin 1. See Rear Frame Harness (W13) Wiring Diagram. (Group 9015-10.) Does brake light assembly illuminate?

– – –1/1

TM10229 (17MAR09)

9001-40-27

544J Loader (S.N. 611800— ) 032409

PN=249

Flex Load Controller (FLC) Diagnostic Trouble Codes 2 Open Circuit Check

Turn key switch OFF.

YES: Go to Reprogram Controller.

Disconnect rear brake light (E16 or E17) and flex load controller (FLC) connector (X42). See Load Center Harness (W3) Component Location and see Rear Frame Harness (W13) Component Location. (Group 9015-10.) 9001 40 28

NO: Go to next step in this check.

Check circuit L04 BRN for continuity between pin 3 at brake light connector and pin C2 on FLC connector (X42). See Rear Frame Harness (W13) Wiring Diagram and see Load Center Harness (W3) Wiring Diagram. (Group 9015-10.) Check circuit L04 BRN for continuity between pin 3 at brake light connector and frame ground. See Rear Frame Harness (W13) Wiring Diagram. (Group 9015-10.) Is continuity indicated?

Key switch OFF.

YES: Go to next step in this check.

Rear brake light (E16 or E17) disconnected. Disconnect rear frame harness-to-engine frame harness connector (X39). See Engine Frame Harness (W5) Component Location. (Group 9015-10.)

NO: Open circuit on rear frame harness (W5). Repair circuit or replace harness.

Check circuit L04 BRN for continuity between pin 1 on rear frame harness side of connector (X39) and pin 3 on brake light connector. See Engine Frame Harness (W5) Wiring Diagram. (Group 9015-10.) Check circuit G02 BLK for continuity between pin 3 on rear frame harness side of connector (X39) and pin 1 on brake light connector. See Engine Frame Harness (W5) Wiring Diagram. (Group 9015-10.) Is continuity indicated?

Key switch OFF.

YES: Open circuit on load center harness (W3). Repair circuit or replace harness.

Rear frame harness-to-engine frame harness connector (X39) disconnected. Disconnect load center harness-to-engine frame harness connector (X3). See Load Center Harness (W3) Wiring Diagram. (Group 9015-10.) Check circuit L04 BRN for continuity between pin 8 on engine frame harness side of connector (X3) and pin 1 on engine frame side of connector (X39). See Engine Frame Harness (W5) Wiring Diagram. (Group 9015-10.)

NO: Open circuit on engine frame harness (W5). Repair circuit or replace harness.

Check circuit G02 BLK for continuity between pin 3 on engine frame harness side of connector (X3) and frame ground. See Engine Frame Harness (W5) Wiring Diagram. (Group 9015-10.) Is continuity indicated?

– – –1/1

3 Reprogram Controller

Reprogram flex load controller (FLC). See Electronic Controller Reconfiguration. (Group 9015-20.)

YES: Replace controller. NO: Checks complete.

Check for active codes. Is FLC code 000880.05 present? – – –1/1

TM10229 (17MAR09)

9001-40-28

544J Loader (S.N. 611800— ) 032409

PN=250

Flex Load Controller (FLC) Diagnostic Trouble Codes

000880.06 — Brake Lights High Current

Left and right brake light circuit current draw is excessive or short to ground.

9001 40 29

TF44157,0000053 –19–13MAR08–1/1

Brake Lights High Current Diagnostic Procedure Alarm Level: No Warning Lamp

– – –1/1

1 Component Check

Turn key switch OFF.

YES: Go to Short Circuit Check.

Remove rear brake light assembly (E16 or E17). See Rear Frame Harness (W13) Component Location. (Group 9015-10.)

NO: Replace brake light assembly.

Apply 24 volts to pin 3 on brake light assembly, and ground to pin 1. See Rear Frame Harness (W13) Wiring Diagram. (Group 9015-10.) Does brake light assembly illuminate?

– – –1/1

TM10229 (17MAR09)

9001-40-29

544J Loader (S.N. 611800— ) 032409

PN=251

Flex Load Controller (FLC) Diagnostic Trouble Codes 2 Short Circuit Check

Turn key switch OFF.

YES: Go to next step in this check.

Disconnect rear brake light assembly (E16 or E17). See Rear Frame Harness (W13) Component Location. (Group 9015-10.)

NO: Go to Continuity Check.

Check circuit L04 BRN for ground at pin 3 on brake light connector. See Rear Frame Harness (W13) Wiring Diagram. (Group 9015-10.)

9001 40 30

Is ground present?

Key switch OFF.

YES: Go to next step in this check.

Disconnect rear frame harness-to-engine frame harness connector (X39). See Rear Frame Harness (W13) Component Location. (Group 9015-10.) Check circuit L04 BRN for ground at pin 1 on engine frame harness side of connector (X39). See Engine Frame Harness (W5) Wiring Diagram. (Group 9015-10.)

NO: Circuit L04 BRN short to ground on rear frame harness (W13). Repair circuit L04 BRN or replace harness.

Is ground present?

Key switch OFF. Disconnect load center harness-to-engine frame harness connector (X3). See Load Center Harness (W3) Component Location. (Group 9015-10.) Check circuit L04 BRN for ground at pin 11 on load center harness side of connector (X3). See Load Center Harness (W3) Wiring Diagram. (Group 9015-10.) Is ground present?

YES: Circuit L04 BRN short to ground on load center harness (W3). Repair circuit L04 BRN or replace harness. NO: Circuit L04 BRN short to ground on engine frame harness (W5). Repair circuit L04 BRN or replace harness.

– – –1/1

TM10229 (17MAR09)

9001-40-30

544J Loader (S.N. 611800— ) 032409

PN=252

Flex Load Controller (FLC) Diagnostic Trouble Codes 3 Continuity Check

YES: Circuit L04 BRN is short to pin that indicated continuity on rear frame harness (W13). Repair circuit L04 BRN or replace harness. NO: Go to next step in this check.

Is continuity indicated between any pins?

Key switch OFF.

YES: Circuit L04 BRN is short to pin that indicated continuity on engine frame harness (W5). Repair circuit L04 BRN or replace harness.

NO: Go to next step in this check.

Is continuity indicated between any pins?

Key switch OFF.

YES: Circuit L04 BRN is short to pin that indicated continuity on load center harness (W3). Repair circuit L04 BRN or replace harness.

NO: Go to Reprogram Controller.

Is continuity indicated between any pins?

– – –1/1

4 Reprogram Controller

Reprogram flex load controller (FLC). See Electronic Controller Reconfiguration. (Group 9015-20.)

YES: Replace controller. NO: Checks complete.

Check for active codes. Is FLC code 000880.06 present? – – –1/1

000977.03 — Rev Fan Solenoid Short to Power

Reverse fan solenoid circuit is short to power.

TF44157,0000054 –19–13MAR08–1/1

TM10229 (17MAR09)

9001-40-31

544J Loader (S.N. 611800— ) 032409

PN=253

9001 40 31

Flex Load Controller (FLC) Diagnostic Trouble Codes Reverse Fan Solenoid Short to Power Diagnostic Procedure Alarm Level: 9001 40 32

No Warning Lamp

– – –1/1

1 Component Check

Turn key switch OFF.

YES: Go to Short Circuit Check.

Disconnect reverse fan solenoid (Y38). See Rear Frame Harness (W13) Component Location. (Group 9015-10.)

NO: Replace reverse fan solenoid.

Check resistance of solenoid across pins 1 and 2. Specification Reverse Fan Solenoid (Y38)— Resistance .......................................................................................... 29.79—36.41 ohms Is solenoid within specification?

– – –1/1

TM10229 (17MAR09)

9001-40-32

544J Loader (S.N. 611800— ) 032409

PN=254

Flex Load Controller (FLC) Diagnostic Trouble Codes 2 Short Circuit Check

Turn key switch OFF.

YES: Go to next step in this check.

Disconnect reverse fan solenoid (Y38). See Rear Frame Harness (W13) Component Location. (Group 9015-10.)

NO: Go to Continuity Check.

Turn key switch ON.

9001 40 33

Check circuit H26 GRN for voltage at pin 2 on fan reverse solenoid connector. See Rear Frame Harness (W13) Wiring Diagram. (Group 9015-10.) Is voltage present?

Turn key switch OFF.

YES: Go to next step in this check.

Disconnect rear frame harness-to-engine frame harness connector (X39). See Engine Frame Harness (W5) Component Location. (Group 9015-10.) Turn key switch ON. Check circuit H26 GRN for voltage at pin 9 on engine frame harness side of connector (X39). See Engine Frame Harness (W5) Wiring Diagram. (Group 9015-10.)

NO: Circuit H26 GRN short to power on rear frame harness (W13). Repair circuit H26 GRN or replace harness.

Is voltage present?

Turn key switch OFF. Disconnect load center harness-to-engine frame harness connector (X3). See Load Center Harness (W3) Component Location. (Group 9015-10.)

YES: Circuit H26 GRN short to power on load center harness (W3). Repair circuit H26 GRN or replace harness.

Turn key switch ON. Check circuit H26 GRN for voltage at pin 5 on load center harness side of connector (X3). See Load Center Harness (W3) Wiring Diagram. (Group 9015-10.) Is voltage present?

NO: Circuit H26 GRN short to power on engine frame harness (W5). Repair circuit H26 GRN or replace harness.

– – –1/1

TM10229 (17MAR09)

9001-40-33

544J Loader (S.N. 611800— ) 032409

PN=255

Flex Load Controller (FLC) Diagnostic Trouble Codes 3 Continuity Check

Turn key switch OFF.

YES: Circuit H26 GRN short to pin that indicated continuity on rear frame harness (W13). Repair circuit H26 GRN or replace harness.

Check continuity between pin 9 (circuit H26 GRN) on rear frame harness side of connector (X39) and all remaining pins on connector (X39). See Rear Frame Harness (W13) Wiring Diagram. (Group 9015-10.)

NO: Go to next step in this check.

Is continuity indicated?

Key switch OFF. Rear frame harness-to-engine frame harness connector (X39) disconnected. See Engine Frame Harness (W5) Component Location. (Group 9015-10.) Disconnect load center harness-to-engine frame harness connector (X3). See Engine Frame Harness (W5) Component Location . (Group 9015-10.) Check continuity between pin 9 (circuit H26 GRN) on engine frame harness side of connector (X39) and all remaining pins on connector (X39). See Engine Frame Harness (W5) Wiring Diagram. (Group 9015-10.)

YES: Circuit H26 GRN short to pin that indicated continuity on engine frame harness (W5). Repair circuit H26 GRN or replace harness. NO: Go to next step in this check.

Is continuity indicated between any pins?

Key switch OFF. Load center harness-to-engine frame harness connector (X3) disconnected. Disconnect flex load center (FLC) connectors (X40, X41, and X42). See Load Center Harness (W3) Component Location. (Group 9015-10.) Check continuity between pin A4 (circuit H26 GRN) on FLC connector (X42) and all remaining pins on connectors (X40, X41, and X42). See Load Center Harness (W3) Wiring Diagram. (Group 9015-10.)

YES: Circuit H26 GRN short to pin that indicated continuity on load center harness (W3). Repair circuit H26 GRN or replace harness. NO: Go to Reprogram Controller.

Is continuity indicated between any pins? – – –1/1

4 Reprogram Controller

Reprogram flex load controller (FLC). See Electronic Controller Reconfiguration. (Group 9015-20.)

YES: Replace controller. NO: Checks complete.

Check for active codes. Is FLC code 000977.03 present? – – –1/1

000977.05 — Rev Fan Sol Open Circuit

Reverse fan solenoid circuit is open.

TF44157,0000055 –19–13MAR08–1/1

TM10229 (17MAR09)

9001-40-34

544J Loader (S.N. 611800— ) 032409

PN=256

Flex Load Controller (FLC) Diagnostic Trouble Codes Reverse Fan Solenoid Open Circuit Diagnostic Procedure Alarm Level: No Warning Lamp

9001 40 35

– – –1/1

1 Component Check

Turn key switch OFF.

YES: Go to Open Circuit Check.

Disconnect reverse fan solenoid (Y38). See Rear Frame Harness (W13) Component Location. (Group 9015-10.)

NO: Replace reverse fan solenoid.

– – –1/1

TM10229 (17MAR09)

9001-40-35

544J Loader (S.N. 611800— ) 032409

PN=257

Flex Load Controller (FLC) Diagnostic Trouble Codes 2 Open Circuit Check

Turn key switch OFF.

YES: Go to Reprogram Controller.

Disconnect reverse fan solenoid (Y38) and flex load controller harness (FLC) connector (X42). See Load Center Harness (W3) Component Location and see Rear Frame Harness (W13) Component Location. (Group 9015-10.) 9001 40 36

NO: Go to next step in this check.

Check circuit H26 GRN for continuity between pin 2 on fan reverse solenoid connector and pin A4 on FLC connector (X42). See Load Center Harness (W3) Wiring Diagram and see Rear Frame Harness (W13) Wiring Diagram. (Group 9015-10.) Check circuit G02 BLK for continuity between pin 1 on fan reverse solenoid connector and frame ground. See Rear Frame Harness (W13) Wiring Diagram. (Group 9015-10.) Is continuity indicated?

Key switch OFF.

YES: Go to next step in this check.

Disconnect rear frame harness-to-engine frame harness connector (X39) and load center harness-to-engine frame harness connector (X3). See Engine Frame Harness (W5) Component Location. (Group 9015-10.) Check circuit H26 GRN for continuity between pin 9 on rear frame harness side of connector (X39) and pin 5 on connector (X3). See Rear Frame Harness (W13) Wiring Diagram. (Group 9015-10.)

NO: Open circuit on rear frame harness (W13). Repair circuit or replace harness.

Check circuit G02 BLK for continuity between pin 4 on rear frame harness side of connector (X39) and frame ground. See Rear Frame Harness (W13) Wiring Diagram. (Group 9015-10.) Is continuity indicated?

Key switch OFF.

YES: Circuit H26 GRN open on load center harness (W3). Repair circuit H26 GRN or replace harness.

Load center harness-to-engine frame harness connector (X3) disconnected. Disconnect FLC connector (X42). See Load Center Harness (W3) Component Location. (Group 9015-10.) Check circuit H26 GRN for continuity between pin A4 on FLC connector (X42) and pin 5 on load center harness side of connector (X3). See Engine Frame Harness (W5) Wiring Diagram. (Group 9015-10.)

NO: Circuit H26 GRN open on engine frame harness (W5). Repair circuit H26 GRN or replace harness.

Is continuity indicated?

– – –1/1

3 Reprogram Controller

Reprogram flex load controller (FLC). See Electronic Controller Reconfiguration. (Group 9015-20.)

YES: Replace controller. NO: Checks complete.

Check for active codes. Is FLC code 000977.05 present? – – –1/1

TM10229 (17MAR09)

9001-40-36

544J Loader (S.N. 611800— ) 032409

PN=258

Flex Load Controller (FLC) Diagnostic Trouble Codes

000977.06 — Rev Fan Sol High Current

Reverse fan solenoid circuit current draw is excessive or short to ground.

9001 40 37

TF44157,0000056 –19–13MAR08–1/1

Reverse Fan Solenoid High Current Diagnostic Procedure Alarm Level: No Warning Lamp

– – –1/1

1 Component Check

Turn key switch OFF.

YES: Go to Short Circuit Check.

Disconnect reverse fan solenoid (Y38). See Rear Frame Harness (W13) Component Location. (Group 9015-10.)

NO: Replace reverse fan solenoid.

– – –1/1

TM10229 (17MAR09)

9001-40-37

544J Loader (S.N. 611800— ) 032409

PN=259

Flex Load Controller (FLC) Diagnostic Trouble Codes 2 Short Circuit Check

Turn key switch OFF.

YES: Go to next step in this check.

Disconnect reverse fan solenoid (Y38). See Rear Frame Harness (W13) Component Location. (Group 9015-10.)

NO: Go to Continuity Check.

Check circuit H26 GRN for ground at pin 2 on sensor connector. See Rear Frame Harness (W13) Wiring Diagram. (Group 9015-10.)

9001 40 38

Is ground present?

Key switch OFF.

YES: Go to next step in this check.

Disconnect rear frame harness-to-engine frame harness connector (X39). See Engine Frame Harness (W5) Component Location. (Group 9015-10.) Check circuit H26 GRN for ground at pin 9 on engine harness side of connector (X39). See Engine Frame Harness (W5) Wiring Diagram. (Group 9015-10.)

NO: Circuit H26 GRN short to ground on rear frame harness (W13). Repair circuit H26 GRN or replace harness.

Is ground present?

Key switch OFF. Disconnected load center harness-to-engine frame harness connector (X3). See Load Center Harness (W3) Component Location. (Group 9015-10.) Check circuit H26 GRN for ground at pin 5 on load center harness side of connector (X3). See Load Center Harness (W3) Wiring Diagram. (Group 9015-10.) Is ground present?

YES: Circuit H26 GRN short to ground on load center harness (W3). Repair circuit H26 GRN or replace harness. NO: Circuit H26 GRN short to ground on engine frame harness (W5). Repair circuit H26 GRN or replace harness.

– – –1/1

TM10229 (17MAR09)

9001-40-38

544J Loader (S.N. 611800— ) 032409

PN=260

Flex Load Controller (FLC) Diagnostic Trouble Codes 3 Continuity Check

Turn key switch OFF.

YES: Circuit H26 GRN short to pin that indicated continuity on rear frame harness (W13). Repair circuit H26 GRN or replace harness.

Disconnect reverse fan solenoid (Y38) and rear frame harness-to-engine frame harness connector (X39). See Rear Frame Harness (W13) Component Location and See Engine Frame Harness (W5) Component Location. (Group 9015-10.) Check continuity between pin 9 (circuit H26 GRN) on rear frame harness side of connector (X39) and all remaining pins on connector (X39). See Rear Frame Harness (W13) Wiring Diagram. (Group 9015-10.)

NO: Go to next step in this check.

Is continuity indicated between any pins?

Key switch OFF. Rear frame harness-to-engine frame harness connector (X39) disconnected. See Engine Frame Harness (W5) Component Location. (Group 9015-10.) Disconnect load center harness-to-engine frame harness connector (X3). See Engine Frame Harness (W5) Component Location. (Group 9015-10.) Check continuity between pin 9 (circuit H26 GRN) on engine frame harness side of connector (X39) and all remaining pins on connector (X39). See Engine Frame Harness (W5) Wiring Diagram. (Group 9015-10.)

YES: Circuit H26 GRN short to pin that indicated continuity on engine frame harness (W5). Repair circuit H26 GRN or replace harness. NO: Go to next step in this check.

Is continuity indicated between any pins?

YES: Circuit H26 GRN short to pin that indicated continuity on load center harness (W3). Repair circuit H26 GRN or replace harness. NO: Go to Reprogram Controller.

Is continuity indicated between any pins? – – –1/1

4 Reprogram Controller

Reprogram flex load controller (FLC). See Electronic Controller Reconfiguration. (Group 9015-20.)

YES: Replace controller. NO: Checks complete.

Check for active codes. Is FLC code 000977.06 present? – – –1/1

001045.04 — Brake Lt Sw Shorted to Gnd

Brake light switch circuit is short to ground.

TF44157,0000057 –19–13MAR08–1/1

TM10229 (17MAR09)

9001-40-39

544J Loader (S.N. 611800— ) 032409

PN=261

9001 40 39

Flex Load Controller (FLC) Diagnostic Trouble Codes Brake Light Switch Shorted to Ground Diagnostic Procedure Alarm Level: 9001 40 40

No Warning Lamp

– – –1/1

1 Component Check

Turn key switch ON.

YES: Replace brake light pressure switch.

Access brake accumulator pressure in CMU menu structure. See CAN Monitor Unit (CMU) Menu Structure—Service Mode. (Group 9015-20.)

NO: Go to Short Circuit Check.

Pump brake pedal until brake pressure reads 0 psi. Turn key switch OFF. Disconnect and remove brake light pressure switch (B40). See Load Center Harness (W3) Component Location. (Group 9015-10.) Check for continuity across pins A and B on brake light pressure switch. Is continuity indicated?

– – –1/1

2 Short Circuit Check

Turn key switch OFF.

YES: Go to Continuity Check.

Disconnect brake light pressure switch (B40) connector. See Load Center Harness (W3) Component Location. (Group 9015-10.) Turn key switch ON. Check circuit L03 BRN for ground at pin B on brake light pressure switch (B40) connector. See Load Center Harness (W3) Wiring Diagram. (Group 9015-10.)

NO: Circuit L03 BRN short to ground on load center harness (W3). Repair circuit L03 BRN or replace harness.

Is ground present?

– – –1/1

TM10229 (17MAR09)

9001-40-40

544J Loader (S.N. 611800— ) 032409

PN=262

Flex Load Controller (FLC) Diagnostic Trouble Codes 3 Continuity Check

Turn key switch OFF. Disconnect brake light pressure switch (B40) and flex load controller (FLC) connectors (X40, X41, and X42). See Load Center Harness (W3) Component Location. (Group 9015-10.) Check for continuity between pin A4 (circuit L03 BRN) on FLC connector (X41) and remaining pins on connectors (X40, X41, and X42). See Load Center Harness (W3) Wiring Diagram. (Group 9015-10.)

YES: Circuit L03 BRN short to pin that indicated continuity on load center harness (W3). Repair circuit L03 BRN or replace harness. NO: Go to Reprogram Controller.

Is continuity indicated between any pins?

– – –1/1

4 Reprogram Controller

Reprogram flex load controller (FLC). See Electronic Controller Reconfiguration. (Group 9015-20.)

YES: Replace controller. NO: Checks complete.

Check for active codes. Is FLC code 001045.04 present? – – –1/1

001069.02 — Tire Size Incorrect

Wrong tire size is programmed in the flex load controller (FLC).

TF44157,0000058 –19–13MAR08–1/1

Tire Size Incorrect Diagnostic Procedure Alarm Level: No Warning Lamp

– – –1/1

1 Component Check

Access the CMU menu structure in service mode. See CAN Monitor Unit (CMU) Menu Structure—Service Mode. (Group 9015-10.)

YES: Go to Reprogram Controller.

Access Machine Configuration / Tires Size.

NO: Select the correct tire size from the list in the CMU.

Does the displayed tire size in the CMU match the tires presently on the machine?

– – –1/1

TM10229 (17MAR09)

9001-40-41

544J Loader (S.N. 611800— ) 032409

PN=263

9001 40 41

Flex Load Controller (FLC) Diagnostic Trouble Codes 2 Reprogram Controller

Reprogram flex load controller (FLC). See Electronic Controller Reconfiguration. (Group 9015-20.)

YES: Replace controller. NO: Checks complete.

Check for active codes. Is FLC code 001069.02 present?

9001 40 42

– – –1/1

001071.31 — Fan Speed Sol Circuit Fault

Fan speed solenoid circuit is faulty.

TF44157,0000059 –19–13MAR08–1/1

Fan Speed Solenoid Circuit Fault Diagnostic Procedure Alarm Level: No Warning Lamp

– – –1/1

1 Component Check

Turn key switch OFF.

YES: Go to Open Circuit Check.

Disconnect proportional fan solenoid (Y37). See Rear Frame Harness (W13) Component Location. (Group 9015-10.)

NO: Replace solenoid.

Check resistance of solenoid across pins A and B. Specification Proportional Fan Solenoid (Y37)— Resistance .............................................................................................. 21.6—26.4 ohms Is solenoid within specification?

– – –1/1

TM10229 (17MAR09)

9001-40-42

544J Loader (S.N. 611800— ) 032409

PN=264

Flex Load Controller (FLC) Diagnostic Trouble Codes 2 Open Circuit Check

Turn key switch OFF.

YES: Go to Continuity Check.

Disconnect fan solenoid (Y37) and flex load controller (FLC) connector (X42). See Load Center Harness (W3) Component Location and see Rear Frame Harness (W13) Component Location. (Group 9015-10.)

NO: Go to next step in this check. 9001 40 43

Check circuit H35 GRN for continuity between pin A on fan solenoid connector and pin D4 on FLC connector (X42). See Load Center Harness (W3) Wiring Diagram and See Rear Frame Harness (W13) Wiring Diagram. (Group 9015-10.) Check circuit R35 BLK for continuity between pin B on fan solenoid connector and pin C4 on FLC connector (X42). See Load Center Harness (W3) Wiring Diagram and See Rear Frame Harness (W13) Wiring Diagram. (Group 9015-10.) Is continuity indicated?

Key switch OFF.

YES: Go to next step in this check.

Fan solenoid (Y37) disconnected. Disconnect rear frame harness-to-engine frame harness connector (X39). See Engine Frame Harness (W5) Component Location. (Group 9015-10.)

NO: Open circuit on rear frame harness (W13). Repair circuit or replace harness.

Check circuit H35 GRN for continuity between pin 10 on rear frame harness side of connector (X39) and pin A on fan solenoid connector. See Rear Frame Harness (W13) Wiring Diagram. (Group 9015-10.) Check circuit R35 BLK for continuity between pin 11 on rear frame harness side of connector (X39) and pin B on fan solenoid connector. See Rear Frame Harness (W13) Wiring Diagram. (Group 9015-10.) Is continuity indicated?

Key switch OFF.

YES: Go to next step in this check.

Rear frame harness-to-engine frame harness connector (X39) disconnected. Disconnect load center harness-to-engine frame harness connector (X3). See Engine Frame Harness (W5) Component Location. (Group 9015-10.)

NO: Open circuit on engine frame harness. Repair circuit or replace harness.

Check circuit H35 GRN for continuity between pin 10 on engine frame harness side of connector (X39) and pin 7 on engine frame harness side of connector (X3). See Engine Frame Harness (W5) Wiring Diagram. (Group 9015-10.) Check circuit R35 BLK for continuity between pin 11 on engine frame harness side of connector (X39) and pin 6 on engine frame harness side of connector (X3). See Engine Frame Harness (W5) Wiring Diagram. (Group 9015-10.) Is continuity indicated?

– – –1/2

TM10229 (17MAR09)

9001-40-43

544J Loader (S.N. 611800— ) 032409

PN=265

Flex Load Controller (FLC) Diagnostic Trouble Codes Key switch OFF.

YES: Go to Reprogram Controller.

Load center harness-to-engine frame harness connector (X3) disconnected. See Load Center Harness (W3) Component Location. (Group 9015-10.) FLC connector (X42) disconnected. See Load Center Harness (W3) Component Location. (Group 9015-10.)

9001 40 44

NO: Open circuit on load center harness (W3). Repair circuit or replace harness.

Check circuit H35 GRN for continuity between pin D4 on FLC connector (X42) and pin 7 on load center harness side of connector (X3). See Load Center Harness (W3) Wiring Diagram. (Group 9015-10.) Check circuit R35 BLK for continuity between pin C4 on FLC connector (X42) and pin 6 on load center harness side of connector (X3). See Load Center Harness (W3) Wiring Diagram. (Group 9015-10.) Is continuity indicated?

–19– –2/2

TM10229 (17MAR09)

9001-40-44

544J Loader (S.N. 611800— ) 032409

PN=266

Flex Load Controller (FLC) Diagnostic Trouble Codes 3 Continuity Check

Turn key switch OFF. Disconnect fan solenoid (Y37). See Rear Frame Harness (W13) Component Location. (Group 9015-10.) Disconnect rear frame harness-to-engine frame harness connector (X39). See Engine Frame Harness (W5) Component Location. (Group 9015-10.)

YES: Short to pin that indicated continuity on rear frame harness (W13). Repair circuit or replace harness. NO: Go to next step in this check.

Check continuity between pin 10 (circuit H26 GRN) on rear frame harness side of connector (X39) and all remaining pins on connector (X39). See Rear Frame Harness (W13) Wiring Diagram. (Group 9015-10.) Check continuity between pin 11 (circuit R35 BLK) on rear frame harness side of connector (X39) and all remaining pins on connector (X39). See Rear Frame Harness (W13) Wiring Diagram. (Group 9015-10.) Is continuity indicated between any pins?

Key switch OFF. Rear frame harness-to-engine frame harness connector (X39) disconnected. Disconnect load center harness-to-engine frame harness connector (X3). See Engine Frame Harness (W5) Component Location. (Group 9015-10.) Check continuity between pin 7 (circuit H26 GRN) on engine frame harness side of connector (X39) and all remaining pins on connector (X39). See Engine Frame Harness (W5) Wiring Diagram. (Group 9015-10.)

YES: Short to pin that indicated continuity on engine frame harness (W5). Repair circuit or replace harness. NO: Go to next step in this check.

Check continuity between pin 6 (circuit R35 BLK) on engine frame harness side of connector (X39) and all remaining pins on connector (X39). See Engine Frame Harness (W5) Wiring Diagram. (Group 9015-10.) Is continuity indicated between any pins?

Key switch OFF. Load center harness-to-engine frame harness connector (X3) disconnected. Disconnect FLC connectors (X40, X41, and X42). See Load Center Harness (W3) Component Location. (Group 9015-10.) Check continuity between pin D4 (circuit H26 GRN) on FLC connector (X42) and all remaining pins on connectors (X40, X41, and X42). See Load Center Harness (W3) Wiring Diagram. (Group 9015-10.)

YES: Short to pin that indicated continuity on load center harness (W3). Repair circuit or replace harness. NO: Go to Reprogram Controller.

Check continuity between pin C4 (circuit R35 BLK) on FLC connector (X42) and all remaining pins on connectors (X40, X41, and X42). See Load Center Harness (W3) Wiring Diagram. (Group 9015-10.) Is continuity indicated between any pins?

– – –1/1

4 Reprogram Controller

Reprogram flex load controller (FLC). See Electronic Controller Reconfiguration. (Group 9015-20.)

YES: Replace controller. NO: Checks complete.

Check for active codes. Is FLC code 001071.31 present? – – –1/1

TM10229 (17MAR09)

9001-40-45

544J Loader (S.N. 611800— ) 032409

PN=267

9001 40 45

Flex Load Controller (FLC) Diagnostic Trouble Codes

001075.00 — Fuel Pump On Too Long

9001 40 46

Electric fuel pump has been left on for more than 15 minutes.

TF44157,000005A –19–13MAR08–1/1

Fuel Pump On Too Long Diagnostic Procedure Alarm Level: Fuel Filter and Caution Light On

– – –1/1

1 Switch Check

Verify that switch by the fuel filters is turned off.

YES: Go to next step in this check.

Is the switch turned off? NO: Turn off switch.

Turn key switch OFF.

YES: Checks complete.

Disconnect electric fuel pump connector (X84). See Engine Harness (W6) Wiring Diagram. (Group 9015-10.)

NO: Replace fuel pump switch.

Check switch for continuity between pins 1 and 2 while toggling switch ON and OFF. Is continuity indicated when switch is in the ON position? – – –1/1

001079.04 — FLC Sensor 1 Voltage Low

BHKO/return-to-dig position sensor 5 volt reference signal is below 4 volts.

TF44157,000005B –19–13MAR08–1/1

TM10229 (17MAR09)

9001-40-46

544J Loader (S.N. 611800— ) 032409

PN=268

Flex Load Controller (FLC) Diagnostic Trouble Codes FLC Sensor 1 Voltage Low Diagnostic Procedure Alarm Level: No Warning Lamp

9001 40 47

– – –1/1

1 Short Circuit Check

Turn key switch OFF.

YES: Go to next step in this check.

Disconnect return-to-dig sensor (B37). See Loader Frame Harness (W2) Component Location. (Group 9015-10.)

NO: Go to Open Circuit Check.

Check circuit P68 RED for ground at pin A on return-to-dig sensor (B45) connector. See Loader Frame Harness (W2) Wiring Diagram. (Group 9015-10.) Is ground present?

Key switch OFF. Disconnect load center harness-to-loader frame harness connector (X67). See Loader Frame Harness (W2) Component Location. (Group 9015-10.) Check circuit P68 RED for ground at pin 20 on load center harness side of connector (X67). See Loader Frame Harness (W2) Wiring Diagram. (Group 9015-10.) Is ground present?

YES: Circuit P68 RED short to ground on load center harness (W3). Repair circuit P68 RED or replace harness. NO: Circuit P68 RED short to ground on loader frame harness (W2). Repair circuit P68 RED or replace harness. – – –1/1

TM10229 (17MAR09)

9001-40-47

544J Loader (S.N. 611800— ) 032409

PN=269

Flex Load Controller (FLC) Diagnostic Trouble Codes 2 Open Circuit Check

Turn key switch OFF.

YES: Go to next step in this check.

Disconnect return-to-dig sensor. See Loader Frame Harness (W2) Component Location. (Group 9015-10.) Disconnect load center harness-to-loader frame harness connector (X67). See Loader Frame Harness (W2) Component Location. (Group 9015-10.)

9001 40 48

NO: Circuit P68 RED open on loader frame harness (W2). Repair circuit P68 RED or replace harness.

Check circuit P68 RED for continuity between pin A on return-to-dig sensor (B45) and pin 20 on loader frame harness side of connector (X67). See Loader Frame Harness (W2) Wiring Diagram. (Group 9015-10.) Is continuity indicated?

Key switch OFF.

YES: Go to Reprogram Controller.

Load center harness-to-loader frame harness connector (X67) disconnected. Disconnect flex load controller (FLC) connector (X41). See Load Center Harness (W3) Component Location. (Group 9015-10.) Check circuit P68 RED for continuity between pin K1 on FLC connector (X41) and pin 20 on FLC side of connector (X67). See Load Center Harness (W3) Wiring Diagram. (Group 9015-10.)

NO: Circuit P68 RED open on load center harness (W3). Repair circuit P68 RED or replace harness.

Is continuity indicated?

– – –1/1

3 Reprogram Controller

Reprogram flex load controller (FLC). See Electronic Controller Reconfiguration. (Group 9015-20.)

YES: Replace controller. NO: Checks complete.

Check for active codes. Is FLC code 001079.04 present? – – –1/1

001080.04 — FLC Sensor 2 Voltage Low

Service brake pressure sensor 5 volt reference signal is below 4 volts.

TF44157,000005C –19–13MAR08–1/1

TM10229 (17MAR09)

9001-40-48

544J Loader (S.N. 611800— ) 032409

PN=270

Flex Load Controller (FLC) Diagnostic Trouble Codes FLC Sensor 2 Voltage Low Diagnostic Procedure Alarm Level: No Warning Lamp

9001 40 49

– – –1/1

1 Short Circuit Check

Turn key switch OFF. Disconnect service brake pressure sensor (B27). See Load Center Harness (W3) Component Location. (Group 9015-10.)

YES: Short to ground on load center harness (W3). Repair circuit or replace harness.

Check circuit P69 RED for ground at pin A on service brake pressure sensor (B27) connector. See Load Center Harness (W3) Wiring Diagram. (Group 9015-10.)

NO: Go to Open Circuit Check.

Is ground present?

– – –1/1

2 Open Circuit Check

Turn key switch OFF. Disconnect service brake pressure sensor (B27) and FLC connector (X41). See Load Center Harness (W3) Component Location. (Group 9015-10.) Check circuit P69 RED for continuity between pin A on service brake pressure sensor (B27) connector and pin K3 on FLC connector (X41). See Load Center Harness (W3) Wiring Diagram. (Group 9015-10.)

YES: Circuit P68 RED open on load center harness (W3). Repair circuit P68 RED or replace harness. NO: Go to Reprogram Controller.

Is ground present?

– – –1/1

3 Reprogram Controller

Reprogram flex load controller (FLC). See Electronic Controller Reconfiguration. (Group 9015-20.)

YES: Replace controller. NO: Checks complete.

Check for active codes. Is FLC code 001080.04 present? – – –1/1

TM10229 (17MAR09)

9001-40-49

544J Loader (S.N. 611800— ) 032409

PN=271

Flex Load Controller (FLC) Diagnostic Trouble Codes

001638.00 — Hydraulic Oil High Temp

9001 40 50

Hydraulic oil temperature is too high.

TF44157,000005D –19–13MAR08–1/1

Hydraulic Oil High Temperature Diagnostic Procedure Alarm Level: No Warning Lamp

– – –1/1

1 Component Check

Turn key switch OFF. Disconnect hydraulic oil temperature sensor (B15). See Engine Frame Harness (W5) Component Location. (Group 9015-10.)

YES: Hydraulic oil is overheating. See Hydraulic System Diagnose Malfunctions. (Group 9025-15.)

Check resistance of sensor across pins A and B. NO: Replace hydraulic oil temperature sensor.

Specification Hydraulic Oil Temperature Sensor (B15)—Resistance ................................................... 90—108 kilo-ohms at -40°C (-40°F) 26—31 kilo-ohms at -20°C (-4°F) 8.7—10.2 kilo-ohms at 0°C (32°F) 3.3—3.8 kilo-ohms at 20°C (68°F) 1.4—1.6 kilo-ohms at 40°C (104°F) 648—708 ohms at 60°C (140°F) 317—350 ohms at 80°C (176°F) 170—186 ohms at 100°C (212°F) 97—105 ohms at 120°C (248°F) Is sensor within specification?

– – –1/1

TM10229 (17MAR09)

9001-40-50

544J Loader (S.N. 611800— ) 032409

PN=272

Flex Load Controller (FLC) Diagnostic Trouble Codes

001638.04 — Hyd Oil Temp Circuit Short to Gnd

9001 40 51

Hydraulic oil temperature sensor circuit is short to ground.

TF44157,000005E –19–13MAR08–1/1

Hydraulic Oil Temperature Circuit Short to Ground Diagnostic Procedure Alarm Level: Gauge at Minimum Status

– – –1/1

1 Component Check

Turn key switch OFF.

YES: Go to Short Circuit Check.

Disconnect hydraulic oil temperature sensor (B15). See Engine Frame Harness (W5) Component Location. (Group 9015-10.)

NO: Replace hydraulic oil temperature sensor.

Check resistance of sensor across pins A and B. Specification Hydraulic Oil Temperature Sensor (B15)—Resistance ................................................... 90—108 kilo-ohms at -40°C (-40°F) 26—31 kilo-ohms at -20°C (-4°F) 8.7—10.2 kilo-ohms at 0°C (32°F) 3.3—3.8 kilo-ohms at 20°C (68°F) 1.4—1.6 kilo-ohms at 40°C (104°F) 648—708 ohms at 60°C (140°F) 317—350 ohms at 80°C (176°F) 170—186 ohms at 100°C (212°F) 97—105 ohms at 120°C (248°F) Is sensor within specification?

– – –1/1

TM10229 (17MAR09)

9001-40-51

544J Loader (S.N. 611800— ) 032409

PN=273

Flex Load Controller (FLC) Diagnostic Trouble Codes 2 Short Circuit Check

Turn key switch OFF.

YES: Go to next step in this check.

Disconnect hydraulic oil temperature sensor (B15). See Engine Frame Harness (W5) Component Location. (Group 9015-10.)

NO: Go to Continuity Check.

Check circuit X01 YEL for ground at pin B on hydraulic oil temperature sensor (B15) connector. See Engine Frame Harness (W5) Wiring Diagram. (Group 9015-10.)

9001 40 52

Is ground present?

Key switch OFF. Disconnect load center-to-engine frame harness connector (X3). See Engine Frame Harness (W5) Component Location. (Group 9015-10.) Check circuit X01 YEL for ground at pin 23 son load center side of connector (X3). See Load Center Harness (W3) Component Location. (Group 9015-10.) Is ground present?

YES: Circuit X01 YEL short to ground on load center harness (W3). Repair circuit X01 YEL or replace harness. NO: Circuit X01 YEL short to ground on engine frame harness (W5). Repair circuit X01 YEL or replace harness. – – –1/1

3 Continuity Check

Turn key switch OFF. Disconnect hydraulic oil temperature sensor (B15) and load center-to-engine frame harness connector (X3). See Engine Frame Harness (W5) Component Location. (Group 9015-10.) Check for continuity between pin B (circuit X01 YEL) on engine frame side of connector (X3) and remaining pins on engine frame side of connector (X3). See Engine Frame Harness (W5) Wiring Diagram. (Group 9015-10.)

YES: Circuit X01 YEL short to pin that indicated continuity on engine frame harness (W5). Repair circuit X01 YEL or replace harness. NO: Go to next step in this check.

Is continuity indicated between any pins?

Key switch OFF. Load center-to-engine frame harness connector (X3) disconnected. Disconnect flex load controller (FLC) connectors (X40, X41, and X42). See Load Center Harness (W3) Component Location. (Group 9015-10.) Check for continuity between pin D4 (circuit X01 YEL) on connector FLC (X42) and remaining pins on connectors (X40, X41, and X42). See Load Center Harness (W3) Wiring Diagram. (Group 9015-10.)

YES: Circuit X01 YEL short to pin that indicated continuity on load center harness (W3). Repair circuit X01 YEL or replace harness. NO: Go to Reprogram Controller.

Is continuity indicated between any pins?

– – –1/1

4 Reprogram Controller

Reprogram flex load controller (FLC). See Electronic Controller Reconfiguration. (Group 9015-20.)

YES: Replace controller. NO: Checks complete.

Check for active codes. Is FLC code 001638.04 present? – – –1/1

TM10229 (17MAR09)

9001-40-52

544J Loader (S.N. 611800— ) 032409

PN=274

Flex Load Controller (FLC) Diagnostic Trouble Codes

001713.01 — Hyd Oil Filter Restricted

Hydraulic oil filter is restricted.

9001 40 53

TF44157,000005F –19–13MAR08–1/1

Hydraulic Oil Filter Restricted Diagnostic Procedure Alarm Level: Hydraulic Oil Filter Icon

– – –1/1

1 Component Check

Turn key switch OFF. Remove hydraulic oil filter restriction switch (B21). See Engine Frame Harness (W5) Component Location. (Group 9015-10.) Check continuity of switch between switch pin and frame ground. See Engine Frame Harness (W5) Wiring Diagram. (Group 9015-10.)

YES: Replace hydraulic oil filter restriction switch (B21). NO: Go to Short Circuit Check.

Is continuity indicated?

– – –1/1

TM10229 (17MAR09)

9001-40-53

544J Loader (S.N. 611800— ) 032409

PN=275

Flex Load Controller (FLC) Diagnostic Trouble Codes 2 Short Circuit Check

Turn key switch OFF.

YES: Go to next step in this check.

Disconnect hydraulic oil filter restriction switch (B21). See Engine Frame Harness (W5) Component Location. (Group 9015-10.)

NO: Go to Continuity Check.

Check circuit N01 YEL for ground at pin on hydraulic oil filter restriction switch (B21). See Engine Frame Harness (W5) Wiring Diagram. (Group 9015-10.)

9001 40 54

Is ground present?

Key switch OFF. Disconnect load center-harness-to-engine frame harness (X3). See Load Center Harness (W3) Component Location. (Group 9015-10.) Check circuit N01 YEL for ground at pin 13 on load center side of harness (X3). See Load Center Harness (W3) Wiring Diagram. (Group 9015-10.) Is ground present?

YES: Circuit N01 YEL short to ground on load center harness (W3). Repair circuit N01 YEL or replace harness. NO: Circuit N01 YEL short to ground on engine frame harness (W5). Repair circuit N01 YEL or replace harness. – – –1/1

3 Continuity Check

Turn key switch OFF. Disconnect hydraulic oil filter restriction switch (B21) and load center-harness-to-engine frame harness (X3). See Engine Frame Harness (W5) Component Location. (Group 9015-10.) Check continuity between pin 13 (circuit N01 YEL) on engine frame harness side of connector (X3) and remaining pins on engine frame side of connector (X3). See Engine Frame Harness (W5) Wiring Diagram. (Group 9015-10.)

YES: Circuit N01 YEL short to pin that indicated continuity on engine frame harness (W5). Repair circuit N01 YEL or replace harness. NO: Go to next step in this check.

Is continuity indicated between any pins?

Key switch OFF. Load center-harness-to-engine frame harness (X3) disconnected. Disconnect flex load controller (FLC) connectors (X40, X41, and X42). See Load Center Harness (W3) Component Location. (Group 9015-10.) Check continuity between pin F2 (circuit N01 YEL) on FLC connector (X41) and remaining pins on FLC connectors (X40, X41, and X42). See Load Center Harness (W3) Wiring Diagram. (Group 9015-10.)

YES: Circuit N01 YEL short to pin that indicated continuity on load center harness (W3). Repair circuit N01 YEL or replace harness. NO: Go to Reprogram Controller.

Is continuity indicated between any pins?

– – –1/1

4 Reprogram Controller

Reprogram flex load controller (FLC). See Electronic Controller Reconfiguration. (Group 9015-20.)

YES: Replace controller. NO: Checks complete.

Check for active codes. Is FLC code 001713.01 present? – – –1/1

TM10229 (17MAR09)

9001-40-54

544J Loader (S.N. 611800— ) 032409

PN=276

Flex Load Controller (FLC) Diagnostic Trouble Codes

001762.03 — Hyd Pressure Short to Power

Hydraulic system pressure sensor circuit is short to power.

9001 40 55

TF44157,0000060 –19–13MAR08–1/1

Hydraulic Pressure Short to Power Diagnostic Procedure Alarm Level: No Warning Lamp

– – –1/1

1 Component Check

Install frame articulation locking bar.

YES: Go to Reprogram Controller.

Install JT02156A Digital Pressure and Temperature Analyzer and connect 5000 psi pressure transducer to pump outlet pressure quick coupler. Perform Digital Pressure and Temperature Analyzer Installation procedure. (Group 9025-25.)

NO: Go to Short Circuit Check.

Using the CAN monitor unit CMU, view the input readings for hydraulic oil pressure from the flex load controller (FLC). Enter the Main Menu / Diagnostics / Hydraulic / Hyd Sys Press. See CAN Monitor Unit (CMU) Menu Structure—Service Mode. (Group 9015-20.) Start engine and curl bucket. Compare the reading on the CMU with the live reading from the digital pressure analyzer. Does the CMU reading match the digital pressure analyzer reading?

– – –1/1

TM10229 (17MAR09)

9001-40-55

544J Loader (S.N. 611800— ) 032409

PN=277

Flex Load Controller (FLC) Diagnostic Trouble Codes 2 Short Circuit Check

Turn key switch OFF.

YES: Go to next step in this check.

Disconnect hydraulic oil pressure sensor (B8). See Engine Frame Harness (W5) Component Location. (Group 9015-10.)

NO: Go to Continuity Check.

Turn key switch ON.

9001 40 56

Check circuit P69 RED at pin B and circuit N05 YEL at pin C for voltage on hydraulic pressure sensor (B8) connector. See Engine Frame Harness (W5) Wiring Diagram. (Group 9015-10.) Is system voltage present?

Turn key switch OFF. Disconnect load center harness-to-engine frame harness connector (X3). See Engine Frame Harness (W5) Component Location. (Group 9015-10.) Turn key switch ON. Check circuit P69 RED at pin 28 and circuit N05 YEL at pin 16 for voltage on load center harness side of connector (X3). See Load Center Harness (W3) Wiring Diagram. (Group 9015-10.) Is system voltage present?

YES: Short to power on circuit that indicated system voltage on load center harness (W3). Repair circuit or replace harness. NO: Short to power on circuit that indicated system voltage on engine frame harness (W5). Repair circuit or replace harness.

– – –1/1

3 Continuity Check

Turn key switch OFF. Disconnect load center harness-to-engine frame harness connector (X3). See Engine Frame Harness (W5) Component Location. (Group 9015-10.) Check continuity between pin 16 (circuit N05 YEL) on engine frame harness side of connector (X3) and remaining pins on connector (X3).

YES: Circuit N05 YEL short to pin that indicated continuity on engine frame harness (W5). Repair circuit N05 YEL or replace harness. NO: Go to next step in this check.

Is continuity indicated between any pins?

Key switch OFF. Disconnect flex load controller (FLC) connectors (X40, X41, and X42). See Load Center Harness (W3) Component Location. (Group 9015-10.) Check continuity between pin D3 (circuit N05 YEL) on FLC connector (X41) and remaining pins on connectors (X40, X41, and X42).

YES: Circuit N05 YEL short to pin that indicated continuity on load center harness (W3). Repair circuit N05 YEL or replace harness. NO: Go to Reprogram Controller.

Is continuity indicated between any pins?

– – –1/1

4 Reprogram Controller

Reprogram flex load controller (FLC). See Electronic Controller Reconfiguration. (Group 9015-20.)

YES: Replace controller. NO: Checks complete.

Check for active codes. Is FLC code 001762.03 present? – – –1/1

TM10229 (17MAR09)

9001-40-56

544J Loader (S.N. 611800— ) 032409

PN=278

Flex Load Controller (FLC) Diagnostic Trouble Codes

001762.04 — Hyd Pressure Open or Short

Hydraulic system pressure sensor circuit is open or short to ground.

9001 40 57

TF44157,0000061 –19–13MAR08–1/1

Hydraulic Pressure Open or Short Diagnostic Procedure Alarm Level: No Warning Lamp

– – –1/1

TM10229 (17MAR09)

9001-40-57

544J Loader (S.N. 611800— ) 032409

PN=279

Flex Load Controller (FLC) Diagnostic Trouble Codes 1 Open Circuit Check

Turn key switch OFF.

YES: Go to Short Circuit Check.

Disconnect hydraulic oil pressure sensor (B8) and flex load controller (FLC) connector (X41.) See Load Center Harness (W3) Component Location and See Engine Frame Harness (W5) Component Location. (Group 9015-10.) 9001 40 58

NO: Go to next step in this check.

Check circuit P69 RED for continuity between pin B on hydraulic pressure sensor (B8) connector and pin K4 on FLC connector (X41). See Load Center Harness (W3) Wiring Diagram and see Engine Frame Harness (W5) Wiring Diagram. (Group 9015-10.) Check circuit N06 YEL for continuity between pin C on hydraulic pressure sensor (B8) connector and pin D3 on FLC connector (X41). See Load Center Harness (W3) Wiring Diagram and see Engine Frame Harness (W5) Wiring Diagram. (Group 9015-10.) Check circuit R69 BLK for continuity between pin A on hydraulic pressure sensor (B8) connector and pin K3 on FLC connector (X41). See Load Center Harness (W3) Wiring Diagram and see Engine Frame Harness (W5) Wiring Diagram. (Group 9015-10.) Is continuity indicated on all circuits?

Key switch OFF. Flex load controller (FLC) connector (X41) disconnected. Disconnect load center harness-to-engine frame harness connector (X3). See Engine Frame Harness (W5) Component Location. (Group 9015-10.) Check circuit P69 RED for continuity between pin 28 on load center side of connector (X3) and pin K4 on FLC connector (X41). See Load Center Harness (W3) Wiring Diagram and see Engine Frame Harness (W5) Wiring Diagram. (Group 9015-10.) Check circuit N06 YEL for continuity between pin 16 on load center harness side of connector (X3) and pin D3 on FLC connector (X41). See Load Center Harness (W3) Wiring Diagram and see Engine Frame Harness (W5) Wiring Diagram. (Group 9015-10.)

YES: Open on circuit that did not indicate continuity on engine frame harness (W5). Repair circuit that did not indicate continuity or replace harness. NO: Open on circuit that did not indicate continuity on load center harness (W3). Repair circuit that did not indicate continuity or replace harness.

Check circuit R69 BLK for continuity between pin 21 on load center harness side of connector (X3) and pin K3 on FLC connector (X41). See Load Center Harness (W3) Wiring Diagram and see Engine Frame Harness (W5) Wiring Diagram. (Group 9015-10.) Is continuity indicated on all circuits?

– – –1/1

TM10229 (17MAR09)

9001-40-58

544J Loader (S.N. 611800— ) 032409

PN=280

Flex Load Controller (FLC) Diagnostic Trouble Codes 2 Short Circuit Check

Turn key switch OFF.

YES: Go to next step in this check.

Disconnect hydraulic oil pressure sensor (B8). See Engine Frame Harness (W5) Component Location. (Group 9015-10.)

NO: Go to Continuity Check.

Check circuit P69 RED at pin B and circuit N05 YEL at pin C for ground on hydraulic pressure sensor (B8) connector. See Engine Frame Harness (W5) Wiring Diagram. (Group 9015-10.)

9001 40 59

Is ground present?

Key switch OFF. Disconnect load center harness-to-engine frame harness connector (X3). See Engine Frame Harness (W5) Component Location. (Group 9015-10.) Turn key switch ON. Check circuit P69 RED at pin 28 and circuit N05 YEL at pin 16 for ground on load center harness side of connector (X3). See Load Center Harness (W3) Wiring Diagram. (Group 9015-10.) Is ground present?

– – –1/1

3 Continuity Check

YES: Circuit N05 YEL short to pin that indicated continuity on engine frame harness. Repair circuit N05 YEL or replace harness. NO: Go to next step in this check.

Is continuity indicated between any pins?

YES: Circuit N05 YEL short to pin that indicated continuity on load center harness (W3). Repair circuit N05 YEL or replace harness. NO: Go to Reprogram Controller.

Is continuity indicated between any pins?

– – –1/1

4 Reprogram Controller

Reprogram flex load controller (FLC). See Electronic Controller Reconfiguration. (Group 9015-20.)

YES: Replace controller. NO: Checks complete.

Check for active codes. Is FLC code 001762.04 present? – – –1/1

TM10229 (17MAR09)

9001-40-59

544J Loader (S.N. 611800— ) 032409

PN=281

Flex Load Controller (FLC) Diagnostic Trouble Codes

002000.09 — CAN Comm Lost for ECU

9001 40 60

CAN communication error; the flex load controller (FLC) has lost communication with the engine control unit (ECU).

TF44157,0000062 –19–13MAR08–1/1

CAN Communication Lost For ECU Diagnostic Procedure Alarm Level: No Warning Lamp

– – –1/1

1 Controller Sensors Check

Using the CAN monitor unit (H2), view the input readings from the engine control unit. Enter the Main Menu / Diagnostics / Engine Sensors / Display All. See CAN Monitor Unit (CMU) Menu Structure—Service Mode. (Group 9015-20.)

YES: Go to Reprogram Flex Load Controller. NO: Go to Fuse Check.

Are engine sensor values displayed in the CMU? – – –1/1

2 Fuse Check

Turn key switch OFF.

YES: Go to Circuit Check.

Check fuses (F03 and F10) for continuity. See Fuse and Relay Specifications. (Group 9015-10.)

NO: Replace fuse(s).

Is continuity indicated? – – –1/1

TM10229 (17MAR09)

9001-40-60

544J Loader (S.N. 611800— ) 032409

PN=282

Flex Load Controller (FLC) Diagnostic Trouble Codes 3 Circuit Check

Turn key switch OFF.

YES: Go to next step in this check.

Disconnect ECU connector (X72). See Load Center Harness (W3) Component Location. (Group 9015-10.)

NO: Circuit P03 RED open on load center harness (W3). Repair 9001 circuit or replace harness. 40 61

Turn key switch ON. Check for voltage at the following pins: • L1—circuit P03 RED • L4—circuit P03 RED • M1—circuit P03 RED • M4—circuit P03 RED Is voltage present at all the pins?

Key switch OFF.

YES: Go to next step in this check.

ECU connector (X72) disconnected. See Load Center Harness (W3) Component Location. (Group 9015-10.) Check for ground at the following pins:

NO: Ciruit G11 BLK open on load center harness (W3). Repair circuit or replace harness.

• L2—circuit G11 BLK • L3—circuit G11 BLK • M2—circuit G11 BLK Is ground present at all the pins?

Perform CAN Circuit Test. (Group 9015-20.)

YES: Go to Reprogram Engine Control Unit.

Does the CAN circuit test good. NO: Repair CAN circuit or replace harness.

– – –1/1

4 Reprogram Engine Control Unit

Reprogram engine control unit (ECU).

YES: Replace controller.

Check for active codes.

NO: Checks complete.

Is FLC code 002000.09 present? – – –1/1

5 Reprogram Flex Load controller

Reprogram flex load controller (FLC). See Electronic Controller Reconfiguration. (Group 9015-20.)

YES: Replace controller. NO: Checks complete.

Check for active codes. Is FLC code 002000.09 present? – – –1/1

TM10229 (17MAR09)

9001-40-61

544J Loader (S.N. 611800— ) 032409

PN=283

Flex Load Controller (FLC) Diagnostic Trouble Codes

002003.09 — CAN Comm Lost for TCU

9001 40 62

CAN communication error; the flex load controller (FLC) has lost communication with the transmission control unit (TCU).

TF44157,0000063 –19–13MAR08–1/1

CAN Communication Lost for TCU Diagnostic Procedure Alarm Level: No Warning Lamp

– – –1/1

1 Controller Sensors Check

YES: Go to Reprogram Flex Load Controller. NO: Go to Fuse Check.

Are transmission sensor values displayed in the CMU? – – –1/1

2 Fuse Check

Turn key switch OFF.

YES: Go to Circuit Check.

Check fuses (F18 and F28) for continuity. See Fuse and Relay Specifications. (Group 9015-10.)

NO: Replace fuse(s).

Is continuity indicated? – – –1/1

TM10229 (17MAR09)

9001-40-62

544J Loader (S.N. 611800— ) 032409

PN=284

Flex Load Controller (FLC) Diagnostic Trouble Codes 3 Circuit Check

Turn key switch OFF.

YES: Go to next step in this check.

Disconnect TCU connector (X23). See Load Center Harness (W3) Component Location. (Group 9015-10.)

NO: Circuit P28 RED or P18 RED open on load center harness (W3). Repair circuit(s) or replace harness.

Turn key switch ON. Check for voltage at the following pins: • 45—circuit P28 RED • 23—circuit P18 RED • 68—circuit P18 RED Is voltage present at all the pins?

Key switch OFF.

YES: Go to next step in this check.

TCU connector (X23) disconnected. See Load Center Harness (W3) Component Location. (Group 9015-10.) Check for ground at the following pins: • L2—circuit G11 BLK • L3—circuit G11 BLK • M2—circuit G11 BLK

NO: Circuit G11 BLK open on load center harness (W3). Repair circuit(s) or replace harness.

Is ground present at all the pins?

Perform CAN Circuit Test. (Group 9015-20.)

YES: Go to Reprogram Transmission Control Unit.

Does the CAN circuit test good.

NO: Repair CAN circuit or replace harness.

– – –1/1

4 Reprogram Transmission Control Unit

Reprogram transmission control unit (TCU).

YES: Replace controller.

Check for active codes.

NO: Checks complete.

Is FLC code 002003.09 present? – – –1/1

5 Reprogram Flex Load Controller

Reprogram flex load controller (FLC). See Electronic Controller Reconfiguration. (Group 9015-20.)

YES: Replace controller. NO: Checks complete.

Check for active codes. Is FLC code 002003.09 present? – – –1/1

TM10229 (17MAR09)

9001-40-63

544J Loader (S.N. 611800— ) 032409

PN=285

9001 40 63

Flex Load Controller (FLC) Diagnostic Trouble Codes

002023.09 — CAN Comm Lost for CMU

9001 40 64

CAN communication error; the flex load controller (FLC) has lost communication with the CAN monitor unit (CMU).

TF44157,0000064 –19–13MAR08–1/1

CAN Communication Lost for CMU Diagnostic Procedure Alarm Level: No Warning Lamp

– – –1/1

1 Component Check

Turn key switch ON.

YES: Go to Code Check.

Is CAN monitor unit (CMU) display visible?

NO: Go to Fuse Check.

– – –1/1

TM10229 (17MAR09)

9001-40-64

544J Loader (S.N. 611800— ) 032409

PN=286

Flex Load Controller (FLC) Diagnostic Trouble Codes 2 Code Check

Connect Service ADVISOR. See Service ADVISOR Connection Procedure. (Group 9015-20.)

YES: Go to Reprogram Flex Load Controller.

From the Service ADVISOR main screen, record the controllers that are communicating with Service ADVISOR.

NO: Go to next step in this check. 9001 40 65

Is the CMU present in the list?

View codes with Service ADVISOR.

YES: Go to next step in this check.

Is the transmission control unit (TCU) reporting code 002023.09—CAN Comm Lost for CMU?

Check connector on CMU and perform CAN Circuit Test. (Group 9015-20.)

NO: Go to Reprogram CAN Monitor Unit.

YES: Go to Reprogram Flex Load Controller.

Do the CAN circuit and connector test good? NO: Repair or replace connector or wires on CAN circuit.

Service ADVISOR is a trademark of Deere & Company

3 Fuse Check

– – –1/1

Turn key switch OFF.

YES: Go to Circuit Check.

Check fuses (F13 and F34) for continuity. See Fuse and Relay Specifications. (Group 9015-10.)

NO: Replace fuse(s).

Is continuity indicated? – – –1/1

4 Circuit Check

Turn key switch OFF.

YES: Go to next step in this check.

Disconnect CMU connector (X48). See Load Center Harness (W3) Component Location. (Group 9015-10.) Turn key switch ON. Check circuit P34 RED for voltage at pin A and circuit P13 RED at pin L on CMU connector (X48).

NO: Circuits P13 RED or P34 RED open on load center harness (W3). Repair circuit(s) or replace harness.

Is voltage present at both pins?

Turn key switch OFF.

YES: Go to Reprogram CAN Monitor Unit.

CMU connector (X48) disconnected. See Load Center Harness (W3) Component Location. (Group 9015-10.) Check circuit G01 BLK for ground at pin P on connector (X48). Is ground present?

NO: Circuit G01 BLK open circuit on load center harness (W3). Repair circuit or replace harness.

– – –1/1

TM10229 (17MAR09)

9001-40-65

544J Loader (S.N. 611800— ) 032409

PN=287

Flex Load Controller (FLC) Diagnostic Trouble Codes 5 Reprogram Flex Load Controller

Reprogram flex load controller (FLC). See Electronic Controller Reconfiguration. (Group 9015-20.)

YES: Replace controller. NO: Checks complete.

Check for active codes. Is FLC code 002023.09 present?

9001 40 66

– – –1/1

6 Reprogram CAN Monitor Unit

Reprogram CAN monitor unit (CMU).

YES: Replace controller.

Check for active codes.

NO: Checks complete.

Is FLC code 002023.09 present? – – –1/1

002140.09 — CAN Comm Lost for SSM

CAN communication error; the flex load controller (FLC) has lost communication with the sealed switch module (SSM).

TF44157,0000065 –19–13MAR08–1/1

CAN Communication Lost for SSM Diagnostic Procedure Alarm Level: No Warning Lamp

– – –1/1

1 Controller Sensors Check

Using the CAN monitor unit (H2), perform SSM test. See Monitor Display Unit—Main Menu—Diagnostics—Switch Module. (Operator’s Manual.)

YES: Go to Reprogram Flex Load Controller.

Does the SSM test good?

NO: Go to Fuse Check.

– – –1/1

2 Fuse Check

Turn key switch OFF.

YES: Go to Circuit Check.

Check fuse (F13) for continuity. See Fuse and Relay Specifications. (Group 9015-10.) NO: Replace fuse. Is continuity indicated? – – –1/1

TM10229 (17MAR09)

9001-40-66

544J Loader (S.N. 611800— ) 032409

PN=288

Flex Load Controller (FLC) Diagnostic Trouble Codes 3 Circuit Check

Turn key switch OFF.

YES: Go to next step in this check.

Disconnect SSM connector (X53). See Load Center Harness (W3) Component Location. (Group 9015-10.) Turn key switch ON. Check circuit P13 RED for voltage at pin 1 on connector (X53). See Load Center Harness (W3) Wiring Diagram. (Group 9015-10.)

NO: Circuit P13 RED open circuit on load center harness (W3). 9001 Repair circuit P13 RED or 40 replace harness. 67

Is voltage present?

Key switch OFF.

YES: Go to next step in this check.

SSM connector (X53) disconnected. See Load Center Harness (W3) Component Location. (Group 9015-10.) Check circuit G01 BLK for ground at pin 2 on connector (X53). See Load Center Harness (W3) Wiring Diagram. (Group 9015-10.)

NO: Circuit G01 BLK open on load center harness (W3). Repair circuit G01 BLK or replace harness.

Is ground present?

Perform CAN Circuit Test. (Group 9015-20.)

YES: Go to Reprogram Sealed Switch Module.

Does the CAN circuit test good? NO: Repair CAN circuits or replace harness.

– – –1/1

4 Reprogram Sealed Switch Module

Reprogram sealed switch module (SSM).

YES: Replace controller.

Check for active codes.

NO: Checks complete.

Is FLC code 002140.09 present? – – –1/1

5 Reprogram Flex Load Controller

Reprogram flex load controller (FLC). See Electronic Controller Reconfiguration. (Group 9015-20.)

YES: Replace controller. NO: Checks complete.

Check for active codes. Is FLC code 002140.09 present? – – –1/1

002350.05 — Drive Lamps Open or Short

Drive lamp circuit is open or short to power.

TF44157,0000066 –19–13MAR08–1/1

TM10229 (17MAR09)

9001-40-67

544J Loader (S.N. 611800— ) 032409

PN=289

Flex Load Controller (FLC) Diagnostic Trouble Codes Drive Lamps Open or Short Diagnostic Procedure Alarm Level: 9001 40 68

No Warning Lamp

– – –1/1

1 Component Check

Turn key switch OFF.

YES: Go to Short Circuit Check.

Disconnect and remove drive lamp (E11 or E12). See Loader Frame Harness (W2) Component Location. (Group 9015-10.)

NO: Replace drive lamp as necessary.

Apply 24 volts to pin A and ground to pin C of malfunctioning drive lamp. Does drive lamp illuminate?

– – –1/1

2 Short Circuit Check

Turn key switch OFF.

YES: Go to next step in this check.

Disconnect left or right drive lamp (E11 or E12). See Loader Frame Harness (W2) Component Location. (Group 9015-10.)

NO: Go to Open Circuit Check.

Turn key switch ON. Verify drive lamps are OFF. Check circuit L19 BRN (left lamp) at pin A for system voltage. See Loader Frame Harness (W2) Wiring Diagram. (Group 9015-10.) Check circuit L27 BRN (right lamp) at pin A for system voltage. Is system voltage present at either pin?

Turn key switch OFF. Disconnect load center harness-to-loader frame harness connector (X67). See Loader Frame Harness (W2) Component Location. (Group 9015-10.) Turn key switch ON. Check circuit L19 BRN (left lamp) at pin 3 on load center harness side of connector (X67) for system voltage. See Load Center Harness (W3) Wiring Diagram. (Group 9015-10.) Check circuit L27 BRN (right lamp) at pin 2 on load center harness side of connector (X67) for system voltage.

YES: Short to power on circuit that has system voltage present on load center harness (W3). Repair circuit or replace harness. NO: Short to power on circuit that has system voltage present on loader frame harness (W5). Repair circuit or replace harness.

Is system voltage present at either pin? – – –1/1

TM10229 (17MAR09)

9001-40-68

544J Loader (S.N. 611800— ) 032409

PN=290

Flex Load Controller (FLC) Diagnostic Trouble Codes 3 Open Circuit Check

Turn key switch OFF.

YES: Go to next step in this check.

Disconnect drive lamp (E11 or E12) and load center harness-to-loader frame harness connector (X67). See Loader Frame Harness (W2) Component Location. (Group 9015-10.) Check circuit L27 BRN for continuity between pin A on left drive lamp connector and pin 3 on loader frame harness side of connector (X67). See Loader Frame Harness (W2) Wiring Diagram. (Group 9015-10.)

NO: Open on circuit that did not indicate continuity on loader frame harness 9001 (W5). Repair circuit with 40 no continuity or replace 69 harness.

Check circuit L19 BRN for continuity between pin A on right drive lamp connector and pin 2 on loader frame harness side of connector (X67). See Loader Frame Harness (W2) Wiring Diagram. (Group 9015-10.) Check circuit G05 BLK for continuity between pin C on right and left drive lamp connector and frame ground. See Loader Frame Harness (W2) Wiring Diagram. (Group 9015-10.) Is continuity indicated?

Key switch OFF.

YES: Go to Continuity Check.

Load center harness-to-loader frame harness connector (X67) disconnected. Disconnect flex load controller (FLC) connector (X40). See Load Center Harness (W3) Component Location. (Group 9015-10.) Check circuit L27 BRN for continuity between pin A4 of FLC connector (X40) and pin 3 on load center side of connector (X67). See Loader Frame Harness (W2) Wiring Diagram. (Group 9015-10.)

NO: Open on circuit that did not indicate continuity on load center harness (W3). Repair circuit with no continuity or replace harness.

Check circuit L19 BRN for continuity between pin A3 of FLC connector (X40) and pin 2 on load center side of connector (X67). See Load Center Harness (W3) Wiring Diagram. (Group 9015-10.) Is continuity indicated?

– – –1/1

TM10229 (17MAR09)

9001-40-69

544J Loader (S.N. 611800— ) 032409

PN=291

Flex Load Controller (FLC) Diagnostic Trouble Codes 4 Continuity Check

Turn key switch OFF.

Disconnect drive lamp (E11 or E12). See Loader Frame Harness (W2) Component Location. (Group 9015-10.)

YES: Short circuit between pins that indicated continuity on loader frame harness (W5). Repair circuit or replace harness.

Disconnect load center harness-to-loader frame harness connector (X67). See Load Center Harness (W3) Wiring Diagram. (Group 9015-10.)

NO: Go to next step in this check.

Identify lamp that is malfunctioning.

9001 40 70

Check for continuity between pin 3 (circuit L27 BRN) on loader frame harness side of connector (X67) and the remaining pins on loader frame side of connector (X67). See Loader Frame Harness (W2) Wiring Diagram. (Group 9015-10.) Check for continuity between pin 2 (circuit L19 BRN) on loader frame harness side of connector (X67) and the remaining pins on loader frame side of connector (X67). See Loader Frame Harness (W2) Wiring Diagram. (Group 9015-10.) Is continuity indicated between any pins?

Key switch OFF.

YES: Short circuit between pins that indicated continuity on load center harness (W3). Repair circuit or replace harness.

Load center harness-to-loader frame harness connector (X67) disconnected. Disconnect flex load center (FLC) connectors (X40, X41, and X42). See Load Center Harness (W3) Component Location. (Group 9015-10.) Check for continuity between pin A4 (circuit L27 BRN) of FLC connector (X40) and the remaining pins on connectors (X40, X41, and X42). See Load Center Harness (W3) Wiring Diagram. (Group 9015-10.)

NO: Go to Reprogram Controller.

Check for continuity between pin A3 (circuit L19 BRN) of FLC connector (X40) and the remaining pins on connectors (X40, X41, and X42). See Load Center Harness (W3) Wiring Diagram. (Group 9015-10.) Is continuity indicated between any pins?

– – –1/1

5 Reprogram Controller

Reprogram flex load controller (FLC). See Electronic Controller Reconfiguration. (Group 9015-20.)

YES: Replace controller. NO: Checks complete.

Check for active codes. Is FLC code 002350.05 present? – – –1/1

002350.06 — Drive Lamps High Current

Drive lamp circuit is short to ground.

TF44157,0000067 –19–13MAR08–1/1

TM10229 (17MAR09)

9001-40-70

544J Loader (S.N. 611800— ) 032409

PN=292

Flex Load Controller (FLC) Diagnostic Trouble Codes Drive Lamps High Current Diagnostic Procedure Alarm Level: No Warning Lamp

9001 40 71

– – –1/1

1 Component Check

Turn key switch OFF.

YES: Go to Short Circuit Check.

Identify lamp that is malfunctioning. Disconnect and remove drive lamp (E11 or E12). See Loader Frame Harness (W2) Component Location. (Group 9015-10.)

NO: Replace drive lamp as necessary.

Apply 24 volts to pin A and ground to pin C of drive light. Does drive light illuminate?

– – –1/1

2 Short Circuit Check

Turn key switch OFF.

YES: Go to next step in this check.

Identify lamp that is malfunctioning. Disconnect left or right drive lamp (E11 or E12). See Loader Frame Harness (W2) Component Location. (Group 9015-10.)

NO: Go to Continuity Check.

Verify drive lamps are OFF. Check circuit L19 BRN (left lamp) at pin A for ground. See Loader Frame Harness (W2) Wiring Diagram. (Group 9015-10.) Check circuit L27 BRN (right lamp) at pin A for ground. Is there ground present at either pin?

Key switch OFF. Disconnect load center harness-to-loader frame harness connector (X67). See Load Center Harness (W3) Component Location. (Group 9015-10.) Check circuit L19 BRN (left lamp) at pin 3 on load center harness side of connector (X67) for ground. Check circuit L27 BRN (right lamp) at pin 2 on load center harness side of connector (X67) for ground.

YES: Short to ground on circuit that has ground present on load center harness (W3). Repair circuit or replace harness. NO: Short to ground on circuit that has ground present on loader frame harness (W5). Repair circuit or replace harness.

Is there ground present at either pin?

– – –1/1

TM10229 (17MAR09)

9001-40-71

544J Loader (S.N. 611800— ) 032409

PN=293

Flex Load Controller (FLC) Diagnostic Trouble Codes 3 Continuity Check

Turn key switch OFF.

Disconnect drive lamp (E11 or E12). See Loader Frame Harness (W2) Component Location. (Group 9015-10.)

YES: Short circuit between pins that indicated continuity on loader frame harness (W5). Repair circuit or replace harness.

Disconnect load center harness-to-loader frame harness connector (X67). See Load Center Harness (W3) Wiring Diagram. (Group 9015-10.)

NO: Go to next step in this check.

Identify lamp that is malfunctioning.

9001 40 72

Key switch OFF.

YES: Short circuit between pins that indicated continuity on load center harness (W3). Repair circuit or replace harness.

NO: Go to Reprogram Controller.

– – –1/1

4 Reprogram Controller

Reprogram flex load controller (FLC). See Electronic Controller Reconfiguration. (Group 9015-20.)

YES: Replace controller. NO: Checks complete.

Check for active codes. Is FLC code 002350.06 present? – – –1/1

002355.05 — Front Work Lts Open or Short

Auxiliary light circuit is open or short to power.

TF44157,0000068 –19–13MAR08–1/1

TM10229 (17MAR09)

9001-40-72

544J Loader (S.N. 611800— ) 032409

PN=294

Flex Load Controller (FLC) Diagnostic Trouble Codes Auxiliary Lights Open or Short Diagnostic Procedure Alarm Level: No Warning Lamp

9001 40 73

– – –1/1

1 Component Check

Turn key switch OFF.

YES: Go to Short Circuit Check.

Identify malfunctioning auxiliary light. Disconnect and remove malfunctioning drive light (E24 or E25). See Cab Roof Harness (W19) Component Location. (Group 9015-10.)

NO: Replace auxiliary light as necessary.

Apply 24 volts to pin 1 and ground to pin 2 of malfunctioning drive light. Does drive light illuminate?

– – –1/1

TM10229 (17MAR09)

9001-40-73

544J Loader (S.N. 611800— ) 032409

PN=295

Flex Load Controller (FLC) Diagnostic Trouble Codes 2 Short Circuit Check

NOTE: Identify the auxiliary light that is malfunctioning. Follow the procedure for that light.

YES: Go to next step in this check.

Turn key switch OFF.

NO: Go to Open Circuit Check.

Left auxiliary light (E24):

9001 40 74

• Disconnect auxiliary light (E24). See Cab Roof Harness (W19) Component Location. (Group 9015-10.) • Turn key switch ON. • Verify auxiliary lights are off. • Check circuit L28 BRN for voltage at pin 1 on left auxiliary light connector. See Cab Roof Harness (W19) Wiring Diagram. (Group 9015-10.) Right auxiliary light (E25): • Disconnect auxiliary light (E25). See Cab Roof Harness (W19) Component Location. (Group 9015-10.) • Turn key switch ON. • Verify auxiliary lights are off. • Check circuit L29 BRN for voltage at pin 1 on right auxiliary light connector. See Cab Roof Harness (W19) Wiring Diagram. (Group 9015-10.) Is system voltage present?

Key switch OFF. Left auxiliary light (E24): • Disconnect load center harness-to-cab roof 12-pin harness connector (X5). See Load Center Harness (W3) Component Location. (Group 9015-10.) • Turn key switch ON. • Verify auxiliary lights are off. • Check circuit L28 BLK at pin 1 for voltage on load center harness side of connector (X5). See Load Center Harness (W3) Wiring Diagram. (Group 9015-10.)

YES: Short to power on circuit that has voltage present on load center harness (W3). Repair circuit or replace harness. NO: Short to power on circuit that has voltage present on cab roof harness (W19). Repair circuit or replace harness.

Right auxiliary light (E25): • Disconnect load center harness-to-cab roof 4-pin harness connector (X6). See Load Center Harness (W3) Component Location. (Group 9015-10.) • Turn key switch ON. • Verify auxiliary lights are off. • Check circuit L29 BLK at pin 3 for voltage on load center harness side of connector (X6). See Load Center Harness (W3) Wiring Diagram. (Group 9015-10.) Is system voltage present?

– – –1/1

TM10229 (17MAR09)

9001-40-74

544J Loader (S.N. 611800— ) 032409

PN=296

Flex Load Controller (FLC) Diagnostic Trouble Codes 3 Open Circuit Check

NOTE: Identify the auxiliary light that is malfunctioning. Follow the procedure for that light.

YES: Go to next step in this check.

Turn key switch OFF.

NO: Open on circuit that does not indicate continuity on cab roof 9001 harness (W19). Repair 40 circuit or replace harness. 75

Left auxiliary light (E24): • Disconnect auxiliary light (E24) and load center harness-to-cab roof 12-pin harness connector (X5). See Cab Roof Harness (W19) Component Location. (Group 9015-10.) • Check circuit L28 BRN for continuity between pin 1 of left auxiliary light connector and pin 1 on cab roof harness side of connector (X5). See Cab Roof Harness (W19) Wiring Diagram. (Group 9015-10.) • Check circuit G04 BLK for continuity between pin 2 of left auxiliary light connector and pin 8 on cab roof harness side of connector (X5). See Cab Roof Harness (W19) Wiring Diagram. (Group 9015-10.) Right auxiliary light (E25): • Disconnect load center harness-to-cab roof 4-pin harness connector (X6). See Cab Roof Harness (W19) Component Location. (Group 9015-10.) • Check circuit L29 BRN for continuity between pin 1 of right auxiliary light connector and pin 3 on cab roof harness side of connector (X6). See Cab Roof Harness (W19) Wiring Diagram. (Group 9015-10.) • Check circuit G04 BLK for continuity between pin 2 of right auxiliary light connector and pin 8 on fcab roof harness side of connector (X5). See Cab Roof Harness (W19) Wiring Diagram. (Group 9015-10.) Is continuity indicated?

Key switch OFF.

YES: Go to Continuity Check.

Left auxiliary light (E24): • Load center harness-to-cab roof 12-pin harness connector (X5) disconnected. • Disconnect flex load controller (FLC) connector (X40). See Load Center Harness (W3) Component Location. (Group 9015-10.) • Check circuit L28 BLK for continuity between pin 1 on load center side of connector (X5) pin F3 of FLC connector (X40). See Load Center Harness (W3) Wiring Diagram. (Group 9015-10.) • Check circuit G04 BLK for continuity between pin 8 on load center side of connector (X5) and frame ground. See Cab Roof Harness (W19) Wiring Diagram. (Group 9015-10.)

NO: Open on circuit that does not indicate continuity on load center harness (W3). Repair circuit or replace harness.

Right auxiliary light (E25): • Load center harness-to-cab roof 4-pin harness connector (X6) disconnected. • Disconnect flex load controller (FLC) connector (X40). See Load Center Harness (W3) Component Location. (Group 9015-10.) • Check circuit L29 BLK for continuity between pin 3 on load center side of connector (X6) pin F4 of FLC connector (X40). See Load Center Harness (W3) Wiring Diagram. (Group 9015-10.) • Check circuit G04 BLK for continuity between pin 8 on load center side of connector (X5) and frame ground. See Cab Roof Harness (W19) Wiring Diagram. (Group 9015-10.) Is continuity indicated? – – –1/1

TM10229 (17MAR09)

9001-40-75

544J Loader (S.N. 611800— ) 032409

PN=297

Flex Load Controller (FLC) Diagnostic Trouble Codes 4 Continuity Check

NOTE: Identify the auxiliary light that is malfunctioning. Follow the procedure for that light. Turn key switch OFF. Left auxiliary light (E24):

9001 40 76

• Disconnect auxiliary light (E24) and load center harness-to-cab roof 12-pin harness connector (X5). See Cab Roof Harness (W19) Component Location. (Group 9015-10.) • Check continuity between pin 1 (circuit L28 BRN) on cab roof harness side of connector (X5) and remaining pins on cab roof harness side of connector (X5). See Cab Roof Harness (W19) Wiring Diagram. (Group 9015-10.)

YES: Short circuit between pins that indicated continuity on cab roof harness (W19). Repair circuit or replace harness. NO: Go to next step in this check.

Right auxiliary light (E25): • Disconnect load center harness-to-cab roof 4-pin harness connector (X6). See Cab Roof Harness (W19) Component Location. (Group 9015-10.) • Check continuity between pin 3 (circuit L29 BRN) on cab roof harness side of connector (X6) and remaining pins on cab roof harness side of connector (X6). See Cab Roof Harness (W19) Wiring Diagram. (Group 9015-10.) Is continuity indicated between any pins?

Key switch OFF. Left auxiliary light (E24): • Load center harness-to-cab roof 12-pin harness connector (X5) disconnected. • Disconnect flex load controller (FLC) connectors (X40, X41, and X42). See Load Center Harness (W3) Component Location. (Group 9015-10.) • Check for continuity between pin F3 (circuit L28 BLK) on FLC connector (X40) and remaining pins on connectors (X40, X41, and X42). See Load Center Harness (W3) Wiring Diagram. (Group 9015-10.)

YES: Short circuit between pins that indicated continuity on load center harness (W3). Repair circuit or replace harness. NO: Go to Reprogram Controller.

Right auxiliary light (E25): • Load center harness-to-cab roof 4-pin harness connector (X6) disconnected. • Disconnect flex load controller (FLC) connectors (X40, X41, and X42). See Load Center Harness (W3) Component Location. (Group 9015-10.) • Check for continuity between pin F4 (circuit L29 BLK) on FLC connector (X40) and remaining pins on connectors (X40, X41, and X42). See Load Center Harness (W3) Wiring Diagram. (Group 9015-10.) Is continuity indicated between any pins?

– – –1/1

5 Reprogram Controller

Reprogram flex load controller (FLC). See Electronic Controller Reconfiguration. (Group 9015-20.)

YES: Replace controller. NO: Checks complete.

Check for active codes. Is FLC code 002355.05 present? – – –1/1

TM10229 (17MAR09)

9001-40-76

544J Loader (S.N. 611800— ) 032409

PN=298

Flex Load Controller (FLC) Diagnostic Trouble Codes

002355.06 — Front Work Lts High Current

Auxiliary lights circuit is short to ground.

9001 40 77

TF44157,0000069 –19–13MAR08–1/1

Auxiliary Lights High Current Diagnostic Procedure Alarm Level: No Warning Lamp

– – –1/1

1 Component Check

Identify auxiliary light that does not illuminate.

YES: Go to Short Circuit Check.

Turn key switch OFF. Disconnect and remove auxiliary light (E24 or E25). See Cab Roof Harness (W19) Component Location. (Group 9015-10.)

NO: Replace auxiliary light as necessary.

Apply 24 volts to pin 1 and ground to pin 2 of malfunctioning auxiliary light. Does auxiliary light illuminate?

– – –1/1

TM10229 (17MAR09)

9001-40-77

544J Loader (S.N. 611800— ) 032409

PN=299

Flex Load Controller (FLC) Diagnostic Trouble Codes 2 Short Circuit Check

NOTE: Identify the auxiliary light that is malfunctioning. Follow the procedure for that light.

YES: Go to next step in this check.

Turn key switch OFF.

NO: Go to Continuity Check.

Left auxiliary light (E24):

9001 40 78

• Disconnect auxiliary light (E24). See Cab Roof Harness (W19) Component Location. (Group 9015-10.) • Check circuit L28 BRN for ground at pin 1 on left auxiliary light connector. See Cab Roof Harness (W19) Wiring Diagram. (Group 9015-10.) Right auxiliary light (E25): • Disconnect auxiliary light (E25). See Cab Roof Harness (W19) Component Location. (Group 9015-10.) • Check circuit L29 BRN for ground at pin 1 on right auxiliary light connector. See Cab Roof Harness (W19) Wiring Diagram. (Group 9015-10.) Is ground present?

Key switch OFF. Left auxiliary light (E24): • Disconnect load center harness-to-cab roof 12-pin harness connector (X5). See Load Center Harness (W3) Component Location. (Group 9015-10.) • Check circuit L28 BLK at for ground pin 1 on load center harness side of connector (X5). See Load Center Harness (W3) Wiring Diagram. (Group 9015-10.) Right auxiliary light (E25):

YES: Short to ground on circuit that has ground present on load center harness (W3). Repair circuit or replace harness. NO: Short to ground on circuit that has ground present on cab roof harness (W19). Repair circuit or replace harness.

• Disconnect load center harness-to-cab roof 4-pin harness connector (X6). See Load Center Harness (W3) Component Location. (Group 9015-10.) • Check circuit L29 BLK for ground at pin 3 on load center harness side of connector (X6). See Load Center Harness (W3) Wiring Diagram. (Group 9015-10.) Is ground present? – – –1/1

TM10229 (17MAR09)

9001-40-78

544J Loader (S.N. 611800— ) 032409

PN=300

Flex Load Controller (FLC) Diagnostic Trouble Codes 3 Continuity Check

NOTE: Identify the auxiliary light that is malfunctioning. Follow the procedure for that light. Turn key switch OFF. Left auxiliary light (E24): • Disconnect auxiliary light (E24) and load center harness-to-cab roof 12-pin harness connector (X5). See Cab Roof Harness (W19) Component Location. (Group 9015-10.) • Check continuity between pin 1 (circuit L28 BRN) on cab roof harness side of connector (X5) and remaining pins on cab roof harness side of connector (X5). See Cab Roof Harness (W19) Wiring Diagram. (Group 9015-10.)

YES: Short circuit between pins that indicated continuity on cab roof harness (W19). Repair circuit or replace harness. NO: Go to next step in this check.

YES: Short circuit between pins that indicated continuity on load center harness (W3). Repair circuit or replace harness. NO: Go to Reprogram Controller.

– – –1/1

4 Reprogram Controller

Reprogram flex load controller (FLC). See Electronic Controller Reconfiguration. (Group 9015-20.)

YES: Replace controller. NO: Checks complete.

Check for active codes. Is FLC code 002355.06 present? – – –1/1

TM10229 (17MAR09)

9001-40-79

544J Loader (S.N. 611800— ) 032409

PN=301

9001 40 79

Flex Load Controller (FLC) Diagnostic Trouble Codes

002356.05 — Front Work Lts Open or Short

9001 40 80

Front work light circuit is open or short to power.

TF44157,000006A –19–13MAR08–1/1

Front Work Lights Open or Short Diagnostic Procedure Alarm Level: No Warning Lamp

– – –1/1

1 Component Check

Identify front work light that does not illuminate.

YES: Go to Short Circuit Check.

Turn key switch OFF. Disconnect and remove front work light (E20 or E21). See Cab Roof Harness (W19) Component Location. (Group 9015-10.)

NO: Replace front work light as necessary.

Apply 24 volts to pin 1 and ground to pin 2 of malfunctioning front work light. Does work light illuminate?

– – –1/1

TM10229 (17MAR09)

9001-40-80

544J Loader (S.N. 611800— ) 032409

PN=302

Flex Load Controller (FLC) Diagnostic Trouble Codes 2 Short Circuit Check

NOTE: Identify the work light that is malfunctioning. Follow the procedure for that light.

YES: Go to next step in this check.

Turn key switch OFF. NO: Go to Open Circuit Check.

Left front work light (E20):

9001 40 81

• Disconnect left front work light (E20). See Cab Roof Harness (W19) Component Location. (Group 9015-10.) • Turn key switch ON. • Verify work lights are OFF. • Check circuit L02 BRN for voltage at pin 1 on left front work light connector. See Cab Roof Harness (W19) Wiring Diagram. (Group 9015-10.) Right front work light (E21): • Disconnect right front work light (E21). See Cab Roof Harness (W19) Component Location. (Group 9015-10.) • Turn key switch ON. • Verify work lights are OFF. • Check circuit L24 BRN for voltage at pin 1 on right front work light connector. See Cab Roof Harness (W19) Wiring Diagram. (Group 9015-10.) Is system voltage present?

Turn key switch OFF. Left front work light (E20): • Disconnect load center harness-to-cab roof 12-pin harness connector (X5). See Load Center Harness (W3) Component Location. (Group 9015-10.) • Turn key switch ON. • Verify work lights are OFF. • Check circuit L02 BRN for voltage at pin 7 on load center harness side of connector (X5). See Load Center Harness (W3) Wiring Diagram. (Group 9015-10.) Right front work light (E21):

YES: Short to power on circuit that has system voltage present on load center harness (W3). Repair circuit or replace harness. NO: Short to power on circuit that has system voltage present on cab roof harness (W19). Repair circuit or replace harness.

• Disconnect right front work light (E21). See Cab Roof Harness (W19) Component Location. (Group 9015-10.) • Turn key switch ON. • Verify work lights are OFF. • Check circuit L24 BRN for voltage at pin 6 on load center harness side of connector (X5). See Load Center Harness (W3) Wiring Diagram. (Group 9015-10.) Is system voltage present?

– – –1/1

TM10229 (17MAR09)

9001-40-81

544J Loader (S.N. 611800— ) 032409

PN=303

Flex Load Controller (FLC) Diagnostic Trouble Codes 3 Open Circuit Check

NOTE: Identify the work light that is malfunctioning. Follow the procedure for that light.

YES: Go to Continuity Check.

Turn key switch OFF. NO: Go to next step in this check.

Left front work light (E20): 9001 40 82

• Disconnect left front work light (E20). See Cab Roof Harness (W19) Component Location. (Group 9015-10.) • Disconnect flex load controller (FLC) connector (X40). See Load Center Harness (W3) Component Location. • Check circuit L02 BRN for continuity between pin 1 on left front work light connector and pin C3 on FLC connector (X40). See Cab Roof Harness (W19) Wiring Diagram and see Load Center Harness (W3) Wiring Diagram. (Group 9015-10.) • Check circuit G04 BLK for continuity between pin 2 of left front work light connector and frame ground. See Cab Roof Harness (W19) Wiring Diagram. (Group 9015-10.) Right front work light (E21): • Disconnect right front work light (E21). See Cab Roof Harness (W19) Component Location. (Group 9015-10.) • Disconnect flex load controller (FLC) connector (X40). See Load Center Harness (W3) Component Location. • Check circuit L24 BRN for continuity between pin 1 on right front work light connector and pin C4 on FLC connector (X40). See Cab Roof Harness (W19) Wiring Diagram and see Load Center Harness (W3) Wiring Diagram. (Group 9015-10.) • Check circuit G04 BLK for continuity between pin 2 of right front work light connector and frame ground. See Cab Roof Harness (W19) Wiring Diagram. (Group 9015-10.) Is continuity indicated?

Key switch OFF. Left front work light (E20): • Disconnect FLC connector (X40) and load center harness-to-cab roof 12-pin harness connector (X5). See Load Center Harness (W3) Component Location. (Group 9015-10.) • Check circuit L02 BRN for continuity between pin 7 on load center harness side of connector (X5) and pin C3 on FLC connector (X40). See Load Center Harness (W3) Wiring Diagram. (Group 9015-10.) • Check circuit G04 BLK for continuity between pin 8 on load center harness side of connector (X5) and frame ground. See Load Center Harness (W3) Wiring Diagram. (Group 9015-10.)

YES: Open on circuit that did not indicate continuity on cab roof harness (W19). Repair circuit or replace harness. NO: Open on circuit that did not indicate continuity on load center harness (W3). Repair circuit or replace harness.

Right front work light (E21): • Disconnect FLC connector (X40) and load center harness-to-cab roof 12-pin harness connector (X5). See Load Center Harness (W3) Component Location. (Group 9015-10.) • Check circuit L24 BRN for continuity between pin 6 on load center harness side of connector (X5) and pin C4 on FLC connector (X40). See Load Center Harness (W3) Wiring Diagram. (Group 9015-10.) • Check circuit G04 BLK for continuity between pin 8 on load center harness side of connector (X5) and frame ground. See Load Center Harness (W3) Wiring Diagram. (Group 9015-10.) Is continuity indicated? – – –1/1

TM10229 (17MAR09)

9001-40-82

544J Loader (S.N. 611800— ) 032409

PN=304

Flex Load Controller (FLC) Diagnostic Trouble Codes 4 Continuity Check

NOTE: Identify the auxiliary light that is malfunctioning. Follow the procedure for that light. Turn key switch OFF. Left front work light (E20): • Disconnect left front work light (E20) and load center harness-to-cab roof 12-pin harness connector (X5). See Cab Roof Harness (W19) Component Location. (Group 9015-10.) • Check continuity between pin 2 (circuit L02 BRN) on cab roof harness side of connector (X5) and remaining pins on cab roof harness side of connector (X5). See Cab Roof Harness (W19) Wiring Diagram. (Group 9015-10.)

YES: Short circuit between pins that indicated continuity on cab roof harness (W19). Repair circuit or replace harness. NO: Go to next step in this check.

Right front work light (E21): • Disconnect right front work light (E21) and load center harness-to-cab roof 12-pin harness connector (X5). See Cab Roof Harness (W19) Component Location. (Group 9015-10.) • Check continuity between pin 3 (circuit L22 BRN) on cab roof harness side of connector (X5) and remaining pins on cab roof harness side of connector (X5). See Cab Roof Harness (W19) Wiring Diagram. (Group 9015-10.) Is continuity indicated between any pins?

Key switch OFF. Left front work light (E20): • Load center harness-to-cab roof 12-pin harness connector (X5) disconnected. • Disconnect flex load controller (FLC) connectors (X40, X41, and X42). See Load Center Harness (W3) Component Location. (Group 9015-10.) • Check for continuity between pin C3 (circuit L02 BRN) on FLC connector (X40) and remaining pins on connectors (X40, X41, and X42). See Load Center Harness (W3) Wiring Diagram. (Group 9015-10.)

YES: Short circuit between pins that indicated continuity on load center harness (W3). Repair circuit or replace harness. NO: Go to Reprogram Controller.

Right front work light (E21): • Load center harness-to-cab roof 4-pin harness connector (X6) disconnected. • Disconnect flex load controller (FLC) connectors (X40, X41, and X42). See Load Center Harness (W3) Component Location. (Group 9015-10.) • Check for continuity between pin C4 (circuit L22 BRN) on FLC connector (X40) and remaining pins on connectors (X40, X41, and X42). See Load Center Harness (W3) Wiring Diagram. (Group 9015-10.) Is continuity indicated between any pins?

– – –1/1

5 Reprogram Controller

Reprogram flex load controller (FLC). See Electronic Controller Reconfiguration. (Group 9015-20.)

YES: Replace controller. NO: Checks complete.

Check for active codes. Is FLC code 002356.05 present? – – –1/1

TM10229 (17MAR09)

9001-40-83

544J Loader (S.N. 611800— ) 032409

PN=305

9001 40 83

Flex Load Controller (FLC) Diagnostic Trouble Codes

002356.06 — Front Work Lts High Current

9001 40 84

Front work light circuit is short to ground.

TF44157,000006B –19–13MAR08–1/1

Front Work Lights High Current Diagnostic Procedure Alarm Level: No Warning Lamp

– – –1/1

1 Component Check

Identify front work light that does not illuminate.

YES: Go to Short Circuit Check.

Turn key switch OFF. Disconnect and remove front work light (E20 or E21). See Cab Roof Harness (W19) Component Location. (Group 9015-10.)

NO: Replace front work light as necessary.

Apply 24 volts to pin 1 and ground to pin 2 of malfunctioning front work light. Does work light illuminate?

– – –1/1

TM10229 (17MAR09)

9001-40-84

544J Loader (S.N. 611800— ) 032409

PN=306

Flex Load Controller (FLC) Diagnostic Trouble Codes 2 Short Circuit Check

NOTE: Identify the work light that is malfunctioning. Follow the procedure for that light.

YES: Go to next step in this check.

Turn key switch OFF. NO: Go to Continuity Check.

Left front work light (E20):

9001 40 85

• Disconnect left front work light (E20). See Cab Roof Harness (W19) Component Location. (Group 9015-10.) • Check circuit L02 BRN for ground at pin 1 on left front work light connector. See Cab Roof Harness (W19) Wiring Diagram. (Group 9015-10.) Right front work light (E21): • Disconnect right front work light (E21). See Cab Roof Harness (W19) Component Location. (Group 9015-10.) • Check circuit L24 BRN for ground at pin 1 on right front work light connector. See Cab Roof Harness (W19) Wiring Diagram. (Group 9015-10.) Is ground present?

Key switch OFF. Left front work light (E20): • Disconnect load center harness-to-cab roof 12-pin harness connector (X5). See Load Center Harness (W3) Component Location. (Group 9015-10.) • Check circuit L02 BRN for ground at pin 7 on load center harness side of connector (X5). See Load Center Harness (W3) Wiring Diagram. (Group 9015-10.) Right front work light (E21): • Disconnect right front work light (E21). See Cab Roof Harness (W19) Component Location. (Group 9015-10.) • Check circuit L24 BRN for ground at pin 6 on load center harness side of connector (X5). See Load Center Harness (W3) Wiring Diagram. (Group 9015-10.)

YES: Short to ground on circuit that has system voltage present on load center harness (W3). Repair circuit or replace harness. NO: Short to ground on circuit that has system voltage present on cab roof harness (W19). Repair circuit or replace harness.

Is ground present?

– – –1/1

TM10229 (17MAR09)

9001-40-85

544J Loader (S.N. 611800— ) 032409

PN=307

Flex Load Controller (FLC) Diagnostic Trouble Codes 3 Continuity Check

NOTE: Identify the auxiliary light that is malfunctioning. Follow the procedure for that light. Turn key switch OFF. Left front work light (E20):

9001 40 86

• Disconnect left front work light (E20) and load center harness-to-cab roof 12-pin harness connector (X5). See Cab Roof Harness (W19) Component Location. (Group 9015-10.) • Check continuity between pin 2 (circuit L02 BRN) on cab roof harness side of connector (X5) and remaining pins on cab roof harness side of connector (X5). See Cab Roof Harness (W19) Wiring Diagram. (Group 9015-10.)

YES: Short circuit between pins that indicated continuity on cab roof harness (W19). Repair circuit or replace harness. NO: Go to next step in this check.

YES: Short circuit between pins that indicated continuity on load center harness (W3). Repair circuit or replace harness. NO: Go to Reprogram Controller.

Right front work light (E21): • Load center harness-to-cab roof 12-pin harness connector (X5) disconnected. • Disconnect flex load controller (FLC) connectors (X40, X41, and X42). See Load Center Harness (W3) Component Location. (Group 9015-10.) • Check for continuity between pin C4 (circuit L22 BRN) on FLC connector (X40) and remaining pins on connectors (X40, X41, and X42). See Load Center Harness (W3) Wiring Diagram. (Group 9015-10.) Is continuity indicated between any pins?

– – –1/1

4 Reprogram Controller

Reprogram flex load controller (FLC). See Electronic Controller Reconfiguration. (Group 9015-20.)

YES: Replace controller. NO: Checks complete.

Check for active codes. Is FLC code 002356.06 present? – – –1/1

TM10229 (17MAR09)

9001-40-86

544J Loader (S.N. 611800— ) 032409

PN=308

Flex Load Controller (FLC) Diagnostic Trouble Codes

002362.05 — Rear Work Lts Open or Short

Rear work light circuit is open or short to power.

9001 40 87

TF44157,000006C –19–13MAR08–1/1

Rear Work Lights Open or Short Diagnostic Procedure Alarm Level: No Warning Lamp

– – –1/1

1 Component Check

Identify rear work light that does not illuminate.

YES: Go to Short Circuit Check.

Turn key switch OFF. Disconnect and remove rear work light (E22 or E23). See Cab Roof Harness (W19) Component Location. (Group 9015-10.)

NO: Replace rear work light as necessary.

Apply 24 volts to pin 1 and ground to pin 2 of malfunctioning rear work light. Does rear work light illuminate?

– – –1/1

TM10229 (17MAR09)

9001-40-87

544J Loader (S.N. 611800— ) 032409

PN=309

Flex Load Controller (FLC) Diagnostic Trouble Codes 2 Short Circuit Check

NOTE: Identify the auxiliary light that is malfunctioning. Follow the procedure for that light.

YES: Go to next step in this check.

Turn key switch OFF.

NO: Go to Open Circuit Check.

Right rear work light (E23):

9001 40 88

• Disconnect rear work light (E23). See Cab Roof Harness (W19) Component Location. (Group 9015-10.) • Turn key switch ON. • Verify rear work lights are OFF. • Check circuit L26 BRN for voltage at pin 1 on right rear light connector. See Cab Roof Harness (W19) Wiring Diagram. (Group 9015-10.) Left rear work light (E22): • Disconnect rear work light (E22). See Cab Roof Harness (W19) Component Location. (Group 9015-10.) • Turn key switch ON. • Verify rear work lights are OFF. • Check circuit L25 BRN for voltage at pin 1 on left rear light connector. See Cab Roof Harness (W19) Wiring Diagram. (Group 9015-10.) Is system voltage present?

NOTE: Identify the auxiliary light that is malfunctioning. Follow the procedure for that light.

Right rear work light (E23):

YES: Short to power on circuit with system voltage present on load center harness (W3). Repair circuit or replace harness.

• Disconnect load center harness-to-cab roof 12-pin harness connector (X5). See Load Center Harness (W3) Component Location. (Group 9015-10.) • Turn key switch ON. • Verify rear work lights are OFF. • Check circuit L26 BRN for voltage at pin 4 on load center harness side of connector (X5). See Load Center Harness (W3) Wiring Diagram. (Group 9015-10.)

NO: Short to power on circuit with system voltage present on cab roof harness (W19). Repair circuit or replace harness.

Turn key switch OFF.

Left rear work light (E22): • Disconnect load center harness-to-cab roof 12-pin harness connector (X5). See Load Center Harness (W3) Component Location. (Group 9015-10.) • Turn key switch ON. • Verify rear work lights are OFF. • Check circuit L25 BRN for voltage at pin 5 on load center harness side of connector (X5). See Load Center Harness (W3) Wiring Diagram. (Group 9015-10.) Is system voltage present?

– – –1/1

TM10229 (17MAR09)

9001-40-88

544J Loader (S.N. 611800— ) 032409

PN=310

Flex Load Controller (FLC) Diagnostic Trouble Codes 3 Open Circuit Check

NOTE: Identify the work light that is malfunctioning. Follow the procedure for that light.

YES: Go to Continuity Check.

Turn key switch OFF. NO: Go to next step in this check.

Left rear work light (E22):

9001 40 89

• Disconnect left rear work light (E22). See Cab Roof Harness (W19) Component Location. (Group 9015-10.) • Disconnect flex load controller (FLC) connector (X40). See Load Center Harness (W3) Component Location. • Check circuit L25 BRN for continuity between pin 1 on left front work light connector and pin B3 on FLC connector (X40). See Cab Roof Harness (W19) Wiring Diagram and see Load Center Harness (W3) Wiring Diagram. (Group 9015-10.) • Check circuit G04 BLK for continuity between pin 2 of left front work light connector and frame ground. See Cab Roof Harness (W19) Wiring Diagram. (Group 9015-10.) Right rear work light (E23): • Disconnect right rear work light (E23). See Cab Roof Harness (W19) Component Location. (Group 9015-10.) • Disconnect flex load controller (FLC) connector (X40). See Load Center Harness (W3) Component Location • Check circuit L26 BRN for continuity between pin on right front work light connector and pin B4 on FLC connector (X40). See Cab Roof Harness (W19) Wiring Diagram and see Load Center Harness (W3) Wiring Diagram. (Group 9015-10.) • Check circuit G04 BLK for continuity between pin 2 on right front work light connector and frame ground. See Cab Roof Harness (W19) Wiring Diagram. (Group 9015-10.) Is continuity indicated?

Key switch OFF. Left rear work light (E22): • Disconnect FLC connector (X40) and load center harness-to-cab roof 12-pin harness connector (X5). See Load Center Harness (W3) Component Location. (Group 9015-10.) • Check circuit L25 BRN for continuity between pin 5 on load center harness side of connector (X5) and pin B3 on FLC connector (X40). See Load Center Harness (W3) Wiring Diagram. (Group 9015-10.) • Check circuit G04 BLK for continuity between pin 8 on load center harness side of connector (X5) and frame ground. See Load Center Harness (W3) Wiring Diagram. (Group 9015-10.)

Right rear work light (E23): • Disconnect FLC connector (X40) and load center harness-to-cab roof 12-pin harness connector (X5). See Load Center Harness (W3) Component Location. (Group 9015-10.) • Check circuit L26 BRN for continuity between pin 4 on load center harness side of connector (X5) and pin B4 on FLC connector (X40). See Load Center Harness (W3) Wiring Diagram. (Group 9015-10.) • Check circuit G04 BLK for continuity between pin 8 on load center harness side of connector (X5) and frame ground. See Load Center Harness (W3) Wiring Diagram. (Group 9015-10.) Is continuity indicated?

– – –1/1

TM10229 (17MAR09)

9001-40-89

544J Loader (S.N. 611800— ) 032409

PN=311

Flex Load Controller (FLC) Diagnostic Trouble Codes 4 Continuity Check

NOTE: Identify the auxiliary light that is malfunctioning. Follow the procedure for that light. Turn key switch OFF. Left rear work light (E22):

9001 40 90

• Disconnect left rear work light (E22) and load center harness-to-cab roof 12-pin harness connector (X5). See Cab Roof Harness (W19) Component Location. (Group 9015-10.) • Check continuity between pin 5 (circuit L25 BRN) on cab roof harness side of connector (X5) and remaining pins on cab roof harness side of connector (X5). See Cab Roof Harness (W19) Wiring Diagram. (Group 9015-10.)

YES: Short circuit between pins that indicated continuity on cab roof harness (W19). Repair circuit or replace harness. NO: Go to next step in this check.

Right rear work light (E23): • Disconnect right rear work light (E21) and load center harness-to-cab roof 12-pin harness connector (X5). See Cab Roof Harness (W19) Component Location. (Group 9015-10.) • Check continuity between pin 4 (circuit L26 BRN) on cab roof harness side of connector (X5) and remaining pins on cab roof harness side of connector (X5). See Cab Roof Harness (W19) Wiring Diagram. (Group 9015-10.) Is continuity indicated between any pins?

Key switch OFF. Left rear work light (E22): • Load center harness-to-cab roof 12-pin harness connector (X5) disconnected. • Disconnect flex load controller (FLC) connectors (X40, X41, and X42). See Load Center Harness (W3) Component Location. (Group 9015-10.) • Check for continuity between pin B3 (circuit L25 BRN) on FLC connector (X40) and remaining pins on connectors (X40, X41, and X42). See Load Center Harness (W3) Wiring Diagram. (Group 9015-10.)

YES: Short circuit between pins that indicated continuity on load center harness (W3). Repair circuit or replace harness. NO: Go to Reprogram Controller.

Right rear work light (E23): • Load center harness-to-cab roof 12-pin harness connector (X5) disconnected. • Disconnect flex load controller (FLC) connectors (X40, X41, and X42). See Load Center Harness (W3) Component Location. (Group 9015-10.) • Check for continuity between pin B4 (circuit L26 BRN) on FLC connector (X40) and remaining pins on connectors (X40, X41, and X42). See Load Center Harness (W3) Wiring Diagram. (Group 9015-10.) Is continuity indicated between any pins?

– – –1/1

5 Reprogram Controller

Reprogram flex load controller (FLC). See Electronic Controller Reconfiguration. (Group 9015-20.)

YES: Replace controller. NO: Checks complete.

Check for active codes. Is FLC code 002362.05 present? – – –1/1

TM10229 (17MAR09)

9001-40-90

544J Loader (S.N. 611800— ) 032409

PN=312

Flex Load Controller (FLC) Diagnostic Trouble Codes

002362.06 — Rear Work Lts High Current

Rear work light circuit is short to ground.

9001 40 91

TF44157,000006D –19–13MAR08–1/1

Rear Work Lights High Current Diagnostic Procedure Alarm Level: No Warning Lamp

– – –1/1

1 Component Check

Identify rear work light that does not illuminate.

YES: Go to Short Circuit Check.

Turn key switch OFF. Disconnect and remove rear work light (E22 or E23). See Cab Roof Harness (W19) Component Location. (Group 9015-10.)

NO: Replace rear work light as necessary.

Apply 24 volts to pin 1 and ground to pin 2 of malfunctioning rear work light. Does rear work light illuminate?

– – –1/1

TM10229 (17MAR09)

9001-40-91

544J Loader (S.N. 611800— ) 032409

PN=313

Flex Load Controller (FLC) Diagnostic Trouble Codes 2 Short Circuit Check

NOTE: Identify the auxiliary light that is malfunctioning. Follow the procedure for that light.

YES: Go to next step in this check.

Turn key switch OFF.

NO: Go to Continuity Check.

Right rear work light (E23):

9001 40 92

• Disconnect rear work light (E23). See Cab Roof Harness (W19) Component Location. (Group 9015-10.) • Check circuit L26 BRN for ground at pin 1 on right rear light connector. See Cab Roof Harness (W19) Wiring Diagram. (Group 9015-10.) Left rear work light (E22): • Disconnect rear work light (E22). See Cab Roof Harness (W19) Component Location. (Group 9015-10.) • Check circuit L25 BRN for ground at pin 1 on left rear light connector. See Cab Roof Harness (W19) Wiring Diagram. (Group 9015-10.) Is ground present?

Turn key switch OFF. Right rear work light (E23): • Disconnect load center harness-to-cab roof 12-pin harness connector (X5). See Load Center Harness (W3) Component Location. (Group 9015-10.) • Check circuit L26 BRN for ground at pin 4 on load center harness side of connector (X5). See Load Center Harness (W3) Wiring Diagram. (Group 9015-10.) Left rear work light (E22):

YES: Short to ground on circuit with ground present on load center harness (W3). Repair circuit or replace harness. NO: Short to ground on circuit with ground present on cab roof Harness (W19). Repair circuit or replace harness.

• Disconnect load center harness-to-cab roof 12-pin harness connector (X5). See Load Center Harness (W3) Component Location. (Group 9015-10.) • Check circuit L25 BRN for ground at pin 5 on load center harness side of connector (X5). See Load Center Harness (W3) Wiring Diagram. (Group 9015-10.) Is ground present? – – –1/1

TM10229 (17MAR09)

9001-40-92

544J Loader (S.N. 611800— ) 032409

PN=314

Flex Load Controller (FLC) Diagnostic Trouble Codes 3 Continuity Check

NOTE: Identify the auxiliary light that is malfunctioning. Follow the procedure for that light. Turn key switch OFF. Left rear work light (E22): • Disconnect left rear work light (E22) and load center harness-to-cab roof 12-pin harness connector (X5). See Cab Roof Harness (W19) Component Location. (Group 9015-10.) • Check continuity between pin 5 (circuit L25 BRN) on cab roof harness side of connector (X5) and remaining pins on cab roof harness side of connector (X5). See Cab Roof Harness (W19) Wiring Diagram. (Group 9015-10.)

YES: Short circuit between pins that indicated continuity on cab roof harness (W19). Repair circuit or replace harness. NO: Go to next step in this check.

YES: Short circuit between pins that indicated continuity on load center harness (W3). Repair circuit or replace harness. NO: Go to Reprogram Controller.

– – –1/1

4 Reprogram Controller

Reprogram flex load controller (FLC). See Electronic Controller Reconfiguration. (Group 9015-20.)

YES: Replace controller. NO: Checks complete.

Check for active codes. Is FLC code 002362.06 present? – – –1/1

TM10229 (17MAR09)

9001-40-93

544J Loader (S.N. 611800— ) 032409

PN=315

9001 40 93

Flex Load Controller (FLC) Diagnostic Trouble Codes

002368.03 — Left Turn Lts Circuit Short to Power

9001 40 94

Left turn light circuit is short to power.

TF44157,000006E –19–13MAR08–1/1

Left Turn Lights Circuit Short to Power Diagnostic Procedure Alarm Level: No Warning Lamp

– – –1/1

1 Component Check

NOTE: Identify the turn light that is malfunctioning. Follow the procedure for that light. Identify turn light that does not illuminate. Disconnect turn light (E2 or E3). See Rear Frame Harness (W13) Component Location and see Loader Frame Harness (W2) Component Location. (Group 9015-10.)

YES: Go to Short Circuit Check—Front Left Turn Light or go to Short Circuit Check—Rear Left Turn Light. NO: Replace turn light(s).

For front left turn light (E2), apply 24 volts to pin B and ground to pin A. See Loader Frame Harness (W2) Wiring Diagram. (Group 9015-10.) For rear left turn light (E3), apply 24 volts to pin 3 and ground to pin 1. See Rear Frame Harness (W13) Wiring Diagram. (Group 9015-10.) Do turn lights illuminate? – – –1/1

TM10229 (17MAR09)

9001-40-94

544J Loader (S.N. 611800— ) 032409

PN=316

Flex Load Controller (FLC) Diagnostic Trouble Codes 2 Short Circuit Check— Front Left Turn Light

Turn key switch OFF.

YES: Go to next step in this check.

Disconnect front left turn light (E2). See Loader Frame Harness (W2) Component Location. (Group 9015-10.) Turn key switch ON.

NO: Go to Continuity Check—Front Left Turn Light.

Verify left turn light is not activated. Check circuit L09 BRN for voltage at pin B on front left turn light connector. See Loader Frame Harness (W2) Wiring Diagram. (Group 9015-10.) Is voltage present?

Turn key switch OFF. Front left turn light (E2) disconnected. Disconnect load center harness-to-loader frame harness connector (X67). See Load Center Harness (W3) Component Location. (Group 9015-10.)

YES: Circuit L09 BRN short to power on load center harness (W3). Repair circuit or replace harness. NO: Circuit L09 BRN short to power on loader frame harness (W2). Repair circuit or replace harness.

Turn key switch ON. Verify left turn light is not activated. Check circuit L09 BRN for voltage at pin 5 on load center side of connector (X67). See Load Center Harness (W3) Wiring Diagram. (Group 9015-10.) Is voltage present?

– – –1/1

TM10229 (17MAR09)

9001-40-95

544J Loader (S.N. 611800— ) 032409

PN=317

9001 40 95

Flex Load Controller (FLC) Diagnostic Trouble Codes 3 Short Circuit Check— Rear Left Turn Light

Turn key switch OFF.

YES: Go to next step in this check.

Disconnect rear left turn light (E3). See Rear Frame Harness (W13) Component Location. (Group 9015-10.) Turn key switch ON.

9001 40 96

NO: Go to Continuity Check—Rear Left Turn Light.

Verify left turn light is not activated. Check circuit L09 BRN for voltage at pin 3 of rear left turn light connector. See Rear Frame Harness (W13) Wiring Diagram. (Group 9015-10.) Is voltage present?

Turn key switch OFF. Disconnect engine frame harness-to-rear frame harness connector (X39). See Rear Frame Harness (W13) Component Location. (Group 9015-10.)

YES: Circuit L09 BRN short to power on rear frame harness (W13). Repair circuit or replace harness.

Turn key switch ON. NO: Go to next step in this check.

Verify left turn light is not activated. Check circuit L09 BRN for voltage on pin 6 on rear frame harness side of connector (X39). See Rear Frame Harness (W13) Wiring Diagram. (Group 9015-10.) Is voltage present?

YES: Circuit L09 BRN short to power on load center harness (W3). Repair circuit or replace harness. NO: Circuit L09 BRN short to power on engine frame harness (W5). Repair circuit or replace harness.

Turn key switch ON. Verify left turn light is not activated. Check circuit L09 BRN for voltage at pin 6 of on load center side of connector (X39). See Load Center Harness (W3) Wiring Diagram. (Group 9015-10.) Is voltage present?

– – –1/1

TM10229 (17MAR09)

9001-40-96

544J Loader (S.N. 611800— ) 032409

PN=318

Flex Load Controller (FLC) Diagnostic Trouble Codes 4 Continuity Check— Front Left Turn Light

Turn key switch OFF. Disconnect front left turn light (E2). See Loader Frame Harness (W2) Component Location. (Group 9015-10.) Disconnect load center harness-to-loader frame harness connector (X67). See Loader Frame Harness (W2) Component Location. (Group 9015-10.) Check continuity between pin 5 (circuit L09 BRN) on loader frame harness side of connector (X67) and remaining pins on connector (X67). See Loader Frame Harness (W2) Wiring Diagram. (Group 9015-10.)

YES: Circuit L09 short to pin that indicated continuity on loader frame harness (W2). Repair circuit L09 BRN or replace harness. NO: Go to next step in this check.

Is continuity indicated between any pins?

Key switch OFF. Load center harness-to-loader frame harness connector (X67) disconnected. Disconnect flex load controller (FLC) connectors (X40, X41, and X42). See Load Center Harness (W3) Component Location. (Group 9015-10.) Check continuity between pin B2 (circuit L09 BRN) on FLC connector (X42) and remaining pins on connectors (X40, X41, and X42). See Load Center Harness (W3) Wiring Diagram. (Group 9015-10.)

YES: Circuit L09 BRN short to pin that indicated continuity on load center harness (W3). Repair circuit L09 BRN or replace harness. NO: Go to Reprogram Controller.

Is continuity indicated between any pins?

– – –1/1

TM10229 (17MAR09)

9001-40-97

544J Loader (S.N. 611800— ) 032409

PN=319

9001 40 97

Flex Load Controller (FLC) Diagnostic Trouble Codes 5 Continuity Check— Rear Left Turn Light

Turn key switch OFF.

YES: Circuit L09 BRN short to pin that indicated continuity on rear frame harness (W13). Repair circuit L09 BRN or replace harness.

9001 40 98

NO: Go to next step in this check.

Check for continuity between pin 6 (circuit L09 BRN) on rear frame harness side of connector (X39) and remaining pins on connector (X39). See Rear Frame Harness (W13) Wiring Diagram. (Group 9015-10.) Is continuity indicated between any pins?

Key switch OFF.

YES: Circuit L09 BRN short to pin that indicated continuity on engine frame harness (W5). Repair circuit L09 BRN or replace harness.

Engine frame harness-to-rear frame harness connector (X39) disconnected. Disconnect load center harness-to-engine frame harness connector (X3). See Engine Frame Harness (W5) Component Location. (Group 9015-10.) Check for continuity between pin 10 (circuit L09 BRN) on engine frame harness side of connector (X3) and remaining pins on connector (X3). See Engine Frame Harness (W5) Wiring Diagram. (Group 9015-10.)

NO: Go to next step in this check.

Is continuity indicated between any pins?

Key switch OFF. Load center harness-to-engine frame harness connector (X3) disconnected. Disconnect flex load controller (FLC) connectors (X40, X41, and X42). See Load Center Harness (W3) Component Location. (Group 9015-10.) Check for continuity between pin B2 (circuit L09 BRN) on FLC connector (X42) and remaining pins on connectors (X40, X41, and X42). See Load Center Harness (W3) Wiring Diagram. (Group 9015-10.)

YES: Circuit L09 BRN short to pin that indicated continuity on load center harness (W3). Repair circuit L09 BRN or replace harness. NO: Go to Reprogram Controller.

Is continuity indicated between any pins? – – –1/1

6 Reprogram Controller

Reprogram flex load controller (FLC). See Electronic Controller Reconfiguration. (Group 9015-20.)

YES: Replace controller. NO: Checks complete.

Check for active codes. Is FLC code 002368.03 present? – – –1/1

002368.05 — Left Turn Lts Open Circuit

Left turn light circuit is open.

TF44157,000006F –19–13MAR08–1/1

TM10229 (17MAR09)

9001-40-98

544J Loader (S.N. 611800— ) 032409

PN=320

Flex Load Controller (FLC) Diagnostic Trouble Codes Left Turn Lights Open Circuit Diagnostic Procedure Alarm Level: No Warning Lamp

9001 40 99

– – –1/1

1 Component Check

NOTE: Identify the turn light that is malfunctioning. Follow the procedure for that light. Identify turn light that does not illuminate. Disconnect and remove turn light (E2 or E3). See Rear Frame Harness (W13) Component Location and see Loader Frame Harness (W2) Component Location. (Group 9015-10.)

YES: Go to Open Circuit Check—Front Left Turn Light or go to Open Circuit Check—Rear Left Turn Light. NO: Replace turn light(s).

– – –1/1

TM10229 (17MAR09)

9001-40-99

544J Loader (S.N. 611800— ) 032409

PN=321

Flex Load Controller (FLC) Diagnostic Trouble Codes 2 Open Circuit Check— Front Left Turn Light

Turn key switch OFF.

YES: Go to next step in this check.

Disconnect front left turn light (E2) and load center harness-to-loader frame harness connector (X67). See Loader Frame Harness (W2) Component Location. (Group 9015-10.) 9001 40 ,100

Check circuit L09 BRN for continuity between pin 5 on loader frame harness side of connector (X67) and pin B on front left turn light (E2). See Loader Frame Harness (W2) Wiring Diagram. (Group 9015-10.)

NO: Circuit L09 BRN open on loader frame harness (W2). Repair circuit or replace harness.

Is continuity indicated?

Key switch OFF.

YES: Go to next step in this check.

Front left turn light (E2) disconnected. See Loader Frame Harness (W2) Component Location. (Group 9015-10.) Check circuit G05 BLK for continuity between pin A on turn light connector and frame ground. See Loader Frame Harness (W2) Wiring Diagram. (Group 9015-10.)

NO: Circuit G05 BLK open circuit on loader frame harness (W2). Repair circuit G05 BLK or replace harness.

Is continuity indicated?

Key switch OFF.

YES: Go to Reprogram Controller.

Disconnect flex load controller (FLC) connector (X42) and load center harness-to-loader frame harness connector (X67). See Loader Frame Harness (W2) Component Location. (Group 9015-10.) Check circuit L09 BRN for continuity between pin 5 on load center harness side of connector (X67) and pin B2 on FLC connector (X42). See Loader Frame Harness (W2) Wiring Diagram. (Group 9015-10.)

NO: Open on circuit L09 BRN on load center harness (W2). Repair circuit or replace harness.

Is continuity indicated?

– – –1/1

TM10229 (17MAR09)

9001-40-100

544J Loader (S.N. 611800— ) 032409

PN=322

Flex Load Controller (FLC) Diagnostic Trouble Codes 3 Open Circuit Check— Rear Left Turn Light

Turn key switch OFF.

YES: Go to next step in this check.

Disconnect rear left turn light (E3). See Rear Frame Harness (W13) Component Location. (Group 9015-10.) Disconnect engine frame harness-to-rear frame harness connector (X39). See Rear Frame Harness (W13) Component Location. (Group 9015-10.) Check circuit L09 BRN for continuity between pin 6 on rear frame harness side of connector (X39) and pin 3 on rear left turn light (E3) connector. See Rear Frame Harness (W13) Wiring Diagram. (Group 9015-10.)

NO: Open on circuit that did not indicate continuity on rear frame harness 9001 (W13). Repair circuit or 40 replace harness. ,101

Check circuit G02 BLK for continuity between pin 4 on rear frame harness side of connector (X39) and pin 1 on rear left turn light (E3) connector. Is continuity indicated?

Key switch OFF.

YES: Go to next step in this check.

Engine frame harness-to-rear frame harness connector (X39) disconnected. Disconnect load center harness-to-engine frame harness connector (X3). See Engine Frame Harness (W5) Component Location. (Group 9015-10.) Check circuit L09 BRN for continuity between pin 6 on engine frame harness side of connector (X39) and pin 10 on engine frame harness side of connector (X3). See Engine Frame Harness (W5) Wiring Diagram. (Group 9015-10.)

NO: Open on circuit that did not indicate continuity on engine frame harness (W5). Repair circuit or replace harness.

Check circuit G02 BLK for continuity between pin 4 on engine frame harness side of connector (X39) and frame ground. Is continuity indicated?

Key switch OFF.

YES: Go to Reprogram Controller.

Load center harness-to-engine frame harness connector (X3) disconnected. NO: Circuit L09 BLK open on load center harness (W3). Repair circuit or replace harness.

Disconnect FLC connector (X42). See Load Center Harness (W3) Component Location. (Group 9015-10.) Check circuit L09 BRN for continuity between pin 10 on load center harness side of connector (X3) and pin B2 on FLC connector (X42). See Load Center Harness (W3) Wiring Diagram. (Group 9015-10.) Is continuity indicated?

– – –1/1

4 Reprogram Controller

Reprogram flex load controller (FLC). See Electronic Controller Reconfiguration. (Group 9015-20.)

YES: Replace controller. NO: Checks complete.

Check for active codes. Is FLC code 002368.05 present? – – –1/1

TM10229 (17MAR09)

9001-40-101

544J Loader (S.N. 611800— ) 032409

PN=323

Flex Load Controller (FLC) Diagnostic Trouble Codes

002368.06 — Left Turn Lts Circuit High Current

9001 40 ,102

Left turn light circuit is short to ground.

TF44157,0000070 –19–13MAR08–1/1

Left Turn Lights Circuit High Current Diagnostic Procedure

– – –1/1

1 Component Check

Identify turn light that does not illuminate. Disconnect turn light (E2 or E3). See Rear Frame Harness (W13) Component Location and see Loader Frame Harness (W2) Component Location. (Group 9015-10.) For front left turn light (E2), apply 24 volts to pin B and ground to pin C. See Loader Frame Harness (W2) Wiring Diagram. (Group 9015-10.)

YES: Go to Short Circuit Check—Front Left Turn Light or go to Short Circuit Check—Rear Left Turn Light. NO: Replace turn light(s).

For rear left turn light (E3), apply 24 volts to pin 3 and ground to pin 1. See Rear Frame Harness (W13) Wiring Diagram. (Group 9015-10.) Do turn lights illuminate?

– – –1/1

TM10229 (17MAR09)

9001-40-102

544J Loader (S.N. 611800— ) 032409

PN=324

Flex Load Controller (FLC) Diagnostic Trouble Codes 2 Short Circuit Check— Front Left Turn Light

Turn key switch OFF.

YES: Go to next step in this check.

Disconnect front left turn light (E2). See Loader Frame Harness (W2) Component Location. (Group 9015-10.) Turn key switch ON.

NO: Go to Continuity Check—Front Left Turn Light.

Check circuit L09 BRN for ground at pin B of front left turn light connector. See Loader Frame Harness (W2) Wiring Diagram. (Group 9015-10.) Is ground present?

Key switch OFF. Disconnect load center harness-to-loader frame harness connector (X67). See Loader Frame Harness (W2) Component Location. (Group 9015-10.) Check circuit L09 BRN for ground at pin 5 on load center side harness side of connector (X67). See Loader Frame Harness (W2) Wiring Diagram. (Group 9015-10.) Is ground present?

YES: Circuit L09 BRN short to ground on loader frame harness (W2). Repair circuit L09 BRN or replace harness. NO: Circuit L09 BRN short to ground on load center harness (W3). Repair circuit L09 BRN or replace harness.

– – –1/1

TM10229 (17MAR09)

9001-40-103

544J Loader (S.N. 611800— ) 032409

PN=325

9001 40 ,103

Flex Load Controller (FLC) Diagnostic Trouble Codes 3 Short Circuit Check— Rear Left Turn Light

Turn key switch OFF.

YES: Go to next step in this check.

Disconnect rear left turn light (E3). See Rear Frame Harness (W13) Component Location. (Group 9015-10.) Check circuit L09 BRN for ground at pin 3 of rear left turn light connector. See Rear Frame Harness (W13) Wiring Diagram. (Group 9015-10.)

9001 40 ,104

NO: Go to Continuity Check—Rear Left Turn Light.

Is ground present?

Key switch OFF. Disconnect engine frame harness-to-rear frame harness connector (X39). See Rear Frame Harness (W13) Component Location. (Group 9015-10.) Check circuit L09 BRN for ground at pin 6 on engine frame harness side of connector (X39). See Rear Frame Harness (W13) Wiring Diagram. (Group 9015-10.)

YES: Circuit L09 BRN short to ground on rear frame harness (W13). Repair circuit L09 BRN or replace harness. NO: Go to next step in this check.

Is ground present?

Key switch OFF. Disconnect load center harness-to-engine frame harness connector (X3). See Engine Frame Harness (W5) Component Location. (Group 9015-10.) Check circuit L09 BRN for ground at pin 10 of on load center harness side of connector (X3). See Load Center Harness (W3) Wiring Diagram. (Group 9015-10.)

YES: Circuit L09 BRN short to ground on circuit L09 on load center harness (W3). Repair circuit L09 BRN or replace harness. NO: Circuit L09 BRN short to ground on circuit L09 on engine frame harness (W5). Repair circuit L09 BRN or replace harness.

Is ground present?

– – –1/1

TM10229 (17MAR09)

9001-40-104

544J Loader (S.N. 611800— ) 032409

PN=326

Flex Load Controller (FLC) Diagnostic Trouble Codes 4 Continuity Check— Front Left Turn Light

YES: Circuit L09 BRN short to pin that indicated continuity on loader frame harness (W2). Repair circuit L09 BRN or replace harness. NO: Go to next step in this check.

Is continuity indicated between any pins?

Key switch OFF. Load center harness-to-loader frame harness connector (X67) disconnected. Disconnect FLC connectors (X40, X41, and X42). See Load Center Harness (W3) Component Location. (Group 9015-10.) Check continuity between pin B2 (circuit L09 BRN) on FLC connector (X42) and remaining pins on connectors (X40, X41, and X42). See Load Center Harness (W3) Wiring Diagram. (Group 9015-10.)

YES: Circuit L09 BRN short to pin that indicated continuity on load center harness (W2). Repair circuit L09 BRN or replace harness. NO: Go to Reprogram Controller.

Is continuity indicated between any pins?

– – –1/1

TM10229 (17MAR09)

9001-40-105

544J Loader (S.N. 611800— ) 032409

PN=327

9001 40 ,105

Flex Load Controller (FLC) Diagnostic Trouble Codes 5 Continuity Check— Rear Left Turn Light

Turn key switch OFF. Disconnect rear left turn light (E3). See Rear Frame Harness (W13) Component Location. (Group 9015-10.) Disconnect engine frame harness-to-rear frame harness connector (X39). See Rear Frame Harness (W13) Component Location. (Group 9015-10.)

9001 40 ,106

Check continuity between pin 6 (circuit L09 BRN) on rear frame harness side of connector (X39) and remaining pins on connector (X39). See Rear Frame Harness (W13) Wiring Diagram. (Group 9015-10.)

YES: Circuit L09 BRN short to pin that indicated continuity on rear frame harness (W13). Repair circuit L09 BRN or replace harness. NO: Go to next step in this check.

Is continuity indicated between any pins?

Key switch OFF. Engine frame harness-to-rear frame harness connector (X39) disconnected. Disconnect load center harness-to-engine frame harness connector (X3). See Engine Frame Harness (W5) Component Location. (Group 9015-10.) Check continuity between pin 10 (circuit L09 BRN) on engine frame harness side of connector (X3) and remaining pins on connector (X3). See Engine Frame Harness (W5) Wiring Diagram. (Group 9015-10.)

YES: Circuit L09 BRN short to pin that indicated continuity on engine frame harness (W5). Repair circuit L09 BRN or replace harness. NO: Go to next step in this check.

Is continuity indicated between any pins?

Key switch OFF. Load center harness-to-engine frame harness connector (X3) disconnected. Disconnect FLC connectors (X40, X41, and X42). See Load Center Harness (W3) Component Location. (Group 9015-10.) Check continuity between pin B2 (circuit L09 BRN) on FLC connector (X42) and remaining pins on connectors (X40, X41, and X42). See Load Center Harness (W3) Wiring Diagram. (Group 9015-10.)

YES: Circuit L09 BRN short to pin that indicated continuity on load center harness (W3). Repair circuit L09 BRN or replace harness. NO: Go to Reprogram Controller.

Is continuity indicated between any pins? – – –1/1

6 Reprogram Controller

Reprogram flex load controller (FLC). See Electronic Controller Reconfiguration. (Group 9015-20.)

YES: Replace controller. NO: Checks complete.

Check for active codes. Is FLC code 002368.06 present? – – –1/1

002370.03 — Right Turn Lts Short to Power

Right turn light circuit is short to power.

TF44157,0000071 –19–13MAR08–1/1

TM10229 (17MAR09)

9001-40-106

544J Loader (S.N. 611800— ) 032409

PN=328

Flex Load Controller (FLC) Diagnostic Trouble Codes Right Turn Lights Short to Power Diagnostic Procedure

– – –1/1

1 Component Check

Identify turn light that does not illuminate. Disconnect turn light (E4 or E5). See Rear Frame Harness (W13) Component Location and see Loader Frame Harness (W2) Component Location. (Group 9015-10.) For front right turn light (E4), apply 24 volts to pin B and ground to pin C. See Loader Frame Harness (W2) Wiring Diagram. (Group 9015-10.)

YES: Go to Short Circuit Check—Front Right Turn Light or go to Short Circuit Check—Rear Right Turn Light. NO: Replace turn light(s).

For rear right turn light (E5), apply 24 volts to pin 3 and ground to pin 1. See Rear Frame Harness (W13) Wiring Diagram. (Group 9015-10.) Do turn lights illuminate?

– – –1/1

2 Short Circuit Check— Front Right Turn Light

Turn key switch OFF.

YES: Go to next step in this check.

Disconnect front right turn light (E4). See Loader Frame Harness (W2) Component Location. (Group 9015-10.) Turn key switch ON.

NO: Go to Continuity Check—Front Right Turn Light.

Verify right turn light is not activated. Check circuit L12 BRN for voltage at pin B of front right turn light connector. See Loader Frame Harness (W2) Wiring Diagram. (Group 9015-10.) Is voltage present?

Turn key switch OFF. Disconnect load center harness-to-loader frame harness connector (X67). See Load Center Harness (W3) Component Location. (Group 9015-10.)

YES: Circuit L12 BRN short to power on load center harness (W3). Repair circuit L12 BRN or replace harness.

Turn key switch ON. Verify right turn light is not activated. Check circuit L09 BRN for voltage at pin 4 on load center side of connector (X67). See Load Center Harness (W3) Wiring Diagram. (Group 9015-10.)

NO: Circuit L12 BRN short to power on loader frame harness (W2). Repair circuit L12 BRN or replace harness.

Is voltage present?

– – –1/1

TM10229 (17MAR09)

9001-40-107

544J Loader (S.N. 611800— ) 032409

PN=329

9001 40 ,107

Flex Load Controller (FLC) Diagnostic Trouble Codes 3 Continuity Check— Front Right Turn Light

Turn key switch OFF. Disconnect front right turn light (E4). See Loader Frame Harness (W2) Component Location. (Group 9015-10.) Disconnect load center harness-to-loader frame harness connector (X67). See Loader Frame Harness (W2) Component Location. (Group 9015-10.)

9001 40 ,108

Check continuity between pin 4 (circuit L12 BRN) on loader frame harness side of connector (X67) and remaining pins on connector (X67). See Loader Frame Harness (W2) Wiring Diagram. (Group 9015-10.)

YES: Circuit L12 BRN short to pin that indicated continuity on loader frame harness (W2). Repair circuit L12 BRN or replace harness. NO: Go to next step in this check.

Is continuity indicated between any pins?

Key switch OFF. Load center harness-to-loader frame harness connector (X67) disconnected. Disconnect FLC connectors (X40, X41, and X42). See Load Center Harness (W3) Component Location. (Group 9015-10.) Check continuity between pin C2 (circuit L12 BRN) on FLC connector (X42) and remaining pins on connectors (X40, X41, and X42). See Load Center Harness (W3) Wiring Diagram. (Group 9015-10.)

YES: Circuit L12 BRN short to power on load center harness (W2). Repair circuit L12 BRN or replace harness. NO: Go to Reprogram Controller.

Is continuity indicated between any pins?

– – –1/1

TM10229 (17MAR09)

9001-40-108

544J Loader (S.N. 611800— ) 032409

PN=330

Flex Load Controller (FLC) Diagnostic Trouble Codes 4 Continuity Check— Rear Right Turn Light

Turn key switch OFF. Disconnect rear right turn light (E5). See Rear Frame Harness (W13) Component Location. (Group 9015-10.) Disconnect engine frame harness-to-rear frame harness connector (X39). See Rear Frame Harness (W13) Component Location. (Group 9015-10.) Check continuity between pin 3 (circuit L12 BRN) on rear frame harness side of connector (X39) and remaining pins on connector (X39). See Rear Frame Harness (W13) Wiring Diagram. (Group 9015-10.)

YES: Circuit L12 BRN short to pin that indicated continuity on rear frame harness (W13). Repair circuit L12 BRN or replace harness. NO: Go to next step in this check.

Is continuity indicated between any pins?

Key switch OFF. Engine frame harness-to-rear frame harness connector (X39) disconnected. Disconnect load center harness-to-engine frame harness connector (X3). See Engine Frame Harness (W5) Component Location. (Group 9015-10.) Check continuity between pin 3 (circuit L12 BRN) on engine frame harness side of connector (X39) and remaining pins on connectors (X40, X41, and X42). See Engine Frame Harness (W5) Wiring Diagram. (Group 9015-10.)

YES: Circuit L12 BRN short to pin that indicated continuity on engine frame harness (W5). Repair circuit L12 BRN or replace harness. NO: Go to next step in this check.

Is continuity indicated between any pins?

Key switch OFF. Load center harness-to-engine frame harness connector (X3) disconnected. Disconnect FLC connectors (X40, X41, and X42). See Load Center Harness (W3) Component Location. (Group 9015-10.) Check continuity between pin B2 (circuit L12 BRN) on FLC connector (X42) and remaining pins on connectors (X40, X41, and X42). See Load Center Harness (W3) Wiring Diagram. (Group 9015-10.)

YES: Circuit L12 BRN short to pin that indicated continuity on load center harness (W3). Repair circuit L12 BRN or replace harness. NO: Go to Reprogram Controller.

Is continuity indicated between any pins? – – –1/1

5 Reprogram Controller

Reprogram flex load controller (FLC). See Electronic Controller Reconfiguration. (Group 9015-20.)

YES: Replace controller. NO: Checks complete.

Check for active codes. Is FLC code 002370.03 present? – – –1/1

002370.05 — Right Turn Lts Open Circuit

Right turn light circuit is open.

TF44157,0000072 –19–13MAR08–1/1

TM10229 (17MAR09)

9001-40-109

544J Loader (S.N. 611800— ) 032409

PN=331

9001 40 ,109

Flex Load Controller (FLC) Diagnostic Trouble Codes Right Turn Lights Open Circuit Diagnostic Procedure

9001 40 ,110

– – –1/1

1 Component Check

YES: Go to Open Circuit Check—Front Right Turn Light or go to Open Circuit Check—Rear Right Turn Light. NO: Replace turn light(s).

For rear right turn light (E5), apply 24 volts to pin 3 and ground to pin 1. See Rear Frame Harness (W13) Wiring Diagram. (Group 9015-10.) Do turn lights illuminate?

– – –1/1

2 Open Circuit Check— Front Right Turn Light

Turn key switch OFF.

YES: Go to Reprogram Controller.

Disconnect front right turn light (E4) and flex load controller (FLC) connector (X42). See Load Center Harness (W3) Component Location and see Loader Frame Harness (W2) Component Location. (Group 9015-10.) Check circuit L12 BRN for continuity between pin C2 on FLC connector (X42) and pin B on front right turn light (E4). See Loader Frame Harness (W2) Wiring Diagram. (Group 9015-10.) Check circuit G05 BLK for continuity between pin B on front right turn light (E4) and frame ground. See Loader Frame Harness (W2) Wiring Diagram. (Group 9015-10.)

NO: If circuit G05 BLK does not indicate continuity, there is an open on loader frame harness (W5). Repair circuit G05 BLK or replace harness. If circuit L12 BRN does not indicate continuity, go to next step in this check.

Is continuity indicated?

Key switch OFF.

YES: Go to Reprogram Controller.

FLC connector (X42) disconnected. Disconnect load center harness-to-loader frame harness connector (X67). See Load Center Harness (W3) Component Location. (Group 9015-10.) Check circuit L12 BRN for continuity between pin 4 on load center side of connector (X67) and pin C2 on FLC connector (X42). See Load Center Harness (W3) Wiring Diagram. (Group 9015-10.)

NO: Circuit L12 BRN open circuit on load center harness (W3). Repair circuit L12 BRN or replace harness.

Is continuity indicated?

– – –1/1

TM10229 (17MAR09)

9001-40-110

544J Loader (S.N. 611800— ) 032409

PN=332

Flex Load Controller (FLC) Diagnostic Trouble Codes 3 Open Circuit Check— Rear Right Turn Light

Turn key switch OFF.

YES: Go to Reprogram Controller.

Disconnect rear right turn light (E5) and flex load controller (FLC) connector (X42). See Load Center Harness (W3) Component Location and see Loader Frame Harness (W2) Component Location. (Group 9015-10.)

NO: Go to next step in this check. 9001 40 ,111

Check circuit L12 BRN for continuity between pin C2 on FLC connector (X42) and pin B on rear right turn light (E4). See Loader Frame Harness (W2) Wiring Diagram. (Group 9015-10.) Check circuit G02 BLK for continuity between pin B on rear right turn light (E5) and frame ground. See Loader Frame Harness (W2) Wiring Diagram. (Group 9015-10.) Is continuity indicated?

Key switch OFF.

YES: Go to next step in this check.

Disconnect engine frame harness-to-rear frame harness connector (X39). See Engine Frame Harness (W5) Component Location. (Group 9015-10.) Check circuit L12 BRN for continuity between pin 3 on rear frame side of connector (X39) and pin 3 on rear right turn light connector. See Load Center Harness (W3) Wiring Diagram. (Group 9015-10.)

NO: Open circuit on rear frame harness (W13). Repair circuit or replace harness.

Check circuit G02 BLK for continuity between pin 1 engine frame side of connector (X39) and pin 1 on rear right turn light connector. See Loader Frame Harness (W2) Wiring Diagram. (Group 9015-10.) Is continuity indicated?

Key switch OFF. Engine frame harness-to-rear frame harness (X39) disconnected. Disconnect load center harness-to-engine frame harness connector (X3). See Engine Frame Harness (W5) Component Location. (Group 9015-10.) Check circuit L12 BRN for continuity between pin 3 on engine frame side of connector (X39) and pin 11 on load center harness connector (X3). See Load Center Harness (W3) Wiring Diagram. (Group 9015-10.)

YES: Circuit L12 BRN open on load center harness (W3). Repair circuit L12 BRN or replace harness. NO: Open circuit on engine frame harness (W5). Repair circuit or replace harness.

Check circuit G02 BLK for continuity between pin 1 engine frame side of connector (X39) and frame ground. See Loader Frame Harness (W2) Wiring Diagram. (Group 9015-10.) Is continuity indicated? – – –1/1

4 Reprogram Controller

Reprogram flex load controller (FLC). See Electronic Controller Reconfiguration. (Group 9015-20.)

YES: Replace controller. NO: Checks complete.

Check for active codes. Is FLC code 002370.05 present? – – –1/1

TM10229 (17MAR09)

9001-40-111

544J Loader (S.N. 611800— ) 032409

PN=333

Flex Load Controller (FLC) Diagnostic Trouble Codes

002370.06 — Right Turn Lts High Current

9001 40 ,112

Right turn light circuit is short to ground.

TF44157,0000073 –19–13MAR08–1/1

Right Turn Lights High Current Diagnostic Procedure

– – –1/1

1 Component Check

YES: Go to Short Circuit Check—Front Right Turn Light or go to Short Circuit Check—Rear Right Turn Light. NO: Replace turn light(s).

For rear right turn light (E5), apply 24 volts to pin 3 and ground to pin 1. See Rear Frame Harness (W13) Wiring Diagram. (Group 9015-10.) Do turn lights illuminate?

– – –1/1

TM10229 (17MAR09)

9001-40-112

544J Loader (S.N. 611800— ) 032409

PN=334

Flex Load Controller (FLC) Diagnostic Trouble Codes 2 Short Circuit Check— Front Right Turn Light

Turn key switch OFF.

YES: Go to next step in this check.

Disconnect front right turn light (E4). See Loader Frame Harness (W2) Component Location. (Group 9015-10.) Turn key switch ON.

NO: Go to Continuity Check—Front Right Turn Light.

Check circuit L12 BRN for ground at pin B of front right turn light connector. See Loader Frame Harness (W2) Wiring Diagram. (Group 9015-10.) Is ground present?

Key switch OFF. Front right turn light (E2) disconnected. Disconnect load center harness-to-loader frame harness connector (X67). See Loader Frame Harness (W2) Component Location. (Group 9015-10.) Check circuit L12 BRN for ground at pin 4 on load center harness side of connector (X67). See Load Center Harness (W3) Wiring Diagram. (Group 9015-10.) Is ground present?

YES: Circuit L12 BRN short to ground on load center frame harness (W3). Repair circuit L12 BRN or replace harness. NO: Circuit L12 BRN short to ground on loader frame harness (W2). Repair circuit L12 BRN or replace harness.

– – –1/1

TM10229 (17MAR09)

9001-40-113

544J Loader (S.N. 611800— ) 032409

PN=335

9001 40 ,113

Flex Load Controller (FLC) Diagnostic Trouble Codes 3 Short Circuit Check— Rear Right Turn Light

Turn key switch OFF.

YES: Go to next step in this check.

Disconnect rear right turn light (E5). See Rear Frame Harness (W13) Component Location. (Group 9015-10.) Check circuit L12 BRN for ground at pin 3 on rear right turn light connector. See Rear Frame Harness (W13) Wiring Diagram. (Group 9015-10.)

9001 40 ,114

NO: Go to Continuity Check—Rear Right Turn Light.

Is ground present?

Key switch OFF.

YES: Go to next step in this check.

Disconnect engine frame harness-to-rear frame harness connector (X39). See Rear Frame Harness (W13) Component Location. (Group 9015-10.) Check circuit 12 BRN for ground at pin 3 on engine frame harness side of connector (X39). See Engine Frame Harness (W5) Wiring Diagram. (Group 9015-10.)

NO: Circuit L12 BRN short to ground on rear frame harness (W13). Repair circuit L12 BRN or replace harness.

Is ground present?

Key switch OFF. Disconnect load center harness-to-engine frame harness connector (X3). See Engine Frame Harness (W5) Component Location. (Group 9015-10.) Check circuit L12 BRN for ground at pin 11 on load center side of connector (X3). See Load Center Harness (W3) Wiring Diagram. (Group 9015-10.) Is ground present?

YES: Circuit L12 BRN short to ground on load center harness (W3). Repair circuit L12 BRN or replace harness. NO: Circuit L12 BRN short to ground on engine frame harness (W5). Repair circuit L12 BRN or replace harness.

– – –1/1

TM10229 (17MAR09)

9001-40-114

544J Loader (S.N. 611800— ) 032409

PN=336

Flex Load Controller (FLC) Diagnostic Trouble Codes 4 Continuity Check— Front Right Turn Light

Turn key switch OFF. Disconnect front right turn light (E5). See Loader Frame Harness (W2) Component Location. (Group 9015-10.) Disconnect load center harness-to-loader frame harness connector (X67). See Loader Frame Harness (W2) Component Location. (Group 9015-10.) Check continuity between pin 4 (circuit L12 BRN) on loader frame harness side of connector (X67) and remaining pins on connector (X67). See Loader Frame Harness (W2) Wiring Diagram. (Group 9015-10.)

YES: Circuit L12 BRN short to pin that indicated continuity on loader frame harness (W2). Repair circuit L12 BRN or replace harness. NO: Go to next step in this check.

Is continuity indicated between any pins?

Key switch OFF. Load center harness-to-loader frame harness connector (X67) disconnected. Disconnect flex load controller (FLC) connectors (X40, X41, and X42). See Load Center Harness (W3) Component Location. (Group 9015-10.) Check continuity between pin C2 (circuit L12 BRN) on FLC connector (X67) and remaining pins on connector (X40, X41, and X42). See Load Center Harness (W3) Wiring Diagram. (Group 9015-10.)

YES: Circuit L12 BRN short to pin that indicated continuity on load center harness (W2). Repair circuit L12 BRN or replace harness. NO: Go to Reprogram Controller.

Is continuity indicated between any pins?

– – –1/1

TM10229 (17MAR09)

9001-40-115

544J Loader (S.N. 611800— ) 032409

PN=337

9001 40 ,115

Flex Load Controller (FLC) Diagnostic Trouble Codes 5 Continuity Check— Rear Right Turn Light

9001 40 ,116

Check continuity between pin 3 (circuit L12 BRN) on rear frame harness side of connector (X39) and remaining pins on connector (X39). See Rear Frame Harness (W13) Wiring Diagram. (Group 9015-10.)

YES: Circuit L12 BRN short to pin that indicated continuity on rear frame harness (W13). Repair circuit L12 BRN or replace harness. NO: Go to next step in this check.

Is continuity indicated between any pins?

Key switch OFF. Engine frame harness-to-rear frame harness connector (X39) disconnected. Disconnect load center harness-to-engine frame harness connector (X3). See Engine Frame Harness (W5) Component Location. (Group 9015-10.) Check continuity between pin 3 (circuit L12 BRN) on engine frame harness side of connector (X39) and remaining pins on connector (X39). See Engine Frame Harness (W5) Wiring Diagram. (Group 9015-10.)

YES: Circuit L12 BRN short to pin that indicated continuity on engine frame harness (W5). Repair circuit L12 BRN or replace harness. NO: Go to next step in this check.

Is continuity indicated between any pins?

Key switch OFF. Load center harness-to-engine frame harness connectors (X3) disconnected. Disconnect FLC connectors (X40, X41, and X42). See Load Center Harness (W3) Component Location. (Group 9015-10.) Check continuity between pin C2 (circuit L12 BRN) on FLC connector (X42) and remaining pins on connectors (X40, X41 and X42). See Load Center Harness (W3) Wiring Diagram. (Group 9015-10.)

YES: Circuit L12 BRN short to pin that indicated continuity on load center harness (W3). Repair circuit L12 BRN or replace harness. NO: Go to Reprogram Controller.

Is continuity indicated between any pins? – – –1/1

6 Reprogram Controller

Reprogram flex load controller (FLC). See Electronic Controller Reconfiguration. (Group 9015-20.)

YES: Replace controller. NO: Checks complete.

Check for active codes. Is FLC code 002370.06 present? – – –1/1

002378.03 — Marker/Tail Lts Short to Power

Marker/tail light circuit is short to power.

TF44157,0000074 –19–13MAR08–1/1

TM10229 (17MAR09)

9001-40-116

544J Loader (S.N. 611800— ) 032409

PN=338

Flex Load Controller (FLC) Diagnostic Trouble Codes Marker/Tail Lights Short to Power Diagnostic Procedure

– – –1/1

1 Component Check

NOTE: Identify the marker/tail light that is malfunctioning. Follow the procedure for that light. Turn key switch OFF. Identify component that does not illuminate (marker light, tail light, or license plate light).

YES: Go to Short Circuit Check—Marker/Tail Lights or go to Short Circuit Check—License Plate Lights. NO: Replace light(s)

Remove marker light, tail light, or license plate light. See Rear Frame Harness (W13) Component Location and see Loader Frame Harness (W2) Component Location. (Group 9015-10.) For tail lights (E8 and E9), apply 24 volts to pin 2 and ground to pin 1 on tail light assembly. See Rear Frame Harness (W13) Wiring Diagram. (Group 9015-10.) For marker lights (E6 and E7), apply 24 volts to pin C and ground to pin A on marker light assembly.See Loader Frame Harness (W2) Wiring Diagram. (Group 9015-10.) For license plate light (E10), apply 24 volts to pin C and ground to pin A on license plate assembly. See Rear Frame Harness (W13) Wiring Diagram. (Group 9015-10.) Does the light illuminate? – – –1/1

TM10229 (17MAR09)

9001-40-117

544J Loader (S.N. 611800— ) 032409

PN=339

9001 40 ,117

Flex Load Controller (FLC) Diagnostic Trouble Codes 2 Short Circuit Check— Marker/Tail Lights

NOTE: Identify the marker/tail light that is malfunctioning. Follow the procedure for that light.

YES: Go to next step in this check.

Turn key switch OFF.

NO: Go to Continuity Check—Marker/Tail Lights.

Disconnect marker light (E6 or E7), or tail light (E8 or E9). See Rear Frame Harness (W13) Component Location or see Rear Frame Harness (W13) Component Location. (Group 9015-10.)

9001 40 ,118

Turn key switch ON. Verify the marker/tail lights are not turned on. For marker lights (E6 and E7), check circuit L06 BRN for voltage at pin C at marker light connector. See Loader Frame Harness (W2) Wiring Diagram. (Group 9015-10.) For tail lights (E8 and E9), check circuit L06 BRN for voltage at pin 2 at tail light connector. See Rear Frame Harness (W13) Wiring Diagram. (Group 9015-10.) Is voltage present?

Turn key switch OFF.

YES: For marker lights— circuit L06 BRN short to power on load center harness (W3). Repair circuit L06 BRN or replace harness.

Marker light (E6 or E7) or tail light (E8 or E9). For marker lights (E6 or E7) check the following: • Disconnect load center harness-to-loader frame harness connector (X67). See Load Center Harness (W3) Component Location. (Group 9015-10.) • Turn key switch ON. • Verify the marker/tail lights are not turned on. • Check circuit L06 BRN for voltage at pin 6 on load center harness side of connector (X67). See Load Center Harness (W3) Wiring Diagram. (Group 9015-10.) For tail lights (E8 or E9) check the following: • Disconnect engine frame harness-to-rear frame harness connector (X39). See Rear Frame Harness (W13) Component Location. (Group 9015-10.) • Turn key switch ON. • Verify the marker/tail lights are not turned on. • Check circuit L06 BRN for voltage at pin 2 on engine frame harness side of connector (X39). See Rear Frame Harness (W13) Wiring Diagram. (Group 9015-10.)

For tail lights—go to next step in this check. NO: For marker lights— circuit L06 BRN short to power on loader frame harness (W2). Repair circuit L06 BRN or replace harness. For tail lights—Circuit L06 BRN short to power on rear frame harness (W13). Repair circuit L06 BRN or replace harness.

Is voltage present?

For tail lights (E8 and E9), check the following: • Disconnect load center harness-to-engine frame harness connector (X3). See Load Center Harness (W3) Component Location. (Group 9015-10.) • Turn key switch ON. • Verify the marker/tail lights are not turned on. • Check circuit L06 BRN for voltage at pin 9 on load center harness side of connector (X3). See Load Center Harness (W3) Wiring Diagram. (Group 9015-10.) Is voltage present?

YES: Circuit L06 BRN short to power on load center harness (W3). Repair circuit L06 BRN or replace harness. NO: Circuit L06 BRN short to power on loader frame harness (W2). Repair circuit L06 BRN or replace harness. – – –1/1

TM10229 (17MAR09)

9001-40-118

544J Loader (S.N. 611800— ) 032409

PN=340

Flex Load Controller (FLC) Diagnostic Trouble Codes 3 Short Circuit Check— License Plate Lights

Turn key switch OFF.

YES: Go to next step in this check.

Disconnect license plate tail light (E10). See Rear Frame Harness (W13) Component Location. (Group 9015-10.) Turn key switch ON.

NO: Go to Continuity Check—License Plate Light.

9001 40 ,119

Verify the marker/tail lights are not turned on. Check circuit L06 BRN for voltage at pin A license plate light connector. See Rear Frame Harness (W13) Wiring Diagram. (Group 9015-10.) Is voltage present?

Turn key switch OFF.

YES: Go to next step in this check.

Disconnect engine frame harness-to-rear frame harness connector (X39). See Engine Frame Harness (W5) Component Location. (Group 9015-10.) Turn key switch ON. Verify the marker/tail lights are not turned on.

NO: Circuit L06 BRN short to power on rear frame harness (W13). Repair circuit L06 BRN or replace harness.

Check circuit L06 BRN for voltage at pin 2 on engine frame harness side of connector (X39). See Engine Frame Harness (W5) Wiring Diagram. (Group 9015-10.) Is voltage present?

Turn key switch OFF. Disconnect load center harness-to-engine frame harness connector (X3). See Load Center Harness (W3) Component Location. (Group 9015-10.)

YES: Circuit L06 BRN short to power on load center harness (W3). Repair circuit L06 BRN or replace harness.

Turn key switch ON. Verify the marker/tail lights are not turned on. Check circuit L06 BRN for voltage at pin 9 on load center harness side of connector (X3). See Load Center Harness (W3) Wiring Diagram. (Group 9015-10.)

NO: Circuit L06 BRN short to power on engine frame harness (W5). Repair circuit L06 BRN or replace harness.

Is voltage present?

– – –1/1

TM10229 (17MAR09)

9001-40-119

544J Loader (S.N. 611800— ) 032409

PN=341

Flex Load Controller (FLC) Diagnostic Trouble Codes 4 Continuity Check— Marker/Tail Lights

NOTE: Identify the marker/tail light that is malfunctioning. Follow the procedure for that light. Turn key switch OFF. Disconnect marker light (E6 or E7) or tail light (E8 or E9). See Loader Frame Harness (W2) Component Location or see Rear Frame Harness (W13) Component Location. (Group 9015-10.)

9001 40 ,120

For marker lights (E6 or E7), check the following: • Disconnect load center harness-to-loader frame harness connector (X67). See Loader Frame Harness (W2) Component Location. (Group 9015-10.) • Check continuity between pin 6 (circuit L06 BRN) on loader frame harness side of connector (X67) and the remaining pins on connector (X67). See Loader Frame Harness (W2) Wiring Diagram. (Group 9015-10.)

YES: For marker light— circuit L06 BRN short to pin that indicated continuity on loader frame harness (W2). Repair circuit L06 BRN or replace harness. For tail light—circuit L06 BRN short to pin that indicated continuity on rear frame harness (W13). Repair circuit L06 BRN or replace harness. NO: Go to next step in this check

For tail lights (E8 and E9), check the following: • Disconnect engine frame harness-to-rear frame harness connector (X39). See Rear Frame Harness (W13) Component Location. (Group 9015-10.) • Check continuity between pin 2 (circuit L06 BRN) on rear frame harness side of connector (X39) and the remaining pins on connector (X39). See Rear Frame Harness (W13) Wiring Diagram. (Group 9015-10.) Is continuity indicated between any pins?

Key switch OFF. For marker light (E6 or E7) check the following: • Load center harness-to-loader frame harness connector (X67) disconnected. • Disconnect flex load controller (FLC) connectors (X40, X41, and X42). See Load Center Harness (W3) Component Location. (Group 9015-10.) • Check continuity between pin D2 (circuit L06 BRN) on FLC connector (X42) and remaining pins on connectors (X40, X41, and X42). See Load Center Harness (W3) Wiring Diagram. (Group 9015-10.) For tail light (E8 or W9) check the following: • Engine frame harness-to-rear frame harness connector (X39) disconnected. • Disconnect load center harness-to-engine frame harness connector (X3). See Engine Frame Harness (W5) Component Location. (Group 9015-10.) • Check continuity between pin 2 (circuit L06 BRN) on engine frame harness side of connector (X39) and remaining pins on connector (X39). See Engine Frame Harness (W5) Wiring Diagram. (Group 9015-10.)

YES: For marker light— circuit L06 BRN short to pin that indicated continuity on load center harness (W3). Repair circuit L06 BRN or replace harness. For tail light—circuit L06 BRN short to pin that indicated continuity on engine frame harness (W5). Repair circuit L06 BRN or replace harness. Repair circuit L06 BRN or replace harness. NO: For marker light—go to Reprogram Controller.

Is continuity indicated between any pins?

For tail light—go to next step in this check.

Key switch OFF.

YES: Circuit L06 BRN short to pin that indicated continuity on load center harness (W3). Repair circuit L06 BRN or replace harness.

Disconnect FLC connectors (X40, X41, and X42). See Load Center Harness (W3) Component Location. (Group 9015-10.) Check continuity between pin D2 (circuit L06 BRN) on FLC connector (X42) and remaining pins on connectors (X40, X41, and X42). See Load Center Harness (W3) Wiring Diagram. (Group 9015-10.)

NO: Go to Reprogram Controller

Is continuity indicated between any pins?

– – –1/1

TM10229 (17MAR09)

9001-40-120

544J Loader (S.N. 611800— ) 032409

PN=342

Flex Load Controller (FLC) Diagnostic Trouble Codes 5 Continuity Check— License Plate Light

Turn key switch OFF.

YES: Circuit L06 BRN short to pin that indicated continuity on rear frame harness (W13). Repair circuit L06 BRN or replace harness.

Disconnect license plate light (E10). See Rear Frame Harness (W13) Component Location. (Group 9015-10.) Disconnect engine frame harness-to-rear frame harness connector (X39). See Rear Frame Harness (W13) Component Location. (Group 9015-10.) Check continuity between pin 2 (circuit L06 BRN) on rear frame harness side of connector (X39) and the remaining pins on connector (X39). See Rear Frame Harness (W13) Wiring Diagram. (Group 9015-10.)

NO: Go to next step in this check.

Is continuity indicated between any pins?

Turn key switch OFF. Engine frame harness-to-rear frame harness connector (X39) disconnected. Disconnect load center harness-to-engine frame harness connector (X3). See Engine Frame Harness (W5) Component Location. (Group 9015-10.) Check continuity between pin 2 (circuit L06 BRN) on engine frame harness side of connector (X39) and remaining pins on connector (X39). See Engine Frame Harness (W5) Wiring Diagram. (Group 9015-10.)

YES: Circuit L06 BRN short to pin that indicated continuity on engine frame harness (W5). Repair circuit L06 BRN or replace harness. NO: Go to next step in this check.

Is continuity indicated between any pins?

Key switch OFF. Load center harness-to-engine frame harness connector (X3) disconnected. Disconnect flex load controller (FLC) connectors (X40, X41, and X42). See Load Center Harness (W3) Component Location. (Group 9015-10.) Check continuity between pin 9 (circuit L06 BRN) on FLC connector (X42) and remaining pins on connectors (X40, X41, and X42). See Load Center Harness (W3) Wiring Diagram. (Group 9015-10.)

YES: Circuit L06 BRN short to pin that indicated continuity on load center harness (W3). Repair circuit L06 BRN or replace harness. NO: Go to Reprogram Controller.

Is continuity indicated between any pins? – – –1/1

6 Reprogram Controller

Reprogram flex load controller (FLC). See Electronic Controller Reconfiguration. (Group 9015-20.)

YES: Replace controller. NO: Checks complete.

Check for active codes. Is FLC code 002378.03 present? – – –1/1

002378.05 — Marker/Tail Lts Open Circuit

Marker/tail lights circuit is open.

TF44157,0000075 –19–13MAR08–1/1

TM10229 (17MAR09)

9001-40-121

544J Loader (S.N. 611800— ) 032409

PN=343

9001 40 ,121

Flex Load Controller (FLC) Diagnostic Trouble Codes Marker/Tail Lights Open Circuit Diagnostic Procedure

9001 40 ,122

– – –1/1

1 Component Check

YES: Go to Open Circuit Check—Marker/Tail Lights or Go to Open Circuit Check—License Plate Lights. NO: Replace light(s)

Remove marker light, tail light, or license plate light. See Rear Frame Harness (W13) Component Location and see Loader Frame Harness (W2) Component Location. (Group 9015-10.) For tail lights (E8 or E9) apply 24 volts to pin 2 and ground to pin 1 on tail light assembly. See Rear Frame Harness (W13) Wiring Diagram. (Group 9015-10.) For marker lights (E6 or E7) apply 24 volts to pin C and ground to pin A on marker light assembly.See Loader Frame Harness (W2) Wiring Diagram. (Group 9015-10.) For license plate light (E10) apply 24 volts to pin C and ground to pin A on license plate assembly. See Rear Frame Harness (W13) Wiring Diagram. (Group 9015-10.) Does the light illuminate? – – –1/1

TM10229 (17MAR09)

9001-40-122

544J Loader (S.N. 611800— ) 032409

PN=344

Flex Load Controller (FLC) Diagnostic Trouble Codes 2 Open Circuit Check— Marker/Tail Lights

NOTE: Identify the marker/tail light that is malfunctioning. Follow the procedure for that light.

YES: Go to Reprogram Controller.

Turn key switch OFF.

NO: Go to next step in this check.

For marker lights (E6 or E7), check the following:

9001 40 ,123

• Disconnect marker light (E6 or E7) and flex load controller (FLC) connector (X42). See Load Center Harness (W3) Component Location and see Loader Frame Harness (W2) Component Location. (Group 9015-10.) • Check circuit L06 BRN for continuity between pin C on marker light connector and pin D2 on FLC connector (X42). See Load Center Harness (W3) Wiring Diagram and see Loader Frame Harness (W2) Wiring Diagram. (Group 9015-10.) • Check circuit G02 BLK for continuity between pin A on marker light connector and frame ground. See Loader Frame Harness (W2) Wiring Diagram. (Group 9015-10.) For tail lights (E8 or E9), check the following: • Disconnect tail light (E8 or E9) and flex load controller (FLC) connector (X42).. See Rear Frame Harness (W13) Component Location and see Load Center Harness (W3) Component Location. (Group 9015-10.) • Check circuit L06 BRN for continuity between pin 2 on tail light connector and pin D2 on FLC connector (X42). See Load Center Harness (W3) Wiring Diagram and see Rear Frame Harness (W13) Wiring Diagram. (Group 9015-10.) • Check circuit G02 BLK for continuity between pin A on marker light connector and frame ground. See Rear Frame Harness (W13) Wiring Diagram. (Group 9015-10.) Is continuity indicated?

Key switch OFF. For marker lights (E6 or E7) check the following: • Disconnect load center harness-to-loader frame harness connector (X67) and FLC connector (X42). See Load Center Harness (W3) Component Location. (Group 9015-10.) • Check circuit L06 BRN for continuity between pin D2 on FLC connector (X42) and pin 6 on load center side of connector (X67). See Load Center Harness (W3) Wiring Diagram. (Group 9015-10.) • Check circuit G05 BLK for continuity between pin A on light connector and frame ground. See Rear Frame Harness (W13) Wiring Diagram. (Group 9015-10.) For tail lights (E8 or E9) check the following: • Engine frame harness-to-rear frame harness connector (X39) disconnected. • Disconnect load center harness-to-engine frame harness connector (X3). See Engine Frame Harness (W5) Component Location. (Group 9015-10.) • Check circuit L06 BRN for continuity between pin 9 on engine frame side of connector (X3) and pin 2 on engine frame side of connector (X39). See Engine Frame Harness (W5) Wiring Diagram. (Group 9015-10.) • Check circuit G05 BLK for continuity between pin A on light connector and frame ground. See Rear Frame Harness (W13) Wiring Diagram. (Group 9015-10.)

YES: For marker lights— open circuit on loader frame harness (W2). Repair circuit or replace harness. For tail light—open circuit rear frame harness (W5). Repair circuit or replace harness. NO: For marker light— open circuit load center harness (W3). Repair circuit or replace harness. For tail lights—go to next step in this check.

Is continuity indicated?

– – –1/2

TM10229 (17MAR09)

9001-40-123

544J Loader (S.N. 611800— ) 032409

PN=345

Flex Load Controller (FLC) Diagnostic Trouble Codes Key switch OFF.

YES: Circuit L06 BRN open on loader frame harness (W2). Repair circuit or replace harness.

Load center harness-to-engine frame harness connector (X3) disconnected. Disconnect FLC connector (X42). See Load Center Harness (W3) Component Location. (Group 9015-10.)

9001 40 ,124

Check circuit L06 BRN for continuity between pin 9 on load center harness side of connector (X3) and pin 2 on FLC connector (X42). See Load Center Harness (W3) Wiring Diagram. (Group 9015-10.)

NO: Circuit L06 BRN open on load center harness (W3). Repair circuit or replace harness.

–19– –2/2

3 Open Circuit Check— License Plate Lights

Turn key switch OFF.

YES: Reprogram Controller.

Disconnect FLC connector (X42) and license plate light (E10). See Rear Frame Harness (W13) Component Location and see Load Center Harness (W3) Component Location. (Group 9015-10.)

NO: Go to next step in this check.

Check continuity between pin A (circuit L06 BRN) on license plate light connector and pin D2 on FLC connector (X42). See Rear Frame Harness (W13) Wiring Diagram and see Load Center Harness (W3) Component Location. (Group 9015-10.) Is continuity indicated?

Key switch OFF. Engine frame harness-to-rear frame harness connector (X39) disconnected. Disconnect load center harness-to-engine frame harness connector (X3). See Engine Frame Harness (W5) Component Location. (Group 9015-10.) Check circuit L06 BRN for continuity between pin 9 on engine frame side of connector (X3) and pin 2 on engine frame side of connector (X39). See Engine Frame Harness (W5) Wiring Diagram. (Group 9015-10.)

YES: Circuit L06 BRN open on rear frame harness (W13). Repair circuit L06 BRN or replace harness. NO: Go to next step in this step.

Is continuity indicated?

Key switch OFF.

YES: Circuit L06 BRN open on engine frame harness (W5). Repair circuit L06 BRN or replace harness.

Load center harness-to-engine frame harness connector (X3) disconnected. Disconnect FLC connector (X42). See Load Center Harness (W3) Component Location. (Group 9015-10.) Check circuit L06 BRN for continuity between pin 9 on load center harness side of connector (X3) and pin D2 on FLC connector (X42). See Load Center Harness (W3) Wiring Diagram. (Group 9015-10.)

NO: Circuit L06 BRN open on load center harness (W3). Repair circuit L06 BRN or replace harness.

Is continuity indicated?

– – –1/1

4 Reprogram Controller

Reprogram flex load controller (FLC). See Electronic Controller Reconfiguration. (Group 9015-20.)

YES: Replace controller. NO: Checks complete.

Check for active codes. Is FLC code 002378.05 present? – – –1/1

TM10229 (17MAR09)

9001-40-124

544J Loader (S.N. 611800— ) 032409

PN=346

Flex Load Controller (FLC) Diagnostic Trouble Codes

002378.06 — Marker/Tail Lts High Current

There is a short to ground present on the marker/tail lights circuit.

9001 40 ,125

TF44157,0000076 –19–13MAR08–1/1

Marker/Tail Lights High Current Diagnostic Procedure

– – –1/1

1 Component Check

NOTE: Identify the marker/tail light that is malfunctioning. Follow the procedure for that light. Turn key switch OFF.

YES: Go to Short Circuit Check—Marker/Tail Lights or Go to Short Circuit Check—License Plate Lights.

Identify maker/tail light that does not illuminate. NO: Replace light(s) Remove marker/tail light or license plate light. See Rear Frame Harness (W13) Component Locationand see Loader Frame Harness (W2) Component Location. (Group 9015-10.) For tail lights (E8 and E9), apply 24 volts to pin 2 and ground to pin 1 on tail light assembly. See Rear Frame Harness (W13) Wiring Diagram. (Group 9015-10.) For marker lights (E6 and E7), apply 24 volts to pin C and ground to pin A on marker light assembly.See Loader Frame Harness (W2) Wiring Diagram. (Group 9015-10.) For license plate light (E10), apply 24 volts to pin C and ground to pin A on license plate assembly. See Rear Frame Harness (W13) Wiring Diagram. (Group 9015-10.) Does the light illuminate?

– – –1/1

TM10229 (17MAR09)

9001-40-125

544J Loader (S.N. 611800— ) 032409

PN=347

Flex Load Controller (FLC) Diagnostic Trouble Codes 2 Short Circuit Check— Marker/Tail Lights

NOTE: Identify the marker/tail light that is malfunctioning. Follow the procedure for that light.

YES: Go to next step in this check.

Turn key switch OFF.

NO: Go to Continuity Check—Marker/Tail Lights.

Disconnect marker light (E6 or E7) or tail light (E8 or E9). See Rear Frame Harness (W13) Component Location. (Group 9015-10.)

9001 40 ,126

Turn key switch ON. For marker lights (E6 or E7), check circuit L06 BRN for ground at pin C on marker light connector. See Loader Frame Harness (W2) Wiring Diagram. (Group 9015-10.) For tail lights (E8 or E9), check circuit L06 BRN for ground at pin 2 on tail light connector. See Rear Frame Harness (W13) Wiring Diagram. (Group 9015-10.) Is ground present?

Key switch OFF.

YES: For marker lights— circuit L06 BRN short to ground on loader frame harness (W2). Repair circuit L06 BRN or replace harness.

Marker light (E6 or E7) or tail light (E8 and E9) disconnected. For marker lights (E6 or E7), check the following: • Disconnect load center harness-to-loader frame harness connector (X67). See Loader Frame Harness (W2) Component Location. (Group 9015-10.) • Check circuit L06 BRN for ground at pin 6 on load center harness side of connector (X67). See Loader Frame Harness (W2) Wiring Diagram. (Group 9015-10.) For tail lights (E8 or E9), check the following: • Disconnect engine frame harness-to-rear frame harness connector (X39). See Rear Frame Harness (W13) Component Location. (Group 9015-10.) • Check circuit L06 BRN for ground at pin 2 on engine frame harness side of connector (X39). See Rear Frame Harness (W13) Wiring Diagram. (Group 9015-10.)

For tail lights—Go to next step in this check. NO: For marker lights— circuit L06 BRN short to ground on load center harness (W3). Repair circuit L06 BRN or replace harness. For tail lights—check for short to ground on circuit L06 BRN on rear frame harness (W13). Repair circuit L06 BRN or replace harness.

Is ground present?

Key switch OFF. • Disconnect load center harness-to-engine frame harness connector (X3). See Engine Frame Harness (W5) Component Location. (Group 9015-10.) • Check circuit L06 BRN for ground at pin 9 on load center harness side of connector (X3). See Engine Frame Harness (W5) Wiring Diagram. (Group 9015-10.)

YES: Circuit L06 BRN short to ground on load center harness (W3). Repair circuit L06 BRN or replace harness. NO: Circuit L06 BRN short to ground on loader frame harness (W2). Repair circuit L06 BRN or replace harness.

Is voltage present?

– – –1/1

TM10229 (17MAR09)

9001-40-126

544J Loader (S.N. 611800— ) 032409

PN=348

Flex Load Controller (FLC) Diagnostic Trouble Codes 3 Short Circuit Check— License Plate Lights

Turn key switch OFF.

YES: Go to next step in this check.

Disconnect license plate tail light (E10). See Rear Frame Harness (W13) Component Location. (Group 9015-10.) Check circuit L06 BRN for ground at pin A license plate light connector. See Rear Frame Harness (W13) Wiring Diagram. (Group 9015-10.)

NO: Go to Continuity Check—License Plate Light.

9001 40 ,127

Is ground present?

Turn key switch OFF.

YES: Go to next step in this check.

Disconnect engine frame harness-to-rear frame harness connector (X39). See Engine Frame Harness (W5) Component Location. (Group 9015-10.) Check circuit L06 BRN for ground at pin 2 on engine frame harness side of connector (X39). See Engine Frame Harness (W5) Wiring Diagram. (Group 9015-10.)

NO: Circuit L06 BRN short to ground on rear frame harness (W13. Repair circuit L06 BRN or replace harness.

Is ground present?

Turn key switch OFF. Disconnect load center harness-to-engine frame harness connector (X3). See Engine Frame Harness (W5) Component Location. (Group 9015-10.) Check circuit L06 BRN for ground at pin 9 on engine frame harness side of connector (X3). See Engine Frame Harness (W5) Wiring Diagram. (Group 9015-10.) Is ground present?

YES: Circuit L06 BRN short to ground on engine frame harness (W5). Repair circuit L06 BRN or replace harness. NO: Circuit L06 BRN short to ground on load center harness (W3). Repair circuit L06 BRN or replace harness.

– – –1/1

TM10229 (17MAR09)

9001-40-127

544J Loader (S.N. 611800— ) 032409

PN=349

Flex Load Controller (FLC) Diagnostic Trouble Codes 4 Continuity Check— Marker/Tail Lights

Turn key switch OFF. Disconnect marker light (E6 or E7) or tail light (E8 or E9). See Loader Frame Harness (W2) Component Location or see Rear Frame Harness (W13) Component Location. (Group 9015-10.)

9001 40 ,128

For tail lights (E8 or E9) check the following: • Disconnect engine frame harness-to-rear frame harness connector (X39). See Rear Frame Harness (W13) Component Location. (Group 9015-10.) • Check continuity between pin 2 (circuit L06 BRN) on rear frame harness side of connector (X39) and the remaining pins on connector (X39). See Rear Frame Harness (W13) Wiring Diagram. (Group 9015-10.)

NO: Go to next step in this check

Is continuity indicated between any pins?

Key switch OFF. For marker light (E6 and E7) check the following: • Load center harness-to-loader frame harness connector (X67) disconnected. • Disconnect flex load controller (FLC) connectors (X40, X41 and X42). See Load Center Harness (W3) Component Location. (Group 9015-10.) • Check continuity between pin D2 (circuit L06 BRN) on FLC connector (X42) and remaining pins on connectors (X40, X41 and X42). See Load Center Harness (W3) Wiring Diagram. (Group 9015-10.) For tail light (E8 and W9) check the following: • Engine frame harness-to-rear frame harness connector (X39) disconnected. • Disconnect load center harness-to-engine frame harness connector (X3). See Engine Frame Harness (W5) Component Location. (Group 9015-10.) • Check continuity between pin 2 (circuit L06 BRN) on engine frame harness side of connector (X39) and remaining pins on connector (X39). See Engine Frame Harness (W5) Wiring Diagram. (Group 9015-10.)

YES: For marker light— circuit L06 BRN short to pin that indicated continuity on load center harness (W3). Repair circuit L06 BRN or replace harness. For tail light—circuit L06 BRN short to pin that indicated continuity on engine frame harness (W5). Repair circuit L06 BRN or replace harness. NO: For marker light—go to next step in this check. For tail light—go to Reprogram Controller.

Is continuity indicated between any pins?

Key switch OFF. Load center harness-to-engine frame harness connector (X3) disconnected. Disconnect FLC connectors (X40, X41 and X42). See Load Center Harness (W3) Component Location. (Group 9015-10.) Check continuity between pin D2 (circuit L06 BRN) on FLC connector (X42) and remaining pins on connectors (X40, X41 and X42). See Engine Frame Harness (W5) Wiring Diagram. (Group 9015-10.)

YES: Circuit L06 BRN short to pin that indicated continuity on load center harness (W3). Repair circuit L06 BRN or replace harness. NO: Go to Reprogram Controller.

Is continuity indicated between any pins?

– – –1/1

TM10229 (17MAR09)

9001-40-128

544J Loader (S.N. 611800— ) 032409

PN=350

Flex Load Controller (FLC) Diagnostic Trouble Codes 5 Continuity Check— License Plate Light

Turn key switch OFF.

YES: Circuit L06 BRN short to pin that indicated continuity on rear frame harness (W13). Repair circuit L06 BRN or replace harness.

NO: Go to next step in this check.

Is continuity indicated between any pins?

YES: Circuit L06 BRN short to pin that indicated continuity on engine frame harness (W5). Repair circuit L06 BRN or replace harness. NO: Go to next step in this check.

Is continuity indicated between any pins?

Key switch OFF. Load center harness-to-engine frame harness connector (X3) disconnected. Disconnect FLC connectors (X40, X1, and X42). See Load Center Harness (W3) Component Location. (Group 9015-10.) Check continuity between pin D2 (circuit L06 BRN) on FLC connector (X3) and remaining pins on connectors (X40, X41 and X42). See Load Center Harness (W3) Wiring Diagram. (Group 9015-10.)

YES: Circuit L06 BRN short to pin that indicated continuity on load center harness (W3). Repair circuit L06 BRN or replace harness. NO: Go to Reprogram Controller.

Is continuity indicated between any pins? – – –1/1

6 Reprogram Controller

Reprogram flex load controller (FLC). See Electronic Controller Reconfiguration. (Group 9015-20.)

YES: Replace controller. NO: Checks complete.

Check for active codes. Is FLC code 002378.06 present? – – –1/1

002386.06 — Beacon Light High Current

Beacon light circuit is short to ground.

TF44157,0000077 –19–13MAR08–1/1

TM10229 (17MAR09)

9001-40-129

544J Loader (S.N. 611800— ) 032409

PN=351

9001 40 ,129

Flex Load Controller (FLC) Diagnostic Trouble Codes Beacon Light High Current diagnostic Procedure

9001 40 ,130

– – –1/1

1 Component Check

Turn key switch OFF.

YES: Go to Short Circuit Check.

Disconnect rotary beacon light (E15). See Cab Roof Harness (W19) Component Location. (Group 9015-10.)

NO: Replace rotary beacon.

Apply 24 volts to pin B and ground to pin A on rotary beacon assembly. Does rotary beacon rotate and illuminate?

– – –1/1

2 Short Circuit Check

Turn key switch OFF.

YES: Go to next step in this check.

Disconnect rotary beacon (E15). See Cab Roof Harness (W19) Component Location. (Group 9015-10.)

NO: Go to Continuity Check.

Check circuit L22 BRN for ground at pin B on rotary beacon (E15) connector. See Cab Roof Harness (W19) Wiring Diagram. (Group 9015-10.) Is ground present?

Key switch OFF. Disconnect load center harness-to-cab roof harness 12-pin connector (X5). See Cab Roof Harness (W19) Component Location. (Group 9015-10.) Check circuit L22 BRN for ground at pin 2 on load center side of connector (X5). See Cab Roof Harness (W19) Wiring Diagram. (Group 9015-10.) Is ground present?

YES: Circuit L22 BRN short to ground on cab roof harness (W19). Repair circuit L22 BRN or replace harness. NO: Circuit L22 BRN short to ground on load center harness (W3). Repair circuit L22 BRN or replace harness. – – –1/1

TM10229 (17MAR09)

9001-40-130

544J Loader (S.N. 611800— ) 032409

PN=352

Flex Load Controller (FLC) Diagnostic Trouble Codes 3 Continuity Check

Turn key switch OFF.

YES: Circuit L22 BRN short to pin that indicated continuity on cab roof harness (W19). Repair circuit L22 BRN or replace harness.

Disconnect rotary beacon (E15). See Cab Roof Harness (W19) Component Location. (Group 9015-10.) Disconnect load center harness-to-cab roof harness 12-pin connector (X5). See Cab Roof Harness (W19) Component Location. (Group 9015-10.) Check continuity between pin 2 (circuit L22 BRN) on cab roof side of connector (X5) and remaining pins on connector (X5). See Cab Roof Harness (W19) Wiring Diagram. (Group 9015-10.)

NO: Go to next step in this check.

Is continuity indicated between any pins?

Key switch OFF. Load center harness-to-cab roof harness 12-pin connector (X5) disconnected. Disconnect FLC connectors (X40, X41, and X42). See Load Center Harness (W3) Component Location. (Group 9015-10.) Check continuity between pins H1 and H2 (circuit L22 BRN) on FLC connector (X40) and the remaining pins on FLC connectors (X40, X41, and X42). See Load Center Harness (W3) Wiring Diagram. (Group 9015-10.)

YES: Circuit L22 BRN short to pin that indicated continuity on load center harness (W3). Repair circuit L22 BRN or replace harness. NO: Go to Reprogram Controller.

Is continuity indicated between any pins?

– – –1/1

4 Reprogram Controller

Reprogram flex load controller (FLC). See Electronic Controller Reconfiguration. (Group 9015-20.)

YES: Replace controller. NO: Checks complete.

Check for active codes. Is FLC code 002386.06 present? – – –1/1

002697.02 — JS Mag Out of Range

Joystick magnitude CAN message is invalid or out of range.

TF44157,0000078 –19–13MAR08–1/1

Joystick Magnitude Out of Range Diagnostic Procedure

– – –1/1

TM10229 (17MAR09)

9001-40-131

544J Loader (S.N. 611800— ) 032409

PN=353

9001 40 ,131

Flex Load Controller (FLC) Diagnostic Trouble Codes 1 Code Check

Check for communication codes in the other controllers. See CAN Monitor Unit (CMU) Menu Structure—Service Mode or see Reading Diagnostic Trouble Codes with Service ADVISOR Diagnostic Application. (Group 9015-20.)Service ADVISOR Are any communication codes present?

9001 40 ,132

YES: Diagnose other communication codes first. For a complete list of codes, see Diagnostic Trouble Codes (DTC) Quick Reference List. (Group 9015-20.) NO: Joystick controller malfunction. The joystick is not serviceable, replace joystick.

Service ADVISOR is a trademark of Deere & Company

– – –1/1

002875.04 — 4-Way Flash Sw Short to Gnd

4-way flasher switch circuit is short to ground.

TF44157,0000079 –19–13MAR08–1/1

4-Way Flasher Switch Short to Ground Diagnostic Procedure Alarm Level: No Warning Lamp

– – –1/1

1 Component Check

Turn key switch OFF.

YES: Go to Short Circuit Check.

Disconnect and remove 4-way flasher switch (S24). See Load Center Harness (W3) Component Location. (Group 9015-10.)

NO: Replace switch.

Check continuity across pins 2 and 3 on switch (S24) when the flasher switch is ON. Is continuity indicated?

– – –1/1

TM10229 (17MAR09)

9001-40-132

544J Loader (S.N. 611800— ) 032409

PN=354

Flex Load Controller (FLC) Diagnostic Trouble Codes 2 Short Circuit Check

Turn key switch OFF. Disconnect 4-way flasher switch (S24). See Load Center Harness (W3) Component Location. (Group 9015-10.) Check circuit L20 BRN for ground at pin 3 on switch (S24) connector. See Load Center Harness (W3) Wiring Diagram. (Group 9015-10.)

YES: Circuit L20 BRN short to ground on load center harness (W3). Repair circuit L20 BRN or replace harness. NO: Go to next step in this check.

Is ground present?

Key switch OFF. 4-way flasher switch (S24) disconnected. Check circuit P01 RED for ground at pin 2 on switch (S24) connector. See Load Center Harness (W3) Wiring Diagram. (Group 9015-10.)

YES: Circuit P01 RED short to ground on load center harness (W3). Repair circuit P01 RED or replace harness. NO: Go to Continuity Check.

Is ground present?

– – –1/1

3 Continuity Check

Turn key switch OFF. Disconnect 4-way flasher switch (S24). See Load Center Harness (W3) Component Location. (Group 9015-10.) Disconnect flex load controller (FLC) connectors (X40, X41, and X42). See Load Center Harness (W3) Component Location. (Group 9015-10.) Check for continuity between pin D2 (circuit L20 BRN) on FLC connector (X41) and the remaining pins on connector (X41). See Load Center Harness (W3) Wiring Diagram. (Group 9015-10.)

YES: Circuit L20 BRN short to pin that indicated continuity on load center harness (W3). Repair circuit L20 BRN or replace harness. NO: Go to Reprogram Controller.

Is continuity indicated between any pins? – – –1/1

4 Reprogram Controller

Reprogram flex load controller (FLC). See Electronic Controller Reconfiguration. (Group 9015-20.)

YES: Replace controller. NO: Checks complete.

Check for active codes. Is FLC code 002875.04 present? – – –1/1

299261.02 — Machine Config Invalid

Flex load controller (FLC), CAN monitor unit (CMU), and transmission control unit (TCU) are not configured to the same machine.

TF44157,000007A –19–13MAR08–1/1

TM10229 (17MAR09)

9001-40-133

544J Loader (S.N. 611800— ) 032409

PN=355

9001 40 ,133

Flex Load Controller (FLC) Diagnostic Trouble Codes Machine Configuration Invalid Diagnostic Procedure Alarm Level: 9001 40 ,134

No Warning Lamp

– – –1/1

1 Controller Configuration

Perform Electronic Controller Reconfiguration. (Group 9015-20.)

YES: Go to Reprogram Controller.

Is FLC code 299261.02 present? NO: Checks complete.

– – –1/1

2 Reprogram Controller

Reprogram flex load controller (FLC). See Electronic Controller Reconfiguration. (Group 9015-20.)

YES: Replace controller. NO: Checks complete.

Check for active codes. Is FLC code 299261.02 present? – – –1/1

522431.02 — Memory Test Failure

The flex load controller (FLC) has had a memory test failure.

TF44157,000007B –19–13MAR08–1/1

Memory Test Failure Diagnostic Procedure Alarm Level: No Warning Lamp

– – –1/1

TM10229 (17MAR09)

9001-40-134

544J Loader (S.N. 611800— ) 032409

PN=356

Flex Load Controller (FLC) Diagnostic Trouble Codes 1 Reprogram Controller

Reprogram flex load controller (FLC). See Electronic Controller Reconfiguration. (Group 9015-20.)

YES: Replace controller. NO: Checks complete.

Check for active codes. Is FLC code 522431.02 present? – – –1/1

522432.05 — R Wiper H-Spd Open Circuit

Rear wiper high speed circuit is open.

TF44157,000007C –19–13MAR08–1/1

Rear Wiper High-Speed Open Circuit Diagnostic Procedure Alarm Level: No Warning Lamp

– – –1/1

1 Component Check

Turn key switch OFF.

YES: Go to Open Circuit Check.

Disconnect rear wiper motor (M5). See Cab Roof Harness (W19) Component Location. (Group 9015-10.)

NO: Replace wiper motor.

Apply 24 volts to pin A on 4-pin connector and ground to single-pin connector on wiper motor. Does wiper motor activate?

– – –1/1

TM10229 (17MAR09)

9001-40-135

544J Loader (S.N. 611800— ) 032409

PN=357

9001 40 ,135

Flex Load Controller (FLC) Diagnostic Trouble Codes 2 Open Circuit Check

Turn key switch OFF.

YES: Go to Reprogram Controller.

Disconnect rear wiper motor (M5) and flex load controller (FLC) connector (X42). See Load Center Harness (W3) Component Location and see Cab Roof Harness (W19) Component Location. (Group 9015-10.) 9001 40 ,136

NO: Go to next step in this check.

Check circuit A11 ORG for continuity between pin 1 on cab roof side of connector (X6) and pin A1 on FLC connector (X42). See Load Center Harness (W3) Wiring Diagram and see Cab Roof Harness (W19) Wiring Diagram. (Group 9015-10.) Check circuit G04 BLK for continuity between rear wiper motor single-pin connector and frame ground. See Cab Roof Harness (W19) Wiring Diagram. (Group 9015-10.) Is continuity indicated?

Key switch OFF. Disconnect load center harness-to-cab roof harness 4-pin connector (X6) and load center harness-to-cab roof harness 12-pin connector (X5). See Cab Roof Harness (W19) Component Location. (Group 9015-10.) Disconnect FLC connector (X42). See Load Center Harness (W3) Component Location. (Group 9015-10.) Check circuit A11 ORG for continuity between pin 1 on load center side of connector (X6) and pin A1 on FLC connector (X42). See Load Center Harness (W3) Wiring Diagram. (Group 9015-10.)

YES: Open on circuit that does not indicate continuity on cab roof harness (W19). Repair circuit or replace harness. NO: Open on circuit that does not indicate continuity on load center harness (W3). Repair circuit or replace harness.

Check circuit G04 BLK for continuity between pin 8 on load center side of connector (X5) and frame ground. See Load Center Harness (W3) Wiring Diagram. (Group 9015-10.) Is continuity indicated?

– – –1/1

3 Reprogram Controller

Reprogram flex load controller (FLC). See Electronic Controller Reconfiguration. (Group 9015-20.)

YES: Replace controller. NO: Checks complete.

Check for active codes. Is FLC code 522432.05 present? – – –1/1

522432.06 — R Wiper H-Spd High Current

Rear wiper high speed circuit is short to ground.

TF44157,000007D –19–13MAR08–1/1

TM10229 (17MAR09)

9001-40-136

544J Loader (S.N. 611800— ) 032409

PN=358

Flex Load Controller (FLC) Diagnostic Trouble Codes Rear Wiper High-Speed High Current Diagnostic Procedure Alarm Level: No Warning Lamp

9001 40 ,137

– – –1/1

1 Component Check

Turn key switch OFF.

YES: Go to Short Circuit Check.

Disconnect rear wiper motor (M5). See Cab Roof Harness (W19) Component Location. (Group 9015-10.)

NO: Replace wiper motor.

Apply 24 volts to pin A on 4-pin connector and ground to single-pin connector on wiper motor. Does wiper motor activate?

– – –1/1

2 Short Circuit Check

Turn key switch OFF.

YES: Go to next step in this check.

Disconnect rear wiper motor (M5). See Cab Roof Harness (W19) Component Location. (Group 9015-10.)

NO: Go to Continuity Check.

Check circuit A11 ORG for ground at pin 1 on rear wiper motor (M5). See Cab Roof Harness (W19) Wiring Diagram. (Group 9015-10.) Is ground present?

Key switch OFF. Disconnect load center harness-to-cab roof harness 4-pin connector (X6). See Load Center Harness (W3) Component Location. (Group 9015-10.) Check circuit A11 ORG for ground at pin 1 on load center side of connector (X6). See Load Center Harness (W3) Wiring Diagram. (Group 9015-10.) Is ground present?

YES: Circuit A11 ORG short to ground on load center harness (W5). Repair circuit A11 ORG or replace harness. NO: Circuit A11 ORG short to ground on cab roof harness (W19). Repair circuit A11 ORG or replace harness. – – –1/1

TM10229 (17MAR09)

9001-40-137

544J Loader (S.N. 611800— ) 032409

PN=359

Flex Load Controller (FLC) Diagnostic Trouble Codes 3 Continuity Check

Turn key switch OFF. Disconnect rear wiper motor (M5). See Cab Roof Harness (W19) Component Location. (Group 9015-10.) Disconnect load center harness-to-cab roof harness 4-pin connector (X6). See Cab Roof Harness (W19) Component Location. (Group 9015-10.)

9001 40 ,138

Check continuity between pin 1 (circuit A11 ORG) on cab roof side of connector (X6) and remaining pins on cab roof side of connector (X6). See Cab Roof Harness (W19) Wiring Diagram. (Group 9015-10.)

YES: Circuit A11 ORG short to pin that indicated continuity on cab roof harness (W19). Repair circuit A11 ORG or replace harness. NO: Go to next step in this check.

Is continuity indicated between any pins?

Key switch OFF. Load center harness-to-cab roof harness 4-pin connector (X6) disconnected. Disconnect FLC connectors (X40, X41, and X42). See Load Center Harness (W3) Component Location. (Group 9015-10.) Check continuity between pin A1 (circuit A11 ORG) on FLC connector (X42) and remaining pins on connectors (X40, X41, and X42). See Load Center Harness (W3) Wiring Diagram. (Group 9015-10.)

YES: Circuit A11 ORG short to ground on load center harness (W5). Repair circuit A11 ORG or replace harness. NO: Go to Reprogram Controller.

Is continuity indicated between any pins?

– – –1/1

4 Reprogram Controller

Reprogram flex load controller (FLC). See Electronic Controller Reconfiguration. (Group 9015-20.)

YES: Replace controller. NO: Checks complete.

Check for active codes. Is FLC code 522432.06 present? – – –1/1

522433.05 — R Wiper L-Spd Open or Short

Rear wiper low speed circuit is open or short to power.

TF44157,000007E –19–13MAR08–1/1

TM10229 (17MAR09)

9001-40-138

544J Loader (S.N. 611800— ) 032409

PN=360

Flex Load Controller (FLC) Diagnostic Trouble Codes Rear Wiper Low-Speed Open or Short Diagnostic Procedure Alarm Level: No Warning Lamp

9001 40 ,139

– – –1/1

1 Component Check

Turn key switch OFF.

YES: Go to Short Circuit Check.

Disconnect rear wiper motor (M5). See Cab Roof Harness (W19) Component Location. (Group 9015-10.)

NO: Replace wiper motor.

Apply 24 volts to pin B on 4-pin connector and ground to single-pin connector on wiper motor. Does wiper motor activate?

– – –1/1

2 Short Circuit Check

Turn key switch OFF.

YES: Go to next step in this check.

Disconnect rear wiper motor (M5). See Cab Roof Harness (W19) Component Location. (Group 9015-10.)

NO: Go to Open Circuit Check.

Turn key switch ON. Verify wiper low speed is not activated. Check circuit A12 ORG for system voltage at pin B on wiper motor connector. See Cab Roof Harness (W19) Wiring Diagram. (Group 9015-10.) Is system voltage present?

Turn key switch OFF. Disconnect load center harness-to-cab roof harness 4-pin connector (X6). See Cab Roof Harness (W19) Component Location. (Group 9015-10.)

YES: Circuit A12 ORG short to power on load center harness (W3). Repair circuit A12 ORG or replace harness.

Turn key switch ON. Verify wiper low speed is not activated. Check circuit A12 ORG for voltage at pin 2 on load center side of connector (X6). See Load Center Harness (W3) Wiring Diagram. (Group 9015-10.)

NO: Circuit A12 ORG short to power on cab frame harness (W19). Repair circuit A12 ORG or replace harness.

Is system voltage present?

– – –1/1

TM10229 (17MAR09)

9001-40-139

544J Loader (S.N. 611800— ) 032409

PN=361

Flex Load Controller (FLC) Diagnostic Trouble Codes 3 Open Circuit Check

Turn key switch OFF.

YES: Go to next step in this check.

Disconnect rear wiper motor (M5), load center harness-to-cab roof harness 4-pin connector (X6), and load center harness-to-cab roof harness 12-pin connector (X5). See Cab Roof Harness (W19) Component Location. (Group 9015-10.) 9001 40 ,140

Check circuit A12 ORG for continuity between pin 2 on cab roof side of connector (X6) and pin B on rear wiper motor connector. See Cab Roof Harness (W19) Wiring Diagram. (Group 9015-10.)

NO: Open on circuit that did not indicate continuity on cab roof harness (W19). Repair circuit or replace harness.

Check circuit G04 BLK for continuity between pin 8 on cab roof side of connector (X5) and single-pin connector on rear wiper motor. See Cab Roof Harness (W19) Wiring Diagram. (Group 9015-10.) Is continuity indicated?

Key switch OFF.

YES: Go to Continuity Check.

Load center harness-to-cab roof harness 4-pin connector (X6) and load center harness-to-cab roof harness 12-pin connector (X5) disconnected. Disconnect flex load controller (FLC) connector (X42). See Load Center Harness (W3) Component Location. (Group 9015-10.)

NO: Open on circuit that indicated continuity on load center harness (W3). Repair circuit or replace harness.

Check circuit A12 ORG for continuity between pin 2 on load center side of connector (X6) and pin D3 on FLC connector (X42). See Load Center Harness (W3) Wiring Diagram. (Group 9015-10.) Check circuit G04 BLK for continuity between pin 8 on load center side of connector (X5) and frame ground. See Load Center Harness (W3) Wiring Diagram. (Group 9015-10.) Is continuity indicated?

– – –1/1

TM10229 (17MAR09)

9001-40-140

544J Loader (S.N. 611800— ) 032409

PN=362

Flex Load Controller (FLC) Diagnostic Trouble Codes 4 Continuity Check

Turn key switch OFF. Disconnect rear wiper motor (M5) and load center harness-to-cab roof harness 4-pin connector (X6). See Cab Roof Harness (W19) Component Location. (Group 9015-10.) Check for continuity between pin 2 (circuit A12 ORG) on cab roof side of connector (X6) and remaining pins on cab roof side of connector (X6). See Cab Roof Harness (W19) Wiring Diagram. (Group 9015-10.)

YES: Circuit A12 ORG short to pin that indicated continuity on cab roof harness (W19). Repair circuit or replace harness. NO: Go to next step in this check.

Is continuity indicated between any pins?

Key switch OFF. Load center harness-to-cab roof harness 4-pin connector (X6) disconnected. Disconnect flex load controller (FLC) connectors (X40, X41, and X42). See Load Center Harness (W3) Component Location. (Group 9015-10.) Check for continuity between pin D3 (circuit A12 ORG) on FLC connector (X40) and remaining pins on FLC connectors (X40, X41, and X42). See Load Center Harness (W3) Wiring Diagram. (Group 9015-10.)

YES: Circuit A12 ORG short to pin that indicated continuity on load center harness (W5). Repair circuit A12 ORG or replace harness. NO: Go to Reprogram Controller.

Is continuity indicated between any pins?

– – –1/1

5 Reprogram Controller

Reprogram flex load controller (FLC). See Electronic Controller Reconfiguration. (Group 9015-20.)

YES: Replace controller. NO: Checks complete.

Check for active codes. Is FLC code 522433.05 present? – – –1/1

522433.06 — R Wiper L-Spd High Current

Rear wiper motor circuit is short to ground.

TF44157,000007F –19–13MAR08–1/1

TM10229 (17MAR09)

9001-40-141

544J Loader (S.N. 611800— ) 032409

PN=363

9001 40 ,141

Flex Load Controller (FLC) Diagnostic Trouble Codes Rear Wiper Low-Speed High Current Diagnostic Procedure Alarm Level: 9001 40 ,142

No Warning Lamp

– – –1/1

1 Component Check

Turn key switch OFF.

YES: Go to Short Circuit Check.

Disconnect rear wiper motor (M5). See Cab Roof Harness (W19) Component Location. (Group 9015-10.)

NO: Replace wiper motor.

Apply 24 volts to pin B on 4-pin connector and ground to single-pin connector on wiper motor. Does wiper motor activate?

– – –1/1

2 Short Circuit Check

Turn key switch OFF. Disconnect rear wiper motor (M5) and load center harness-to-cab roof harness 4-pin connector (X6). See Cab Roof Harness (W19) Component Location. (Group 9015-10.) Check circuit A12 ORG for ground at pin 2 on cab roof side of connector (X6). See Cab Roof Harness (W19) Wiring Diagram. (Group 9015-10.)

YES: Circuit A12 ORG short to ground on cab roof harness (W19). Repair circuit A12 ORG or replace harness. NO: Go to next step in this check.

Is ground present?

Key switch OFF. Load center harness-to-cab roof harness 4-pin connector (X6) disconnected. Disconnect flex load controller (FLC) connector (X42). See Load Center Harness (W3) Component Location. (Group 9015-10.) Check circuit A12 ORG for ground at pin 2 on load center side of connector (X6). See Load Center Harness (W3) Wiring Diagram. (Group 9015-10.)

YES: Circuit A12 ORG short to ground on load center harness (W5). Repair circuit A12 ORG or replace harness. NO: Go to Continuity Check.

Is ground present? – – –1/1

TM10229 (17MAR09)

9001-40-142

544J Loader (S.N. 611800— ) 032409

PN=364

Flex Load Controller (FLC) Diagnostic Trouble Codes 3 Continuity Check

YES: Circuit A12 ORG short to pin that indicated continuity on cab roof harness (W19). Repair circuit A12 ORG or replace harness. NO: Go to next step in this check.

Is continuity indicated between any pins?

YES: Circuit A12 ORG short to pin that indicated continuity on load center harness (W5). Repair circuit A12 ORG or replace harness. NO: Go to Reprogram Controller.

Is continuity indicated between any pins?

– – –1/1

4 Reprogram Controller

Reprogram flex load controller (FLC). See Electronic Controller Reconfiguration. (Group 9015-20.)

YES: Replace controller. NO: Checks complete.

Check for active codes. Is FLC code 522433.06 present? – – –1/1

522434.05 — F Wiper L-Spd Open or Short

Front wiper motor circuit is open or short to power.

TF44157,0000080 –19–13MAR08–1/1

TM10229 (17MAR09)

9001-40-143

544J Loader (S.N. 611800— ) 032409

PN=365

9001 40 ,143

Flex Load Controller (FLC) Diagnostic Trouble Codes Front Wiper Low-Speed Open or Short Diagnostic Procedure Alarm Level: 9001 40 ,144

No Warning Lamp

– – –1/1

1 Component Check

Turn key switch OFF.

YES: Go to Short Circuit Check.

Disconnect front wiper motor (M3). See Front Console Harness (W4) Component Location. (Group 9015-10.)

NO: Replace wiper motor.

Apply 24 volts to pin B on 4-pin connector and ground to single-pin connector on wiper motor. Does wiper motor activate?

– – –1/1

2 Short Circuit Check

Turn key switch OFF.

YES: Go to next step in this check.

Disconnect front wiper motor (M3). See Front Console Harness (W4) Component Location. (Group 9015-10.)

NO: Go to Open Circuit Check.

Turn key switch ON. Verify front wiper motor is not activated. Check circuit A08 ORG for voltage at pin B on wiper motor connector. See Front Console Harness (W4) Wiring Diagram. (Group 9015-10.) Is system voltage present?

Turn key switch OFF. Disconnect load center harness-to-front console harness connector (X30). See Front Console Harness (W4) Component Location. (Group 9015-10.)

YES: Circuit A08 ORG short to power on load center harness (W3). Repair circuit A08 ORG or replace harness.

Turn key switch ON. Verify front wiper motor is not activated. Check circuit A08 ORG for voltage at pin 2 on load center side of connector (X30). See Front Console Harness (W4) Wiring Diagram. (Group 9015-10.)

NO: Circuit A08 short to power on front console harness (W4). Repair circuit A08 ORG or replace harness.

Is system voltage present?

– – –1/1

TM10229 (17MAR09)

9001-40-144

544J Loader (S.N. 611800— ) 032409

PN=366

Flex Load Controller (FLC) Diagnostic Trouble Codes 3 Open Circuit Check

Turn key switch OFF.

YES: Go to next step in this check.

Disconnect front wiper motor (M3) and load center harness-to-front console harness connector (X30). See Front Console Harness (W4) Component Location. (Group 9015-10.) Check circuit A08 ORG for continuity between pin 2 on front console harness side of connector (X30) and pin B on front wiper motor connector. See Front Console Harness (W4) Wiring Diagram. (Group 9015-10.)

NO: Open on circuit that did not indicate continuity on front console harness 9001 (W4). Repair circuit or 40 replace harness. ,145

Check circuit G08 BLK for continuity between pin 12 on front console harness side of connector (X30) and single-pin connector on front wiper motor connector. See Front Console Harness (W4) Wiring Diagram. (Group 9015-10.) Is continuity indicated?

Key switch OFF.

YES: Go to Continuity Check.

Load center harness-to-front console harness connector (X30) disconnected. Disconnect flex load controller (FLC) connector (X42). See Load Center Harness (W3) Component Location. (Group 9015-10.) Check circuit A08 ORG for continuity between pin 2 on load center side of connector (X30) and pin E3 on FLC connector (X42). See Load Center Harness (W3) Wiring Diagram. (Group 9015-10.)

NO: Open on circuit that did not indicate continuity on load center harness (W3). Repair circuit or replace harness.

Check circuit G08 BLK for continuity between pin 12 on load center side of connector (X30) and frame ground. See Load Center Harness (W3) Wiring Diagram. (Group 9015-10.) Is continuity indicated?

– – –1/1

TM10229 (17MAR09)

9001-40-145

544J Loader (S.N. 611800— ) 032409

PN=367

Flex Load Controller (FLC) Diagnostic Trouble Codes 4 Continuity Check

Turn key switch OFF.

YES: Go to next step in this check.

Disconnect front wiper motor (M3) and load center harness-to-front console harness connector (X30). See Front Console Harness (W4) Component Location. (Group 9015-10.) 9001 40 ,146

Check for continuity between pin 2 (circuit A08 ORG) on front console harness side of connector (X30) and remaining pins on front console side of connector (X30). See Front Console Harness (W4) Wiring Diagram. (Group 9015-10.)

NO: Circuit A08 ORG short to pin that indicated continuity on front console harness (W4). Repair circuit A08 ORG or replace harness.

Is continuity indicated between any pins?

Key switch OFF.

YES: Go to Reprogram Controller.

Load center harness-to-front console harness connector (X30) disconnected. Disconnect flex load controller (FLC) connectors (X40, X41, and X42). See Load Center Harness (W3) Component Location. (Group 9015-10.) Check for continuity between pin E3 (circuit A08 ORG) on FLC connector (X40) and remaining pins on connectors (X40, X41, and X42). See Load Center Harness (W3) Wiring Diagram. (Group 9015-10.)

NO: Circuit A08 ORG short to pin that indicated continuity on load center harness (W3). Repair circuit A08 ORG or replace harness.

Is continuity indicated between any pins?

– – –1/1

5 Reprogram Controller

Reprogram flex load controller (FLC). See Electronic Controller Reconfiguration. (Group 9015-20.)

YES: Replace controller. NO: Checks complete.

Check for active codes. Is FLC code 522434.05 present? – – –1/1

522434.06 — F Wiper L-Spd High Current

Front wiper motor low speed circuit is short to ground.

TF44157,0000081 –19–13MAR08–1/1

TM10229 (17MAR09)

9001-40-146

544J Loader (S.N. 611800— ) 032409

PN=368

Flex Load Controller (FLC) Diagnostic Trouble Codes Front Wiper Low-Speed High Current Diagnostic Procedure Alarm Level: No Warning Lamp

9001 40 ,147

– – –1/1

1 Component Check

Turn key switch OFF.

YES: Go to Short Circuit Check.

Disconnect front wiper motor (M3). See Front Console Harness (W4) Component Location. (Group 9015-10.)

NO: Replace wiper motor.

Apply 24 volts to pin B on 4-pin connector and ground to single-pin connector on wiper motor. Does wiper motor activate?

– – –1/1

2 Short Circuit Check

Turn key switch OFF. Disconnect front wiper motor (M3) and load center harness-to-front console harness connector (X30). See Front Console Harness (W4) Component Location. (Group 9015-10.)

YES: Circuit A08 ORG short to ground on front console harness (W4). Repair circuit A08 ORG or replace harness.

Check circuit A08 ORG for ground at pin 2 on front console harness side of connector (X30). See Front Console Harness (W4) Wiring Diagram. (Group 9015-10.)

NO: Go to next step in this check.

Is ground present?

Key switch OFF. Load center harness-to-front console harness connector (X30) disconnected. Disconnect flex load controller (FLC) connector (X42). See Load Center Harness (W3) Component Location. (Group 9015-10.) Check circuit A08 ORG for ground at pin 2 on load center harness side of connector (X30). See Load Center Harness (W3) Wiring Diagram. (Group 9015-10.)

YES: Circuit A08 ORG short to ground on load center harness (W5). Repair circuit A08 ORG or replace harness. NO: Go to Continuity Check.

Is ground present? – – –1/1

TM10229 (17MAR09)

9001-40-147

544J Loader (S.N. 611800— ) 032409

PN=369

Flex Load Controller (FLC) Diagnostic Trouble Codes 3 Continuity Check

Turn key switch OFF. Disconnect front wiper motor (M3) and load center harness-to-front console harness connector (X30). See Front Console Harness (W4) Component Location. (Group 9015-10.)

9001 40 ,148

Check continuity between pin 2 (circuit A08 ORG) on front console side of connector (X30) and remaining pins on cab roof side of connector (X30). See Front Console Harness (W4) Wiring Diagram. (Group 9015-10.)

YES: Circuit A08 ORG short to pin that indicated continuity on front console harness (W4). Repair circuit A08 ORG or replace harness. NO: Go to next step in this check.

Is continuity indicated between any pins?

Key switch OFF. Load center harness-to-front console harness connector (X30) disconnected. Disconnect flex load controller (FLC) connectors (X40, X41, and X42). See Load Center Harness (W3) Component Location. (Group 9015-10.) Check continuity between pin E3 (circuit A08 ORG) on FLC connector (X40) and remaining pins on connectors (X40, X41, and X42) See Load Center Harness (W3) Wiring Diagram. (Group 9015-10.)

YES: Circuit A08 ORG short to pin that indicated continuity on load center harness (W3). Repair circuit A08 ORG or replace harness. NO: Go to Reprogram Controller.

Is continuity indicated between any pins?

– – –1/1

4 Reprogram Controller

Reprogram flex load controller (FLC). See Electronic Controller Reconfiguration. (Group 9015-20.)

YES: Replace controller. NO: Checks complete.

Check for active codes. Is FLC code 522434.06 present? – – –1/1

522435.05 — F Wiper H-Spd Open Circuit

Front wiper high speed circuit is open.

TF44157,0000082 –19–13MAR08–1/1

TM10229 (17MAR09)

9001-40-148

544J Loader (S.N. 611800— ) 032409

PN=370

Flex Load Controller (FLC) Diagnostic Trouble Codes Front Wiper High-Speed Open Circuit Diagnostic Procedure Alarm Level: No Warning Lamp

9001 40 ,149

– – –1/1

1 Component Check

Turn key switch OFF.

YES: Go to Open Circuit Check.

Disconnect front wiper motor (M3). See Front Console Harness (W4) Component Location. (Group 9015-10.)

NO: Replace wiper motor.

Apply 24 volts to pin B on 4-pin connector and ground to single-pin connector on wiper motor. Does wiper motor activate?

– – –1/1

TM10229 (17MAR09)

9001-40-149

544J Loader (S.N. 611800— ) 032409

PN=371

Flex Load Controller (FLC) Diagnostic Trouble Codes 2 Open Circuit Check

Turn key switch OFF.

YES: Go to next step in this check.

Disconnect front wiper motor (M3) and load center harness-to-front console harness connector (X30). See Front Console Harness (W4) Component Location. (Group 9015-10.) 9001 40 ,150

Check circuit A07 ORG for continuity between pin 1 on front console harness side of connector (X30) and pin A on front wiper motor connector. See Front Console Harness (W4) Wiring Diagram. (Group 9015-10.)

NO: Open circuit on front console harness (W4). Repair circuit or replace harness.

Check circuit G08 BLK for continuity between pin 21 on front console harness side of connector (X30) and single-pin connector on front wiper motor. See Front Console Harness (W4) Wiring Diagram. (Group 9015-10.) Is continuity indicated?

Key switch OFF.

YES: Go to Reprogram Controller.

Load center harness-to-front console harness connector (X30) disconnected. Disconnect flex load controller (FLC) connector (X42). See Load Center Harness (W3) Component Location. (Group 9015-10.)

NO: Open circuit on load center harness (W3). Repair circuit or replace harness.

Check circuit A07 ORG for continuity between pin 1 on load center side of connector (X30) and pin C1 on FLC connector (X42). See Load Center Harness (W3) Wiring Diagram. (Group 9015-10.) Check circuit G08 BLK for continuity between pin 21 on load center side of connector (X30) and frame ground. See Load Center Harness (W3) Wiring Diagram. (Group 9015-10.) Is continuity indicated?

– – –1/1

3 Reprogram Controller

Reprogram flex load controller (FLC). See Electronic Controller Reconfiguration. (Group 9015-20.)

YES: Replace controller. NO: Checks complete.

Check for active codes. Is FLC code 522435.05 present? – – –1/1

522435.06 — F Wiper H-Spd High Current

Front wiper high speed circuit is short to ground.

TF44157,0000083 –19–13MAR08–1/1

TM10229 (17MAR09)

9001-40-150

544J Loader (S.N. 611800— ) 032409

PN=372

Flex Load Controller (FLC) Diagnostic Trouble Codes Front Wiper High-Speed High Current Diagnostic Procedure Alarm Level: No Warning Lamp

9001 40 ,151

– – –1/1

1 Component Check

Turn key switch OFF.

YES: Go to Short Circuit Check.

Disconnect front wiper motor (M3). See Front Console Harness (W4) Component Location. (Group 9015-10.)

NO: Replace wiper motor.

Apply 24 volts to pin B on 4-pin connector and ground to single-pin connector on wiper motor. Does wiper motor activate?

– – –1/1

2 Short Circuit Check

Turn key switch OFF. Disconnect front wiper motor (M3) and load center harness-to-front console harness connector (X30). See Front Console Harness (W4) Component Location. (Group 9015-10.)

YES: Circuit A07 ORG short to ground on front console harness (W4). Repair circuit A07 ORG or replace harness.

Check circuit A07 ORG for ground at pin 1 on front console harness side of connector (X30). See Front Console Harness (W4) Wiring Diagram. (Group 9015-10.)

NO: Go to next step in this check.

Is ground present?

Key switch OFF. Load center harness-to-front console harness connector (X30) disconnected. Disconnect flex load center harness (FLC) connector (X42). See Load Center Harness (W3) Component Location. (Group 9015-10.) Check circuit A07 ORG for ground at pin 1 on load center side of connector (X30). See Load Center Harness (W3) Wiring Diagram. (Group 9015-10.)

YES: Circuit A07 ORG short to ground on load center harness (W5). Repair circuit A07 ORG or replace harness. NO: Go to Continuity Check.

Is ground present? – – –1/1

TM10229 (17MAR09)

9001-40-151

544J Loader (S.N. 611800— ) 032409

PN=373

Flex Load Controller (FLC) Diagnostic Trouble Codes 3 Continuity Check

Turn key switch OFF. Disconnect front wiper motor (M3) and load center harness-to-front console harness connector (X30). See Front Console Harness (W4) Component Location. (Group 9015-10.)

9001 40 ,152

Check continuity between pin 1 (circuit A07 ORG) on front console side of connector (X30) and remaining pins on cab roof side of connector (X30). See Front Console Harness (W4) Wiring Diagram. (Group 9015-10.)

YES: Circuit A07 ORG short to pin that indicated continuity on front console harness (W4). Repair circuit A07 ORG or replace harness. NO: Go to next step in this check.

Is continuity indicated between any pins?

Key switch OFF. Load center harness-to-front console harness connector (X30) disconnected. Disconnect FLC connectors (X40, X41, and X42). See Load Center Harness (W3) Component Location. (Group 9015-10.) Check continuity between pin C1 (circuit A07 ORG) on FLC connector (X42) and remaining pins on connectors (X40, X41, and X42). See Load Center Harness (W3) Wiring Diagram. (Group 9015-10.)

YES: Circuit A07 ORG short to pin that indicated continuity on load center harness (W3). Repair circuit A07 ORG or replace harness. NO: Go to Reprogram Controller.

Is continuity indicated between any pins?

– – –1/1

4 Reprogram Controller

Reprogram flex load controller (FLC). See Electronic Controller Reconfiguration. (Group 9015-20.)

YES: Replace controller. NO: Checks complete.

Check for active codes. Is FLC code 522435.06 present? – – –1/1

522436.03 — Bucket Pos Short to Power

Return-to-dig sensor circuit is short to power.

TF44157,0000084 –19–13MAR08–1/1

TM10229 (17MAR09)

9001-40-152

544J Loader (S.N. 611800— ) 032409

PN=374

Flex Load Controller (FLC) Diagnostic Trouble Codes Bucket Position Short to Power Diagnostic Procedure Alarm Level: No Warning Lamp

9001 40 ,153

– – –1/1

1 Component Check

Turn key switch OFF.

YES: Go to Short Circuit Check.

Disconnect return-to-dig sensor (B37). See Loader Frame Harness (W2) Component Location. (Group 9015-10.)

NO: Replace sensor.

Check for resistance across pins A and C on sensor (B37). Specification Analog Return-to-Dig Sensor (B37) (Powerllel linkage only)—Resistance ........................................................ 4—6 kilo-ohms Is sensor within specification?

– – –1/1

TM10229 (17MAR09)

9001-40-153

544J Loader (S.N. 611800— ) 032409

PN=375

Flex Load Controller (FLC) Diagnostic Trouble Codes 2 Short Circuit Check

Turn key switch OFF.

YES: Go to next step in this check.

Disconnect return-to-dig sensor (B37). See Loader Frame Harness (W2) Component Location. (Group 9015-10.)

NO: Go to Continuity Check.

Turn key switch ON.

9001 40 ,154

Check circuit H05 GRN for voltage at pin B on return-to-dig sensor connector. See Loader Frame Harness (W2) Wiring Diagram. (Group 9015-10.) Is system voltage present?

Turn key switch OFF. Return-to-dig sensor (B37) disconnected. Disconnect load center harness-to-loader frame harness connector (X67). See Loader Frame Harness (W2) Component Location. (Group 9015-10.)

YES: Circuit H05 GRN short to power on loader frame harness (W2). Repair circuit H05 GRN or replace harness. NO: Go to next step in this check.

Turn key switch ON. Check circuit H05 GRN for voltage at pin 15 on loader frame side of connector (X67). See Loader Frame Harness (W2) Wiring Diagram. (Group 9015-10.) Is system voltage present?

Turn key switch OFF. Load center harness-to-loader frame harness connector (X67) disconnected. Disconnect flex load controller (FLC) connector (X41). See Load Center Harness (W3) Component Location. (Group 9015-10.)

YES: Circuit H05 GRN short to power on load center harness (W3). Repair circuit H05 GRN or replace harness. NO: Go to Continuity Check.

Turn key switch ON. Check circuit H05 GRN for voltage at pin 15 on load center side of connector (X67). See Load Center Harness (W3) Wiring Diagram. (Group 9015-10.) Is system voltage present?

– – –1/1

TM10229 (17MAR09)

9001-40-154

544J Loader (S.N. 611800— ) 032409

PN=376

Flex Load Controller (FLC) Diagnostic Trouble Codes 3 Continuity Check

Turn key switch OFF. Disconnect return-to-dig sensor (B37) and load center harness-to-loader frame harness connector (X67). See Loader Frame Harness (W2) Component Location. (Group 9015-10.) Check continuity between pin 15 (circuit H05 GRN) on loader frame side of connector (X67) and remaining pins on connector (X67). See Loader Frame Harness (W2) Wiring Diagram. (Group 9015-10.)

YES: Circuit H05 GRN short to pin that indicated continuity on loader frame harness (W2). Repair circuit H05 GRN or replace harness. NO: Go to next step in this check.

Is continuity indicated between any pins?

Key switch OFF. Load center harness-to-loader frame harness connector (X67) disconnected. Disconnect FLC connectors (X40, X41, and X42). See Load Center Harness (W3) Component Location. (Group 9015-10.) Check continuity between pin C3 (circuit H05 GRN) on FLC connector (X41) and remaining pins on connectors (X40, X41, and X42). See Load Center Harness (W3) Wiring Diagram. (Group 9015-10.)

YES: Circuit H05 GRN short to pin that indicated continuity on load center harness (W3). Repair circuit H05 GRN or replace harness. NO: Go to Reprogram Controller.

Is continuity indicated between any pins?

– – –1/1

4 Reprogram Controller

Reprogram flex load controller (FLC). See Electronic Controller Reconfiguration. (Group 9015-20.)

YES: Replace controller. NO: Checks complete.

Check for active codes. Is FLC code 522436.03 present? – – –1/1

522436.04 — Bucket Pos Open or Short

Return-to-dig sensor circuit is open or short to ground.

TF44157,0000085 –19–13MAR08–1/1

TM10229 (17MAR09)

9001-40-155

544J Loader (S.N. 611800— ) 032409

PN=377

9001 40 ,155

Flex Load Controller (FLC) Diagnostic Trouble Codes Bucket Position Open or Short Diagnostic Procedure Alarm Level: 9001 40 ,156

No Warning Lamp

– – –1/1

1 Component Check

Turn key switch OFF.

YES: Go to Short Circuit Check.

Disconnect return-to-dig sensor (B37). See Loader Frame Harness (W2) Component Location. (Group 9015-10.)

NO: Replace sensor.

– – –1/1

2 Short Circuit Check

Turn key switch OFF. Disconnect return-to-dig sensor (B37) load center harness-to-loader frame harness connector (X67). See Loader Frame Harness (W2) Component Location. (Group 9015-10.)

YES: Circuit H05 GRN short to power on loader frame harness (W2). Repair circuit H05 GRN or replace harness.

Check circuit H05 GRN for voltage at pin B on return-to-dig sensor connector. See Loader Frame Harness (W2) Wiring Diagram. (Group 9015-10.)

NO: Go to next step I this check.

Is system voltage present?

Key switch OFF. Load center harness-to-loader frame harness connector (X67) disconnected. Disconnect flex load controller (FLC) connector (X41). See Load Center Harness (W3) Component Location. (Group 9015-10.) Check circuit H05 GRN for voltage at pin 15 on load center side of connector (X67). See Load Center Harness (W3) Wiring Diagram. (Group 9015-10.)

YES: Circuit H05 GRN short to power on load center harness (W3). Repair circuit H05 GRN or replace harness. NO: Go to Open Circuit Check.

Is system voltage present? – – –1/1

TM10229 (17MAR09)

9001-40-156

544J Loader (S.N. 611800— ) 032409

PN=378

Flex Load Controller (FLC) Diagnostic Trouble Codes 3 Open Circuit Check

Turn key switch OFF.

YES: Go to next step in this check.

Disconnect return-to-dig sensor (B37) and load center harness-to-loader frame harness connector (X67). See Loader Frame Harness (W2) Component Location. (Group 9015-10.) Check circuit H05 GRN for continuity between pin 15 on loader frame side of connector (X67) and pin B on return-to-dig sensor (B37). See Loader Frame Harness (W2) Wiring Diagram. (Group 9015-10.)

NO: Open on loader frame harness (W2). Repair circuit or replace harness.

Check circuit P68 RED for continuity between pin 20 on loader frame side of connector (X67) and pin C on return-to-dig sensor (B37). See Loader Frame Harness (W2) Wiring Diagram. (Group 9015-10.) Check circuit R68 BLK for continuity between pin 7 on loader frame side of connector (X67) and pin A on return-to-dig sensor (B37). See Loader Frame Harness (W2) Wiring Diagram. (Group 9015-10.) Is continuity indicated?

Key switch OFF.

YES: Go to Continuity Check.

Load center harness-to-loader frame harness connector (X67) disconnected. Disconnect flex load controller (FLC) connector (X41). See Load Center Harness (W3) Component Location. (Group 9015-10.)

NO: Open on load center harness (W3). Repair circuit or replace harness.

Check circuit H05 GRN for continuity between pin 15 on load center side of connector (X67) and pin C3 on FLC connector (X41). See Load Center Harness (W3) Wiring Diagram. (Group 9015-10.) Check circuit P68 RED for continuity between pin 20 on load center side of connector (X67) and pin K1 on FLC connector (X41). See Load Center Harness (W3) Wiring Diagram. (Group 9015-10.) Check circuit R68 BLK for continuity between pin 7 on load center side of connector (X67) and pin K2 on FLC connector (X41). See Load Center Harness (W3) Wiring Diagram. (Group 9015-10.) Is continuity indicated?

– – –1/1

TM10229 (17MAR09)

9001-40-157

544J Loader (S.N. 611800— ) 032409

PN=379

9001 40 ,157

Flex Load Controller (FLC) Diagnostic Trouble Codes 4 Continuity Check

Turn key switch OFF.

YES: Go to next step in this check.

Disconnect return-to-dig sensor (B37) and load center harness-to-loader frame harness connector (X67). See Loader Frame Harness (W2) Component Location. (Group 9015-10.) 9001 40 ,158

Check for continuity between pin 15 (circuit H05 GRN) on loader frame side of connector (X67) and the remaining pins on loader frame side of connector (X67). See Loader Frame Harness (W2) Wiring Diagram. (Group 9015-10.)

NO: Circuit H05 GRN short to pin that indicated continuity on loader frame harness (W2). Repair circuit H05 GRN or replace harness.

Is continuity indicated between any pins?

Key switch OFF.

YES: Go to Reprogram Controller.

Load center harness-to-loader frame harness connector (X67) disconnected. Disconnect FLC connectors (X40, X41, and X42). See Load Center Harness (W3) Component Location. (Group 9015-10.) Check for continuity between pin C3 (circuit H05 GRN) on FLC connector (X41) and the remaining pins on FLC connectors (X40, X41, and X42). See Load Center Harness (W3) Wiring Diagram. (Group 9015-10.)

NO: Circuit H05 GRN open on load center harness (W3). Repair circuit H05 GRN or replace harness.

Is continuity indicated between any pins?

– – –1/1

5 Reprogram Controller

Reprogram flex load controller (FLC). See Electronic Controller Reconfiguration. (Group 9015-20.)

YES: Replace controller. NO: Checks complete.

Check for active codes. Is FLC code 522436.04 present? – – –1/1

522437.04 — RTDig Switch 1 Short to Gnd

Return-to-dig sensor circuit is short to ground.

TF44157,0000086 –19–13MAR08–1/1

TM10229 (17MAR09)

9001-40-158

544J Loader (S.N. 611800— ) 032409

PN=380

Flex Load Controller (FLC) Diagnostic Trouble Codes Return-to-dig Switch 1 Short to Ground Diagnostic Procedure Alarm Level: No Warning Lamp

9001 40 ,159

– – –1/1

1 Component Check

Raise boom and dump bucket. Verify LED on switch is lit.

YES: Go to Short Circuit Check.

Curl bucket to carry position. Verify that the LED is not lit. NO: Replace return-to-dig switch.

Is LED on return-to-dig switch functioning properly?

– – –1/1

2 Short Circuit Check

Turn key switch OFF. Disconnect return-to-dig switch (S17) and load center harness-to-loader frame harness connector (X67). See Loader Frame Harness (W2) Component Location. (Group 9015-10.)

YES: Circuit H04 GRN short to ground on loader frame harness (W2). Repair circuit H04 GRN or replace harness.

Check circuit H04 GRN for ground at pin B on return-to-dig switch connector. See Loader Frame Harness (W2) Wiring Diagram. (Group 9015-10.)

NO: Go to next step in this check.

Is ground present?

Key switch OFF. Load center harness-to-loader frame harness connector (X67) disconnected. Disconnect flex load controller (FLC) connector (X41). See Load Center Harness (W3) Component Location. (Group 9015-10.) Check circuit H04 GRN for ground at pin 21 on load center side of connector (X67). See Load Center Harness (W3) Wiring Diagram. (Group 9015-10.)

YES: Circuit H04 GRN short to ground on load center harness (W3). Repair circuit H04 GRN or replace harness. NO: Go to Continuity Check.

Is ground present? – – –1/1

TM10229 (17MAR09)

9001-40-159

544J Loader (S.N. 611800— ) 032409

PN=381

Flex Load Controller (FLC) Diagnostic Trouble Codes 3 Continuity Check

Turn key switch OFF. Disconnect return-to-dig switch (S17) and load center harness-to-loader frame harness connector (X67). See Loader Frame Harness (W2) Component Location. (Group 9015-10.)

9001 40 ,160

Check for continuity between pin 21 (circuit H04 GRN) on loader frame side of connector (X67) and remaining pins on loader frame side of connector (X67). See Loader Frame Harness (W2) Wiring Diagram. (Group 9015-10.)

YES: Circuit H04 GRN short to pin that indicated continuity on loader frame harness (W2). Repair circuit H04 GRN or replace harness. NO: Go to next step in this check.

Is continuity indicated between any pins?

Key switch OFF. Load center harness-to-loader frame harness connector (X67) disconnected. Disconnect FLC connectors (X40, X41, and X42). See Load Center Harness (W3) Component Location. (Group 9015-10.) Check for continuity between pin C2 (circuit H04 GRN) on FLC connector (X41) and remaining pins on FLC connectors (X40, X41, and X42). See Load Center Harness (W3) Wiring Diagram. (Group 9015-10.)

YES: Circuit H04 GRN short to pin that indicated continuity on load center harness (W3). Repair circuit H04 GRN or replace harness. NO: Go to Reprogram Controller.

Is continuity indicated between any pins?

– – –1/1

4 Reprogram Controller

Reprogram flex load controller (FLC). See Electronic Controller Reconfiguration. (Group 9015-20.)

YES: Replace controller. NO: Checks complete.

Check for active codes. Is FLC code 522437.04 present? – – –1/1

522438.03 — Pin Disc Sol Short to Power

Pin disconnect solenoid circuit is short to power.

TF44157,0000087 –19–13MAR08–1/1

TM10229 (17MAR09)

9001-40-160

544J Loader (S.N. 611800— ) 032409

PN=382

Flex Load Controller (FLC) Diagnostic Trouble Codes Pin Disconnect Solenoid Short to Power Diagnostic Procedure Alarm Level: No Warning Lamp

9001 40 ,161

– – –1/1

1 Component Check

Turn key switch OFF.

YES: Go to Short Circuit Check.

Disconnect pin disconnect solenoid (Y20). NO: Replace pin disconnect sensor.

Check resistance across pins A and B. Specification Pin Disconnect Solenoid (Y20)— Resistance .......................................................................................... 25.65—31.35 ohms Is sensor within specification?

– – –1/1

TM10229 (17MAR09)

9001-40-161

544J Loader (S.N. 611800— ) 032409

PN=383

Flex Load Controller (FLC) Diagnostic Trouble Codes 2 Short Circuit Check

Turn key switch OFF.

YES: Go to next step in this check.

Disconnect the pin disconnect solenoid (Y20). See Loader Frame Harness (W2) Component Location. (Group 9015-10.)

NO: Go to Continuity Check.

Turn key switch ON.

9001 40 ,162

Verify pin disconnect is not activated. Check circuit H15 GRN for voltage at pin B on pin disconnect solenoid connector. See Loader Frame Harness (W2) Wiring Diagram. (Group 9015-10.) Is system voltage present?

Turn key switch OFF. Pin disconnect solenoid (Y20) disconnected. Disconnect load center harness-to-loader frame harness connector (X67). See Loader Frame Harness (W2) Component Location. (Group 9015-10.)

YES: Circuit H15 GRN short to power on loader frame harness (W2). Repair circuit H15 GRN or replace harness. NO: Go to next step in this check.

Turn key switch ON. Verify pin disconnect is not activated. Check circuit H15 GRN for voltage at pin 11 on loader frame side of connector (X67). See Loader Frame Harness (W2) Wiring Diagram. (Group 9015-10.) Is system voltage present?

YES: Circuit H15 GRN short to power on load center harness (W3). Repair circuit H15 GRN or replace harness. NO: Go to Continuity Check.

Turn key switch ON. Verify pin disconnect is not activated. Check circuit H15 GRN for voltage at pin 11 on load center side of connector (X67). See Load Center Harness (W3) Wiring Diagram. (Group 9015-10.) Is system voltage present?

– – –1/1

TM10229 (17MAR09)

9001-40-162

544J Loader (S.N. 611800— ) 032409

PN=384

Flex Load Controller (FLC) Diagnostic Trouble Codes 3 Continuity Check

Turn key switch OFF.

YES: Circuit H15 GRN short to pin that indicated continuity on loader frame harness (W2). Repair circuit H15 GRN or replace harness.

Disconnect pin disconnect solenoid (Y20) and load center harness-to-loader frame harness connector (X67). See Loader Frame Harness (W2) Component Location. (Group 9015-10.) Check continuity between pin 11 (circuit H15 GRN) on loader frame harness side of connector (X67) and the remaining pins on connector (X67). See Loader Frame Harness (W2) Wiring Diagram. (Group 9015-10.)

NO: Go to next step in this check.

Is continuity indicated between any pins?

Key switch OFF.

YES: Circuit H15 GRN short to power on load center harness (W3). Repair circuit H15 GRN or replace harness.

Load center harness-to-loader frame harness connector (X67) disconnected. Disconnect FLC connectors (X40, X41, and X42). See Load Center Harness (W3) Wiring Diagram. (Group 9015-10.) Check continuity between pin C2 (circuit H15 GRN) on FLC connector (X67) and the remaining pins on connectors (X40, X41, and X42). See Loader Frame Harness (W2) Wiring Diagram. (Group 9015-10.)

NO: Go to Reprogram Controller.

Is continuity indicated between any pins?

– – –1/1

4 Reprogram Controller

Reprogram flex load controller (FLC). See Electronic Controller Reconfiguration. (Group 9015-20.)

YES: Replace controller. NO: Checks complete.

Check for active codes. Is FLC code 522438.03 present? – – –1/1

522438.05 — Pin Disc Sol Open Circuit

Pin disconnect solenoid circuit is open.

TF44157,0000088 –19–13MAR08–1/1

TM10229 (17MAR09)

9001-40-163

544J Loader (S.N. 611800— ) 032409

PN=385

9001 40 ,163

Flex Load Controller (FLC) Diagnostic Trouble Codes Pin Disconnect Solenoid Open Circuit Diagnostic Procedure Alarm Level: 9001 40 ,164

No Warning Lamp

– – –1/1

1 Component Check

Turn key switch OFF.

YES: Go to Open Circuit Check.

Disconnect pin disconnect solenoid (Y20). NO: Replace pin disconnect sensor.

– – –1/1

TM10229 (17MAR09)

9001-40-164

544J Loader (S.N. 611800— ) 032409

PN=386

Flex Load Controller (FLC) Diagnostic Trouble Codes 2 Open Circuit Check

Turn key switch OFF.

YES: Open circuit on loader frame harness (W2). Repair circuit or replace harness.

Disconnect pin disconnect solenoid (Y20) and load center harness-to-loader frame harness connector (X67). See Loader Frame Harness (W2) Component Location. (Group 9015-10.) Check circuit H15 GRN for continuity between pin 11 on loader frame harness side of connector (X67) and pin B on pin disconnect solenoid (Y20). See Loader Frame Harness (W2) Wiring Diagram. (Group 9015-10.)

NO: Go to next step in this check.

Check circuit G05 BLK for continuity between pin 18 on loader frame harness side of connector (X67) and pin A on pin disconnect solenoid (Y20). See Loader Frame Harness (W2) Wiring Diagram. (Group 9015-10.) Is continuity indicated?

Key switch OFF.

YES: Open circuit on load center harness (W3). Repair circuit or replace harness.

Load center harness-to-loader frame harness connector (X67) disconnected. Disconnect flex load controller (FLC) connector (X41). See Load Center Harness (W3) Wiring Diagram. (Group 9015-10.)

NO: Go to Reprogram Controller.

Check circuit H15 GRN for continuity between pin 11 on load center harness side of connector (X67) and pin F4 on FLC connector (X41). See Loader Frame Harness (W2) Wiring Diagram. (Group 9015-10.) Check circuit G05 BLK for continuity between pin 18 on load center harness side of connector (X67) and frame ground. See Loader Frame Harness (W2) Wiring Diagram. (Group 9015-10.) Is continuity indicated?

– – –1/1

3 Reprogram Controller

Reprogram flex load controller (FLC). See Electronic Controller Reconfiguration. (Group 9015-20.)

YES: Replace controller. NO: Checks complete.

Check for active codes. Is FLC code 522438.05 present? – – –1/1

522438.06 — Pin Disc Sol High Current

Pin disconnect solenoid circuit is short to ground.

TF44157,0000089 –19–13MAR08–1/1

TM10229 (17MAR09)

9001-40-165

544J Loader (S.N. 611800— ) 032409

PN=387

9001 40 ,165

Flex Load Controller (FLC) Diagnostic Trouble Codes Pin Disconnect Solenoid High Current Diagnostic Procedure Alarm Level: 9001 40 ,166

No Warning Lamp

– – –1/1

1 Component Check

Turn key switch OFF.

YES: Go to Short Circuit Check.

Disconnect pin disconnect solenoid (Y20). NO: Replace pin disconnect sensor.

– – –1/1

TM10229 (17MAR09)

9001-40-166

544J Loader (S.N. 611800— ) 032409

PN=388

Flex Load Controller (FLC) Diagnostic Trouble Codes 2 Short Circuit Check

Turn key switch OFF.

YES: Go to next step in this check.

Disconnect pin disconnect solenoid (Y20). See Loader Frame Harness (W2) Component Location. (Group 9015-10.)

NO: Go to Continuity Check.

Turn key switch ON.

9001 40 ,167

Check circuit H15 GRN for ground at pin B on pin disconnect solenoid connector. See Loader Frame Harness (W2) Wiring Diagram. (Group 9015-10.) Is ground present?

YES: Circuit H15 GRN short to ground on loader frame harness (W2). Repair circuit H15 GRN or replace harness. NO: Go to next step in this check.

Turn key switch ON. Check circuit H15 GRN for ground at pin 11 on loader frame side of connector (X67). See Loader Frame Harness (W2) Wiring Diagram. (Group 9015-10.) Is ground present?

YES: Circuit H15 GRN short to ground on load center harness (W3). Repair circuit H15 GRN or replace harness. NO: Go to Continuity Check.

Turn key switch ON. Check circuit H15 GRN for ground at pin 11 on load center side of connector (X67). See Load Center Harness (W3) Wiring Diagram. (Group 9015-10.) Is ground present?

– – –1/1

TM10229 (17MAR09)

9001-40-167

544J Loader (S.N. 611800— ) 032409

PN=389

Flex Load Controller (FLC) Diagnostic Trouble Codes 3 Continuity Check

Turn key switch OFF.

YES: Circuit H15 GRN short to pin that indicated continuity on loader frame harness (W2). Repair circuit H15 GRN or replace harness.

Disconnect pin disconnect solenoid (Y20) and load center harness-to-loader frame harness connector (X67). See Loader Frame Harness (W2) Component Location. (Group 9015-10.) 9001 40 ,168

Check continuity between pin 11 (circuit H15 GRN) on loader frame harness side of connector (X67) and the remaining pins on connector (X67). See Loader Frame Harness (W2) Wiring Diagram. (Group 9015-10.)

NO: Go to next step in this check.

Is continuity indicated between any pins?

Key switch OFF.

YES: Circuit H15 GRN short to pin that indicated continuity on load center harness (W3). Repair circuit H15 GRN or replace harness.

Load center harness-to-loader frame harness connector (X67) disconnected. Disconnect FLC connectors (X40, X41, and X42). See Load Center Harness (W3) Wiring Diagram. (Group 9015-10.) Check continuity between pin F4 (circuit H15 GRN) on FLC connector (X41) and the remaining pins on connectors (X40, X41, and X42). See Loader Frame Harness (W2) Wiring Diagram. (Group 9015-10.)

NO: Go to Reprogram Controller.

Is continuity indicated between any pins?

– – –1/1

4 Reprogram Controller

Reprogram flex load controller (FLC). See Electronic Controller Reconfiguration. (Group 9015-20.)

YES: Replace controller. NO: Checks complete.

Check for active codes. Is FLC code 522438.06 present? – – –1/1

522796.05 — R Washer Pump Open Circuit

Rear washer pump circuit is open.

TF44157,000008A –19–13MAR08–1/1

TM10229 (17MAR09)

9001-40-168

544J Loader (S.N. 611800— ) 032409

PN=390

Flex Load Controller (FLC) Diagnostic Trouble Codes Rear Washer Pump Open Circuit Diagnostic Procedure Alarm Level: No Warning Lamp

9001 40 ,169

– – –1/1

1 Component Check

Turn key switch OFF.

YES: Go to Open Circuit Check.

Disconnect rear washer pump motor (M4). See Engine Frame Harness (W5) Component Location. (Group 9015-10.)

NO: Replace rear washer pump.

Apply 24 volts to pin 1 (circuit A05 ORG) and ground to pin 2 (circuit G02 BLK) on washer pump motor. Does washer pump run and pump fluid?

– – –1/1

2 Open Circuit Check

Turn key switch OFF.

YES: Go to next step in this check.

Disconnect rear washer pump motor (M4) and load center harness-to-engine frame harness connector (X3). See Engine Frame Harness (W5) Component Location. (Group 9015-10.) Check circuit A05 ORG for continuity between pin 2 on engine frame harness side of connector (X3) and pin 1 on washer pump (M4) connector. Engine Frame Harness (W5) Wiring Diagram. (Group 9015-10.)

NO: Open circuit on engine frame harness (W5). Repair circuit or replace harness.

Check circuit G02 BLK for continuity between pin 1 on washer pump (M4) connector and frame ground. Engine Frame Harness (W5) Wiring Diagram. (Group 9015-10.) Is continuity indicated?

Key switch OFF.

YES: Go to Reprogram Controller.

Load center harness-to-engine frame harness connector (X3) disconnected. Disconnect flex load controller (FLC) connector (X42). See Load Center Harness (W3) Component Location. (Group 9015-10.) Check circuit A05 ORG for continuity between pin 2 on load center harness side of connector (X3) and pin B1 on FLC connector (X42). See Load Center Harness (W3) Wiring Diagram. (Group 9015-10.)

NO: Circuit A05 ORG open on load center harness (W3). Repair circuit A05 ORG or replace harness.

Is continuity indicated?

– – –1/1

TM10229 (17MAR09)

9001-40-169

544J Loader (S.N. 611800— ) 032409

PN=391

Flex Load Controller (FLC) Diagnostic Trouble Codes 3 Reprogram Controller

Reprogram flex load controller (FLC). See Electronic Controller Reconfiguration. (Group 9015-20.)

YES: Replace controller. NO: Checks complete.

Check for active codes. Is FLC code 522796.05 present?

9001 40 ,170

– – –1/1

522796.06 — R Washer Pump High Current

Rear washer pump circuit is short to ground.

TF44157,000008B –19–13MAR08–1/1

Rear Washer Pump High Current Diagnostic Procedure Alarm Level: No Warning Lamp

– – –1/1

1 Component Check

Turn key switch OFF.

YES: Go to Short Circuit Check.

Disconnect rear washer pump motor (M4). See Engine Frame Harness (W5) Component Location. (Group 9015-10.)

NO: Replace rear washer pump.

Apply 24 volts to pin 1 (circuit A05 ORG) and ground to pin 2 (circuit G02 BLK) on washer pump motor. Does washer pump run and pump fluid?

– – –1/1

TM10229 (17MAR09)

9001-40-170

544J Loader (S.N. 611800— ) 032409

PN=392

Flex Load Controller (FLC) Diagnostic Trouble Codes 2 Short Circuit Check

Turn key switch OFF.

YES: Go to next step in this check.

Disconnect rear washer pump motor (M4). See Engine Frame Harness (W5) Component Location. (Group 9015-10.)

NO: Go to Continuity Check.

Check circuit A05 ORG for ground at pin 1 on rear washer pump (M4) connector. Engine Frame Harness (W5) Wiring Diagram. (Group 9015-10.)

9001 40 ,171

Is ground present?

Key switch OFF. Disconnect load center harness-to-engine frame harness connector (X3). See Load Center Harness (W3) Component Location. (Group 9015-10.) Check circuit A05 ORG for ground at pin 2 on load center harness side of connector (X3). See Load Center Harness (W3) Wiring Diagram. (Group 9015-10.) Is ground present?

YES: Circuit A05 ORG short to ground on load center harness (W3). Repair circuit A05 ORG or replace harness. NO: Circuit A05 ORG short to ground on engine frame harness (W5). Repair circuit A05 ORG or replace harness. – – –1/1

3 Continuity Check

Turn key switch OFF. Disconnect rear washer pump motor (M4) and load center harness-to-engine frame harness connector (X3). See Engine Frame Harness (W5) Component Location. (Group 9015-10.) Check continuity between pin 2 (circuit A05 ORG) on engine frame harness side of connector (X3) and remaining pins on connector (X3). See Engine Frame Harness (W5) Wiring Diagram. (Group 9015-10.)

YES: Circuit A05 ORG short to pin that indicated continuity on load center harness (W3). Repair circuit A05 ORG or replace harness. NO: Go to next step in this check.

Is continuity indicated between any pins?

Key switch OFF. Load center harness-to-engine frame harness connector (X3) disconnected. See Engine Frame Harness (W5) Component Location. (Group 9015-10.) Disconnect flex load controller (FLC) connectors (X40, X41, and X42). See Load Center Harness (W3) Component Location. (Group 9015-10.) Check continuity between pin B1 (circuit A05 ORG) on FLC connector (X3) and remaining pins on connectors (X40, X41, and X42). See Load Center Harness (W3) Wiring Diagram. (Group 9015-10.)

YES: Circuit A05 ORG short to pin that indicated continuity on load center harness (W3). Repair circuit A05 ORG or replace harness. NO: Go to Reprogram Controller.

Is ground present?

– – –1/1

4 Reprogram Controller

Reprogram flex load controller (FLC). See Electronic Controller Reconfiguration. (Group 9015-20.)

YES: Replace controller. NO: Checks complete.

Check for active codes. Is FLC code 522796.05 present? – – –1/1

TM10229 (17MAR09)

9001-40-171

544J Loader (S.N. 611800— ) 032409

PN=393

Flex Load Controller (FLC) Diagnostic Trouble Codes

522797.05 — F Washer Pump Open Circuit

9001 40 ,172

Front washer pump circuit is open.

TF44157,000008C –19–13MAR08–1/1

Front Washer Pump Open Circuit Diagnostic Procedure Alarm Level: No Warning Lamp

– – –1/1

1 Component Check

Turn key switch OFF.

YES: Go to Open Circuit Check.

Disconnect front washer pump motor (M2). See Engine Frame Harness (W5) Component Location. (Group 9015-10.)

NO: Replace front washer pump.

Apply 24 volts to pin 1 (circuit A04 ORG) and ground to pin 2 (circuit G02 BLK) on washer pump motor. Does washer pump run and pump fluid?

– – –1/1

TM10229 (17MAR09)

9001-40-172

544J Loader (S.N. 611800— ) 032409

PN=394

Flex Load Controller (FLC) Diagnostic Trouble Codes 2 Open Circuit Check

Turn key switch OFF.

YES: Go to next step in this check.

Disconnect front washer pump (M2) and load center harness-to-engine frame harness connector (X3). See Engine Frame Harness (W5) Component Location. (Group 9015-10.) Check circuit A04 ORG for continuity between pin 1 on engine frame harness side of connector (X3) and pin 1 on front washer pump. See Engine Frame Harness (W5) Wiring Diagram.

NO: Open circuit on engine frame harness (W5). Repair circuit or replace harness.

9001 40 ,173

Check circuit G02 BLK for continuity between pin 1 on engine frame harness side of connector (X3) and frame ground. Is continuity indicated?

Key switch OFF.

YES: Go to next step in this check.

Load center harness-to-engine frame harness connector (X3) disconnected. Disconnect flex load controller (FLC) connector (X42). See Load Center Harness (W3) Component Location. (Group 9015-10.) Check circuit A04 ORG for continuity between pin 1 on load center harness side of connector (X3) and pin D1 on FLC connector (X42). See Load Center Harness (W3) Wiring Diagram. (Group 9015-10.)

NO: Circuit A04 ORG open on load center harness (W3). Repair circuit A04 ORG or replace harness.

Is continuity indicated?

– – –1/1

3 Reprogram Controller

Reprogram flex load controller (FLC). See Electronic Controller Reconfiguration. (Group 9015-20.)

YES: Replace controller. NO: Checks complete.

Check for active codes. Is FLC code 522797.05 present? – – –1/1

522797.06 — F Washer Pump High Current

Front washer pump circuit is short to ground.

TF44157,000008D –19–13MAR08–1/1

TM10229 (17MAR09)

9001-40-173

544J Loader (S.N. 611800— ) 032409

PN=395

Flex Load Controller (FLC) Diagnostic Trouble Codes Front Washer Pump High Current Diagnostic Procedure Alarm Level: 9001 40 ,174

No Warning Lamp

– – –1/1

1 Component Check

Turn key switch OFF.

YES: Go to Short Circuit Check.

Disconnect front washer pump motor (M2). See Engine Frame Harness (W5) Component Location. (Group 9015-10.)

NO: Replace front washer pump.

Apply 24 volts to pin 1 (circuit A04 ORG) and ground to pin 2 (circuit G02 BLK) on washer pump motor. Does washer pump run and pump fluid?

– – –1/1

2 Short Circuit Check

Turn key switch OFF.

YES: Go to next step in this check.

Disconnect front washer pump (M2). See Engine Frame Harness (W5) Component Location. (Group 9015-10.)

NO: Go to Continuity Check.

Check circuit A04 ORG for ground at pin 1 on front washer pump connector. See Engine Frame Harness (W5) Wiring Diagram. (Group 9015-10.) Is ground present?

Turn key switch OFF. Disconnect load center harness-to-engine frame harness connector (X3). See Load Center Harness (W3) Component Location. (Group 9015-10.) Check circuit A04 ORG for ground at pin 1 on load center side of connector (X3). See Load Center Harness (W3) Wiring Diagram. (Group 9015-10.)

YES: Circuit A04 ORG short to ground on load center harness (W3). Repair circuit A04 ORG or replace harness. NO: Go to Continuity Check.

Is ground present?

– – –1/1

TM10229 (17MAR09)

9001-40-174

544J Loader (S.N. 611800— ) 032409

PN=396

Flex Load Controller (FLC) Diagnostic Trouble Codes 3 Continuity Check

Turn key switch OFF. Disconnect front washer pump (M2) and load center harness-to-engine frame harness connector (X3). See Engine Frame Harness (W5) Component Location. (Group 9015-10.) Check continuity between pin 1 (circuit A04 ORG) on engine frame side of connector (X3) and remaining pins on engine frame side of connector (X3). See Engine Frame Harness (W5) Wiring Diagram. (Group 9015-10.)

YES: Circuit A04 ORG short to pin that indicated continuity on engine frame harness (W5). Repair circuit A04 ORG or replace harness. NO: Go to next step in this check.

Is continuity indicated between any pins?

Key switch OFF. Load center harness-to-engine frame harness connector (X3) disconnected. Disconnect flex load controller (FLC) connectors (X40, X41, and X42). See Load Center Harness (W3) Component Location. (Group 9015-10.) Check continuity between pin D1 (circuit A04 ORG) on FLC connector (X42) and remaining pins on load center side of connectors (X40, X41, and X42). See Load Center Harness (W3) Wiring Diagram. (Group 9015-10.)

YES: Circuit A04 ORG short to pin that indicated continuity ground on load center harness (W3). Repair circuit A04 ORG or replace harness. NO: Go to Reprogram Controller.

Is continuity indicated between any pins?

– – –1/1

4 Reprogram Controller

Reprogram flex load controller (FLC). See Electronic Controller Reconfiguration. (Group 9015-20.)

YES: Replace controller. NO: Checks complete.

Check for active codes. Is FLC code 522797.06 present? – – –1/1

523137.04 — Steering Press Sw Shrt to Gnd

Steering pressure switch circuit is short to ground.

TF44157,000008E –19–13MAR08–1/1

TM10229 (17MAR09)

9001-40-175

544J Loader (S.N. 611800— ) 032409

PN=397

9001 40 ,175

Flex Load Controller (FLC) Diagnostic Trouble Codes Steering Pressure Switch Short to Ground Diagnostic Procedure Alarm Level: 9001 40 ,176

No Warning Lamp

– – –1/1

1 Component Check

Turn key switch OFF.

YES: Go to Short Circuit Check.

Disconnect steering pressure switch (B25). See Load Center Harness (W3) Component Location. (Group 9015-10.)

NO: Replace steering pressure switch.

Check resistance of sensor across pins A and B. Is continuity indicated?

– – –1/1

2 Short Circuit Check

Turn key switch OFF.

YES: Circuit N08 YEL short to ground on load center harness (W3). Repair circuit N08 YEL or replace harness.

Disconnect steering pressure switch (B25). See Load Center Harness (W3) Component Location. (Group 9015-10.) Check circuit N08 YEL for ground at pin A on steering pressure switch. See Load Center Harness (W3) Wiring Diagram. (Group 9015-10.)

NO: Go to Continuity Check.

Is ground present?

– – –1/1

3 Continuity Check

Turn key switch OFF. Disconnect steering system pressure sensor (B25). See Load Center Harness (W3) Component Location. (Group 9015-10.) Disconnect FLC connectors (X40, X41, and X42). See Load Center Harness (W3) Component Location. (Group 9015-10.) Check continuity between pin C1 (circuit N08 YEL) on FLC connector (X41) and the remaining pins on connectors (X40, X41, and X42). See Load Center Harness (W3) Wiring Diagram. (Group 9015-10.)

YES: Circuit N08 YEL short to pin that indicated continuity on load center harness (W3). Repair Circuit N08 YEL or replace harness. NO: Go to Reprogram Controller.

Is continuity indicated between any pins? – – –1/1

TM10229 (17MAR09)

9001-40-176

544J Loader (S.N. 611800— ) 032409

PN=398

Flex Load Controller (FLC) Diagnostic Trouble Codes 4 Reprogram Controller

Reprogram flex load controller (FLC). See Electronic Controller Reconfiguration. (Group 9015-20.)

YES: Replace controller. NO: Checks complete.

Check for active codes. Is FLC code 523137.04 present? – – –1/1

523214.05 — No Voltage to FLC on VP6

Valve power control 6 circuit is open or short to ground (circuit B15 RED).

TF44157,000008F –19–13MAR08–1/1

No Voltage to FLC on VP6 Diagnostic Procedure Alarm Level: No Warning Lamp

– – –1/1

1 Fuse Check

Turn key switch OFF.

YES: Go to Short Circuit Check.

Remove fuse (F23) and check for continuity. NO: Replace fuse (F23). Is continuity indicated? – – –1/1

2 Short Circuit Check

Turn key switch OFF. Disconnect flex load controller (FLC) connector (X41). See Load Center Harness (W3) Component Location. (Group 9015-10.) Check circuit B15 RED for ground at pins H3 and H4 on connector (X41). See Load Center Harness (W3) Wiring Diagram. (Group 9015-10.)

YES: Circuit B15 RED short to ground on load center harness (W3). Repair circuit B15 RED or replace harness. NO: Go to Open Circuit Check.

Is ground present?

– – –1/1

TM10229 (17MAR09)

9001-40-177

544J Loader (S.N. 611800— ) 032409

PN=399

9001 40 ,177

Flex Load Controller (FLC) Diagnostic Trouble Codes 3

Open Circuit Check

Turn key switch OFF.

YES: Go to Continuity Check.

Disconnect vehicle electrical center 8-pin BLK connector (X10). See Load Center Harness (W3) Component Location. (Group 9015-10.) Check circuit B15 RED for continuity between pin A on connector (X10) and pins H3 and H4 on connector (X41). See Load Center Harness (W3) Wiring Diagram. (Group 9015-10.)

9001 40 ,178

NO: Circuit B15 RED open on load center harness (W3). Repair circuit B15 RED or replace harness.

Is continuity indicated?

– – –1/1

4 Continuity Check

Turn key switch OFF. Vehicle electrical center 8-pin BLK connector (X10) disconnected. Disconnect flex load controller (FLC) connectors (X40, X41, and X42). See Load Center Harness (W3) Component Location. (Group 9015-10.) Check for continuity between pins H3 and H4 (circuit B15 RED) on FLC connector (X41) and remaining pins on FLC connectors (X40, X41, and X42). See Load Center Harness (W3) Wiring Diagram. (Group 9015-10.)

YES: Circuit B15 RED short between pins that indicated continuity on load center harness (W3). Repair circuit B15 RED or replace harness. NO: Go to Reprogram Controller.

Is continuity indicated between any pins?

– – –1/1

5 Reprogram Controller

Reprogram flex load controller (FLC). See Electronic Controller Reconfiguration. (Group 9015-20.)

YES: Replace controller. NO: Checks complete.

Check for active codes. Is FLC code 523214.05 present? – – –1/1

523215.05 — No Voltage to FLC on VP5

Valve power control 5 circuit is open or short to ground (circuit B15 RED).

TF44157,0000090 –19–13MAR08–1/1

TM10229 (17MAR09)

9001-40-178

544J Loader (S.N. 611800— ) 032409

PN=400

Flex Load Controller (FLC) Diagnostic Trouble Codes No Voltage to FLC on VP5 Diagnostic Procedure Alarm Level: No Warning Lamp

9001 40 ,179

– – –1/1

1 Fuse Check

Turn key switch OFF.

YES: Go to Short Circuit Check.

Remove fuse (F23) and check for continuity. NO: Replace fuse (F23). Is continuity indicated? – – –1/1

2 Short Circuit Check

Turn key switch OFF. Disconnect flex load controller (FLC) connector (X41). See Load Center Harness (W3) Component Location. (Group 9015-10.) Check circuit B15 RED for ground at pins L4 and M4 on connector (X41). See Load Center Harness (W3) Wiring Diagram. (Group 9015-10.)

YES: Circuit B15 RED short to ground on load center harness (W3). Repair circuit B15 RED or replace harness. NO: Go to Open Circuit Check.

Is ground present?

– – –1/1

3 Open Circuit Check

Turn key switch OFF.

YES: Go to Continuity Check.

Disconnect FLC connector (X41) and vehicle electrical center 8-pin BLK connector (X10). See Load Center Harness (W3) Component Location. (Group 9015-10.) Check circuit B15 RED for continuity between pin A on connector (X10) and pins M4 and L4 on connector (X41). See Load Center Harness (W3) Wiring Diagram. (Group 9015-10.)

NO: Circuit B15 RED open on load center harness (W3). Repair circuit B15 RED or replace harness.

Is continuity indicated?

– – –1/1

TM10229 (17MAR09)

9001-40-179

544J Loader (S.N. 611800— ) 032409

PN=401

Flex Load Controller (FLC) Diagnostic Trouble Codes 4 Continuity Check

Turn key switch OFF.

YES: Go to Reprogram Controller.

Disconnect FLC connectors (X40, X41, and X42) and vehicle electrical center 8-pin BLK connector (X10). See Load Center Harness (W3) Component Location. (Group 9015-10.) 9001 40 ,180

Check continuity between pins L4 and M4 (circuit B15 RED) on FLC connector (X41) and remaining pins on FLC connectors (X40, X41, and X42). See Load Center Harness (W3) Wiring Diagram. (Group 9015-10.)

NO: Circuit B15 RED short to pin that indicated continuity on load center harness (W3). Repair circuit B15 RED or replace harness.

Is continuity indicated between any pins?

– – –1/1

5 Reprogram Controller

Reprogram flex load controller (FLC). See Electronic Controller Reconfiguration. (Group 9015-20.)

YES: Replace controller. NO: Checks complete.

Check for active codes. Is FLC code 523215.05 present? – – –1/1

523216.05 — No Voltage to FLC on VP4

Valve power control 4 circuit is open or short to ground (circuit B16 RED).

TF44157,0000091 –19–13MAR08–1/1

No Voltage to FLC on VP4 Diagnostic Procedure Alarm Level: No Warning Lamp

– – –1/1

TM10229 (17MAR09)

9001-40-180

544J Loader (S.N. 611800— ) 032409

PN=402

Flex Load Controller (FLC) Diagnostic Trouble Codes 1 Short Circuit Check

Turn key switch OFF. Disconnect flex load controller (FLC) connector (X41). See Load Center Harness (W3) Component Location. (Group 9015-10.) Check circuit B16 RED for ground at pins L3 and L4 on connector (X41). See Load Center Harness (W3) Wiring Diagram. (Group 9015-10.)

YES: Circuit B16 RED short to ground on load center harness (W3). Repair circuit B16 RED or replace harness. NO: Go to Open Circuit Check.

Is ground present?

– – –1/1

2 Open Circuit Check

Turn key switch OFF.

YES: Go to Continuity Check.

Disconnect FLC connector (X41) and vehicle electrical center 8-pin GRY connector (X11). See Load Center Harness (W3) Component Location. (Group 9015-10.) Check circuit B16 RED for continuity between pin C on connector (X11) and pins L3 and L4 on connector (X41). See Load Center Harness (W3) Wiring Diagram. (Group 9015-10.)

NO: Circuit B16 RED open on load center harness (W3). Repair circuit B16 RED or replace harness.

Is continuity indicated?

– – –1/1

3 Continuity Check

Turn key switch OFF.

YES: Go to Reprogram Controller.

Disconnect FLC connectors (X40, X41, and X42) and vehicle electrical center 8-pin GRY connector (X11). See Load Center Harness (W3) Component Location. (Group 9015-10.) Check continuity between pins L3 and L4 (circuit B16 RED) on FLC connector (X41) and remaining pins on FLC connectors (X40, X41, and X42). See Load Center Harness (W3) Wiring Diagram. (Group 9015-10.)

NO: Circuit B16 RED short to pin that indicated continuity on load center harness (W3). Repair circuit B16 RED or replace harness.

Is continuity indicated between any pins?

– – –1/1

4 Reprogram Controller

Reprogram flex load controller (FLC). See Electronic Controller Reconfiguration. (Group 9015-20.)

YES: Replace controller. NO: Checks complete.

Check for active codes. Is FLC code 523216.05 present? – – –1/1

TM10229 (17MAR09)

9001-40-181

544J Loader (S.N. 611800— ) 032409

PN=403

9001 40 ,181

Flex Load Controller (FLC) Diagnostic Trouble Codes

523217.05 — No Voltage to FLC on VP3

9001 40 ,182

Valve power control 3 circuit is open or short to ground (circuit B16 RED).

TF44157,0000092 –19–13MAR08–1/1

No Voltage to FLC on VP3 Diagnostic Procedure Alarm Level: No Warning Lamp

– – –1/1

1 Short Circuit Check

Turn key switch OFF. Disconnect flex load controller (FLC) connector (X41). See Load Center Harness (W3) Component Location. (Group 9015-10.) Check circuit B16 RED for ground at pins G3 and G4 on connector (X41). See Load Center Harness (W3) Wiring Diagram. (Group 9015-10.)

YES: Circuit B16 RED short to ground on load center harness (W3). Repair circuit B16 RED or replace harness. NO: Go to Open Circuit Check.

Is ground present?

– – –1/1

2 Open Circuit Check

Turn key switch OFF.

YES: Go to Continuity Check.

Disconnect FLC connector (X41) and vehicle electrical center 8-pin GRY connector (X11). See Load Center Harness (W3) Component Location. (Group 9015-10.) Check circuit B16 RED for continuity between pin C on connector (X11) and pins G3 and G4 on connector (X41). See Load Center Harness (W3) Wiring Diagram. (Group 9015-10.)

NO: Circuit B16 RED open on load center harness (W3). Repair circuit B16 RED or replace harness.

Is continuity indicated?

– – –1/1

TM10229 (17MAR09)

9001-40-182

544J Loader (S.N. 611800— ) 032409

PN=404

Flex Load Controller (FLC) Diagnostic Trouble Codes 3 Continuity Check

Turn key switch OFF.

YES: Go to Reprogram Controller.

Disconnect FLC connectors (X40, X41, and X42) and vehicle electrical center 8-pin GRY connector (X11). See Load Center Harness (W3) Component Location. (Group 9015-10.) Check for continuity between pins G3 and G4 (circuit B16 RED) on FLC connector (X41) and remaining pins on FLC connectors (X40, X41, and X42). See Load Center Harness (W3) Wiring Diagram. (Group 9015-10.)

NO: Circuit B16 RED short to pin that indicated continuity on load center 9001 harness (W3). Repair 40 circuit B16 RED or ,183 replace harness.

Is continuity indicated between any pins?

– – –1/1

4 Reprogram Controller

Reprogram flex load controller (FLC). See Electronic Controller Reconfiguration. (Group 9015-20.)

YES: Replace controller. NO: Checks complete.

Check for active codes. Is FLC code 523217.05 present? – – –1/1

523218.05 — No Voltage to FLC on VP2

Valve power control 2 circuit is open or short to ground (circuit B17 RED).

TF44157,0000093 –19–13MAR08–1/1

No Voltage to FLC on VP2 Diagnostic Procedure Alarm Level: No Warning Lamp

– – –1/1

TM10229 (17MAR09)

9001-40-183

544J Loader (S.N. 611800— ) 032409

PN=405

Flex Load Controller (FLC) Diagnostic Trouble Codes 1 Short Circuit Check

Turn key switch OFF. Disconnect flex load controller (FLC) connector (X42). See Load Center Harness (W3) Component Location. (Group 9015-10.) Check circuit B17 RED for ground at pins G1 and G2 on connector (X42). See Load Center Harness (W3) Wiring Diagram. (Group 9015-10.)

9001 40 ,184

YES: Circuit B17 RED short to ground on load center harness (W3). Repair circuit B17 RED or replace harness. NO: Go to Open Circuit Check.

Is ground present?

– – –1/1

2 Open Circuit Check

Turn key switch OFF.

YES: Go to Continuity Check.

Disconnect FLC connector (X42) and vehicle electrical center 8-pin GRY connector (X11). See Load Center Harness (W3) Component Location. (Group 9015-10.) Check circuit B17 RED for continuity between pin D on connector (X11) and pins G1 and G2 on FLC connector (X41). See Load Center Harness (W3) Wiring Diagram. (Group 9015-10.)

NO: Circuit B17 RED open on load center harness (W3). Repair circuit B17 RED or replace harness.

Is continuity indicated?

– – –1/1

3 Continuity Check

Turn key switch OFF.

YES: Go to Reprogram Controller.

Disconnect FLC connectors (X40, X41, and X42) and vehicle electrical center 8-pin GRY connector (X11). See Load Center Harness (W3) Component Location. (Group 9015-10.) Check continuity between pins G1 and G2 (circuit B17 RED) on FLC connector (X42) and remaining pins on FLC connectors (X40, X41, and X42). See Load Center Harness (W3) Wiring Diagram. (Group 9015-10.)

NO: Circuit B17 RED short to pin that indicated continuity on load center harness (W3). Repair circuit B17 RED or replace harness.

Is continuity indicated between any pins?

– – –1/1

4 Reprogram Controller

Reprogram flex load controller (FLC). See Electronic Controller Reconfiguration. (Group 9015-20.)

YES: Replace controller. NO: Checks complete.

Check for active codes. Is FLC code 523218.05 present? – – –1/1

TM10229 (17MAR09)

9001-40-184

544J Loader (S.N. 611800— ) 032409

PN=406

Flex Load Controller (FLC) Diagnostic Trouble Codes

523219.05 — No Voltage to FLC on VP1

Valve power control 1 circuit is open or short to ground (circuit B17 RED).

9001 40 ,185

TF44157,0000094 –19–13MAR08–1/1

No Voltage to FLC on VP1 Diagnostic Procedure Alarm Level: No Warning Lamp

– – –1/1

1 Short Circuit Check

Turn key switch OFF. Disconnect flex load controller (FLC) connector (X42). See Load Center Harness (W3) Component Location. (Group 9015-10.) Check circuit B17 RED for ground at pins H3 and H4 on connector (X42). See Load Center Harness (W3) Wiring Diagram. (Group 9015-10.)

YES: Circuit B17 RED short to ground on load center harness (W3). Repair circuit B17 RED or replace harness. NO: Go to Open Circuit Check.

Is ground present?

– – –1/1

2 Open Circuit Check

Turn key switch OFF.

YES: Go to Continuity Check.

Disconnect FLC connector (X42) and vehicle electrical center 8-pin GRY connector (X11). See Load Center Harness (W3) Component Location. (Group 9015-10.) Check circuit B17 RED for continuity between pin D on connector (X11) and pins H3 and H4 on FLC connector (X42). See Load Center Harness (W3) Wiring Diagram. (Group 9015-10.)

NO: Circuit B17 RED is open on load center harness (W3). Repair circuit or replace harness.

Is continuity indicated?

– – –1/1

TM10229 (17MAR09)

9001-40-185

544J Loader (S.N. 611800— ) 032409

PN=407

Flex Load Controller (FLC) Diagnostic Trouble Codes 3 Continuity Check

Turn key switch OFF.

YES: Go to Reprogram Controller.

Disconnect FLC connectors (X40, X41, and X42) and vehicle electrical center 8-pin GRY connector (X11). See Load Center Harness (W3) Component Location. (Group 9015-10.) 9001 40 ,186

Check for continuity between pins H3 and H4 (circuit B17 RED) on FLC connector (X42) and remaining pin on connectors (X40, X41, and X42). See Load Center Harness (W3) Wiring Diagram. (Group 9015-10.)

NO: Circuit B17 RED short to pin that indicated continuity on load center harness (W3). Repair circuit B17 RED or replace harness.

Is continuity indicated between any pins?

– – –1/1

4 Reprogram Controller

Reprogram flex load controller (FLC). See Electronic Controller Reconfiguration. (Group 9015-20.)

YES: Replace controller. NO: Checks complete.

Check for active codes. Is FLC code 523219.05 present? – – –1/1

523436.17 — FLC Watchdog Timed Out

Flex load controller (FLC) watchdog has timed out.

TF44157,0000095 –19–13MAR08–1/1

FLC Watchdog Timed Out Diagnostic Procedure Alarm Level: No Warning Lamp

– – –1/1

1 Configure Flex Load Controller (FLC)

Reconfigure FLC controller. See Electronic Controller Reconfiguration. (Group 9015-25.)

YES: Go to Reprogram Controller.

Is FLC code 523436.17 present?

NO: Checks complete.

– – –1/1

TM10229 (17MAR09)

9001-40-186

544J Loader (S.N. 611800— ) 032409

PN=408

Flex Load Controller (FLC) Diagnostic Trouble Codes 2 Reprogram Controller

Reprogram flex load controller (FLC). See Electronic Controller Reconfiguration. (Group 9015-20.)

YES: Replace controller. NO: Checks complete.

Check for active codes. Is FLC code 523436.17 present? – – –1/1

523577.03 — 2nd Steer Pump Short to Power

Secondary steering pump circuit is short to power.

TF44157,0000096 –19–13MAR08–1/1

Secondary Steering Pump Short to Power Diagnostic Procedure Alarm Level: No Warning Lamp

– – –1/1

TM10229 (17MAR09)

9001-40-187

544J Loader (S.N. 611800— ) 032409

PN=409

9001 40 ,187

Flex Load Controller (FLC) Diagnostic Trouble Codes 1 Short Circuit Check

Turn key switch OFF.

YES: Go to next step in this check.

Disconnect secondary steering pump terminal (circuit H13 GRN, connector M8) at pump. See Secondary Steering Harness (W17) Component Location. (Group 9015-10.)

NO: Go to Continuity Check.

Turn key switch ON.

9001 40 ,188

Check circuit H13 GRN for voltage at terminal connector (M8). See Secondary Steering Harness (W17) Wiring Diagram. (Group 9015-10.) Is voltage present?

Turn key switch OFF.

YES: Go to next step in this check.

Disconnect engine harness-to-secondary steering motor connector (X79). See Secondary Steering Harness (W17) Component Location. (Group 9015-10.) Turn key switch ON. Check circuit H13 GRN for voltage at pin 1 on engine harness side of connector (X79). See Secondary Steering Harness (W17) Wiring Diagram. (Group 9015-10.)

NO: Circuit H13 GRN short to power on secondary steering harness (W17). Repair circuit H13 GRN or replace harness.

Is voltage present?

Turn key switch OFF.

YES: Circuit H13 GRN short to power on engine harness (W6). Repair circuit H13 GRN or replace harness.

Disconnect load center harness-to-engine harness connector (X4). See Engine Harness (W6) Component Location. (Group 9015-10.) Turn key switch ON. Check circuit H13 GRN for voltage at pin 3 on load center harness side of connector (X4). See Engine Harness (W6) Wiring diagram. (Group 9015-10.) Is voltage present?

NO: Circuit H13 GRN short to power on load center harness (W3). Repair circuit H13 GRN or replace harness.

– – –1/1

TM10229 (17MAR09)

9001-40-188

544J Loader (S.N. 611800— ) 032409

PN=410

Flex Load Controller (FLC) Diagnostic Trouble Codes 2 Continuity Check

Turn key switch OFF.

YES: Circuit H13 GRN short to power on engine harness (W6). Repair circuit H13 GRN or replace harness.

Disconnect engine harness-to-secondary steering motor connector (X79) and load center harness-to-engine harness connector (X4). See Engine Harness (W6) Component Location and see Secondary Steering Harness (W17) Component Location. (Group 9015-10.) Check continuity between pin 3 (circuit H13 GRN) on engine harness side of connector (X4) and remaining pins on engine harness side of connector (X4). See Engine Harness (W6) Wiring diagram. (Group 9015-10.)

NO: Go to next step in this check.

Is continuity indicated?

Key switch OFF. Load center harness-to-engine harness connector (X4) disconnected. Disconnect flex load controller (FLC) connectors (X40, X41, and X42). See Load Center Harness (W3) Component Location. (Group 9015-10.) Check continuity between pin F1 (circuit H13 GRN) on FLC connector (X42) and remaining pins on FLC connectors (X40, X41, and X42). See Load Center Harness (W3) Wiring diagram. (Group 9015-10.)

YES: Circuit H13 GRN short to pin that indicated continuity on engine harness (W6). Repair circuit H13 GRN or replace harness. NO: Go to Reprogram Controller.

Is continuity indicated between any pins?

– – –1/1

3 Reprogram Controller

Reprogram flex load controller (FLC). See Electronic Controller Reconfiguration. (Group 9015-20.)

YES: Replace controller. NO: Checks complete.

Check for active codes. Is FLC code 523577.03 present? – – –1/1

523577.05 — 2nd Steer Pump Open Circuit

Secondary steering pump circuit is open.

TF44157,0000097 –19–13MAR08–1/1

TM10229 (17MAR09)

9001-40-189

544J Loader (S.N. 611800— ) 032409

PN=411

9001 40 ,189

Flex Load Controller (FLC) Diagnostic Trouble Codes Secondary Steering Pump Open Circuit Diagnostic Procedure Alarm Level: 9001 40 ,190

No Warning Lamp

– – –1/1

TM10229 (17MAR09)

9001-40-190

544J Loader (S.N. 611800— ) 032409

PN=412

Flex Load Controller (FLC) Diagnostic Trouble Codes 1 Open Circuit Check

Turn key switch OFF.

YES: Go to next step in this check.

Disconnect secondary steering pump terminal (circuit H13 GRN, connector M8) at pump. See Secondary Steering Harness (W17) Component Location. (Group 9015-10.) Disconnect engine harness-to-secondary steering motor connector (X79). See Secondary Steering Harness (W17) Component Location. (Group 9015-10.)

NO: Circuit H13 GRN open on secondary steering harness (W17). Repair circuit H13 GRN or replace harness.

Check circuit H13 GRN for continuity between pin 1 on secondary steering motor connector (X79) and secondary steering pump terminal (connector M8) at pump. See Secondary Steering Harness (W17) Wiring Diagram. (Group 9015-10.) Is continuity indicated?

Key switch OFF.

YES: Go to next step in this check.

Disconnect secondary steering pump terminal (circuit G20 BLK, connectors M8 and M1) at pump. See Secondary Steering Harness (W17) Component Location. (Group 9015-10.) Check circuit G20 BLK for continuity between terminals M1 and M8 on steering pump harness and frame ground. See Secondary Steering Harness (W17) Wiring Diagram. (Group 9015-10.)

NO: Circuit G20 BLK open on secondary steering harness (W17). Repair circuit G20 BLK or replace harness.

Is continuity indicated?

Key switch OFF.

YES: Circuit H13 GRN open on engine harness (W6). Repair Circuit H13 GRN or replace harness.

Engine harness-to-secondary steering motor connector (X79) disconnected. Disconnect load center harness-to-engine harness connector (X4). See Engine Harness (W6) Component Location. (Group 9015-10.)

NO: Go to next step in this check.

Check circuit H13 GRN for continuity between pin 3 on engine harness side of connector (X4) and pin 1 on connector (X79). See Engine Harness (W6) Wiring diagram. (Group 9015-10.) Is continuity indicated?

Key switch OFF.

YES: Circuit H13 GRN open on engine harness (W6). Repair circuit H13 GRN or replace harness.

Load center harness-to-engine harness connector (X4) disconnected. Disconnect flex load controller (FLC) connector (X42). See Load Center Harness (W3) Component Location. (Group 9015-10.)

NO: Go to Reprogram Controller.

Check circuit H13 GRN for continuity between pin 3 on load center harness side of connector (X4) and pin F1 on FLC connector (X42). See Load Center Harness (W3) Wiring diagram. (Group 9015-10.) Is continuity indicated?

– – –1/1

2 Reprogram Controller

Reprogram flex load controller (FLC). See Electronic Controller Reconfiguration. (Group 9015-20.)

YES: Replace controller. NO: Checks complete.

Check for active codes. Is FLC code 523577.05 present? – – –1/1

TM10229 (17MAR09)

9001-40-191

544J Loader (S.N. 611800— ) 032409

PN=413

9001 40 ,191

Flex Load Controller (FLC) Diagnostic Trouble Codes

523577.06 — 2nd Steer Pump High Current

9001 40 ,192

Secondary steering pump circuit is short to ground.

TF44157,0000098 –19–13MAR08–1/1

Secondary Steer Pump High Current Diagnostic Procedure Alarm Level: No Warning Lamp

– – –1/1

TM10229 (17MAR09)

9001-40-192

544J Loader (S.N. 611800— ) 032409

PN=414

Flex Load Controller (FLC) Diagnostic Trouble Codes 1 Short Circuit Check

Turn key switch OFF.

YES: Go to next step in this check.

Disconnect secondary steering pump terminal (circuit H13 GRN, connector M8) at pump. See Secondary Steering Harness (W17) Component Location. (Group 9015-10.)

NO: Go to Continuity Check.

Check circuit H13 GRN for ground at terminal, connector (M8). See Secondary Steering Harness (W17) Wiring Diagram. (Group 9015-10.)

9001 40 ,193

Is ground present?

Key switch OFF.

YES: Circuit H13 GRN short to ground on secondary steering harness (W17). Repair circuit or replace harness.

Disconnect engine harness-to-secondary steering motor connector (X79). See Secondary Steering Harness (W17) Component Location. (Group 9015-10.) Check circuit H13 GRN for ground at pin 1 on engine harness side of connector (X79). See Secondary Steering Harness (W17) Wiring Diagram. (Group 9015-10.)

NO: Go to next step in this check.

Is ground present?

Key switch OFF.

YES: Circuit H13 GRN short to ground on load center harness (W3). Repair circuit H13 GRN or replace harness.

Disconnect load center harness-to-engine harness connector (X4). See Engine Harness (W6) Component Location. (Group 9015-10.) Check circuit H13 GRN for ground at pin 3 on load center side of connector (X4). See Engine Harness (W6) Wiring diagram. (Group 9015-10.) Is ground present?

NO: Circuit H13 GRN short to ground on engine frame harness (W6). Repair circuit H13 GRN or replace harness.

– – –1/1

TM10229 (17MAR09)

9001-40-193

544J Loader (S.N. 611800— ) 032409

PN=415

Flex Load Controller (FLC) Diagnostic Trouble Codes 2 Continuity Check

Turn key switch OFF.

YES: Circuit H13 GRN short to power on engine harness (W6). Repair circuit H13 GRN or replace harness.

9001 40 ,194

Check continuity between pin 3 (circuit H13 GRN) on engine harness side of connector (X4) and remaining pins on engine harness side of connector (X4). See Engine Harness (W6) Wiring diagram. (Group 9015-10.)

NO: Go to next step in this check.

Is continuity indicated?

YES: Circuit H13 GRN short to pin that indicated continuity on engine harness (W6). Repair circuit H13 GRN or replace harness. NO: Go to Reprogram Controller.

Is continuity indicated between any pins?

– – –1/1

3 Reprogram Controller

Reprogram flex load controller (FLC). See Electronic Controller Reconfiguration. (Group 9015-20.)

YES: Replace controller. NO: Checks complete.

Check for active codes. Is FLC code 523577.06 present? – – –1/1

523786.03 — Boom Position Short to Power

Boom position sensor circuit is short to power.

TF44157,0000099 –19–13MAR08–1/1

TM10229 (17MAR09)

9001-40-194

544J Loader (S.N. 611800— ) 032409

PN=416

Flex Load Controller (FLC) Diagnostic Trouble Codes Boom Position Short to Power Diagnostic Procedure Alarm Level: No Warning Lamp

9001 40 ,195

– – –1/1

1 Component Check

Turn key switch OFF.

YES: Go to Short Circuit Check.

Remove BHKO/RTD position sensor (B45). See Loader Frame Harness (W2) Component Location. (Group 9015-10.)

NO: Replace sensor.

Check resistance of sensor across pins A and C. Specification Analog BHKO/RTC Position Sensor (B45)—Resistance .................................................................................... 4—6 kilo-ohms Is sensor within specification?

– – –1/1

2 Short Circuit Check

Turn key switch OFF. Disconnect BHKO/RTD position sensor (B45). See Loader Frame Harness (W2) Component Location. (Group 9015-10.) Disconnect load center harness-to-loader frame harness connector (X67). See Loader Frame Harness (W2) Component Location. (Group 9015-10.) Turn key switch ON. Check circuit H28 GRN for voltage at pin 19 on load center harness side of connector (X67). See Load Center Harness (W3) Wiring Diagram. (Group 9015-10.)

YES: Circuit H28 GRN short to power on load center harness (W3). Repair circuit H28 GRN or replace harness. NO: Circuit H28 GRN short to power on loader frame harness (W2). Repair circuit H28 GRN or replace harness.

Is voltage present? – – –1/1

TM10229 (17MAR09)

9001-40-195

544J Loader (S.N. 611800— ) 032409

PN=417

Flex Load Controller (FLC) Diagnostic Trouble Codes 3 Continuity Check

Turn key switch OFF. Disconnect BHKO/RTD position sensor (B45) and load center harness-to-loader frame harness connector (X67). See Loader Frame Harness (W2) Component Location. (Group 9015-10.)

9001 40 ,196

Check continuity between pin 19 (circuit H28 GRN) on loader frame harness side of connector (X67) and remaining pins on loader frame harness side of connector (X67). See Loader Frame Harness (W2) Wiring Diagram. (Group 9015-10.)

YES: Circuit H28 GRN short to pin that indicated continuity on loader frame harness (W2). Repair circuit H28 GRN or replace harness. NO: Go to next step in this check.

Is continuity indicated between any pins?

Key switch OFF. Load center harness-to-loader frame harness connector (X67) disconnected. Disconnect flex load controller (FLC) connectors (X40, X41, and X42). See Load Center Harness (W3) Component Location. (Group 9015-10.) Check continuity between pin E3 (circuit H28 GRN) on FLC connector (X41) and remaining pins on FLC connectors (X40, X41, and X42). See Load Center Harness (W3) Wiring Diagram. (Group 9015-10.)

YES: Circuit H28 GRN short to pin that indicated continuity on load center harness (W3). Repair circuit H28 GRN or replace harness. NO: Go to Reprogram Controller.

Is continuity indicated between any pins?

– – –1/1

4 Reprogram Controller

Reprogram flex load controller (FLC). See Electronic Controller Reconfiguration. (Group 9015-20.)

YES: Replace controller. NO: Checks complete.

Check for active codes. Is FLC code 523786.03 present? – – –1/1

523786.04 — Boom Position Open or Short

Boom position sensor circuit is open or short to power.

TF44157,000009A –19–13MAR08–1/1

TM10229 (17MAR09)

9001-40-196

544J Loader (S.N. 611800— ) 032409

PN=418

Flex Load Controller (FLC) Diagnostic Trouble Codes Boom Position Open or Short Diagnostic Procedure Alarm Level: No Warning Lamp

9001 40 ,197

– – –1/1

1 Component Check

Turn key switch OFF.

YES: Go to Short Circuit Check.

Remove BHKO/RTD position sensor (B45). See Loader Frame Harness (W2) Component Location. (Group 9015-10.)

NO: Replace sensor.

– – –1/1

2 Short Circuit Check

Turn key switch OFF.

YES: Go to next step in this check.

Disconnect BHKO/RTD position sensor (B45). See Loader Frame Harness (W2) Component Location. (Group 9015-10.)

NO: Go to Open Circuit Check.

Turn key switch ON. Check circuit H28 GRN for voltage at pin B on sensor connector. See Loader Frame Harness (W2) Wiring Diagram. (Group 9015-10.) Check circuit P28 RED for voltage at pin B on sensor connector. See Loader Frame Harness (W2) Wiring Diagram. (Group 9015-10.) Is system voltage present?

Turn key switch OFF. Disconnect load center harness-to-loader frame harness connector (X67). See Loader Frame Harness (W2) Component Location. (Group 9015-10.) Turn key switch ON. Check circuit H28 GRN for voltage at pin 28 on load center side of connector (X67). See Load Center Harness (W3) Wiring Diagram. (Group 9015-10.) Check circuit P28 RED for voltage at pin 20 on load center side of connector (X67). See Load Center Harness (W3) Wiring Diagram. (Group 9015-10.)

Is system voltage present?

– – –1/1

TM10229 (17MAR09)

9001-40-197

544J Loader (S.N. 611800— ) 032409

PN=419

Flex Load Controller (FLC) Diagnostic Trouble Codes 3 Open Circuit Check

Turn key switch OFF.

YES: Go to Continuity Check.

Disconnect BHKO/RTD position sensor (B45) and flex load controller (FLC) connector (X41). See Load Center Harness (W3) Component Location and see Loader Frame Harness (W2) Component Location. (Group 9015-10.) 9001 40 ,198

NO: Go to next step in this check.

Check circuit R68 BLK for continuity between pin A on sensor connector and pin K2 on FLC connector (X41). See Load Center Harness (W3) Component Location and see Loader Frame Harness (W2) Component Location. (Group 9015-10.) Check circuit H28 GRN for continuity between pin B on sensor connector and pin E3 on FLC connector (X41). See Load Center Harness (W3) Component Location and see Loader Frame Harness (W2) Component Location. (Group 9015-10.) Check circuit P68 RED for continuity between pin C on sensor connector and pin K1 on FLC connector (X41). See Load Center Harness (W3) Component Location and see Loader Frame Harness (W2) Component Location. (Group 9015-10.) Is continuity indicated?

Turn key switch OFF. Disconnect load center harness-to-loader frame harness connector (X67) and FLC connector (X41). See Load Center Harness (W3) Component Location. (Group 9015-10.). Check circuit R68 BLK for continuity between pin 7 on load center harness side of connector (X67) and pin K2 on FLC connector (X41). See Load Center Harness (W3) Wiring Diagram. (Group 9015-10.) Check circuit H28 GRN for continuity between pin 19 on load center harness side of connector (X67) and pin E3 on FLC connector (X41). See Load Center Harness (W3) Wiring Diagram. (Group 9015-10.)

YES: Open on circuit that did not indicate continuity on loader frame harness (W2). Repair circuit or replace harness. NO: Open on circuit that did not indicate continuity on load center harness (W3). Repair circuit or replace harness.

Check circuit P68 RED for continuity between pin 20 on load center harness side of connector (X67) and pin K1 on FLC connector (X41). See Load Center Harness (W3) Wiring Diagram. (Group 9015-10.) Is continuity indicated? – – –1/1

TM10229 (17MAR09)

9001-40-198

544J Loader (S.N. 611800— ) 032409

PN=420

Flex Load Controller (FLC) Diagnostic Trouble Codes 4 Continuity Check

Turn key switch OFF. Disconnect BHKO/RTD position sensor (B45). See Loader Frame Harness (W2) Component Location. (Group 9015-10.) Disconnect load center harness-to-loader frame harness connector (X67). See Loader Frame Harness (W2) Component Location. (Group 9015-10.) Check continuity between pin 19 (circuit H28 GRN) on loader frame harness side of connector (X67) and remaining pins on loader frame harness side of connector (X67). See Loader Frame Harness (W2) Wiring Diagram. (Group 9015-10.)

YES: Circuit H28 GRN short to pin that indicated continuity on loader frame harness (W2). Repair circuit H28 GRN or replace harness. NO: Go to next step in this check.

Is continuity indicated between any pins?

Key switch OFF. Load center harness-to-loader frame harness connector (X67) disconnected. Disconnect FLC connectors (X40, X41, and X42). See Load Center Harness (W3) Component Location. (Group 9015-10.) Check continuity between pin E3 (circuit H28 GRN) on FLC connector (X41) and remaining pins on FLC connectors (X40, X41, and X42). See Load Center Harness (W3) Wiring Diagram. (Group 9015-10.)

YES: Circuit H28 GRN short to pin that indicated continuity on load center harness (W3). Repair circuit H28 GRN or replace harness. NO: Go to Reprogram Controller.

Is continuity indicated between any pins?

– – –1/1

5 Reprogram Controller

Reprogram flex load controller (FLC). See Electronic Controller Reconfiguration. (Group 9015-20.)

YES: Replace controller. NO: Checks complete.

Check for active codes. Is FLC code 523786.04 present? – – –1/1

523837.01 — Brake Pressure Low-Rear

Rear axle accumulator service brake pressure is too low.

TF44157,000009B –19–13MAR08–1/1

TM10229 (17MAR09)

9001-40-199

544J Loader (S.N. 611800— ) 032409

PN=421

9001 40 ,199

Flex Load Controller (FLC) Diagnostic Trouble Codes Brake Pressure Low-Rear Diagnostic Procedure Alarm Level: 9001 40 ,200

No Warning Lamp

– – –1/1

1 Component Check

Perform Brake Valve Pressure Test. (Group 9025-25.) Compare pressure readings from brake valve pressure test to readings displayed in the CAN monitor unit (CMU). Does the gauge reading coincide with the CMU reading?

YES: See Pump Load Sense Differential and Standby Pressure Test. (Group 9025-25.) NO: Replace service brake pressure sensor.

– – –1/1

523837.04 — Rr Brake Pressure Open or Short

Rear brake pressure sensor circuit is open or short to ground.

TF44157,000009C –19–13MAR08–1/1

Rear Brake Pressure Sensor Open or Short Diagnostic Procedure Alarm Level: No Warning Lamp

– – –1/1

TM10229 (17MAR09)

9001-40-200

544J Loader (S.N. 611800— ) 032409

PN=422

Flex Load Controller (FLC) Diagnostic Trouble Codes 1 Component Check

Perform Brake Valve Pressure Test. (Group 9025-25.)

YES: Go to Short Circuit Check.

Compare pressure readings from brake valve pressure test to readings displayed in the CAN monitor unit (CMU).

NO: Replace service brake pressure sensor.

Does the gauge reading coincide with the CMU reading? – – –1/1

2 Short Circuit Check

Turn key switch OFF.

YES: Circuit N11 YEL short to ground on load center harness (W3). Repair circuit N11 YEL or replace harness.

Disconnect rear brake pressure sensor (B52). See Load Center Harness (W3) Component Location. (Group 9015-10.) Check circuit N11 YEL for ground at pin C on pressure sensor (B52). See Load Center Harness (W3) Wiring Diagram. (Group 9015-10.

NO: Go to Open Circuit Check.

Is ground present?

– – –1/1

3 Open Circuit Check

Turn key switch OFF. Disconnect rear brake pressure sensor (B52) and flex load controller (FLC) connector (X41). See Load Center Harness (W3) Component Location. (Group 9015-10.) Check circuit N11 YEL for continuity between pin C on pressure sensor (B52) and pin G2 on FLC connector (X41). See Load Center Harness (W3) Wiring Diagram. (Group 9015-10.)

YES: Circuit N11 YEL open on load center harness (W3). Repair circuit N11 YEL or replace harness. NO: Go to Continuity Check.

Is continuity indicated?

– – –1/1

4 Continuity Check

Turn key switch OFF. Disconnect rear brake pressure sensor (B52) and FLC connectors (X40, X41, and X42). See Load Center Harness (W3) Component Location. (Group 9015-10.) Check for continuity between pin G2 (circuit N11 YEL) on FLC connector (X41) and remaining pins on FLC connectors (X40, X41, and X42). See Load Center Harness (W3) Wiring Diagram. (Group 9015-10.)

YES: Circuit N11 YEL short to pin that indicated continuity on load center harness (W3). Repair circuit N11 YEL or replace harness. NO: Go to Reprogram Controller.

Is continuity indicated between any pins?

– – –1/1

5 Reprogram Controller

Reprogram flex load controller (FLC). See Electronic Controller Reconfiguration. (Group 9015-20.)

YES: Replace controller. NO: Checks complete.

Check for active codes. Is FLC code 523837.04 present? – – –1/1

TM10229 (17MAR09)

9001-40-201

544J Loader (S.N. 611800— ) 032409

PN=423

9001 40 ,201

Flex Load Controller (FLC) Diagnostic Trouble Codes

523840.01 — Brake Pressure Low-Front

9001 40 ,202

Front axle accumulator service brake pressure is too low.

TF44157,000009D –19–13MAR08–1/1

Brake Pressure Low-Front Diagnostic Procedure Alarm Level: No Warning Lamp

– – –1/1

1 Component Check

YES: See Pump Load Sense Differential and Standby Pressure Test. (Group 9025-25.) NO: Replace service brake pressure sensor.

– – –1/1

523840.03 — Ft Brake Pressure Short to Power

Front brake pressure sensor circuit is short to power.

TF44157,000009E –19–13MAR08–1/1

TM10229 (17MAR09)

9001-40-202

544J Loader (S.N. 611800— ) 032409

PN=424

Flex Load Controller (FLC) Diagnostic Trouble Codes Front Brake Pressure Sensor Short to Power Diagnostic Procedure Alarm Level: No Warning Lamp

9001 40 ,203

– – –1/1

1 Component Check

Perform Brake Valve Pressure Test. (Group 9025-25.)

YES: Go to Short Circuit Check.

Compare pressure readings from brake valve pressure test to readings displayed in the CAN monitor unit (CMU).

NO: Replace service brake pressure sensor.

Does the gauge reading coincide with the CMU reading? – – –1/1

2 Short Circuit Check

Turn key switch OFF.

YES: Circuit N06 YEL short to power on load center harness (W3). Repair circuit N06 YEL or replace harness.

Disconnect front brake pressure sensor (B51). See Load Center Harness (W3) Component Location. (Group 9015-10.) Check circuit N06 YEL for system voltage at pin C on pressure sensor (B51). See Load Center Harness (W3) Wiring Diagram. (Group 9015-10.)

NO: Go to Continuity Check.

Is system voltage present?

– – –1/1

3 Continuity Check

Turn key switch OFF. Disconnect front brake pressure sensor (B51) and FLC connector (X41). See Load Center Harness (W3) Component Location. (Group 9015-10.) Check continuity between pin G1 (circuit N06 YEL) on FLC connector (X41) and remaining pins on FLC connector (X41)

YES: Short to pins that indicated continuity on load center harness (W3). Repair circuit or replace harness. NO: Go to Reprogram Controller.

Check continuity between pin K4 (circuit P69 RED) on FLC connector (X41) and remaining pins on FLC connectors (X41) Check continuity between pin K3 (circuit R69 BLK) on FLC connector (X41) and remaining pins on FLC connectors (X41) See Load Center Harness (W3) Wiring Diagram. (Group 9015-10.) Is continuity indicated between any pins?

– – –1/1

TM10229 (17MAR09)

9001-40-203

544J Loader (S.N. 611800— ) 032409

PN=425

Flex Load Controller (FLC) Diagnostic Trouble Codes 4 Reprogram Controller

Reprogram flex load controller (FLC). See Electronic Controller Reconfiguration. (Group 9015-20.)

YES: Replace controller. NO: Checks complete.

Check for active codes. Is FLC code 523840.03 present?

9001 40 ,204

– – –1/1

523840.04 — Ft Brake Pressure Open or Short

Front brake pressure sensor circuit is open or short to ground.

TF44157,000009F –19–13MAR08–1/1

Front Brake Pressure Sensor Open or Short Diagnostic Procedure Alarm Level: No Warning Lamp

– – –1/1

1 Component Check

Perform Brake Valve Pressure Test. (Group 9025-25.)

YES: Go to Short Circuit Check.

Compare pressure readings from brake valve pressure test to readings displayed in the CAN monitor unit (CMU).

NO: Replace service brake pressure sensor.

Does the gauge reading coincide with the CMU reading? – – –1/1

2 Short Circuit Check

Turn key switch OFF.

YES: Circuit N06 YEL short to ground on load center harness (W3). Repair circuit N06 YEL or replace harness.

Disconnect front brake pressure sensor (B51). See Load Center Harness (W3) Component Location. (Group 9015-10.) Check circuit N06 YEL for ground at pin C on pressure sensor (B51). See Load Center Harness (W3) Wiring DiagramSee Load Center Harness (W3) Wiring Diagram. (Group 9015-10.)

NO: Go to Open Circuit Check.

Is ground present?

– – –1/1

TM10229 (17MAR09)

9001-40-204

544J Loader (S.N. 611800— ) 032409

PN=426

Flex Load Controller (FLC) Diagnostic Trouble Codes 3 Open Circuit Check

Turn key switch OFF. Disconnect front brake pressure sensor (B51) and flex load controller (FLC) connector (X41). See Load Center Harness (W3) Component Location. (Group 9015-10.) Check circuit N06 YEL for continuity between pin C on pressure sensor (B51) and pin G1 on FLC connector (X41). See Load Center Harness (W3) Wiring Diagram. (Group 9015-10.)

YES: Circuit N06 YEL open circuit on load center harness (W3). Repair circuit N06 YEL or replace harness. 9001 40 ,205

NO: Go to Continuity Check.

Is continuity indicated?

– – –1/1

4 Continuity Check

Turn key switch OFF. Disconnect front brake pressure sensor (B51) and FLC connectors (X40, X41, and X42). See Load Center Harness (W3) Component Location. (Group 9015-10.) Check continuity between pin G2 (circuit N06 YEL) on FLC connector (X41) and remaining pins on FLC connectors (X40, X41, and X42). See Load Center Harness (W3) Wiring Diagram. (Group 9015-10.)

YES: Circuit N06 YEL short to pin that indicated continuity on load center harness (W3). Repair circuit N06 YEL or replace harness. NO: Go to Reprogram Controller.

Is continuity indicated between any pins?

– – –1/1

5 Reprogram Controller

Reprogram flex load controller (FLC). See Electronic Controller Reconfiguration. (Group 9015-20.)

YES: Replace controller. NO: Checks complete.

Check for active codes. Is FLC code 523840.04 present? – – –1/1

523911.31 — Hyd Pwr Sol Circuit Fault

Hydraulic power limiting circuit fault (field option).

TF44157,00000A0 –19–13MAR08–1/1

TM10229 (17MAR09)

9001-40-205

544J Loader (S.N. 611800— ) 032409

PN=427

Flex Load Controller (FLC) Diagnostic Trouble Codes

523948.03 — Ride Contrl Sol Short to Power

9001 40 ,206

Ride control solenoid circuit is short to power.

TF44157,00000A1 –19–13MAR08–1/1

Ride Control Solenoid Short to Power Diagnostic Procedure Alarm Level: No Warning Lamp

– – –1/1

1 Component Check

Turn key switch OFF.

YES: Go to Short Circuit Check.

Disconnect ride control solenoids (Y18 and Y34). See Loader Frame Harness (W2) Component Location. (Group 9015-10.)

NO: Replace solenoid(s).

Check resistance of solenoid across pins A and B. Specification Ride Control (On/Off) Solenoid (Y18 and Y34)—Resistance ............................................................................... 29.79—36.41 ohms Is sensor within specification?

– – –1/1

TM10229 (17MAR09)

9001-40-206

544J Loader (S.N. 611800— ) 032409

PN=428

Flex Load Controller (FLC) Diagnostic Trouble Codes 2 Short Circuit Check

Turn key switch OFF.

YES: Go to next step in this check.

Disconnect ride control solenoids (Y18 and Y34). See Loader Frame Harness (W2) Component Location. (Group 9015-10.)

NO: Go to Continuity Check.

Turn key switch ON.

9001 40 ,207

Check circuit H02 GRN for voltage at pin A on ride control solenoids (Y18 and Y34). See Loader Frame Harness (W2) Wiring Diagram. (Group 9015-10.) Is system voltage present?

Turn key switch OFF. Disconnect load center harness-to-loader frame harness connector (X67). See Load Center Harness (W3) Component Location. (Group 9015-10.)

YES: Circuit H02 GRN short to power on load center harness (W3). Repair circuit H02 GRN or replace harness.

Turn key switch ON. Check circuit H02 GRN for voltage at pin 9 on load center harness side of connector (X67). See Load Center Harness (W3) Wiring Diagram. (Group 9015-10.) Is system voltage present?

NO: Circuit H02 GRN short to power on loader frame harness (W2). Repair circuit H02 GRN or replace harness.

– – –1/1

3 Continuity Check

Turn key switch OFF. Disconnect ride control solenoids (Y18 and Y34) and load center harness-to-loader frame harness connector (X67). See Loader Frame Harness (W2) Component Location. (Group 9015-10.) Check continuity between pin 9 (circuit H02 GRN) on loader frame harness side of connector (X67) and remaining pins on loader frame harness side of connector (X67). See Loader Frame Harness (W2) Wiring Diagram. (Group 9015-10.)

YES: Circuit H02 GRN short to pin that indicated continuity on loader frame harness (W2). Repair circuit H02 GRN or replace harness. NO: Go to next step in this check.

Is continuity indicated between any pins?

Key switch OFF. Load center harness-to-loader frame harness connector (X67) disconnected. Disconnect flex load controller (FLC) connectors (X40, X41, and X42). See Load Center Harness (W3) Component Location. (Group 9015-10.) Check continuity between pin G4 (circuit H02 GRN) on FLC connector (X41) and remaining pins on load center harness side of FLC connectors (X40, X41, and X42). See Load Center Harness (W3) Wiring Diagram. (Group 9015-10.)

YES: Circuit H02 GRN short to pin that indicated continuity on load center harness (W3). Repair circuit H02 GRN or replace harness. NO: Go to Reprogram Controller.

Is continuity indicated between any pins?

– – –1/1

TM10229 (17MAR09)

9001-40-207

544J Loader (S.N. 611800— ) 032409

PN=429

Flex Load Controller (FLC) Diagnostic Trouble Codes 4 Reprogram Controller

Reprogram flex load controller (FLC). See Electronic Controller Reconfiguration. (Group 9015-20.)

YES: Replace controller. NO: Checks complete.

Check for active codes. Is FLC code 523577.03 present?

9001 40 ,208

– – –1/1

523948.05 — Ride Contrl Sol Open Circuit

Ride control solenoid circuit is open.

TF44157,00000A2 –19–13MAR08–1/1

Ride Control Solenoid Open Circuit Diagnostic Procedure Alarm Level: No Warning Lamp

– – –1/1

1 Component Check

Turn key switch OFF.

YES: Go to Open Circuit Check.

Disconnect ride control solenoids (Y18 and Y34). See Loader Frame Harness (W2) Component Location. (Group 9015-10.)

NO: Replace solenoid(s).

– – –1/1

TM10229 (17MAR09)

9001-40-208

544J Loader (S.N. 611800— ) 032409

PN=430

Flex Load Controller (FLC) Diagnostic Trouble Codes 2 Open Circuit Check

Turn key switch OFF.

YES: Go to Reprogram Controller.

Disconnect ride control solenoids (Y18 and Y34) and flex load controller (FLC) connector (X41). See Load Center Harness (W3) Component Location and see Loader Frame Harness (W2) Component Location. (Group 9015-10.)

NO: Go to next step in this check. 9001 40 ,209

Check circuit H02 GRN for continuity between pin A on solenoid connector and pin G4 on FLC connector (X41). See Load Center Harness (W3) Wiring Diagram and see Loader Frame Harness (W2) Wiring Diagram. (Group 9015-10.) Check circuit G05 BLK for continuity between pin B on solenoid connector and frame ground. See Loader Frame Harness (W2) Wiring Diagram. (Group 9015-10.) Is continuity indicated?

Key switch OFF.

YES: Open circuit on loader frame harness (W2). Repair circuit or replace harness.

Load center harness-to-loader frame harness connector (X67) and FLC connector (X41) disconnected. Check circuit H02 GRN for continuity between pin 9 on load center harness side of connector (X67) and pin G4 on FLC connector (X41). See Load Center Harness (W3) Wiring Diagram. (Group 9015-10.)

NO: Open circuit on load center harness (W3). Repair circuit or replace harness.

Check circuit G05 BLK for continuity between pin 1 on load center harness side of connector (X67) and frame ground. See Load Center Harness (W3) Wiring Diagram. (Group 9015-10.) Is continuity indicated?

– – –1/1

3 Reprogram Controller

Reprogram flex load controller (FLC). See Electronic Controller Reconfiguration. (Group 9015-20.)

YES: Replace controller. NO: Checks complete.

Check for active codes. Is FLC code 523948.05 present? – – –1/1

523948.06 — Ride Contrl Sol High Current

Ride control solenoid circuit is short to ground.

TF44157,00000A3 –19–13MAR08–1/1

TM10229 (17MAR09)

9001-40-209

544J Loader (S.N. 611800— ) 032409

PN=431

Flex Load Controller (FLC) Diagnostic Trouble Codes Ride Control Solenoid High Current Diagnostic Procedure Alarm Level: 9001 40 ,210

No Warning Lamp

– – –1/1

1 Component Check

Turn key switch OFF.

YES: Go to Short Circuit Check.

Disconnect ride control solenoids (Y18 and Y34). See Loader Frame Harness (W2) Component Location. (Group 9015-10.)

NO: Replace solenoid(s).

– – –1/1

2 Short Circuit Check

Turn key switch OFF.

YES: Go to next step in this check.

Disconnect ride control solenoids (Y18 and Y34). See Loader Frame Harness (W2) Component Location. (Group 9015-10.)

NO: Go to Continuity Check.

Check circuit H02 GRN for ground at pin A on solenoid connector. See Loader Frame Harness (W2) Wiring Diagram. (Group 9015-10.) Is ground present?

Key switch OFF. Disconnect load center harness-to-loader frame harness connector (X67). See Load Center Harness (W3) Component Location. (Group 9015-10.) Check circuit H02 GRN for ground at pin 9 on load center harness side of connector (X67). See Load Center Harness (W3) Wiring Diagram. (Group 9015-10.) Is ground present?

YES: Circuit H02 GRN short to ground on load center harness (W3). Repair circuit H02 GRN or replace harness. NO: Circuit H02 GRN short to ground on loader frame harness (W2). Repair circuit H02 GRN or replace harness. – – –1/1

TM10229 (17MAR09)

9001-40-210

544J Loader (S.N. 611800— ) 032409

PN=432

Flex Load Controller (FLC) Diagnostic Trouble Codes 3 Continuity Check

Turn key switch OFF.

YES: Circuit H02 GRN short to pin that indicated continuity on loader frame harness (W2). Repair circuit H02 GRN or replace harness.

Disconnect ride control solenoids (Y18 and Y34) and load center harness-to-loader frame harness connector (X67). See Loader Frame Harness (W2) Component Location. (Group 9015-10.) Check continuity between pin 9 (circuit H02 GRN) on loader frame harness side of connector (X67) and remaining pins on loader frame harness side of connector (X67). See Loader Frame Harness (W2) Wiring Diagram. (Group 9015-10.)

NO: Go to next step in this check.

Is continuity indicated between any pins?

Key switch OFF. Load center harness-to-loader frame harness connector (X67) disconnected. Disconnect flex load controller (FLC) connectors (X40, X41, and X42). See Load Center Harness (W3) Component Location. (Group 9015-10.) Check continuity between pin G4 (circuit H02 GRN) on FLC connector (X41) and remaining pins on load center harness side of FLC connectors (X40, X41, and X42). See Load Center Harness (W3) Wiring Diagram. (Group 9015-10.)

YES: Circuit H02 GRN short to pin that indicated continuity on load center harness (W3). Repair circuit H02 GRN or replace harness. NO: Go to Reprogram Controller.

Is continuity indicated between any pins?

– – –1/1

4 Reprogram Controller

Reprogram flex load controller (FLC). See Electronic Controller Reconfiguration. (Group 9015-20.)

YES: Replace controller. NO: Checks complete.

Check for active codes. Is FLC code 523948.06 present? – – –1/1

524265.19 — Check Sum Error

Checksum error; the EOL data is invalid.

TF44157,00000A4 –19–13MAR08–1/1

TM10229 (17MAR09)

9001-40-211

544J Loader (S.N. 611800— ) 032409

PN=433

9001 40 ,211

Flex Load Controller (FLC) Diagnostic Trouble Codes Check Sum Error Diagnostic Procedure Alarm Level: 9001 40 ,212

No Warning Lamp

– – –1/1

1 Reprogram Controller

Reprogram flex load controller (FLC). See Electronic Controller Reconfiguration. (Group 9015-20.)

YES: Replace controller. NO: Checks complete.

Check for active codes. Is FLC code 524265.19 present? – – –1/1

TM10229 (17MAR09)

9001-40-212

544J Loader (S.N. 611800— ) 032409

PN=434

Group 50

Sealed Switch Module (SSM) Diagnostic Trouble Codes Sealed Switch Module (SSM) Diagnostic Trouble Codes The diagnostic trouble code number is indicated by a (SPN) Suspect Parameter Number and a (FMI) Failure Mode Indicator number. In the example 000628.12, 628 is the SPN and 12 is the FMI number.

9001 50 1

To view diagnostic trouble codes, use one of the following methods: • Service ADVISOR system. See Service ADVISOR Diagnostic Application. (Group 9015-20.) • CAN Monitor Unit (CMU). See CAN Monitor Unit (CMU) Menu Structure—Service Mode. (Group 9015-20.) Note: For in-depth diagnostics on SSM diagnostic trouble codes, see specific code diagnostic procedure. (Group 9001-50.)

Service ADVISOR is a trademark of Deere & Company

WS68074,0000B4D –19–09MAY07–1/1

000628.12 — Controller Not Programmed

Sealed switch module (SSM) is not programmed.

WS68074,000071E –19–06JUN07–1/1

TM10229 (17MAR09)

9001-50-1

544J Loader (S.N. 611800— ) 032409

PN=435

Sealed Switch Module (SSM) Diagnostic Trouble Codes Controller Not Programmed Diagnostic Procedure Alarm Level: 9001 50 2

No Warning Lamp

– – –1/1

1 Reprogram Controller

Reprogram sealed switch module (SSM).

YES: Replace controller.

Check for active codes.

NO: Checks complete.

Is SSM code 000628.12 present? – – –1/1

000629.12 — SSM Watchdog Time Out

Sealed switch module (SSM) has timed out.

WS68074,000071F –19–06JUN07–1/1

SSM Watchdog Time Out Diagnostic Procedure Alarm Level: No Warning Lamp

– – –1/1

TM10229 (17MAR09)

9001-50-2

544J Loader (S.N. 611800— ) 032409

PN=436

Sealed Switch Module (SSM) Diagnostic Trouble Codes 1 Reset Controller

NOTE: The sealed switch module (SSM) will not store diagnostic trouble codes; once key switch is cycled, the SSM will reset and all codes will be lost.

YES: Go to Reprogram Controller.

Document all diagnostic trouble codes.

NO: Checks complete.

Turn key switch OFF.

9001 50 3

Wait 20 seconds. Turn key switch ON. Is SSM code 000629.12 present?

– – –1/1

2 Reprogram Controller

Reprogram sealed switch module (SSM).

YES: Replace controller.

Check for active codes.

NO: Checks complete.

Is SSM code 000628.12 present? – – –1/1

000639.12 — SSM Lost Message

Sealed switch module (SSM) has lost a CAN message.

WS68074,0000720 –19–05JUN07–1/1

SSM Lost Message Diagnostic Procedure Alarm Level: No Warning Lamp

– – –1/1

TM10229 (17MAR09)

9001-50-3

544J Loader (S.N. 611800— ) 032409

PN=437

Sealed Switch Module (SSM) Diagnostic Trouble Codes 1 Sealed Switch Module Check

Perform SSM test. See Monitor Display Unit—Main Menu—Diagnostics—Switch Module. (Operator’s Manual.) Press buttons on the SSM while monitoring display and LED lights on SSM buttons. Does the CMU display the button that is being pressed?

9001 50 4

Does the LED light on the button illuminate when it is pressed?

YES: Go to next step in this check. NO: Go to Reprogram Sealed Switch Module.

YES: Go to Reprogram Sealed Switch Module. NO: Go to Code Check.

– – –1/1

2 Code Check

Are any CAN communication codes present?

YES: Diagnose CAN communication codes first. See Diagnostic Trouble Codes Quick Reference List. (Group 9015-20.) NO: Go to Circuit Check.

– – –1/1

3 Circuit Check

Perform CAN Circuit Test. (Group 9015-20.)

YES: Go to Reprogram Sealed Switch Module.

Does the CAN circuit test good? NO: Repair wires or replace harness on CAN circuit. – – –1/1

4 Reprogram sealed Switch Module

Reprogram sealed switch module (SSM).

YES: Replace controller.

Check for active codes.

NO: Checks complete.

Is SSM code 000639.12 present? – – –1/1

000639.19 — SSM Lost CAN Communications

Sealed switch module (SSM) has lost CAN communications.

WS68074,0000721 –19–05JUN07–1/1

TM10229 (17MAR09)

9001-50-4

544J Loader (S.N. 611800— ) 032409

PN=438

Sealed Switch Module (SSM) Diagnostic Trouble Codes SSM Lost CAN Communications Diagnostic Procedure Alarm Level: No Warning Lamp

9001 50 5

– – –1/1

1 Sealed Switch Module Check

Does the LED light on button light when it is pressed?

YES: Go to next step in this check. NO: Go to Reprogram Sealed Switch Module.

YES: Go to Reprogram Sealed Switch Module. NO: Go to Code Check.

– – –1/1

2 Code Check

Are any CAN communication codes present?

YES: Diagnose CAN communication codes first. See Diagnostic Trouble Codes Quick Reference List. (Group 9015-20.) NO: Go to Circuit Check.

– – –1/1

3 Circuit Check

Perform CAN Circuit Test. (Group 9015-20.)

YES: Go to Reprogram Sealed Switch Module.

Does the CAN circuit test good? NO: Repair wires or replace harness on CAN circuit. – – –1/1

4 Reprogram sealed Switch Module

Reprogram sealed switch module (SSM).

YES: Replace controller.

Check for active codes.

NO: Checks complete.

Is SSM code 000639.19 present? – – –1/1

TM10229 (17MAR09)

9001-50-5

544J Loader (S.N. 611800— ) 032409

PN=439

Sealed Switch Module (SSM) Diagnostic Trouble Codes

002033.09 — SSM Lost Communications

9001 50 6

Sealed switch module (SSM) lost communications with the flex load controller (FLC).

WS68074,0000722 –19–06JUN07–1/1

SSM Lost Communications Diagnostic Procedure Alarm Level: No Warning Lamp

– – –1/1

1 Controller Sensors Check

Using the CAN monitor unit (H2), view the input readings from the engine control unit. Enter the Main Menu—Diagnostics—Hydraulics—Display All. See CAN Monitor Unit (CMU) Menu Structure—Service Mode. (Group 9015-20.)

YES: Go to Reprogram Sealed Switch Module. NO: Go to Fuse Check.

Are hydraulics values displayed in the CMU? – – –1/1

2 Fuse Check

Turn key switch OFF.

YES: Go to Circuit Check.

Check fuses (F15 and F21) for continuity. See Fuse and Relay Specifications. (Group 9015-10.)

NO: Replace fuse(s).

Is continuity indicated? – – –1/1

TM10229 (17MAR09)

9001-50-6

544J Loader (S.N. 611800— ) 032409

PN=440

Sealed Switch Module (SSM) Diagnostic Trouble Codes 3 Circuit Check

Turn key switch OFF.

YES: Go to next step in this check.

Disconnect flex load controller (FLC) connector (X41). See Load Center Harness (W3) Component location. (Group 9015-10.) Turn key switch ON. Check for voltage at the following pins:

NO: Circuit P15 RED or P21 RED open on load center harness (W3). 9001 Repair circuit P15 RED or 50 P21 RED or replace 7 harness.

• L1—wire P21 RED • M1—wire P15 RED Is voltage present at the pins?

Key switch OFF.

YES: Go to next step in this check.

FLC connector (X41) disconnected. See Load Center Harness (W3) Component location. (Group 9015-10.) Check for ground at the following pins: • L2—wire G01 BLK • M2—wire G01 BLK

NO: Circuit G01 BLK open on load center harness (W3). Repair circuit G01 BLK or replace harness.

Is ground present at all the pins?

Perform CAN Circuit Test. (Group 9015-20.)

YES: Go to Reprogram Flex Load Controller.

Does the CAN circuit test good? NO: Repair wires or replace harness on CAN circuit.

– – –1/1

4 Reprogram Flex Load Controller

Reprogram flex load controller (FLC).

YES: Replace controller.

Check for active codes.

NO: Checks complete.

Is SSM code 002033.09 present? – – –1/1

5 Reprogram sealed Switch Module

Reprogram sealed switch module (SSM).

YES: Replace controller.

Check for active codes.

NO: Checks complete.

Is SSM code 002033.09 present? – – –1/1

TM10229 (17MAR09)

9001-50-7

544J Loader (S.N. 611800— ) 032409

PN=441

Sealed Switch Module (SSM) Diagnostic Trouble Codes

523523.10 — Rear Wiper Keypad Stuck

9001 50 8

Rear wiper keypad on the sealed switch module (SSM) is stuck.

WS68074,0000723 –19–06JUN07–1/1

Rear Wiper Keypad Stuck Diagnostic Procedure Alarm Level: No Warning Lamp

– – –1/1

1 Reset Controller

NOTE: The sealed switch module (SSM) will not store diagnostic trouble codes; once key switch is cycled, the SSM will reset and all codes will be lost.

YES: Go to Component Check.

Document all diagnostic codes.

NO: Checks complete.

Turn key switch OFF. Wait 20 seconds. Turn key switch ON. Is SSM code 523523.10 present?

– – –1/1

2 Component Check

Perform SSM test to verify keypad is malfunctioning. See Monitor Display Unit—Main Menu—Diagnostics—Switch Module. (Operator’s Manual.)

YES: Go to Reprogram Controller.

Does SSM test good?

NO: Go to CAN Circuit Check. – – –1/1

3 CAN Circuit Check

Perform CAN Circuit Test. (Group 9015-20.)

YES: Go to Reprogram Controller.

Does CAN circuit test good? NO: Repair CAN circuit.

– – –1/1

TM10229 (17MAR09)

9001-50-8

544J Loader (S.N. 611800— ) 032409

PN=442

Sealed Switch Module (SSM) Diagnostic Trouble Codes 4 Reprogram Controller

Reprogram sealed switch module (SSM).

YES: Replace controller.

Check for active codes.

NO: Checks complete.

Is SSM code 523523.10 present? – – –1/1

523524.10 — Front Wiper Keypad Stuck

Front wiper keypad on the sealed switch module (SSM) is stuck.

WS68074,0000724 –19–06JUN07–1/1

Front Wiper Keypad Stuck Diagnostic Procedure Alarm Level: No Warning Lamp

– – –1/1

1 Reset Controller

NOTE: The sealed switch module (SSM) will not store diagnostic trouble codes; once key switch is cycled, the SSM will reset and all codes will be lost.

YES: Go to Component Check.

Document all diagnostic codes.

NO: Checks complete.

Turn key switch OFF. Wait 20 seconds. Turn key switch ON. Is SSM code 523524.10 present?

– – –1/1

2 Component Check

Perform SSM test to verify keypad is malfunctioning. See Monitor Display Unit—Main Menu—Diagnostics—Switch Module. (Operator’s Manual.)

YES: Go to Reprogram Controller.

Does SSM test good?

NO: Go to CAN Circuit Check. – – –1/1

TM10229 (17MAR09)

9001-50-9

544J Loader (S.N. 611800— ) 032409

PN=443

9001 50 9

Sealed Switch Module (SSM) Diagnostic Trouble Codes 3 CAN Circuit Check

Perform CAN Circuit Test. (Group 9015-20.)

YES: Go to Reprogram Controller.

Does CAN circuit test good? NO: Repair CAN circuit. 9001 50 10

– – –1/1

4 Reprogram Controller

Reprogram sealed switch module (SSM).

YES: Replace controller.

Check for active codes.

NO: Checks complete.

Is SSM code 523524.10 present? – – –1/1

523525.10 — Front Washer Keypad Stuck

Front washer keypad on the sealed switch module (SSM) is stuck.

WS68074,0000725 –19–15DEC06–1/1

Front Washer Keypad Stuck Diagnostic Procedure Alarm Level: No Warning Lamp

– – –1/1

1 Reset Controller

NOTE: The sealed switch module (SSM) will not store diagnostic trouble codes; once key switch is cycled, the SSM will reset and all codes will be lost.

YES: Go to Component Check.

Document all diagnostic codes.

NO: Checks complete.

Turn key switch OFF. Wait 20 seconds. Turn key switch ON. Is SSM code 523525.10 present?

– – –1/1

TM10229 (17MAR09)

9001-50-10

544J Loader (S.N. 611800— ) 032409

PN=444

Sealed Switch Module (SSM) Diagnostic Trouble Codes 2 Component Check

Perform SSM test to verify keypad is malfunctioning. See Monitor Display Unit—Main Menu—Diagnostics—Switch Module. (Operator’s Manual.)

YES: Go to Reprogram Controller.

Does SSM test good?

NO: Go to CAN Circuit Check. – – –1/1

3 CAN Circuit Check

Perform CAN Circuit Test. (Group 9015-20.)

YES: Go to Reprogram Controller.

Does CAN circuit test good? NO: Repair CAN circuit.

– – –1/1

4 Reprogram Controller

Reprogram sealed switch module (SSM).

YES: Replace controller.

Check for active codes.

NO: Checks complete.

Is SSM code 523525.10 present? – – –1/1

523526.10 — Reverse Fan Keypad Stuck

Reverse fan keypad on the sealed switch module (SSM) is stuck.

WS68074,0000726 –19–15DEC06–1/1

Reverse Fan Keypad Stuck Diagnostic Procedure Alarm Level: No Warning Lamp

– – –1/1

TM10229 (17MAR09)

9001-50-11

544J Loader (S.N. 611800— ) 032409

PN=445

9001 50 11

Sealed Switch Module (SSM) Diagnostic Trouble Codes 1 Reset Controller

NOTE: The sealed switch module (SSM) will not store diagnostic trouble codes; once key switch is cycled, the SSM will reset and all codes will be lost.

YES: Go to Component Check.

Document all diagnostic codes.

NO: Checks complete.

Turn key switch OFF.

9001 50 12

Wait 20 seconds. Turn key switch ON. Is SSM code 523526.10 present?

– – –1/1

2 Component Check

Perform SSM test to verify keypad is malfunctioning. See Monitor Display Unit—Main Menu—Diagnostics—Switch Module. (Operator’s Manual.)

YES: Go to Reprogram Controller.

Does SSM test good?

NO: Go to CAN Circuit Check. – – –1/1

3 CAN Circuit Check

Perform CAN Circuit Test. (Group 9015-20.)

YES: Go to Reprogram Controller.

Does CAN circuit test good? NO: Repair CAN circuit.

– – –1/1

4 Reprogram Controller

Reprogram sealed switch module (SSM).

YES: Replace controller.

Check for active codes.

NO: Checks complete.

Is SSM code 523526.10 present? – – –1/1

523527.10 — Pin Disconnect Keypad Stuck

Pin disconnect keypad on the sealed switch module (SSM) is stuck.

WS68074,0000727 –19–15DEC06–1/1

TM10229 (17MAR09)

9001-50-12

544J Loader (S.N. 611800— ) 032409

PN=446

Sealed Switch Module (SSM) Diagnostic Trouble Codes Pin Disconnect Keypad Stuck Diagnostic Procedure Alarm Level: No Warning Lamp

9001 50 13

– – –1/1

1 Reset Controller

NOTE: The sealed switch module (SSM) will not store diagnostic trouble codes; once key switch is cycled, the SSM will reset and all codes will be lost.

YES: Go to Component Check.

Document all diagnostic codes.

NO: Checks complete.

Turn key switch OFF. Wait 20 seconds. Turn key switch ON. Is SSM code 523527.10 present?

– – –1/1

2 Component Check

Perform SSM test to verify keypad is malfunctioning. See Monitor Display Unit—Main Menu—Diagnostics—Switch Module. (Operator’s Manual.)

YES: Go to Reprogram Controller.

Does SSM test good?

NO: Go to CAN Circuit Check. – – –1/1

3 CAN Circuit Check

Perform CAN Circuit Test. (Group 9015-20.)

YES: Go to Reprogram Controller.

Does CAN circuit test good? NO: Repair CAN circuit.

– – –1/1

4 Reprogram Controller

Reprogram sealed switch module (SSM).

YES: Replace controller.

Check for active codes.

NO: Checks complete.

Is SSM code 523527.10 present? – – –1/1

TM10229 (17MAR09)

9001-50-13

544J Loader (S.N. 611800— ) 032409

PN=447

Sealed Switch Module (SSM) Diagnostic Trouble Codes

523528.10 — A/C Keypad Stuck

9001 50 14

Air conditioning keypad on the sealed switch module (SSM) is stuck.

WS68074,0000728 –19–15DEC06–1/1

A/C Keypad Stuck Diagnostic Procedure Alarm Level: No Warning Lamp

– – –1/1

1 Reset Controller

NOTE: The sealed switch module (SSM) will not store diagnostic trouble codes; once key switch is cycled, the SSM will reset and all codes will be lost.

YES: Go to Component Check.

Document all diagnostic codes.

NO: Checks complete.

Turn key switch OFF. Wait 20 seconds. Turn key switch ON. Is SSM code 523528.10 present?

– – –1/1

2 Component Check

Perform SSM test to verify keypad is malfunctioning. See Monitor Display Unit—Main Menu—Diagnostics—Switch Module. (Operator’s Manual.)

YES: Go to Reprogram Controller.

Does SSM test good?

NO: Go to CAN Circuit Check. – – –1/1

3 CAN Circuit Check

Perform CAN Circuit Test. (Group 9015-20.)

YES: Go to Reprogram Controller.

Does CAN circuit test good? NO: Repair CAN circuit.

– – –1/1

TM10229 (17MAR09)

9001-50-14

544J Loader (S.N. 611800— ) 032409

PN=448

Sealed Switch Module (SSM) Diagnostic Trouble Codes 4 Reprogram Controller

Reprogram sealed switch module (SSM).

YES: Replace controller.

Check for active codes.

NO: Checks complete.

Is SSM code 523528.10 present? – – –1/1

523529.10 — Work Lights Keypad Stuck

Work lights keypad on the sealed switch module (SSM) is stuck.

WS68074,0000729 –19–15DEC06–1/1

Work Lights Keypad Stuck Diagnostic Procedure Alarm Level: No Warning Lamp

– – –1/1

1 Reset Controller

NOTE: The sealed switch module (SSM) will not store diagnostic trouble codes; once key switch is cycled, the SSM will reset and all codes will be lost.

YES: Go to Component Check.

Document all diagnostic codes.

NO: Checks complete.

Turn key switch OFF. Wait 20 seconds. Turn key switch ON. Is SSM code 523529.10 present?

– – –1/1

2 Component Check

Perform SSM test to verify keypad is malfunctioning. See Monitor Display Unit—Main Menu—Diagnostics—Switch Module. (Operator’s Manual.)

YES: Go to Reprogram Controller.

Does SSM test good?

NO: Go to CAN Circuit Check. – – –1/1

TM10229 (17MAR09)

9001-50-15

544J Loader (S.N. 611800— ) 032409

PN=449

9001 50 15

Sealed Switch Module (SSM) Diagnostic Trouble Codes 3 CAN Circuit Check

Perform CAN Circuit Test. (Group 9015-20.)

YES: Go to Reprogram Controller.

Does CAN circuit test good? NO: Repair CAN circuit. 9001 50 16

– – –1/1

4 Reprogram Controller

Reprogram sealed switch module (SSM).

YES: Replace controller.

Check for active codes.

NO: Checks complete.

Is SSM code 523529.10 present? – – –1/1

523530.10 — Beacon Light Keypad Stuck

Beacon light keypad on the sealed switch module (SSM) is stuck.

WS68074,000072A –19–15DEC06–1/1

Beacon Light Keypad Stuck Diagnostic Procedure Alarm Level: No Warning Lamp

– – –1/1

1 Reset Controller

NOTE: The sealed switch module (SSM) will not store diagnostic trouble codes; once key switch is cycled, the SSM will reset and all codes will be lost.

YES: Go to Component Check.

Document all diagnostic codes.

NO: Checks complete.

Turn key switch OFF. Wait 20 seconds. Turn key switch ON. Is SSM code 523530.10 present?

– – –1/1

TM10229 (17MAR09)

9001-50-16

544J Loader (S.N. 611800— ) 032409

PN=450

Sealed Switch Module (SSM) Diagnostic Trouble Codes 2 Component Check

Perform SSM test to verify keypad is malfunctioning. See Monitor Display Unit—Main Menu—Diagnostics—Switch Module. (Operator’s Manual.)

YES: Go to Reprogram Controller.

Does SSM test good?

NO: Go to CAN Circuit Check. – – –1/1

3 CAN Circuit Check

Perform CAN Circuit Test. (Group 9015-20.)

YES: Go to Reprogram Controller.

Does CAN circuit test good? NO: Repair CAN circuit.

– – –1/1

4 Reprogram Controller

Reprogram sealed switch module (SSM).

YES: Replace controller.

Check for active codes.

NO: Checks complete.

Is SSM code 523530.10 present? – – –1/1

523532.10 — Spin Control Keypad Stuck

Spin control keypad on the sealed switch module (SSM) is stuck.

WS68074,000072C –19–15DEC06–1/1

Spin Control Keypad Stuck Diagnostic Procedure Alarm Level: No Warning Lamp

– – –1/1

TM10229 (17MAR09)

9001-50-17

544J Loader (S.N. 611800— ) 032409

PN=451

9001 50 17

Sealed Switch Module (SSM) Diagnostic Trouble Codes 1 Reset Controller

NOTE: The sealed switch module (SSM) will not store diagnostic trouble codes; once key switch is cycled, the SSM will reset and all codes will be lost.

YES: Go to Component Check.

Document all diagnostic codes.

NO: Checks complete.

Turn key switch OFF.

9001 50 18

Wait 20 seconds. Turn key switch ON. Is SSM code 523532.10 present?

– – –1/1

2 Component Check

Perform SSM test to verify keypad is malfunctioning. See Monitor Display Unit—Main Menu—Diagnostics—Switch Module. (Operator’s Manual.)

YES: Go to Reprogram Controller.

Does SSM test good?

NO: Go to CAN Circuit Check. – – –1/1

3 CAN Circuit Check

Perform CAN Circuit Test. (Group 9015-20.)

YES: Go to Reprogram Controller.

Does CAN circuit test good? NO: Repair CAN circuit.

– – –1/1

4 Reprogram Controller

Reprogram sealed switch module (SSM).

YES: Replace controller.

Check for active codes.

NO: Checks complete.

Is SSM code 523532.10 present? – – –1/1

523533.10 — Clutch Cut-Off Keypad Stuck

Clutch cutoff keypad on the sealed switch module (SSM) is stuck.

WS68074,000072D –19–15DEC06–1/1

TM10229 (17MAR09)

9001-50-18

544J Loader (S.N. 611800— ) 032409

PN=452

Sealed Switch Module (SSM) Diagnostic Trouble Codes Clutch Cut-Off Keypad Stuck Diagnostic Procedure Alarm Level: No Warning Lamp

9001 50 19

– – –1/1

1 Reset Controller

NOTE: The sealed switch module (SSM) will not store diagnostic trouble codes; once key switch is cycled, the SSM will reset and all codes will be lost.

YES: Go to Component Check.

Document all diagnostic codes.

NO: Checks complete.

Turn key switch OFF. Wait 20 seconds. Turn key switch ON. Is SSM code 523533.10 present?

– – –1/1

2 Component Check

Perform SSM test to verify keypad is malfunctioning. See Monitor Display Unit—Main Menu—Diagnostics—Switch Module. (Operator’s Manual.)

YES: Go to Reprogram Controller.

Does SSM test good?

NO: Go to CAN Circuit Check. – – –1/1

3 CAN Circuit Check

Perform CAN Circuit Test. (Group 9015-20.)

YES: Go to Reprogram Controller.

Does CAN circuit test good? NO: Repair CAN circuit.

– – –1/1

4 Reprogram Controller

Reprogram sealed switch module (SSM).

YES: Replace controller.

Check for active codes.

NO: Checks complete.

Is SSM code 523533.10 present? – – –1/1

TM10229 (17MAR09)

9001-50-19

544J Loader (S.N. 611800— ) 032409

PN=453

Sealed Switch Module (SSM) Diagnostic Trouble Codes

523534.10 — Pilot Enable Keypad Stuck

9001 50 20

Pilot enable keypad on the sealed switch module (SSM) is stuck.

WS68074,000072E –19–15DEC06–1/1

Pilot Enable Keypad Stuck Diagnostic Procedure Alarm Level: No Warning Lamp

– – –1/1

1 Reset Controller

NOTE: The sealed switch module (SSM) will not store diagnostic trouble codes; once key switch is cycled, the SSM will reset and all codes will be lost.

YES: Go to Component Check.

Document all diagnostic codes.

NO: Checks complete.

Turn key switch OFF. Wait 20 seconds. Turn key switch ON. Is SSM code 523534.10 present?

– – –1/1

2 Component Check

Perform SSM test to verify keypad is malfunctioning. See Monitor Display Unit—Main Menu—Diagnostics—Switch Module. (Operator’s Manual.)

YES: Go to Reprogram Controller.

Does SSM test good?

NO: Go to CAN Circuit Check. – – –1/1

3 CAN Circuit Check

Perform CAN Circuit Test. (Group 9015-20.)

YES: Go to Reprogram Controller.

Does CAN circuit test good? NO: Repair CAN circuit.

– – –1/1

TM10229 (17MAR09)

9001-50-20

544J Loader (S.N. 611800— ) 032409

PN=454

Sealed Switch Module (SSM) Diagnostic Trouble Codes 4 Reprogram Controller

Reprogram sealed switch module (SSM).

YES: Replace controller.

Check for active codes.

NO: Checks complete.

Is SSM code 523534.10 present? – – –1/1

523535.10 — Ride Control Keypad Stuck

Ride control keypad on the sealed switch module (SSM) is stuck.

WS68074,000072F –19–15DEC06–1/1

Ride Control Keypad Stuck Diagnostic Procedure Alarm Level: No Warning Lamp

– – –1/1

1 Reset Controller

NOTE: The sealed switch module (SSM) will not store diagnostic trouble codes; once key switch is cycled, the SSM will reset and all codes will be lost.

YES: Go to Component Check.

Document all diagnostic codes.

NO: Checks complete.

Turn key switch OFF. Wait 20 seconds. Turn key switch ON. Is SSM code 523535.10 present?

– – –1/1

2 Component Check

Perform SSM test to verify keypad is malfunctioning. See Monitor Display Unit—Main Menu—Diagnostics—Switch Module. (Operator’s Manual.)

YES: Go to Reprogram Controller.

Does SSM test good?

NO: Go to CAN Circuit Check. – – –1/1

TM10229 (17MAR09)

9001-50-21

544J Loader (S.N. 611800— ) 032409

PN=455

9001 50 21

Sealed Switch Module (SSM) Diagnostic Trouble Codes 3 CAN Circuit Check

Perform CAN Circuit Test. (Group 9015-20.)

YES: Go to Reprogram Controller.

Does CAN circuit test good? NO: Repair CAN circuit. 9001 50 22

– – –1/1

4 Reprogram Controller

Reprogram sealed switch module (SSM).

YES: Replace controller.

Check for active codes.

NO: Checks complete.

Is SSM code 523535.10 present? – – –1/1

523536.10 — Auto Transmission Keypad Stuck

Auto transmission keypad on the sealed switch module (SSM) is stuck.

WS68074,0000730 –19–15DEC06–1/1

Auto Transmission Keypad Stuck Diagnostic Procedure Alarm Level: No Warning Lamp

– – –1/1

1 Reset Controller

NOTE: The sealed switch module (SSM) will not store diagnostic trouble codes; once key switch is cycled, the SSM will reset and all codes will be lost.

YES: Go to Component Check.

Document all diagnostic codes.

NO: Checks complete.

Turn key switch OFF. Wait 20 seconds. Turn key switch ON. Is SSM code 523536.10 present?

– – –1/1

TM10229 (17MAR09)

9001-50-22

544J Loader (S.N. 611800— ) 032409

PN=456

Sealed Switch Module (SSM) Diagnostic Trouble Codes 2 Component Check

Perform SSM test to verify keypad is malfunctioning. See Monitor Display Unit—Main Menu—Diagnostics—Switch Module. (Operator’s Manual.)

YES: Go to Reprogram Controller.

Does SSM test good?

NO: Go to CAN Circuit Check. – – –1/1

3 CAN Circuit Check

Perform CAN Circuit Test. (Group 9015-20.)

YES: Go to Reprogram Controller.

Does CAN circuit test good? NO: Repair CAN circuit.

– – –1/1

4 Reprogram Controller

Reprogram sealed switch module (SSM).

YES: Replace controller.

Check for active codes.

NO: Checks complete.

Is SSM code 523536.10 present? – – –1/1

523537.10 — Drive Lights Keypad Stuck

Drive lights keypad on the sealed switch module (SSM) is stuck.

WS68074,0000731 –19–06JUN07–1/1

Drive Lights Keypad Stuck Diagnostic Procedure Alarm Level: No Warning Lamp

– – –1/1

TM10229 (17MAR09)

9001-50-23

544J Loader (S.N. 611800— ) 032409

PN=457

9001 50 23

Sealed Switch Module (SSM) Diagnostic Trouble Codes 1 Reset Controller

NOTE: The sealed switch module (SSM) will not store diagnostic trouble codes; once key switch is cycled, the SSM will reset and all codes will be lost.

YES: Go to Component Check.

Document all diagnostic codes.

NO: Checks complete.

Turn key switch OFF.

9001 50 24

Wait 20 seconds. Turn key switch ON. Is SSM code 523537.10 present?

– – –1/1

2 Component Check

Perform SSM test to verify keypad is malfunctioning. See Monitor Display Unit—Main Menu—Diagnostics—Switch Module. (Operator’s Manual.)

YES: Go to Reprogram Controller.

Does SSM test good?

NO: Go to CAN Circuit Check. – – –1/1

3 CAN Circuit Check

Perform CAN Circuit Test. (Group 9015-20.)

YES: Go to Reprogram Controller.

Does CAN circuit test good? NO: Repair CAN circuit.

– – –1/1

4 Reprogram Controller

Reprogram sealed switch module (SSM).

YES: Replace controller.

Check for active codes.

NO: Checks complete.

Is SSM code 523537.10 present? – – –1/1

523538.10 — Keypad Not Used

Axle disconnect keypad on the sealed switch module (SSM) is stuck.

WS68074,0000732 –19–06JUN07–1/1

TM10229 (17MAR09)

9001-50-24

544J Loader (S.N. 611800— ) 032409

PN=458

Sealed Switch Module (SSM) Diagnostic Trouble Codes Keypad Not Used Diagnostic Procedure Alarm Level: No Warning Lamp

9001 50 25

– – –1/1

1 Reset Controller

NOTE: The sealed switch module (SSM) will not store diagnostic trouble codes; once key switch is cycled, the SSM will reset and all codes will be lost.

YES: Go to Component Check.

Document all diagnostic codes.

NO: Checks complete.

Turn key switch OFF. Wait 20 seconds. Turn key switch ON. Is SSM code 523538.10 present?

– – –1/1

2 Component Check

Perform SSM test to verify keypad is malfunctioning. See Monitor Display Unit—Main Menu—Diagnostics—Switch Module. (Operator’s Manual.)

YES: Go to Reprogram Controller.

Does SSM test good?

NO: Go to CAN Circuit Check. – – –1/1

3 CAN Circuit Check

Perform CAN Circuit Test. (Group 9015-20.)

YES: Go to Reprogram Controller.

Does CAN circuit test good? NO: Repair CAN circuit.

– – –1/1

4 Reprogram Controller

Reprogram sealed switch module (SSM).

YES: Replace controller.

Check for active codes.

NO: Checks complete.

Is SSM code 523538.10 present? – – –1/1

TM10229 (17MAR09)

9001-50-25

544J Loader (S.N. 611800— ) 032409

PN=459

Sealed Switch Module (SSM) Diagnostic Trouble Codes

523607.10 — Return to Dig Keypad Stuck

9001 50 26

Return-to-dig keypad on the sealed switch module (SSM) is stuck.

WS68074,0000733 –19–06JUN07–1/1

Return-to-Dig Keypad Stuck Diagnostic Procedure Alarm Level: No Warning Lamp

– – –1/1

1 Reset Controller

NOTE: The sealed switch module (SSM) will not store diagnostic trouble codes; once key switch is cycled, the SSM will reset and all codes will be lost.

YES: Go to Component Check.

Document all diagnostic codes.

NO: Checks complete.

Turn key switch OFF. Wait 20 seconds. Turn key switch ON. Is SSM code 523607.10 present?

– – –1/1

2 Component Check

Perform SSM test to verify keypad is malfunctioning. See Monitor Display Unit—Main Menu—Diagnostics—Switch Module. (Operator’s Manual.)

YES: Go to Reprogram Controller.

Does SSM test good?

NO: Go to CAN Circuit Check. – – –1/1

3 CAN Circuit Check

Perform CAN Circuit Test. (Group 9015-20.)

YES: Go to Reprogram Controller.

Does CAN circuit test good? NO: Repair CAN circuit.

– – –1/1

TM10229 (17MAR09)

9001-50-26

544J Loader (S.N. 611800— ) 032409

PN=460

Sealed Switch Module (SSM) Diagnostic Trouble Codes 4 Reprogram Controller

Reprogram sealed switch module (SSM).

YES: Replace controller.

Check for active codes.

NO: Checks complete.

Is SSM code 523607.10 present? – – –1/1

523608.10 — BHKO Keypad Stuck

Boom height kickout keypad on the sealed switch module (SSM) is stuck.

WS68074,0000734 –19–15DEC06–1/1

Boom Height Kickout Keypad Stuck Diagnostic Procedure Alarm Level: No Warning Lamp

– – –1/1

1 Reset Controller

NOTE: The sealed switch module (SSM) will not store diagnostic trouble codes; once key switch is cycled, the SSM will reset and all codes will be lost.

YES: Go to Component Check.

Document all diagnostic codes.

NO: Checks complete.

Turn key switch OFF. Wait 20 seconds. Turn key switch ON. Is SSM code 523608.10 present?

– – –1/1

2 Component Check

Perform SSM test to verify keypad is malfunctioning. See Monitor Display Unit—Main Menu—Diagnostics—Switch Module. (Operator’s Manual.)

YES: Go to Reprogram Controller.

Does SSM test good?

NO: Go to CAN Circuit Check. – – –1/1

TM10229 (17MAR09)

9001-50-27

544J Loader (S.N. 611800— ) 032409

PN=461

9001 50 27

Sealed Switch Module (SSM) Diagnostic Trouble Codes 3 CAN Circuit Check

Perform CAN Circuit Test. (Group 9015-20.)

YES: Go to Reprogram Controller.

Does CAN circuit test good? NO: Repair CAN circuit. 9001 50 28

– – –1/1

4 Reprogram Controller

Reprogram sealed switch module (SSM).

YES: Replace controller.

Check for active codes.

NO: Checks complete.

Is SSM code 523608.10 present? – – –1/1

523609.10 — RTCarry Keypad Stuck

Return-to-carry keypad on the sealed switch module (SSM) is stuck.

WS68074,0000735 –19–06JUN07–1/1

Return-to-Carry Keypad Stuck Diagnostic Procedure Alarm Level: No Warning Lamp

– – –1/1

1 Reset Controller

NOTE: The sealed switch module (SSM) will not store diagnostic trouble codes; once key switch is cycled, the SSM will reset and all codes will be lost.

YES: Go to Component Check.

Document all diagnostic codes.

NO: Checks complete.

Turn key switch OFF. Wait 20 seconds. Turn key switch ON. Is SSM code 523609.10 present?

– – –1/1

TM10229 (17MAR09)

9001-50-28

544J Loader (S.N. 611800— ) 032409

PN=462

Sealed Switch Module (SSM) Diagnostic Trouble Codes 2 Component Check

Perform SSM test to verify keypad is malfunctioning. See Monitor Display Unit—Main Menu—Diagnostics—Switch Module. (Operator’s Manual.)

YES: Go to Reprogram Controller.

Does SSM test good?

NO: Go to CAN Circuit Check. – – –1/1

3 CAN Circuit Check

Perform CAN Circuit Test. (Group 9015-20.)

YES: Go to Reprogram Controller.

Does CAN circuit test good? NO: Repair CAN circuit.

– – –1/1

4 Reprogram Controller

Reprogram sealed switch module (SSM).

YES: Replace controller.

Check for active codes.

NO: Checks complete.

Is SSM code 523609.10 present? – – –1/1

523610.10 — Rear Washer Keypad Stuck

Rear washer keypad on the sealed switch module (SSM) is stuck.

WS68074,0000736 –19–15DEC06–1/1

Rear Washer Keypad Stuck Diagnostic Procedure Alarm Level: No Warning Lamp

– – –1/1

TM10229 (17MAR09)

9001-50-29

544J Loader (S.N. 611800— ) 032409

PN=463

9001 50 29

Sealed Switch Module (SSM) Diagnostic Trouble Codes 1 Reset Controller

NOTE: The sealed switch module (SSM) will not store diagnostic trouble codes; once key switch is cycled, the SSM will reset and all codes will be lost.

YES: Go to Component Check.

Document all diagnostic codes.

NO: Checks complete.

Turn key switch OFF.

9001 50 30

Wait 20 seconds. Turn key switch ON. Is SSM code 523610.10 present?

– – –1/1

2 Component Check

Perform SSM test to verify keypad is malfunctioning. See Monitor Display Unit—Main Menu—Diagnostics—Switch Module. (Operator’s Manual.)

YES: Go to Reprogram Controller.

Does SSM test good?

NO: Go to CAN Circuit Check. – – –1/1

3 CAN Circuit Check

Perform CAN Circuit Test. (Group 9015-20.)

YES: Go to Reprogram Controller.

Does CAN circuit test good? NO: Repair CAN circuit.

– – –1/1

4 Reprogram Controller

Reprogram sealed switch module (SSM).

YES: Replace controller.

Check for active codes.

NO: Checks complete.

Is SSM code 523610.10 present? – – –1/1

TM10229 (17MAR09)

9001-50-30

544J Loader (S.N. 611800— ) 032409

PN=464

Section 9005

Operational Checkout Procedure Contents Page

Group 10—Operational Checkout Procedure Operational Checkout . . . . . . . . . . . . . . . . . .9005-10-1 Diagnostic Trouble Code Check . . . . . . . . . .9005-10-1 Operational Checks—Key Switch OFF, Engine OFF Checks . . . . . . . . . . . . . . . . .9005-10-1 Operational Checks—Key Switch ON, Engine OFF Checks . . . . . . . . . . . . . . . . . . . . . . .9005-10-2 Operational Checks—Key Switch ON, Engine ON Checks . . . . . . . . . . . . . . . . . . . . . . . .9005-10-5

TM10229 (17MAR09)

9005-1

9005

544J Loader (S.N. 611800— ) 032409

PN=1

Contents

9005

TM10229 (17MAR09)

9005-2

544J Loader (S.N. 611800— ) 032409

PN=2

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 checkout. Most checks will require machine systems to be at normal operating temperatures and a level area with

adequate space to operate machine. Some checks may require varied surfaces. No special tools are necessary to perform the checkout. If no problem is found, go to next check. If problem is indicated, an additional check or repair procedure will be suggested.

RK98916,0000194 –19–03APR08–1/1

Diagnostic Trouble Code Check

– – –1/1

Display and Clear Trouble Codes

Always check for diagnostic trouble codes 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) Menu Structure— Service Mode. (Group 9015-20.) • 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.) LOOK: Are diagnostic trouble codes present?

YES: Correct all diagnostic trouble codes before proceeding. See Diagnostic Trouble Codes Quick Reference List. (Group 9015-20.) NO: Continue with operational checkout.

– – –1/1

Operational Checks—Key Switch OFF, Engine OFF Checks

– – –1/1

TM10229 (17MAR09)

9005-10-1

544J Loader (S.N. 611800— ) 032409

PN=467

9005 10 1

Operational Checkout Procedure Battery Check

65.1 25.0

Key switch OFF.

YES: Check Complete.

Push SELECT button and hold until battery volts are displayed.

NO: Check and recharge batteries. See Check Battery Electrolyte Level and Terminals. (Operator’s Manual.) Check voltage on each battery before recharging.

LOOK: Does battery volts read a minimum of 24 volts?

T194308 –UN–11SEP03

NOTE: If one battery will not hold a charge, replace both batteries.

9005 10 2

– – –1/1

Horn Check

Push horn button.

YES: Check Complete.

LISTEN: Does horn activate?

NO: Check horn circuit. See System Functional Schematic and Section Legend. (Group 9015-10.) – – –1/1

Seat Control Checks

NOTE: For seat adjustment procedures, see Adjusting Seat. (Operator’s Manual.)

YES: Check Complete.

If machine is equipped with air seat, key switch must be ON to raise seat.

NO: Inspect linkage and repair.

Does seat raise and lower easily? Does seat angle change easily? Does lever move easily to unlock seat support? Does seat move forward and rearward easily? Does lever lock seat support in position when released? Does seat back tilt forward and rearward easily? Does lever unlock and lock easily to hold seat back in position?

– – –1/1

Operational Checks—Key Switch ON, Engine OFF Checks

– – –1/1

TM10229 (17MAR09)

9005-10-2

544J Loader (S.N. 611800— ) 032409

PN=468

Operational Checkout Procedure Monitor Check

Turn key switch ON.

YES: Check Complete.

Observe monitor and note changes for first 3 seconds (bulbs, indicators and gauges).

NO: Check CMU/SSM ignition power 5A fuse (F13). See Fuse and Relay Specifications. (Group 9015-10.)

LOOK/LISTEN: Do all lights come on and is the audible alarm activated? LOOK: Does the monitor display show “John Deere” and the model number? LOOK: Do all the gauge indicators point to approximately 12:00 o’clock position? LOOK: Is backlighting of gauges on? After 4 seconds, observe changes in monitor.

9005 10 3

LOOK: Does the monitor display show gear selection and engine speed? NOTE: The monitor display will show either the odometer, hour meter, or speedometer reading. When powered up, the monitor will default to what was last displayed when the key switch was turned off. LOOK: Does the monitor display show odometer, hour meter, or speedometer reading? LOOK: Do gauge indicators change from 12:00 o’clock to normal readings? – – –1/1

Cab System Checks

Check the following for proper working order:

YES: Check Complete.

• Dome light • Front and rear windshield wiper and washer • Four-speed (five-position) blower fan • Front and rear work lights • Front and rear drive and marker lights • Turn signals

NO: Go to specific circuit. See System Functional Schematic and Section Legend. (Group 9015-10.)

– – –1/1

TM10229 (17MAR09)

9005-10-3

544J Loader (S.N. 611800— ) 032409

PN=469

Operational Checkout Procedure Transmission Gear Shift Switch and Neutral Lock Latch Checks—Steering Column Mount Only

Push automatic transmission switch to OFF position. (LED off.)

Move transmission control lever (TCL) to forward (F), neutral (N), and reverse (R) positions. LOOK: Does TCL move into forward, neutral, and reverse positions?

T194310 –UN–11SEP03

LOOK: Does TCL stay in detented positions? LISTEN: Does backup alarm activate when TCL is in reverse position?

9005 10 4

YES: Check Complete. NO: If lever does not move or lock properly, replace lever. NO: If gear selection does not change on monitor, check gear shift circuit. See Transmission Control Unit (TCU) Circuit Theory of Operation. (Group 9015-15.)

Put neutral lock in LOCKED position. Using a light force, try to move TCL into forward and reverse positions. LOOK: Does neutral lock stay engaged and TCL stay in neutral? Put neutral lock in UNLOCK position. Rotate TCL handle to select each gear: 1st, 2nd, 3rd, and 4th. LOOK: Does gear number align with pointer in each detented position? LOOK/FEEL: Does handle remain in detented positions? LOOK: Does monitor display indicate the neutral position (1 N) and correct gear (1, 2, 3, and 4)?

– – –1/1

Transmission Gear Shift Switch Checks— Hydraulic Control Lever Mount Only

Push automatic transmission switch to OFF position. (LED off.)

Put gear shift switch in forward (F), neutral (N), and reverse (R) positions. LOOK: Does switch move into forward, neutral, and reverse positions?

T194310 –UN–11SEP03

LOOK: Does switch stay in detented positions? LISTEN: Does backup alarm activate when switch is in reverse position?

YES: Check Complete. NO: If gear shift switch does not move properly or stay in detented position, replace switch. NO: If gear selection does not change on monitor, check gear shift circuit. See Transmission Control Unit (TCU) Circuit Theory of Operation. (Group 9015-15.)

Push the upshift button and downshift buttons on the hydraulic control lever. LOOK: Does monitor display indicate the neutral position (1 N) and correct gear (1, 2, 3, and 4)?

– – –1/1

TM10229 (17MAR09)

9005-10-4

544J Loader (S.N. 611800— ) 032409

PN=470

Operational Checkout Procedure Neutral Start Check

Put automatic transmission gear shift switch in 1st gear forward (1F) or 1st gear reverse (1R) position, then turn key switch to START position. LOOK/LISTEN: Does engine start? LOOK: Does the gear displayed on the monitor indicate a neutral gear selection?

YES: Check Complete. NO: See Starting and Charging Circuit Theory of Operation. (Group 9015-15.)

NOTE: F or R will not appear in the gear display until gear shift switch is cycled back to neutral and park brake is released.

– – –1/1

Operational Checks—Key Switch ON, Engine ON Checks

– – –1/1

Hydraulic and Transmission Oil Warmup Procedure

IMPORTANT: For the following checks, all systems must be warmed up to operating range to get accurate test results.

YES: Go to next check.

See Hydraulic Oil Warmup Procedure. (Group 9025-25.) See Transmission Oil Warmup Procedure. (Group 9020-25.) – – –1/1

TM10229 (17MAR09)

9005-10-5

544J Loader (S.N. 611800— ) 032409

PN=471

9005 10 5

Operational Checkout Procedure Park Brake Check

YES: Check Complete. CAUTION: Prevent possible injury from machine movement. Perform this check in an open area away from other people and machinery. Release park brake by pushing park brake switch to OFF position. For switch operation, see Park Brake Switch. (Operator’s Manual.) LOOK: Does park brake indicator go off when brake is released?

T103441 –UN–09SEP96

9005 10 6

CAUTION: Prevent possible injury from sudden machine stops. Wear seat belt while operating machine.

NO: See Transmission Control Unit (TCU) Circuit Theory of Operation. (Group 9015-15.) NO: If machine does not stop within specified distance, see Diagnose Park Brake Malfunctions. (Group 9020-15.)

Fasten seat belt. Put transmission in 1st gear forward. LOOK: Does machine move when put in gear? Drive machine at 5 km/h (3 mph) and push park brake switch to on. LOOK/FEEL: Does machine come to a stop within 1 meter (3 feet) when park brake is engaged at 5 km/h (3 mph)? FEEL: Does transmission shift to neutral? LISTEN: Does audible alarm activate?

– – –1/1

TM10229 (17MAR09)

9005-10-6

544J Loader (S.N. 611800— ) 032409

PN=472

Operational Checkout Procedure Service Brake Check

Move each pedal by hand to check free travel.

YES: Go to next step in this check.

FEEL: Does each pedal have about 6 mm (0.25 in.) free travel? NO: Inspect for debris under brake pedal. Inspect brake pedal linkage for damage.

Push clutch cut-off switch until function is off. (LEDs off.)

YES: Check Complete.

Fully apply either service brake pedal.

NO: See External Service Brake Inspection. (Group 9005 9020-20.) 10 7 IF OK: Inspect for leaks from brake system. see Diagnose Service Brake Malfunctions. (Group 9020-15.)

Push park brake switch to off. Put transmission in 2nd forward. T194311 –UN–11SEP03

Increase engine speed to fast idle. LOOK: Does machine remain stationary or move very slowly? Repeat check three times to ensure accurate results.

– – –1/1

Clutch Cut-Off Check

Push clutch cut-off switch to enable clutch cut-off at any slope. (LEDs on.)

NO: Check clutch cut-off sensor.

Apply brake. Increase engine rpm to 1500.

T194311 –UN–11SEP03

Push clutch cut-off switch until clutch cut-off function is off. (All LEDs off.) LISTEN/LOOK: Does engine rpm drop? FEEL: Does machine pull against brakes?

YES: Check Complete.

IF OK: Check clutch cut-off sensor by accessing the Diagnostics/Transmission Sensors menu. See CAN Monitor Unit (CMU) Menu Structure—Service Mode. (Group 9015-20.) See Clutch Cut-Off Sensor Check and Adjustment. (Group 9015-20.)

– – –1/1

TM10229 (17MAR09)

9005-10-7

544J Loader (S.N. 611800— ) 032409

PN=473

Operational Checkout Procedure Automatic Shift and Speedometer Check

YES: Check Complete. CAUTION: Prevent possible injury from machine movement. Perform this check in an open area away from other people and machinery. NOTE: In the AUTOMATIC mode, transmission will shift to highest gear selected as ground speed increases, or will downshift to 2nd as ground speed decreases. Transmission will never shift to 1st gear. In AUTO MODE TO FIRST, the transmission will start in 1st when initially shifted from neutral. After the initial shift from neutral, the transmission will downshift no lower than 2nd unless a high load is encountered. Transmission will upshift or downshift as ground speed dictates. Automatic transmission switch to AUTO. (LED on.)

9005 10 8

Release park brake and shift to 4th forward.

T194310 –UN–11SEP03

Drive machine on level ground and slowly accelerate to fast idle speed. Note speed when shifts are made until 4th gear is obtained. Reduce engine speed to slow idle and note speed when transmission makes each downshift.

NO: CMU is programmed for wrong tire size. Enter service menu in the CMU, choose Machine Config, then Tire Size. See CAN Monitor Unit (CMU) Menu Structure—Service Mode. (Group 9015-20.) IF OK: Check transmission output shaft speed sensor. If sensor malfunctions, speedometer will not work and transmission will not shift above 2nd gear. See Transmission Control Unit (TCU) Circuit Theory of Operation. (Group 9015-15.)

LOOK: Does the transmission shift at the following approximate speeds? Shift

mph

km/h

2nd to 3rd

3rd to 4th

4th to 3rd

3rd to 2nd

NOTE: When in 4th forward automatic, the transmission starts out in 2nd gear and upshifts to 3rd, then 4th as the machine accelerates. As the machine decelerates, the transmission downshifts until 2nd gear is obtained. Transmission will shift at different speeds, depending on machine loads. Use only as reference. – – –1/1

TM10229 (17MAR09)

9005-10-8

544J Loader (S.N. 611800— ) 032409

PN=474

Operational Checkout Procedure Transmission Shift Mode Check

YES: Check Complete. CAUTION: Prevent possible injury from machine movement. Perform this check in an open area away from other people and machinery.

NOTE: On machines equipped with single lever pilot controls, the quick shift switch is the raised switch on the top of the control lever. On machines equipped with two lever pilot controls, the quick shift switch is located on the top of the boom (left) pilot control lever. The Quick Shift feature operates in all gears.

T194310 –UN–11SEP03

Automatic Transmission Switch

Down/Up Mode: 1. Push automatic transmission switch to put transmission in manual mode. (LED off.) 2. Push MENU to access the main menu. Select Machine Settings, then Quick Shift menu. 3. Push SELECT to set quick shift in Down/Up mode. 4. Release park brake and shift to 3rd forward. 5. Drive machine at approximately 1600 rpm and push quick shift switch once. LOOK/FEEL: Does transmission shift to and remain in 2nd gear? 6. Push quick shift switch once more. LOOK/FEEL: Does transmission shift back to 3rd gear?

NO: Check restriction switch/radio ignition power 10A fuse (F11). See Fuse and Relay Specifications. (Group 9015-10.) NO: Check quick shift switch. See Transmission Control Unit (TCU) Circuit Theory of Operation. 9005 (Group 9015-15.) 10 9

NOTE: If the quick shift switch is pushed twice, the transmission will shift down one gear, then immediately shift back to where it was. Down Only Mode: 1. Automatic transmission switch in manual mode. (LED off.) 2. Push MENU to access the main menu. Select Machine Settings, then Quick Shift menu. 3. Push NEXT to highlight Down Only, then push SELECT to set quick shift in Down Only mode. 4. Release park brake and shift to 4th forward. 5. Drive machine at approximately 1200 rpm and push quick shift switch once. LOOK/FEEL: Does transmission shift to and remain in 3rd gear? 6. Push quick shift switch once more. LOOK/FEEL: Does transmission shift to and remain in 2nd gear? 7. Push quick shift switch once more. LOOK/FEEL: Does transmission shift to and remain in 1st gear? 8. Push quick shift switch once more. LOOK/FEEL: Does transmission stay in 1st gear? NOTE: When in DOWN ONLY mode, pushing the quick shift switch will not change gears once 1st gear is reached unless a direction or gear change is made. – – –1/1

TM10229 (17MAR09)

9005-10-9

544J Loader (S.N. 611800— ) 032409

PN=475

Operational Checkout Procedure Transmission Shift Modulation Check

YES: Check Complete. CAUTION: Prevent possible injury from machine movement. Perform this check in an open area away from other people and machinery. Push clutch cut-off switch to disengage clutch cut-off (all LEDs off). Push automatic transmission switch to put transmission in manual mode. (LED off.)

T194311 –UN–11SEP03

9005 10 10

NO: If transmission shifts too slow or transmission shifts too fast, see Diagnose Transmission System Malfunctions. (Group 9020-15.)

CAUTION: Fasten seat belt before performing this check. Machine will change directions abruptly! Shift transmission to 1st forward. Increase engine speed to fast idle and allow machine to reach full travel speed in 1st gear. Shift from forward to reverse, then reverse to forward several times while allowing machine to reach full speed in forward and reverse before changing directions. Repeat check in 2nd gear. LOOK: Does machine slow down and change direction smoothly? Drive machine in 2nd gear with engine speed at fast idle. Apply service brakes to slow engine down to 1800 rpm, then while still holding service brakes, shift to 1st gear. FEEL: Does transmission shift smooth without jerking?

– – –1/1

TM10229 (17MAR09)

9005-10-10

544J Loader (S.N. 611800— ) 032409

PN=476

Operational Checkout Procedure Torque Converter and Engine Power Check

YES: Check Complete. NO: If stall speed is outside range, problem may be engine power or torque converter.

T194311 –UN–11SEP03

To test engine power, see Intake Manifold Pressure Test—Turbocharger Boost. (Group 9010-25.)

T106883 –UN–14FEB97

Release park brake.

To test torque converter, see Torque Converter Stall Speed Test. (Group 9020-25.)

Push clutch cut-off switch to disengage clutch cut-off. (All LEDs off.) Apply service brakes so machine does not move. Shift transmission to 3rd forward. Push accelerator pedal until it touches stop bolt. Record engine speed that appears in monitor display window. LOOK: Is torque converter stall speed within following range?

IF OK: If power is okay, see Diagnose Transmission System Malfunctions. (Group 9020-15.)

• No. 1 fuel: 2040—2170 rpm • No. 2 fuel: 2070—2190 rpm Put transmission in neutral and run for 15 seconds to cool oil.

– – –1/1

Differential Lock Check

Park machine on a hard surface.

YES: Check Complete.

Release brakes.

NO: Check differential lock circuit. See Flex Load Controller (FLC) Circuit Theory of Operation. (Group 9015-15.)

Push differential lock switch and steer machine left and right. Release switch and steer machine left and right. LOOK: Do front wheels slide with differential lock on? NOTE: It is normal to get a clunk sound when you release switch.

NO: See Differential Lock Pressure Test. (Group 9020-25.)

LOOK: Do front wheels rotate in opposite directions with differential lock switch released?

T103168 –UN–05SEP96

– – –1/1

TM10229 (17MAR09)

9005-10-11

544J Loader (S.N. 611800— ) 032409

PN=477

9005 10 11

Operational Checkout Procedure Service Brake Pressure Switch and Brake Accumulator Precharge

Stop engine.

YES: Check Complete.

Turn key switch to ON position.

NO: If brake oil pressure indicator does not come on after at least 12 brake pedal applications, check service brake accumulator charge pressure switch (B27). See Electrical Component Specifications. (Group 9015-20.)

Push and hold pilot enable/boom down switch and cycle hydraulic control lever in all directions 20 times to bleed charge pressure from PRV/brake accumulator. T194312 –UN–11SEP03

Push brake pedal and record number of applications until brake pressure indicator comes on. Continue pushing brake pedal and counting applications until brake lights do not come on.

9005 10 12

LOOK: Are at least 12 brake pedal applications needed before brake pressure indicator comes on? LOOK: Are at least 30 brake pedal applications needed before brake lights do not come on?

NO: If brake lights still come on after at least 30 brake pedal applications, check brake light pressure switch (B40). See Electrical Component Specifications. (Group 9015-20.) IF OK: If fewer than 12 brake pedal applications are required to turn brake oil pressure indicator on, accumulator charge pressure may be low. See Brake Accumulator Precharge Test. (Group 9025-25.) – – –1/1

TM10229 (17MAR09)

9005-10-12

544J Loader (S.N. 611800— ) 032409

PN=478

Operational Checkout Procedure Pilot Controller Lock Check

YES: Check Complete.

T194312 –UN–11SEP03

NO: Check pilot enable/boom down switch and circuit. See Flex Load Controller (FLC) Circuit Theory of Operation. (Group 9015-15.)

T103429 –UN–09SEP96

NO: See Diagnose Hydraulic System Malfunctions. (Group 9025-15.)

Run machine at slow idle. Push pilot enable/boom down switch to lock the pilot controls. (LED off.)

9005 10 13

Hold control lever in boom raise position. Push pilot enable/boom down switch to unlock the pilot controls. (LED on.) LOOK: Does boom rise when pilot controls are unlocked? Push pilot enable/boom down switch to lock the pilot controls (LED off) and observe boom. LOOK: Does boom stop when controls are locked? Unlock pilot controls and check all hydraulic functions. • Boom up/down • Bucket roll/dump • Auxiliary functions • Steering (left and right) • Pin disconnect LOOK: Do all equipped hydraulic functions operate correctly?

– – –1/1

Pilot Enable/Boom Down Solenoid Check

Raise boom.

YES: Check Complete.

Stop engine.

NO: Check boom down accumulator solenoid (Y15). See Engine Frame Harness (W5) Component Location. (Group 9015-10.)

Turn key switch to ON position. Push and hold pilot enable/boom down switch. T194312 –UN–11SEP03

CAUTION: Prevent possible crushing injury. Stay clear of area around boom. Boom will quickly lower to ground. Move control lever to boom lower position. LOOK: Does boom lower?

– – –1/1

TM10229 (17MAR09)

9005-10-13

544J Loader (S.N. 611800— ) 032409

PN=479

Operational Checkout Procedure Pilot Control Valve Boom Float Check

YES: Check Complete. NO: See Pressure Reducing Valve Pressure Test. (Group 9025-25.)

T194313 –UN–11SEP03

T194315 –UN–11SEP03

Run engine at slow idle. Push ride control switch to disable ride control. (LED off.)

9005 10 14

Push return-to-carry switch to disable return to carry. (LED off.) With the bucket partially dumped, lower boom to raise front of machine. Push control lever to the float detent position and release lever. LOOK: Does front of machine lower to the ground and control lever remain in float detent position when released? – – –1/1

Return-to-Dig Check

Raise the boom to about eye level.

YES: Check Complete.

Fully dump the bucket.

NO: Verify that the sensor is adjusted correctly. See Return-to-Dig Adjustment. (Group 9015-20.)

Verify that return-to-dig function is enabled. (LED on.) Put control lever in the bucket load detent position. T194314 –UN–11SEP03

LOOK/FEEL: Does pilot control lever stay in the detent position? LOOK: Does bucket travel stop upon reaching dig position?

NO: Check return-to-dig circuit. See Flex Load Controller (FLC) Circuit Theory of Operation. (Group 9015-15.) – – –1/1

Return-to-Carry Check

Fully raise boom.

YES: Check Complete.

Put bucket in dig position.

NO: Verify that the sensor is adjusted correctly. See Boom Height Kickout/Return-to-Carry Adjustment. (Group 9015-20.)

Verify that the return-to-carry function is enabled. (LED on.) Put control lever in the boom down detent position. T194315 –UN–11SEP03

LOOK/FEEL: Does pilot control lever stay in the detent position? LOOK: Does boom travel stop upon reaching carry position?

NO: Check return-to-carry circuit. See Flex Load Controller (FLC) Circuit Theory of Operation. (Group 9015-15.)

– – –1/1

TM10229 (17MAR09)

9005-10-14

544J Loader (S.N. 611800— ) 032409

PN=480

Operational Checkout Procedure Boom Height Kickout Check

Lower boom to the ground.

YES: Check Complete.

Put bucket in dig position.

NO: Verify that the sensor is adjusted correctly. See Boom Height Kickout/Return-to-Carry Adjustment. (Group 9015-20.)

Verify that boom height kickout function is enabled. Put controller in the boom up detent position. T194316 –UN–11SEP03

LOOK/FEEL: Does pilot controller detent? LOOK: Does boom travel stop before reaching full height?

NO: Check boom height kickout circuit. See Flex Load Controller (FLC) Circuit Theory of Operation. (Group 9015-15.)

– – –1/1

Pin Disconnect System Check (If Equipped)

Run engine at slow idle.

YES: Check Complete.

Position bucket flat on the ground.

NO: Verify that function is enabled in the CMU machine configuration menu. See CAN Monitor Unit (CMU) Menu Structure—Service Mode. (Group 9015-20.)

Push and hold pin disconnect switch. LOOK: Does pin disconnect cylinder retract both pins while switch is pressed? T194317 –UN–11SEP03

NO: Check the pin disconnect circuit. See Flex Load Controller (FLC) Circuit Theory of Operation. (Group 9015-15.) IF OK: See Diagnose Hydraulic System Malfunctions. (Group 9025-15.)

– – –1/1

TM10229 (17MAR09)

9005-10-15

544J Loader (S.N. 611800— ) 032409

PN=481

9005 10 15

Operational Checkout Procedure YES: Check Complete.

Ride Control Check CAUTION: Boom will jump upward during this check. Make sure area around bucket is clear. Disable ride control by pushing the ride control switch until all ride control switch LEDs are off. T194313 –UN–11SEP03

Raise boom to maximum height and hold control lever over relief for 2 seconds. Lower boom and bucket to eye level. Push ride control switch once to enable manual mode (left LED on) and observe loader bucket.

9005 10 16

NOTE: The amount that boom jumps upward will vary from machine to machine depending on weight of bucket or attachments used. Use good judgement in evaluating this visual check. LOOK/FEEL: Does boom jump and bucket move upward 100 mm (4 in.) or more? Push ride control switch on the SSM once more to enable auto mode. (All LEDs on). Raise boom to maximum height and hold control lever over relief for 2 seconds.

NO: Check ride control circuit. See Flex Load Controller (FLC) Circuit Theory of Operation. (Group 9015-15.) NO: Verify that function is enabled in the CMU machine configuration menu. See CAN Monitor Unit (CMU) Menu Structure—Service Mode. (Group 9015-20.) IF OK: Check ride control accumulator charge pressure. See Ride Control Accumulator Charge Procedure. (Group 9025-20.) IF OK: Check valve or solenoid valve in ride control manifold is stuck open. See Ride Control Remove and Install. (Group 3160.)

Lower boom and bucket to eye level and slowly accelerate to 8 km/h (5 mph) while watching speedometer and bucket. LOOK/FEEL: Does ride control come on at approximately 5 km/h (3 mph) and bucket rise slightly?

– – –1/1

Reverse Fan Check (If Equipped)

Push the reverse fan switch to enable manual mode (LED on.) NOTE: Reverse fan function cannot be operated twice within one minute. Wait one minute before attempting to reverse fan direction again.

T194319 –UN–11SEP03

LISTEN/LOOK: Does fan reverse direction and operate at full speed for 15 seconds? Fan will change directions and operate at normal speed.

YES: Check Complete. NO: Verify that function is enabled in the CMU machine configuration menu. See CAN Monitor Unit (CMU) Menu Structure—Service Mode. (Group 9015-20.) NO: Check reverse fan circuit and proportional fan circuit. See Flex Load Controller (FLC) Circuit Theory of Operation. (Group 9015-15.) IF OK: Check fan hydraulic circuit. See Hydraulic Fan Drive Operation. (Group 9025-05.) – – –1/1

TM10229 (17MAR09)

9005-10-16

544J Loader (S.N. 611800— ) 032409

PN=482

Operational Checkout Procedure Proportional Fan Check (If Equipped)

Push and hold the MENU button on the CAN Monitor Unit (CMU) for five seconds to enter service mode.

YES: Check Complete. NO: Verify that function is enabled in the CMU machine configuration menu. See CAN Monitor Unit (CMU) Menu Structure—Service Mode. (Group 9015-20.)

Push NEXT until MACHINE CONFIG is highlighted, then push SELECT. Push NEXT until FAN SPEED % is highlighted, then push SELECT. Push SELECT to manually set the fan speed to 0%. The CMU will confirm the selection. LOOK/FEEL: Observe fan speed.

NO: Check proportional fan circuit. See Flex Load Controller (FLC) Circuit 9005 Theory of Operation. 10 (Group 9015-15.) 17

Push BACK, then SELECT, to manually set the fan speed to 100%. LOOK/FEEL: Is the fan speed higher than at 0%?

IF OK: Check fan hydraulic circuit. See Hydraulic Fan Drive Operation. (Group 9025-05.)

– – –1/1

Boom and Bucket Cylinder Drift Check

Set bucket flat on the ground and raise about 50 mm (2 in.). Stop engine. Observe bucket for one minute. LOOK: Does bucket remain in position? Bucket should not settle to the ground. T6564NZ –UN–19OCT88

YES: Check Complete. NO: To isolate cylinder or valve leakage, see Boom, Bucket and Steering Cylinder Leakage Test. (Group 9025-25.)

NOTE: Use good judgment to determine if the amount of drift is objectionable for specific application.

– – –1/1

Steering Valve Check

Transmission in neutral.

YES: Check Complete.

Run engine at slow idle.

NO: See Steering Valve Leakage Test. (Group 9025-25.)

Remove foot from brake pedal. Release park brake. T6471AQ –UN–19OCT88

Turn steering wheel until machine frames contact right (A) and left (B) frame stops. LOOK: Does machine steer smoothly in both directions? NOTE: It is normal for machine frames to drift away from frame stops when steering wheel is released. When steering wheel is stopped, frames must stop. FEEL: Is excessive effort required to turn steering wheel?

– – –1/1

TM10229 (17MAR09)

9005-10-17

544J Loader (S.N. 611800— ) 032409

PN=483

Operational Checkout Procedure Secondary Steering System Check (If Equipped)

IMPORTANT: Do not operate secondary steering pump for more than 15 seconds with the steering in neutral or damage to the pump and motor can occur. Park machine on a hard, level surface with machine frames straight. Remove ECU ignition power 5A fuse (F10). See Fuse and Relay Specifications. (Group 9015-10.) Secondary steering will activate. Steer machine to right and left. LOOK: Does machine steer approximately halfway to stops in both directions?

9005 10 18

LOOK: Does secondary steering light come on and stay on until key switch is turned OFF?

YES: Check Complete. NO: Verify that function is enabled in the CMU machine configuration menu. See CAN Monitor Unit (CMU) Menu Structure—Service Mode. (Group 9015-20.) NO: Check secondary steering circuit. See Flex Load Controller (FLC) Circuit Theory of Operation. (Group 9015-15.) IF OK: If secondary steering pump and motor operate but machine does not steer, see Secondary Steering Pump Relief Valve Pressure Test. (Group 9025-25.)

– – –1/1

Cycle Time Check

Use the CAN monitor unit (CMU) or Service ADVISOR diagnostic application to read engine rpm and hydraulic oil temperature. Hydraulic Oil Temp and Engine Speed—Specification Hydraulic Oil—Temperature ........................................................ 44—56°C (110—130°F) Engine Fast Idle—Speed ....................................................................... 2325—2375 rpm 544J Cycle Times—Specification Boom Raise (Z-Bar)—Cycle Time ................................................................. 6.0 seconds Boom Raise (Powerllel)—Cycle Time ............................................................ 6.0 seconds Boom Lower (Float) (Z-Bar)—Cycle Time ..................................................... 3.5 seconds Boom Lower (Float) (Powerllel)—Cycle Time ................................................................................................................ 3.5 seconds Bucket Dump (Boom at Full Height) (Z-Bar)—Cycle Time ...................................................................................... 1.7 seconds Bucket Dump (Boom at Full Height) (Powerllel)—Cycle Time ................................................................................. 2.2 seconds Steering (Stop to Stop)—Cycle Time ............................................................. 2.7 seconds Steering Wheel Revolutions ................................................................................. 3.5—4.5

YES: Check Complete. NO: Check pilot pressure. See Pilot Control Valve Pressure Test—Single Lever or see Pilot Control Valve Pressure Test— Two Lever. (Group 9025-25.) IF OK: Check hydraulic pump. See Hydraulic Pump Flow Test. (Group 9025-25.)

Are cycle times equal to or faster than specification?

Service ADVISOR is a trademark of Deere & Company

TM10229 (17MAR09)

– – –1/1

9005-10-18

544J Loader (S.N. 611800— ) 032409

PN=484

Section 9010

Engine Contents Page

Group 05—Theory of Operation PowerTech E 4.5L (4045) John Deere Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . .9010-05-1 Group 15—Diagnostic Information Engine Cooling System Component Location. . . . . . . . . . . . . . . . . . . . . . . . . . .9010-15-2 Engine Fuel System Component Location. . .9010-15-3 Engine Intake and Exhaust Component Location. . . . . . . . . . . . . . . . . . . . . . . . . . .9010-15-6

9010

Group 25—Tests Engine Speed Check and Adjust. . . . . . . . . .9010-25-1 Intake Manifold Pressure Test— Turbocharger Boost . . . . . . . . . . . . . . . . . .9010-25-5

TM10229 (17MAR09)

9010-1

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PN=1

Contents

9010

TM10229 (17MAR09)

9010-2

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PN=2

Group 05

Theory of Operation PowerTech E 4.5L (4045) John Deere Engine For additional information on John Deere engines and components, see the following Component Technical Manuals. • POWERTECH4.5 L and 6.8 L, 4045 and 6068 Diesel Engines, Base Engine. (CTM104.) • PowerTech E 4.5 L & 6.8 L Diesel Engines with Level 16 Electronic Fuel Systems with High Pressure Common Rail (HPCR) Fuel System (Two-Valve Cylinder Head). (CTM502.) • Alternators and Starting Motors. (CTM77.)

9010 05 1 POWERTECH is a trademark of Deere & Company PowerTech E is a trademark of Deere & Company

TM10229 (17MAR09)

WS68074,000119B –19–14MAY07–1/1

9010-05-1

544J Loader (S.N. 611800— ) 032409

PN=487

Theory of Operation

9010 05 2

TM10229 (17MAR09)

9010-05-2

544J Loader (S.N. 611800— ) 032409

PN=488

Group 15

Diagnostic Information PowerTech E 4.5L (4045) John Deere Engine For additional information on John Deere engines and components, see the following Component Technical Manuals. • POWERTECH 4.5 L and 6.8 L, 4045 and 6068 Diesel Engines, Base Engine. (CTM104.) • PowerTech E 4.5 L & 6.8 L Diesel Engines with Level 16 Electronic Fuel Systems with High Pressure Common Rail (HPCR) Fuel System (Two-Valve Cylinder Head). (CTM502.) • Alternators and Starting Motors. (CTM77.)

9010 15 1 POWERTECH is a trademark of Deere & Company PowerTech E is a trademark of Deere & Company

TM10229 (17MAR09)

TW70818,0000079 –19–05JUN07–1/1

9010-15-1

544J Loader (S.N. 611800— ) 032409

PN=489

Diagnostic Information

Engine Cooling System Component Location

7 2 6

4 9010 15 2

TX1015109

–UN–20NOV06

TX1015109 Engine Cooling System Component Location 1—Water Pump 2—Surge Tank 3—Radiator

4—Coolant Supply Hose to Main Suction Line 5—Overflow from Radiator

6—Supply Hose from Engine Coolant Manifold

7—Pressure Regulating Cap 8—Surge Tank Overflow Hose TW70818,000007A –19–05JUN07–1/1

TM10229 (17MAR09)

9010-15-2

544J Loader (S.N. 611800— ) 032409

PN=490

Diagnostic Information

Engine Fuel System Component Location

9010 15 3

3 4

TX1015111

–UN–20NOV06

TX1015111 Engine Fuel System Component Location 1—In-Line Fuel Filter

2—Pre-Filter

3—Mechanical Fuel Transfer Pump Continued on next page

TM10229 (17MAR09)

9010-15-3

4—Final Fuel Filter

TW70818,000007B –19–05JUN07–1/2

544J Loader (S.N. 611800— ) 032409

PN=491

Diagnostic Information

9010 15 4

14 11 8

TX1015113

–UN–20NOV06

TX1015113 Engine Fuel System Component Location 5—Fuel Inlet 6—Fuel Return-to-Tank 7—High Pressure Fuel Pump 8—High Pressure Fuel Pump Delivery Lines (2 used)

9—Fuel Rail Pressure Sensor 10—Fuel Pressure Limiter 11—High Pressure Common Rail (HPCR)

12—High Pressure Common Rail Delivery Lines (4 used) 13—Fuel Injectors (FIs) (4 used)

14—Pump Control Valve (PCV) Solenoid 15—Fuel Temp Sensor

TW70818,000007B –19–05JUN07–2/2

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PN=492

Diagnostic Information

9010 15 5

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PN=493

Diagnostic Information

Engine Intake and Exhaust Component Location

–UN–18MAY07

TX1023779

9010 15 6

TX1023779 Intake and Exhaust System (Right Side) Continued on next page

TM10229 (17MAR09)

9010-15-6

TW70818,000007C –19–06JUN07–1/3

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PN=494

Diagnostic Information 1—Charge Air Cooler 2—Air Filter Housing

3—Muffler

4—Turbocharger Turbine

Continued on next page

5—Turbocharger Compressor

TW70818,000007C –19–06JUN07–2/3

9010 15 7

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Diagnostic Information

9010 15 8

TX1023780

–UN–18MAY07

TX102380 Intake and Exhaust System (Left Side) 1—Charge Air Cooler

2—Air Filter Housing

3—Muffler TW70818,000007C –19–06JUN07–3/3

TM10229 (17MAR09)

9010-15-8

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PN=496

Group 25

Tests Engine Speed Check and Adjust SPECIFICATIONS Engine Normal Operating Temperature

71°C 160°F

Slow Idle Engine Speed

875—925 rpm

Fast Idle Engine Speed

2325—2375 rpm

NOTE: The slow idle engine speed adjustment is used on higher altitude applications only and can be adjusted through the monitor when in the service mode. The fast idle engine speed is not adjustable. 1. Make sure the transmission control lever is in the neutral (N) position and park brake is applied.

9010 25 1

2. Start engine. Run engine until it is at normal operating temperature. Specification Engine Normal Operating— Temperature ....................................................................................... 71°C 160°F

3. Use monitor display unit to display engine rpm. 4. Record slow idle engine speed. 5. Depress accelerator foot pedal to stop and record fast idle engine speed. 6. Compare readings to specifications. Specification Slow Idle Engine—Speed ................................................... 875—925 rpm Fast Idle Engine—Speed ................................................ 2325—2375 rpm

7. If engine idle speeds are not within specifications: • Check for diagnostic trouble codes. See Diagnostic Trouble Codes (DTC) Quick Reference List—Engine Control Unit (ECU). (Group 9015-20.) • Check B14—Analog Throttle Position Sensor. See Sensor Circuitry Check. (Group 9015-20.) • If no diagnostic trouble codes, see Engine Control Unit (ECU) Circuit Theory of Operation. (Group 9015-15.)

Continued on next page

TM10229 (17MAR09)

9010-25-1

MH66O88,0000283 –19–04JAN07–1/5

544J Loader (S.N. 611800— ) 032409

PN=497

Tests If slow idle engine speed requires adjustment, proceed with the following steps. 8. With engine running at normal operating temperature, press and hold the MENU key on the monitor. The Main Menu screen will be displayed. After approximately 5 seconds, one “beep” will sound and a Service Mode message box will be displayed on the Main Menu Screen. Release the MENU key.

MH66O88,0000283 –19–04JAN07–2/5

5/5

5-Conf mâquina

–19–24OCT06

Main Menu 1-Codes 2-Machine Settings 3-Diagnostics 4-Monitor Settings 5-Machine Config

10. Press the SELECT key.

TX1013805

9010 25 2

9. Press the NEXT key until Machine Config is highlighted.

Machine Config

Continued on next page

TM10229 (17MAR09)

9010-25-2

MH66O88,0000283 –19–04JAN07–3/5

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PN=498

Tests

NOTE: Entering the Low Idle Adjust screen will force the ECU to set the throttle to 0%, to ensure that the machine’s low idle setpoint is being adjusted. This is accomplished when the CMU sets the “Idle Bump Active” to on via the CAN message. When leaving the Low Idle Adjust screen, the CMU will then set the “Idle Bump Active” to off.

6/8 Machine Config 1-Manufacturer 2-Machine Model 3-Tire Size 4-Enable Options 5-Max High Gear 6-Low Idle Adjust 7-Trans Clutch Cal 8-More Mach Config

TX1013802

12. Press the SELECT key.

–19–24OCT06

11. Press the NEXT key until Low Idle Adjust is highlighted.

Low Idle Adjust

Continued on next page

TM10229 (17MAR09)

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PN=499

9010 25 3

Tests 13. The Low Idle Adjust screen will now be displayed.

BACK to decrease NEXT to increase SELECT to Store

–19–24OCT06

9010 25 4

• Pressing the NEXT key will increase the slow idle engine speed in increments of 50; each following press of the NEXT key will increase the slow idle engine speed by 50 rpm until the maximum slow idle engine speed of 1250 rpm is obtained. Pressing the NEXT key after the maximum slow idle engine speed is reached will not allow the slow idle engine speed to roll over to 900 rpm; it will remain at 1250 rpm. • Pressing the BACK key will decrease the slow idle engine speed in increments of 50; each following press of the next key will decrease the slow idle engine speed by 50 rpm until the minimum slow idle engine speed of 900 rpm is obtained. Pressing the NEXT key after the minimum slow idle engine speed is reached, will not allow the slow idle engine speed to roll over to 1250 rpm; it will remain at 900 rpm. • Pressing the SELECT key will store the currently displayed slow idle engine speed value in the ECU. With the press of the SELECT key, the CMU will toggle the “Idle Bump Active” on and off three times within 2 seconds. In addition, the CMU will display “Stored” in the lower left corner of the monitor display, and one “beep” will sound. If the SELECT key is not used after the new value is selected, the slow idle engine speed will default to the last stored value. If no previous value has been stored the slow idle engine speed will default to 900 rpm.

Low Idle Adjust

TX1013803

Low Idle Adjustment—This mode allows the adjustment of the slow idle engine speed on higher altitude applications only. Low Idle Adjustment is made through the monitor when in the service mode.

Low Idle Adjust

MH66O88,0000283 –19–04JAN07–5/5

TM10229 (17MAR09)

9010-25-4

544J Loader (S.N. 611800— ) 032409

PN=500

Tests

Intake Manifold Pressure Test—Turbocharger Boost SPECIFICATIONS Engine Coolant Normal Operating Temperature

72—92°C 160—200°F

Transmission Oil Normal Operating Temperature

72—92°C 160—200°F

Turbocharger Boost Pressure

62—83 kPa 0.62—0.83 bar 9—12 psi

SERVICE EQUIPMENT AND TOOLS JT07248 Turbo Boost Test Kit

Continued on next page

MH66O88,00002A9 –19–25JAN07–1/3

9010 25 5

TM10229 (17MAR09)

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544J Loader (S.N. 611800— ) 032409

PN=501

Tests NOTE: This procedure should be used ONLY as a guide to determine engine condition.

–UN–09OCT03

1. Remove plug or ether start aid adapter (if equipped) (1). Install components of JT07248 Turbo Boost Test Kit.

9010 25 6

T195489A

NOTE: Maximum boost pressure is obtained by pulling engine down below rated speed, which causes the pressure to drop, then slowly releasing load and let engine slowly increase rpm. This cycle will have to be repeated a minimum of six times in succession to ensure that maximum boost pressure is obtained.

Test Port

2. Warm engine and transmission to normal operating temperature. Perform Transmission Oil Warmup Procedure. (Group 9020-25.) IMPORTANT: Do not overheat hydraulic or transmission oil during this test. Stalling the converter will rapidly increase transmission temperature. Watch transmission temperature gauge on the monitor. If it goes into the red zone, stop test until transmission has cooled (temperature gauge in the safe, green zone). 3. Release park brake and apply service brake. Shift to 3rd forward gear and stall torque converter to warm transmission oil to normal operating range on temperature gauge. With engine at normal operating temperature: • Put transmission in 3rd gear forward. Hold service brake, release park brake, and push accelerator pedal to stop. • Slowly move control lever into bucket rollback and boom down to pull down engine speed. • Slowly return control lever to neutral. Specification Turbocharger Boost—Pressure ............................................... 62—83 kPa 0.62—0.83 bar 9—12 psi

Continued on next page

TM10229 (17MAR09)

9010-25-6

MH66O88,00002A9 –19–25JAN07–2/3

544J Loader (S.N. 611800— ) 032409

PN=502

Tests 4. Repeat Step 3 six times recording maximum reading each time. 5. Compare highest reading to specification. 6. If boost pressure is low, remove muffler and recheck boost pressure. If pressure is still low, check for the following: • Wrong fuel • Restricted air filter elements • Restricted fuel filter elements • Incorrect fast idle adjustment • Exhaust manifold leaks • Intake manifold leaks • Faulty fuel pump • Low compression pressure • Cam lobe wear (valve clearance) • Carbon build-up in turbocharger • Turbocharger compressor or turbine wheel rubbing housing • Faulty injectors

9010 25 7

MH66O88,00002A9 –19–25JAN07–3/3

TM10229 (17MAR09)

9010-25-7

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PN=503

Tests

9010 25 8

TM10229 (17MAR09)

9010-25-8

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PN=504

Section 9015

Electrical System Contents Page

Page

Group 05—System Information Electrical Diagram Information. . . . . . . . . . . .9015-05-2

Cab Roof Harness (W19) Component Location. . . . . . . . . . . . . . . . . . . . . . . . . 9015-10-100 Cab Roof Harness (W19) Wiring Diagram. . . . . . . . . . . . . . . . . . . . . . . . . 9015-10-102 Heater and Air Conditioner Harness (W20) Component Location . . . . . . . . . . . . . . . 9015-10-104 Heater and Air Conditioner Harness (W20) Wiring Diagram . . . . . . . . . . . . . . . . . . . 9015-10-106 JDLink System Harnesses (W29, and W30) Component Location—If Equipped (S. N. 615706— ). . . . . . . . . . . . . . . . . . . . . . . 9015-10-108 GlobalTRACS Terminal (GTT) Harness (W29) Wiring Diagram—If Equipped (S.N. 615706— ). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9015-10-110 Machine Information Gateway (MIG) Harness (W30) Wiring Diagram—If Equipped (S.N. 615706—619284 ) . . . . . . . . . . . . 9015-10-112 Machine Information Gateway (MIG) Harness (W30) Wiring Diagram—If Equipped (S.N. 619285— ). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9015-10-114 Radio Harness (W34) Component Location. . . . . . . . . . . . . . . . . . . . . . . . . 9015-10-116 Radio Harness (W34) Wiring Diagram. . . . 9015-10-118

Group 10—System Diagrams Fuse and Relay Specifications . . . . . . . . . . .9015-10-2 System Functional Schematic, Wiring Diagram and Component Location Legend . . . . . . . . . . . . . . . . . . . . . . . . . . .9015-10-4 System Functional Schematic and Section Legend . . . . . . . . . . . . . . . . . . . . . . . . . .9015-10-10 JDLink System Functional Schematic—If Equipped (S.N. 615706—619284 ) . . . . .9015-10-26 JDLink System Functional Schematic—If Equipped (S.N. 619285— ) . . . . . . . . . . .9015-10-28 Loader Frame Harness (W2) Component Location. . . . . . . . . . . . . . . . . . . . . . . . . .9015-10-30 Loader Frame Harness (W2) Wiring Diagram. . . . . . . . . . . . . . . . . . . . . . . . . .9015-10-34 Load Center Harness (W3) Component Location. . . . . . . . . . . . . . . . . . . . . . . . . .9015-10-38 Load Center Harness (W3) Wiring Diagram. . . . . . . . . . . . . . . . . . . . . . . . . .9015-10-40 Front Console Harness (W4) Component Location. . . . . . . . . . . . . . . . . . . . . . . . . .9015-10-68 Front Console Harness (W4) Wiring Diagram. . . . . . . . . . . . . . . . . . . . . . . . . .9015-10-70 Engine Frame Harness (W5) Component Location. . . . . . . . . . . . . . . . . . . . . . . . . .9015-10-72 Engine Frame Harness (W5) Wiring Diagram. . . . . . . . . . . . . . . . . . . . . . . . . .9015-10-74 Engine Harness (W6) Component Location. . . . . . . . . . . . . . . . . . . . . . . . . .9015-10-78 Engine Harness (W6) Wiring Diagram. . . . .9015-10-82 Transmission Harness (W10) Component Location. . . . . . . . . . . . . . . . . . . . . . . . . .9015-10-86 Transmission Harness (W10) Wiring Diagram. . . . . . . . . . . . . . . . . . . . . . . . . .9015-10-88 Rear Frame Harness (W13) Component Location. . . . . . . . . . . . . . . . . . . . . . . . . .9015-10-90 Rear Frame Harness (W13) Wiring Diagram. . . . . . . . . . . . . . . . . . . . . . . . . .9015-10-94 Secondary Steering Harness (W17) Component Location . . . . . . . . . . . . . . . .9015-10-96 Secondary Steering Harness (W17) Wiring Diagram. . . . . . . . . . . . . . . . . . . . . . . . . .9015-10-98 TM10229 (17MAR09)

Group 15—Sub-System Diagnostics Starting and Charging Circuit Theory of Operation. . . . . . . . . . . . . . . . . . . . . . . . . .9015-15-1 Controller Area Network (CAN) Theory of Operation. . . . . . . . . . . . . . . . . . . . . . . . . .9015-15-4 Engine Control Unit (ECU) Circuit Theory of Operation. . . . . . . . . . . . . . . . . . . . . . . . . .9015-15-6 Flex Load Controller (FLC) Circuit Theory of Operation. . . . . . . . . . . . . . . . . . . . . . . . .9015-15-12 Transmission Control Unit (TCU) Circuit Theory of Operation. . . . . . . . . . . . . . . . .9015-15-28 CAN Monitor Unit (CMU) Circuit Theory of Operation. . . . . . . . . . . . . . . . . . . . . . . . .9015-15-32 Group 20—References Diagnostic Trouble Codes (DTC) Quick Reference List . . . . . . . . . . . . . . . . . . . . . .9015-20-1 Service ADVISOR Diagnostic Application . . . . . . . . . . . . . . . . . . . . . . . .9015-20-13

9015-1

Continued on next page

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PN=1

9015

Contents

9015

Page

Service ADVISOR Connection Procedure . . . . . . . . . . . . . . . . . . . . . . . .9015-20-14 Reading Diagnostic Trouble Codes with Service ADVISOR Diagnostic Application . . . . . . . . . . . . . . . . . . . . . . . .9015-20-16 JDLink Connection Procedure—If Equipped (S.N. 615706— ) . . . . . . . . . . .9015-20-19 CAN Monitor Unit (CMU) Menu Structure— Service Mode. . . . . . . . . . . . . . . . . . . . . .9015-20-20 Flex Load Controller (FLC) Fault Exceptions . . . . . . . . . . . . . . . . . . . . . . . .9015-20-38 CAN Circuit Test . . . . . . . . . . . . . . . . . . . . .9015-20-41 Controller Area Network (CAN) Diagnostics . . . . . . . . . . . . . . . . . . . . . . .9015-20-41 Electrical Component Specifications . . . . . .9015-20-47 Transmission Control Valve Solenoid Check . . . . . . . . . . . . . . . . . . . . . . . . . . .9015-20-52 Clutch Cut-Off Sensor Check and Adjustment. . . . . . . . . . . . . . . . . . . . . . . .9015-20-53 Boom Height Kickout/Return-to-Carry Adjustment. . . . . . . . . . . . . . . . . . . . . . . .9015-20-54 Return-To-Dig Adjustment—Z-Bar Linkage . . . . . . . . . . . . . . . . . . . . . . . . . .9015-20-55 Return-To-Dig Adjustment—Powerllel Linkage . . . . . . . . . . . . . . . . . . . . . . . . . .9015-20-56 Sensor Circuitry Check . . . . . . . . . . . . . . . .9015-20-57 Diagnostic Trouble Codes—After Machine Repair . . . . . . . . . . . . . . . . . . . . . . . . . . .9015-20-60 Change Backup Alarm Volume . . . . . . . . . .9015-20-61 Pressure Switches Remove and Install . . . .9015-20-62 Alternator Test Procedure . . . . . . . . . . . . . .9015-20-63 Replace (Push Type) Metri-Pack Connectors . . . . . . . . . . . . . . . . . . . . . . .9015-20-65 Replace METRI-PACK Connectors . . . . . . .9015-20-66 Install METRI-PACK Contact. . . . . . . . . . . .9015-20-67 Replace DEUTSCH Connectors . . . . . . . . .9015-20-68 Install DEUTSCH Contact . . . . . . . . . . . . . .9015-20-69 Replace WEATHER PACK Connector. . . . .9015-20-71 Install WEATHER PACK Contact . . . . . . . .9015-20-72 Replace CINCH Connectors . . . . . . . . . . . .9015-20-73 Install CINCH Contact . . . . . . . . . . . . . . . . .9015-20-75 Repair 32 and 48 Way CINCH Connectors . . . . . . . . . . . . . . . . . . . . . . .9015-20-76 Remove Connector Body from Blade Terminals. . . . . . . . . . . . . . . . . . . . . . . . .9015-20-79 Engine Control Unit (ECU) Remove and Install. . . . . . . . . . . . . . . . . . . . . . . . . . . .9015-20-79 Flex Load Controller (FLC) Remove and Install. . . . . . . . . . . . . . . . . . . . . . . . . . . .9015-20-81 Transmission Control Unit (TCU) Remove and Install . . . . . . . . . . . . . . . . . . . . . . . .9015-20-82 Sealed Switch Module (SSM) Remove and Install . . . . . . . . . . . . . . . . . . . . . . . .9015-20-83

CAN Monitor Unit (CMU) Remove and Install. . . . . . . . . . . . . . . . . . . . . . . . . . . .9015-20-84 Reprogram CAN Monitor Unit (CMU) . . . . .9015-20-84 Electronic Controller Reconfiguration. . . . . .9015-20-86

TM10229 (17MAR09)

9015-2

544J Loader (S.N. 611800— ) 032409

PN=2

Group 05

System Information

9015 05 1

TM10229 (17MAR09)

9015-05-1

544J Loader (S.N. 611800— ) 032409

PN=507

System Information

Electrical Diagram Information

T128818

–UN–16MAR09

9015 05 2

Continued on next page

TM10229 (17MAR09)

9015-05-2

CS33148,00014B3 –19–31OCT06–1/6

544J Loader (S.N. 611800— ) 032409

PN=508

System Information 1—Continuity Chart 2—Power Wires 3—Routing Location Information

4—Wire Identification 5—Ground Wires 6—Circuit Name

7—Section Number 8—Component Name 9—Component Identification Number

NOTE: All System Functional Schematics, Circuit Schematics, and Wiring Diagrams are shown with key switch in the off position. System Functional Schematic Diagram The System Functional Schematic is made up of sections which contain one or more Subsystem Functional Schematics laid out side by side in a logical sequence of related functions. Each subsystem is a major group of components like starting components or charging components. Each section of the System Functional Schematic is assigned a number (7) and a name (6) that reflects a group of components. The System Functional Schematic is formatted with power supply wires (2) shown across the top of the drawing and ground wires (5) across the bottom. The schematic contains no harness or connector information.

Each electrical component is shown by a schematic symbol (10), the component name (8), and a component identification number (9). A component identification number and name will remain the same throughout the Operation and Test Technical Manual. This will allow for easy cross-referencing of all electrical drawings (Schematics, Wiring Diagrams, and Component Location). A continuity chart (1) is included for each multi-terminal switch. Routing location information (3) is presented to let the reader know when a wire is connected to a component in another section. TO and FROM statements identify when power is going “To” or coming “From” a component in a different location. The section and component number are given in parenthesis at the bottom of the statement. In the example, power is going to component F15 Horn Fuse, in section SE15.

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TM10229 (17MAR09)

10—Component Schematic Symbol

9015-05-3

CS33148,00014B3 –19–31OCT06–2/6

544J Loader (S.N. 611800— ) 032409

PN=509

9015 05 3

System Information

T195714

–UN–30OCT03

9015 05 4

Continued on next page

TM10229 (17MAR09)

9015-05-4

CS33148,00014B3 –19–31OCT06–3/6

544J Loader (S.N. 611800— ) 032409

PN=510

System Information 1—Component Identification Number 2—Connector 3—Connector End View

4—Wire Harness 5—Wire Number 6—Wire Splice

7—Wire End #1 Termination Location 8—Wire Number

Wiring Diagram Each harness on the machine is drawn showing connectors, wires, and splices. A “W” component identification number identifies harnesses. (W6, Etc.) The harness is drawn showing spatial arrangement of components and branches. A component identification or connector number (1) identifies each component. The harness branch (4) is terminated by a top or side view of the connector (2). If more than one wire is supplied to the connector, a harness side connector end view (3) is provided. Each wire number is labeled for the appropriate pin. If only one wire is supplied to the connector, the wire number (5) is indicated.

9—Wire Color 10—Wire End #2 Termination Location

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.

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.

Continued on next page

TM10229 (17MAR09)

9015-05-5

CS33148,00014B3 –19–31OCT06–4/6

544J Loader (S.N. 611800— ) 032409

PN=511

9015 05 5

System Information T128823 –UN–16MAR09

Continued on next page

TM10229 (17MAR09)

9015-05-6

CS33148,00014B3 –19–31OCT06–5/6

544J Loader (S.N. 611800— ) 032409

PN=512

System Information 1—Battery 2—Wire Splice 3—Fuse 4—Circuit Breaker 5—Fusible Link 6—Power Outlet 7—Alternator 8—Air Conditioner Compressor 9—Compressor 10—Liquid Pump 11—Antenna 12—Diode 13—Zener Diode 14—Capacitor 15—Magnet 16—Flasher 17—Buzzer 18—Horn 19—Alarm 20—Clock 21—Internal Ground 22—Single Point Ground 23—External Ground

24—Sensor 25—Sensor with Normally Open Switch 26—Speed Sensor 27—Rotary Sensor 28—Single Element Bulb 29—Dual Element Bulb 30—Electrically Operated hydraulic Valve 31—Solenoid Normally Open 32—Solenoid Normally Closed 33—Starter Motor 34—Starter Motor 35—DC Motor 36—DC Stepping Motor 37—Wiper Motor 38—Blower Motor 39—Servo Motor 40—Speedometer 41—Tachometer 42—Temperature Gauge 43—Liquid Level Gauge 44—Gauge 45—Hourmeter

46—Resistor 47—Variable Resistor 48—Multi-Pin Connector 49—Single Pin Connector 50—Connector 51—4 Pin Relay 52—5 Pin Relay 53—5 Pin Relay With Internal Suppression Diode 54—5 Pin Relay With Internal Suppression Resistor 55—Key Switch 56—Temperature Switch Normally Open 57—Temperature Switch Normally Closed 58—Pressure Switch Normally Open 59—Pressure Switch Normally Closed 60—Liquid Level Switch Normally Open 61—Liquid Level Switch Normally Closed

62—Momentary Switch Normally Open 63—Momentary Switch Normally Closed 64—Toggle Switch Normally Open 65—Toggle Switch Normally Closed 66—2 Way Toggle Switch Normally Open 67—2 Way Toggle Switch Normally Closed 68—Manual Switch Operation 69—Push Switch Operation 70—Pull Switch Operation 71—Turn Switch Operation 72—Toggle Switch Operation 73—Pedal Switch Operation 74—Key Switch Operation 75—Detent Switch Operation 76—Temperature Sensor 77—Solar Sensor 78—Pressure Sensor 79—Liquid Level Sensor

Electrical Schematic Symbols

9015 05 7

CS33148,00014B3 –19–31OCT06–6/6

TM10229 (17MAR09)

9015-05-7

544J Loader (S.N. 611800— ) 032409

PN=513

System Information

9015 05 8

TM10229 (17MAR09)

9015-05-8

544J Loader (S.N. 611800— ) 032409

PN=514

Group 10

System Diagrams

9015 10 1

TM10229 (17MAR09)

9015-10-1

544J Loader (S.N. 611800— ) 032409

PN=515

System Diagrams

Fuse and Relay Specifications

T192491

–UN–12SEP03

9015 10 2

Continued on next page

TM10229 (17MAR09)

9015-10-2

WS68074,0000785 –19–01NOV07–1/2

544J Loader (S.N. 611800— ) 032409

PN=516

System Diagrams F01—Flasher 5 Amp Fuse F02—Brake Light Pressure Switch 5 Amp Fuse F03—ECU Battery Power 20 Amp Fuse F04—Converter Battery Power 15 Amp Fuse F05—Blower Motor 25 Amp Fuse F08—Electric Adjust Seat 20 Amp Fuse F09—Converter Ignition Power 10 Amp Fuse F10—ECU Ignition Power 5 Amp Fuse F11—Restriction Switch/Radio Ignition Power 10 Amp Fuse F13—CMU/SSM Ignition Power 10 Amp Fuse

F15—FLC Ignition Power 5 Amp Fuse F16—Spare Ignition Power 15 Amp Fuse F17—Spare Battery Power 15 Amp Fuse (S.N. 611800— 615705); JDLink Unswitched Power 15 Amp Fuse (S.N. 615706— ) F18—TCU Battery power 5 Amp Fuse F19—Horn 5 Amp Fuse F20—Spare Battery Power 5 Amp Fuse F21—FLC Battery Power 10 Amp Fuse F23—Brake/Steering Pressure Switch 5 Amp Fuse F28—TCU Ignition power 5 Amp Fuse

IMPORTANT: Install fuse with correct amperage rating to prevent electrical system damage from overload. The Vehicle Electrical Center (VEC) is located in the load center. For more information on the VEC, see Load Center Harness (W3) Wiring Diagram. (Group 9015-15.)

F29—Spare Ignition Power 5 Amp Fuse F31—Spare Ignition Power 5 Amp Fuse (S.N. 611800— 615705); TPMS/JDLink Switched Power 5 Amp Fuse (S.N. 615706— ) F32—Park Brake Release Switch/Backup Alarm 5 Amp Fuse F33—Pressurizer Motor 10 Amp Fuse F34—CMU Battery Power 5 Amp Fuse F38—Differential Lock Foot Switch 5 Amp Fuse F40—Transmission Output Speed Sensor 5 Amp Fuse F41—Start Relay 5 Amp Fuse F46—Start Aid Solenoid Switch 10 Amp Fuse

F49—Radio/Diagnostic Connector/Dome Light Battery Power 10 Amp Fuse F53—Alternator Excitation 5 Amp Fuse F55—Rear Wiper Motor 5 Amp Fuse F56—Front Wiper Motor 5 Amp Fuse K1—Horn Relay V2—Start Aid Solenoid 3 Amp Diode V3—Ignition Relay 3 Amp Diode V4—Start Relay 3 Amp Diode V5—Alternator Excitation 3 Amp Diode V7—Ignition Relay 3 Amp Diode

• F66—JDLink Ground 7.5 Amp Fuse (S.N. 615706— ) • K3—Start Relay • K4—Ignition Relay • V1—Starter Coil Suppression 5 Amp Diode • V11—A/C Compressor Clutch 1 Amp Diode

9015 10 3

NOTE: The following items are located outside of the VEC:

JDLink is a trademark of Deere & Company

TM10229 (17MAR09)

WS68074,0000785 –19–01NOV07–2/2

9015-10-3

544J Loader (S.N. 611800— ) 032409

PN=517

System Diagrams

System Functional Schematic, Wiring Diagram and Component Location Legend

• A1—Engine Control Unit (ECU) (SE41, W3) • A2—Flex Load Controller (FLC) (SE18, SE19, SE21, W3) • A3—Transmission Control Unit (TCU) (SE23, W3) • A4—Pilot Controller (SE27, W3) • A5—12V Radio (SE38, W34) • A6—Sealed Switch Module (SSM) (SE39, W3) • A9—GlobalTRACS Terminal (GTT) Controller—If Equipped (S.N. 615706— ) (W29) • A10—Machine Information Gateway (MIG) Controller—If Equipped (S.N. 615706— ) (W30) • B1—Engine Coolant Temperature Sensor (SE40, W6) • B3—Camshaft Position Sensor (SE41, W6) • B4—Crankshaft Position Sensor (SE41, W6) • B5—Fuel Temperature Sensor (SE40, W6) • B7—Manifold Air Temperature Sensor (SE40, W6) • B8—Hydraulic System Pressure Sensor (If Equipped) (SE19, W5) • B10—Ambient Air Temperature Sensor (SE42, W6) • B14—Analog Throttle Position Sensor (SE40, W3) • B15—Hydraulic Oil Temperature Sensor (SE19, W5) • B17—Fuel Level Sensor (SE15, W5) • B19—Engine Air Filter Restriction Switch (Closed With Restriction) (SE42, W6)

• B20—Transmission Oil Filter Restriction Switch (SE24, W10) • B21—Hydraulic Oil Filter Restriction Switch (SE20, W5) • B23—Engine Oil Pressure Sensor (SE40, W6) • B25—Steering System Pressure Switch (closes with high pressure) (SE20, W3) • B27—Service Brake Accumulator Charge Pressure Switch (closes with high pressure) (SE19, W3) • B28—Torque Converter Input Speed Sensor (engine speed) (SE22, W10) • B29—Torque Converter Output Speed Sensor (SE22, W10) • B30—Internal Clutch Speed Sensor (SE22, W10) • B31—Transmission Output Speed Sensor (SE22, W10) • B32—Transmission Oil Temperature Sensor (SE24) • B33—Clutch Cut-Off Sensor (SE24, W3) • B34—Park Brake Pressure Switch (closes with low pressure) (SE24, W2) • B35—Freeze Control Switch (opens with freeze condition) (SE32, W20) • B37—Analog Return-to-Dig Sensor (Powerllel linkage only) (SE26, W2) • B38—Horn (SE11, W2) • B40—Brake Light Pressure Switch (closes with pressure) (SE36, W3) • B41—Ride Control Pressure Switch (closes with pressure) (SE10, W2) • B42—Left Speaker (SE38, W34) • B43—Right Speaker (SE38, W34) • B45—Analog BHKO/RTC Position Sensor (SE27, W2) • B48—Water in Fuel Sensor (SE41, W6) • B49—Fuel Rail Pressure Sensor (SE41, W6) • B50—A/C Binary Pressure Switch (opens with high and low pressures) (SE32, W20) • B51—Not Used (W3) • B52—Not Used (W3) • E2—Left Front Turn Light (SE11, W2) • E3—Left Rear Turn Light (SE33, W13) • E4—Right Front Turn Light (SE33, W2) • E5—Right Rear Turn light (SE33, W13)

GlobalTRACS is a registered trademark of Qualcomm Incorporated

Continued on next page

NOTE: A1—Engine Control Unit (ECU) (SE41, W3) A1 indicates component identification number. Engine Control Unit indicates component name. SE41 indicates section number of System Functional Schematic where component is located. W3 is the identification number of the Component Location and Harness Connector (With Wire and Pin Location) drawings for the component. This would indicate that the Engine Control Unit is connected to W3 Load Center Harness.

9015 10 4

TM10229 (17MAR09)

9015-10-4

WS68074,0001167 –19–26FEB09–1/6

544J Loader (S.N. 611800— ) 032409

PN=518

System Diagrams • E6—Left Front Marker Light (SE34, W2) • E7—Right Front Marker Light (SE34, W2) • E8—Left Tail Light (SE34, W13) • E9—Right Tail Light (SE34, W13) • E10—License Plate Light (SE34, W13) • E11—Left Front Drive Light (SE35, W2) • E12—Right Front Drive Light (SE35, W2) • E15—Beacon Light (SE35, W19) • E16—Left Rear Brake Light (SE36, W13) • E17—Right Rear Brake Light (SE36, W13) • E18—Dome Light (SE36, W19) • E20—Left Front Work Light (SE37, W19) • E21—Right Front Work Light (SE37, W19) • E22—Left Rear Work Light (SE37, W19) • E23—Right Rear Work Light (SE37, W19) • E24—Left Auxiliary Light (SE37, W19) • E25—Right Auxiliary Light (SE37, W19) • F01—Flashers 5 A Fuse (SE4, W3) • F02—Brake Light Pressure Switch 5 A Fuse (SE4, W3) • F03—ECU Battery Power 20 A Fuse (SE4, W3) • F04—Converter Battery Power A Fuse (SE4, W3) • F05—Blower Motor 25 A Fuse (SE4, W3) • F08—Electric Adjust Seat 20 A Fuse (SE4, W3) • F09—Converter Ignition Power 10 A Fuse (SE5, W3) • F10—ECU Ignition Power 5 A Fuse (SE5, W3) • F11—Restriction Switch/Radio Ignition Power 10 A Fuse (SE5, W3) • F13—CMU/SSM Ignition Power 5 A Fuse (SE5, W3) • F15—FLC Ignition Power 5 A Fuse (SE5, W3) • F16—Spare Ignition Power 15 A Fuse (SE5, W3) • F17—Spare Battery Power 15 Amp Fuse (S.N. 611800—615705); JDLink Unswitched Power 15 Amp Fuse (S.N. 615706— ) (SE6, W3) • F18—TCU Battery Power 5 A Fuse (SE6, W3) • F19—Horn 10 A Fuse (SE6, W3) • F20—Spare Battery Power 5 A Fuse (SE6, W3) • F21—FLC Battery Power 10 A Fuse (SE6, W3) • F23—Brake/Steering Pressure Switch 5 A Fuse (SE6, W3) • F28—TCU Ignition Power 5 A Fuse (SE6, W3) • F29—Spare Ignition Power 5 A Fuse (SE6, W3)

• F31—Spare Ignition Power 5 Amp Fuse (S.N. 611800—615705); TPMS/JDLink Switched Power 5 Amp Fuse (S.N. 615706— ) (SE7, W3) • F32—Park Brake Release Switch/Backup Alarm 5 A Fuse (SE7, W3) • F33—Pressurizer Motor 10 A Fuse (SE7, W3) • F34—CMU Battery Power 5 A Fuse (SE7, W3) • F38—Differential Lock Foot Switch 5 A Fuse (SE7, W3) • F40—Transmission Output Speed Sensor 5 A Fuse (SE8, W3) • F41—Start Relay 5 A Fuse (SE8, W3) • F46—Start Aid Solenoid Switch 10 A Fuse (SE8, W3) • F49—Radio/Diagnostic/Dome Light Battery Power 10 A Fuse (SE8, W3) • F53—Alternator Excitation 5 A Fuse (SE9, W3) • F55—Rear Wiper Motor 5 A Fuse (SE9, W3) • F56—Front Wiper Motor 5 A Fuse (SE9, W3) • F66—JDLink Ground 7.5 A Fuse (S.N. 615706— ) (SE??, W5) • G1—Batteries (SE1, W6) • G2—Emergency (Jump) Starting Terminal (SE1, W6) • G4—24V 80 Amp Alternator (SE2, W6) • G5—12V Power Plug (SE38, W3) • G6—24V to 12V Voltage Converter (SE38) • G7—24V to 12V Voltage Converter (radio) (SE38, W34) • G8—Vehicle Electrical Center (VEC) (SE4, SE8, W3) • G9—Power Plug (SE38, W3) • H1—Monitor Alarm (SE14, W4) • H2—CAN Monitor Unit (CMU) (SE14, W4) • H3—Backup Alarm (SE22, W13) • K1—Horn Relay (VEC) (SE6, W3) • K3—Start Relay (SE3, W3) • K4—Ignition Relay (SE3, W3) • M1—Starter Motor (SE1, W3) • M2—Front Washer Pump (SE29, W5) • M3—Front Wiper Motor (SE29, W4) • M4—Rear Washer Pump (SE30, W5) • M5—Rear Wiper Motor (SE30, W19)

JDLink is a trademark of Deere & Company

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TM10229 (17MAR09)

9015-10-5

WS68074,0001167 –19–26FEB09–2/6

544J Loader (S.N. 611800— ) 032409

PN=519

9015 10 5

System Diagrams

9015 10 6

• M6—Blower Motor (SE31, W20) • M7—Pressurizer Motor (SE31, W20) • M8—Secondary Steering Pump Motor (SE20, W17) • M9—Air Adjust Seat Motor (SE12, SE3) • R1—CAN Termination Node (SE13, SE3) • R2—CAN Termination Node (SE15, W4) • R3—Blower Speed Resistor (SE31, W20) • S1—Key Switch (SE1, W2) • S2—Manual Battery Disconnect (SE1) • S3—Start-Aid Switch (SE12, W4) • S6—Automatic Transmission Switch (SSM) (SE39, W3) • S7—Quick Shift Switch (SE22, W3) • S8—Park Brake Release Switch (SE22, W4) • S9—Joystick Shifter Switch (SE21) • S10—Shifter Switch (SE23) • S11—Clutch Cutoff Enable Switch (SSM) (SE39, W3) • S12—Pin Disconnect Switch (SSM) (SE39, W3) • S13—Differential Lock Foot Switch (SE28, W3) • S17—Return-to-Dig Switch (closed while sensing metal) (Z-bar linkage only) (SE26, W2) • S18—Pilot Enable Switch (SSM) (SE39,W3) • S19—Front Wiper Switch (SSM) (SE39, W3) • S20—Rear Wiper Switch (SSM) (SE39,W3) • S21—Blower Speed Switch (SE31, W3) • S22—A/C (on/off) Switch (SSM) (SE39, W3) • S23—Horn Switch (SE11, W4) • S24—4-Way Flasher Switch (SE33, W3) • S25—Turn Switch (SE33, W4) • S26—Drive Light Switch (SSM) (SE39, W3) • S27—Beacon Light Switch (SSM) (SE39, W3) • S28—Dome Light Switch (SE36, W19) • S29—Door Switch (opens with door closed) (SE36, W3) • S30—Work Light Switch (SSM) (SE39, W3) • S31—Ride Control Switch (SSM) (SE39, W3) • S32—Up/Down Electric Air Adjust Seat Switch (SE12, W3) • S33—Spin Control Switch (SSM) (not used) • S35—Axle Disconnect Switch (SSM) (SE39, W3) • S37—Analog Return-to-Dig Sensor (closed while sensing metal) (SE27, W2) • S39—Boom Height Kick Out Enable Switch (SSM) (SE39, W3)

• S40—Return-to-Carry Enable Switch (SSM) (SE39, W3) • S41—Reverse Fan Switch (SSM) (SE39, W3) • S42—Return-to-Dig Enable Switch (SSM) (SE39, W3) • S43—Front Washer Switch (SSM) (SE39, W3) • S44—Rear Washer Switch (SSM) (SE39, W3) • V1—Starter Coil Suppression 5 A Diode (SE1, W3) • V2—Start Aid Solenoid Coil 3 A Diode (VEC) (SE4, W3) • V3—Ignition Relay 3 A Diode (VEC) (SE7, W3) • V4—Start Relay 3 A Diode (VEC) (SE8, W3) • V5—Alternator Excitation 3 A Diode (VEC) (SE9, W3) • V11—A/C Compressor Clutch 1 A Diode (SE32, W6, W6) • W1—Antenna (SE38) • W2—Loader Frame Harness • W3—Load Center Harness • W4—Front Console Harness • W5—Engine Frame Harness • W6—Engine Harness • W10—Transmission Harness • W13—Rear Frame Harness • W17—Secondary Steering Harness • W18—Transmission Control Valve Harness (Not Shown) • W19—Cab Roof Harness • W20—Heater and Air Conditioner Harness • W22—Return to Dig Harness (Not Shown) • W25—G01 BLK Ground for CMU, TCU, CCU at Starter • W26—G02 BLK Ground for Engine Frame Components at Starter • W27—G03 BLk Ground for Engine Components at Starter • W28—Ground at Cab Front Right • W29—GlobalTRACS Terminal (GTT) Harness—If Equipped (S.N. 615706— ) • W30—Machine Information Gateway (MIG) Harness—If Equipped (S.N. 615706—619284 ) • W30—Machine Information Gateway (MIG) Harness—If Equipped (S.N. 619285— ) • W34—Radio Harness

Continued on next page

TM10229 (17MAR09)

9015-10-6

WS68074,0001167 –19–26FEB09–3/6

544J Loader (S.N. 611800— ) 032409

PN=520

System Diagrams • W36—GlobalTRACS Terminal (GTT) Chassis Ground (W29) • W37—Machine Information Gateway (MIG) Chassis Ground (S.N. 619285— ), (SE63) • X1—Service ADVISOR System Connector (SE13, W3) • X2—TCU Diagnostic and Programming Connector (SE24, W3) • X3—Load Center Harness-to-Engine Frame Harness Connector (W3) • X4—Load Center Harness-to-Engine Harness Connector (W3) • X5—Load Center Harness-to-Cab Roof Harness 12-Pin Connector (W3) • X6—Load Center Harness-to-Cab Roof Harness 4-Pin Connector (W3) • X7—Load Center Harness-to-Heater and Air Conditioner Harness 3-Pin Connector (W3) • X8—Load Center Harness-to-Heater and Air Conditioner Harness 2-Pin Connector (W3, W20) • X9—Load Center Harness-to-Heater and Air Conditioner Harness 4-Pin Connector (W3, W20) • X10—Vehicle Electrical Center 8-Pin BLK Connector (W3) • X11—Vehicle Electrical Center 8-Pin GRY Connector (W3) • X12—Vehicle Electrical Center 8-Pin BLU Connector (W3) • X13—Vehicle Electrical Center 8-Pin GRN Connector (W3 • X14—Vehicle Electrical Center 2-Pin GRY Connector (W3) • X15—Vehicle Electrical Center 2-Pin BLK Connector (W3) • X16—Vehicle Electrical Center 8-Pin ORG Connector (W3) • X17—Vehicle Electrical Center 8-Pin YEL Connector (W3) • X18—Vehicle Electrical Center 8-Pin RED Connector (W3) • X19—Load Center Harness Spare BAT Connector (W3) • X20—Load Center Harness Spare IGN Connector (W3) • X21—Load Center Harness Spare GND Connector (W3)

• X22—Load Center Harness-to-Transmission Harness Connector (W3, W10) • X23—Transmission Control Unit (TCU) Connector (W3) • X26—Shifter Switch Connector 1 (W3) • X27—Joystick Shifter Switch Connector 1 (W3) • X28—Shifter Switch Connector 2 (W3) • X29—Joystick Shifter Switch Connector 2 (W3) • X30—Load Center Harness-to-Front Console Harness Connector (W3, W4) • X33—Load Center Harness-to-Air Adjust Seat Harness Connector (W3) • X34—Load Center Harness-to-Radio Harness Connector (W3) • X35—Load Center Harness-to-Converter and Power Plug Harness Connector (W3) • X36—Transmission Harness-to-Transmission Control Valve Harness Connector (W3) • X39—Engine Frame Harness-to-Rear Frame Harness Connector (W5, W13) • X40—Flex Load Controller Connector (J1) (RED) (W3) • X41—Flex Load Controller Connector (J2) (RED) (W3) • X42—Flex Load Controller Connector (J3) (BLU) (W3) • X43—12V Center Tap Battery Connector (W5) • X46—Not Used (W2) • X48—CAN Monitor Unit Connector (W4) • X50—Shifter Switch Connector (W4) • X51—Shifter Switch Connector (W4) • X52—A/C Pressure Switch Jumpered Connector (W2) • X53—Sealed Switch Module Connector (W3) • X67—Load Center Harness-to-Loader Frame Harness Connector (W3, W2) • X71—Engine Control Unit (ECU) Connector (W3) • X72—Engine Control Unit (ECU) Connector (W3) • X75—Load Center Harness-to-Machine Information Gateway (MIG) Harness 4-Pin Connector (W3, W30) • X76—Load Center Harness-to-Machine Information Gateway (MIG) Harness 8-Pin Connector (W3, W30) • X77—Load Center Harness Spare 12V Connector (W3) • X78—Ether Start Solenoid Connector (W13)

Continued on next page

TM10229 (17MAR09)

9015-10-7

WS68074,0001167 –19–26FEB09–4/6

544J Loader (S.N. 611800— ) 032409

PN=521

9015 10 7

System Diagrams

9015 10 8

• X79—Engine Harness-to-Secondary Steering Motor Connector (W6) • X80—2-Pin Connector (not used) • X81—Fuel Injector Harness Connector (W6) • X82—3-Pin Connector (not used) • X83—2-Pin Connector (not used) • X84—Low Pressure Fuel Pump Connector (field option) • X85—Loader Frame Harness-to-Return to Dig Harness Connector (W2) • X100—Splice L06 BRN (W2) • X102—Splice G05 BLK (W2) • X103—Splice G05 BLK (W2) • X104—Splice A15 ORG (W3) • X105—Splice B10 RED (W3) • X106—Splice G04 BLK (W3) • X107—Splice L22 BRN (W3) • X108—Splice B02 RED (W3) • X109—Splice L06 BRN (W3) • X110—Splice B17 RED (W3) • X111—Splice B16 RED (W3) • X112—Splice B15 RED (W3) • X113—Splice A12 ORG (W3) • X115—Splice M12 YEL (W3) • X116—Splice M13 GRN (W3) • X117—Splice R12 BLK (W3) • X118—Splice G04 BLK (W3) • X119—Splice P28 RED (W3) • X120—Splice R20 BLK (W3) • X121—Splice P18 RED (W3) • X122—Splice P78 RED (W3) • X123—Splice R09 BLK (W3) • X124—Splice G01 BLK (W3) • X127—Splice L09 BRN (W3) • X130—Splice A08 ORG (W3) • X133—Splice P11 RED (W3) • X134—Splice R68 BLK (W3) • X135—Splice P23 RED (W3) • X136—Splice N06 YEL (W3) • X137—Splice M12 YEL (W4) • X138—Splice M13 GRN (W4) • X139—Splice R12 BLK (W4) • X140—Splice G02 BLK (W5) • X142—Splice H24 GRN (W5) • X152—Splice R06 BLK (W10)

• X157—Splice G04 BLK (W19) • X158—Splice G04 BLK (W19) • X160—Splice P49 RED (W19) • X161—Splice A18 ORG (W20) • X163—Splice P13 RED (W4) • X164—Splice G08 BLK (W4) • X165—Splice P61 RED (W34) • X167—Splice G11 BLK (W3) • X168—Splice P03 RED (W3) • X170—Splice P32 RED (W3) • X171—Splice G04 BLK (W3) • X172—Splice P68 RED (W2) • X173—Splice R68 BLK (W2) • X174—Splice H02 GRN (W2) • X177—Splice R12 BLK (W3) • X178—Splice M13 GRN (W3) • X179—Splice M12 YEL (W3) • X187—Splice R12 BLK (W3) • X188—Splice M13 GRN (W3) • X189—Splice M12 YEL (W3) • X190—Splice P13 RED (W3) • X191—Splice P79 RED (W3) • X192—Splice P11 RED (W6) • X193—Splice R73 BLK (W6) • X199—Splice G02 BLK (W13) • X200—Splice L06 BRN (W13) • X201—Splice L04 BRN (W13) • X202—Splice P83 RED (W3) • X203—Splice G06 BLK (W3) • X204—Splice R12 BLK (W3) • X205—Splice G01 BLU (W3) • X206—Splice M13 GRN (W3) • X207—Splice M12 YEL (W3) • X208—Splice M13 GRN (W3) • X209—Splice R12 BLK (W3) • X210—Splice M12 YEL (W3) • X211—Splice L12 BRN (W3) • X212—Splice E04 WHT (W3) • X213—Splice P69 RED (W3) • X214—Splice R69 BLK (W3) • X215—Splice P49 RED (W19) • X216—GlobalTRACS Terminal (GTT) Controller 70-Pin Connector—If Equipped (S.N. 615706— ) (W29)

Continued on next page

TM10229 (17MAR09)

9015-10-8

WS68074,0001167 –19–26FEB09–5/6

544J Loader (S.N. 611800— ) 032409

PN=522

System Diagrams • X217—GlobalTRACS Terminal (GTT) Harness-to-Machine Information Gateway (MIG) Harness 10-Pin Connector—If Equipped (S.N. 615706— ) (W29, W30) • X218—GlobalTRACS Terminal (GTT) Harness-to-Machine Information Gateway (MIG) Harness 4-Pin Connector—If Equipped (S.N. 615706— ) (W29, W30) • X219—GT Config Tool Adapter 6-Pin Connector (RS232)—If Equipped (S.N. 615706— ) (W29) • X220—R01 BLK Splice (W29) • X221—Machine Information Gateway (MIG) Connector 30-Pin (L1—Y3) Connector—If Equipped (S.N. 615706— ) (W30) • X222—Machine Information Gateway (MIG) Connector 30-Pin (A1—K3) Connector—If Equipped (S.N. 615706— ) (W30) • X223—JDLink MMS Direct Connector (Ethernet)— If Equipped (S.N. 615706— ) (W30) • X224—G01 BLK Splice (W30) • X225—P01 RED Splice (W30) • X226—G01 BLK Splice (W30) • X227—2-Pin Connector (Not Used), (S.N. 615706— 619284 ), (W30) • X228—2-Pin Connector (Not Used), (S.N. 619285— ), (SE63, W30) • X229—2-Pin Connector (Not Used), (S.N. 619285— ), (SE63, W30)

• X230—G02BLK Splice (S.N. 619285— ), (W30) • Y1—Transmission Control Solenoid 1 (SE23) • Y2—Transmission Control Solenoid 2 (SE23) • Y3—Transmission Control Solenoid 3 (SE23) • Y4—Transmission Control Solenoid 4 (SE23) • Y5—Transmission Control Solenoid 5 (SE23) • Y6—Transmission Control Solenoid 6 (SE23) • Y7—Start Aid Solenoid (SE12, W5) • Y8—High Pressure Fuel Pump Solenoid (SE42, W6) • Y13—Differential Lock Solenoid (SE28, W5 or W2) • Y14—Pilot Enable Solenoid (SE25, W5) • Y15—Boom Down Accumulator Solenoid (SE25, W5) • Y17—Ride Control Boom Solenoid (SE10, W2) • Y16—A/C Compressor Clutch (SE32, W6) • Y18—Ride Control (on/off) Solenoid (SE10, W2) • Y19—Park Brake Release Solenoid (SE24, W2) • Y20—Pin Disconnect Solenoid (SE28) • Y21—Electronic Injector (EI) 1 (SE43) • Y22—Electronic Injector (EI) 2 (SE43) • Y23—Electronic Injector (EI) 3 (SE43) • Y24—Electronic Injector (EI) 4 (SE43) • Y34—Ride Control (on/off) Solenoid (SE10, W2) • Y37—Proportional Fan Solenoid (SE18, W5) • Y38—Reverse Fan Solenoid (SE17, W5)

GlobalTRACS is a registered trademark of Qualcomm Incorporated JDLink is a trademark of Deere & Company

TM10229 (17MAR09)

9015-10-9

WS68074,0001167 –19–26FEB09–6/6

544J Loader (S.N. 611800— ) 032409

PN=523

9015 10 9

System Diagrams

System Functional Schematic and Section Legend TX1031432 –19–02NOV07

System Functional Schematic—(SE1, SE2, and SE3) WS68074,0001168 –19–26FEB09–1/16

TM10229 (17MAR09)

9015-10-10

544J Loader (S.N. 611800— ) 032409

PN=524

System Diagrams TX1031433 –19–02NOV07

System Functional Schematic—(SE4, SE5, and SE6)

WS68074,0001168 –19–26FEB09–2/16

TM10229 (17MAR09)

9015-10-11

544J Loader (S.N. 611800— ) 032409

PN=525

System Diagrams TX1031434 –19–02NOV07

WS68074,0001168 –19–26FEB09–3/16

TM10229 (17MAR09)

9015-10-12

544J Loader (S.N. 611800— ) 032409

PN=526

System Diagrams TX1014482 –19–15NOV06

WS68074,0001168 –19–26FEB09–4/16

TM10229 (17MAR09)

9015-10-13

544J Loader (S.N. 611800— ) 032409

PN=527

System Diagrams TX1031435 –19–02NOV07

System Functional Schematic—(SE13, SE14, and SE15)

WS68074,0001168 –19–26FEB09–5/16

TM10229 (17MAR09)

9015-10-14

544J Loader (S.N. 611800— ) 032409

PN=528

System Diagrams TX1014485 –19–08JAN07

WS68074,0001168 –19–26FEB09–6/16

TM10229 (17MAR09)

9015-10-15

544J Loader (S.N. 611800— ) 032409

PN=529

System Diagrams TX1041924 –19–15MAY08

WS68074,0001168 –19–26FEB09–7/16

TM10229 (17MAR09)

9015-10-16

544J Loader (S.N. 611800— ) 032409

PN=530

System Diagrams TX1041925 –19–15MAY08

WS68074,0001168 –19–26FEB09–8/16

TM10229 (17MAR09)

9015-10-17

544J Loader (S.N. 611800— ) 032409

PN=531

System Diagrams TX1014489 –19–15NOV06

WS68074,0001168 –19–26FEB09–9/16

TM10229 (17MAR09)

9015-10-18

544J Loader (S.N. 611800— ) 032409

PN=532

System Diagrams TX1014490 –19–22DEC06

WS68074,0001168 –19–26FEB09–10/16

TM10229 (17MAR09)

9015-10-19

544J Loader (S.N. 611800— ) 032409

PN=533

System Diagrams TX1014491 –19–15NOV06

WS68074,0001168 –19–26FEB09–11/16

TM10229 (17MAR09)

9015-10-20

544J Loader (S.N. 611800— ) 032409

PN=534

System Diagrams TX1014492 –19–15NOV06

WS68074,0001168 –19–26FEB09–12/16

TM10229 (17MAR09)

9015-10-21

544J Loader (S.N. 611800— ) 032409

PN=535

System Diagrams TX1031436 –19–02NOV07

WS68074,0001168 –19–26FEB09–13/16

TM10229 (17MAR09)

9015-10-22

544J Loader (S.N. 611800— ) 032409

PN=536

System Diagrams TX1056445 –19–05MAR09

WS68074,0001168 –19–26FEB09–14/16

TM10229 (17MAR09)

9015-10-23

544J Loader (S.N. 611800— ) 032409

PN=537

System Diagrams

TX1056446

–19–05MAR09

9015 10 24

Continued on next page

TM10229 (17MAR09)

9015-10-24

WS68074,0001168 –19–26FEB09–15/16

544J Loader (S.N. 611800— ) 032409

PN=538

System Diagrams NOTE: SE1—Battery, Ignition Power Circuit (24 V System) SE1 indicates section number of System Functional Schematic where circuit is located. Battery, Ignition Power Circuit (24 V System) indicates circuit name. • SE1—Battery, Ignition Power Circuit (24 Volt System) • SE2—Alternator Circuit • SE3—Starting Circuit • SE4—Vehicle Electrical Center Circuit • SE5—Vehicle Electrical Center Circuit • SE6—Vehicle Electrical Center Circuit • SE7—Vehicle Electrical Center Circuit • SE8—Vehicle Electrical Center Circuit • SE9—Vehicle Electrical Center Circuit • SE10—Ride Control Circuit • SE11—Horn Circuit • SE12—Start Aid and Electric Adjust Seat Circuit • SE13—CAN Circuit • SE14—CAN Monitor Unit Circuit • SE15—CAN Monitor Unit Circuit • SE16—Flex Load Controller Circuit • SE17—Flex Load Controller Circuit • SE18—Flex Load Controller Circuit • SE19—Flex Load Controller Circuit

• SE20—Flex Load Controller Circuit • SE21—Joystick Pilot Controller FNR/Gear Select Circuit (Option) • SE22—Transmission Control Unit Circuit • SE23—Transmission Control Unit Circuit • SE24—Transmission Control Unit Circuit • SE25—Pilot Enable and Boom Down Circuit • SE26—Return-to-Dig Circuit • SE27—Boom Height Kickout and Return-to-Dig Circuit • SE28—Differential Lock and Pin Disconnect Circuit • SE29—Front Wiper Circuit • SE30—Rear Wiper Circuit • SE31—Heater/Pressurizer Circuit • SE32—Air Conditioning Circuit • SE33—Flasher and Turn Signal Circuit • SE34—Tail/Marker Light Circuit • SE35—Drive Light and Rotary Beacon Circuit • SE36—Brake Light and Dome Light Circuit • SE37—Cab Work Light Circuit • SE38—Converter and Radio Circuits • SE39—Sealed Switch Module Circuit • SE40—Engine Control Unit Input Circuit • SE41—Engine Control Unit Circuit • SE42—Engine Control Unit Output Circuit • SE43—Engine Control Unit Input Circuit • SE61—Machine Interface Circuit • SE62—GlobalTRACS Terminal (GTT) Circuit • SE63—Machine Information Gateway (MIG) Circuit

GlobalTRACS is a trademark of Qualcomm Incorporated

TM10229 (17MAR09)

WS68074,0001168 –19–26FEB09–16/16

9015-10-25

544J Loader (S.N. 611800— ) 032409

PN=539

9015 10 25

System Diagrams

JDLink System Functional Schematic—If Equipped (S.N. 615706—619284 ) TX1027227 –19–22AUG07

JDLink System Functional Schematic AA95137,0000C8C –19–28MAY08–1/2

TM10229 (17MAR09)

9015-10-26

544J Loader (S.N. 611800— ) 032409

PN=540

System Diagrams A9—GlobalTRACS Terminal (GTT) Controller A10—Machine Information Gateway (MIG) Controller F66—JDLink Ground 7.5 A Fuse W40—GTT Antenna W41—GTT Harness Ground X75—Load Center Harness-to-Machine Information Gateway (MIG) Harness 4-Pin Connector

X76—Load Center Harness-to-Machine Information Gateway (MIG) Harness 8-Pin Connector X86—Engine Frame Harness-to-Negative Battery Cable 2-Pin Connector X216—GlobalTRACS Terminal (GTT) Controller 70-Pin Connector X217—GlobalTRACS Terminal (GTT) Harness-to-Machine Information Gateway (MIG) Harness 10-Pin Connector

X218—GlobalTRACS Terminal (GTT) Harness-to-Machine Information Gateway (MIG) Harness 4-Pin Connector X219—GT Config Tool AdapterConnector (RS232) X221—Machine Information Gateway (MIG) Connector 30-Pin (L1— Y3) Connector

X222—Machine Information Gateway (MIG) Connector 30-Pin (A1— K3) Connector X223—JDLink MMS Direct Connector (Ethernet) X227—2-Pin Connector (Not Used)

9015 10 27

GlobalTRACS is a registered trademark of Qualcomm Incorporated

TM10229 (17MAR09)

9015-10-27

AA95137,0000C8C –19–28MAY08–2/2

544J Loader (S.N. 611800— ) 032409

PN=541

System Diagrams

JDLink System Functional Schematic—If Equipped (S.N. 619285— ) TX1042018 –19–04JUN08

JDLink System Functional Schematic TF44157,0000328 –19–28MAY08–1/2

TM10229 (17MAR09)

9015-10-28

544J Loader (S.N. 611800— ) 032409

PN=542

System Diagrams A9—GlobalTRACS Terminal (GTT) Controller A10—Machine Information Gateway (MIG) Controller F66—JDLink Ground 7.5 A Fuse W37—Machine Information Gateway (MIG) Harness Ground W40—GTT Antenna W41—GTT Harness Ground X75—Load Center Harness-to-Machine Information Gateway (MIG) Harness 4-Pin Connector

X222—Machine Information Gateway (MIG) Connector 30-Pin (A1— K3) Connector X223—JDLink MMS Direct Connector (Ethernet) X228—2-Pin Connector (Not Used) X229—2-Pin Connector (Not Used)

9015 10 29

GlobalTRACS is a registered trademark of Qualcomm Incorporated

TM10229 (17MAR09)

9015-10-29

TF44157,0000328 –19–28MAY08–2/2

544J Loader (S.N. 611800— ) 032409

PN=543

System Diagrams

Loader Frame Harness (W2) Component Location

E12

E4 E7 E11 X85

B45

E2 E6

S17 9015 10 30

Y34

X67 B38

Y18 Y17

B34 X46

Y13 Y19

B41

TX1023301

–UN–23MAY07

Y20

TX1023301 Loader Frame Harness (W2) Component Location (Z-Bar Linkage) Continued on next page

TM10229 (17MAR09)

9015-10-30

AA95137,0000AF6 –19–06JUN07–1/4

544J Loader (S.N. 611800— ) 032409

PN=544

System Diagrams B34—Park Brake Pressure Switch (closes with low pressure) B38—Horn B41—Ride Control Pressure Switch (closes with pressure) B45—Analog BHKO/RTC Position Sensor

E2—Left Front Turn Light E4—Right Front Turn Light E6—Left Front Marker Light E7—Right Front Marker Light E11—Left Front Drive Light E12—Right Front Drive Light S17—Return-to-Dig Switch X46—2-Pin Connector (not used)

X67—Load Center Harness-to-Loader Frame Harness Connector Y13—Differential Lock Solenoid Y17—Ride Control Boom Solenoid

Continued on next page

Y18—Ride Control (On/Off) Solenoid Y19—Park Brake Release Solenoid Y20—Pin Disconnect Solenoid Y34—Ride Control (On/Off) Solenoid

AA95137,0000AF6 –19–06JUN07–2/4

9015 10 31

TM10229 (17MAR09)

9015-10-31

544J Loader (S.N. 611800— ) 032409

PN=545

System Diagrams

E4,E7

E11

E12 B38

E2,E6 B45

9015 10 32

X67

Y34

Y18

B34 Y20 Y17 Y13 Y19

B41 X46

TX1023300

–UN–23MAY07

B37

TX1023300 Loader Frame Harness (W2) Component Location (Powerllel Linkage)

Continued on next page

TM10229 (17MAR09)

9015-10-32

AA95137,0000AF6 –19–06JUN07–3/4

544J Loader (S.N. 611800— ) 032409

PN=546

System Diagrams B34—Park Brake Pressure Switch (closes with low pressure) B37—Analog Return-to-Dig Sensor B38—Horn B41—Ride Control Pressure Switch (closes with pressure) B45—Analog BHKO/RTC Position Sensor

E2—Left Front Turn Light E4—Right Front Turn Light E6—Left Front Marker Light E7—Right Front Marker Light E11—Left Front Drive Light E12—Right Front Drive Light X45—Loader Frame Harness-to-Pin Disconnect Harness Connector

X46—2-Pin Connector (not used) X67—Load Center Harness-to-Loader Frame Harness Connector Y13—Differential Lock Solenoid

Y17—Ride Control Boom Solenoid Y18—Ride Control (On/Off) Solenoid Y19—Park Brake Release Solenoid Y34—Ride Control (On/Off) Solenoid

AA95137,0000AF6 –19–06JUN07–4/4

9015 10 33

TM10229 (17MAR09)

9015-10-33

544J Loader (S.N. 611800— ) 032409

PN=547

System Diagrams

Loader Frame Harness (W2) Wiring Diagram TX1022549 –19–25APR07

Loader Frame Harness (W2) Wiring Diagram (Z-Bar Linkage) WS68074,0001169 –19–20APR07–1/4

TM10229 (17MAR09)

9015-10-34

544J Loader (S.N. 611800— ) 032409

PN=548

System Diagrams B34—Park Brake Pressure Switch (closes with low pressure) B38—Horn B41—Ride Control Pressure Switch (closes with pressure) B45—Analog BHKO/RTC Position Sensor E2—Left Front Turn Light

E4—Right Front Turn Light E6—Left Front Marker Light E7—Right Front Marker Light E11—Left Front Drive Light E12—Right Front Drive Light X46—Not Used X67—Load Center Harness-to-Loader Frame Harness X74—Loader Frame-to-Return-to-Dig Harness Connector

X85—Loader Frame Harness-to- Return to Dig Harness X100—Splice L06 BRN X102—Splice G05 BLK X103—Splice G05 BLK X174—Splice H02 GRN Y13—Differential Lock Solenoid

Continued on next page

Y17—Ride Control Boom Solenoid Y18—Ride Control (On/Off) Solenoid Y19—Park Brake Release Solenoid Y20—Pin Disconnect Solenoid Y34—Ride Control (On/Off) Solenoid

WS68074,0001169 –19–20APR07–2/4

9015 10 35

TM10229 (17MAR09)

9015-10-35

544J Loader (S.N. 611800— ) 032409

PN=549

System Diagrams TX1022548 –19–25APR07

Loader Frame Harness (W2) Wiring Diagram (Powerllel Linkage)

Continued on next page

TM10229 (17MAR09)

9015-10-36

WS68074,0001169 –19–20APR07–3/4

544J Loader (S.N. 611800— ) 032409

PN=550

E2—Left Front Turn Light E4—Right Front Turn Light E6—Left Front Marker Light E7—Right Front Marker Light E11—Left Front Drive Light E12—Right Front Drive Light X44—Loader Frame Harness-to-Ride Control Harness Connector X46—Not Used

X67—Load Center Harness-to-Loader Frame Harness X100—Splice L06 BRN X102—Splice G05 BLK X103—Splice G05 BLK X172—Splice P68 RED X173—Splice R68 BLK X174—Splice H02 GRN Y13—Differential Lock Solenoid

Y17—Ride Control Boom Solenoid Y18—Ride Control (On/Off) Solenoid Y19—Park Brake Release Solenoid Y20—Pin Disconnect Solenoid Y34—Ride Control (On/Off) Solenoid

WS68074,0001169 –19–20APR07–4/4

9015 10 37

TM10229 (17MAR09)

9015-10-37

544J Loader (S.N. 611800— ) 032409

PN=551

System Diagrams

Load Center Harness (W3) Component Location TX1016009 –UN–20DEC06

X15 X10 X11 X18

X14

X27

X12 X13

X53 R1 X72

X17

X71 G9

X40 S21

A1 X41

S24 X30 S13

X42

B14 X8

B40

X75

X33 X5

X6 X7

B33 B27 X67

X23

X34

X35

B25 X20 A2

B52

X19

X21

X22

X76

X3 X77 W30

B51 M1

TX1016009 WS68074,0001172 –19–25APR07–1/2

TM10229 (17MAR09)

9015-10-38

544J Loader (S.N. 611800— ) 032409

PN=552

System Diagrams A1—Engine Control Unit (ECU) A2—Flex Load Controller (FLC) A3—Transmission Control Unit (TCU) A6—Sealed Switch Module (SSM) B14—Analog Throttle Position Sensor B25—Steering System Pressure Switch B27—Service Brake Accumulator Charge Pressure Switch B33—Clutch Cut-Off Sensor B40—Brake Light Pressure Switch B51—Not Used B52—Not Used G9—Power Plug K3—Start Relay K4—Ignition Relay M1—Starter Motor R1—CAN Termination Node S1—Key Switch S13—Differential Lock Foot Switch S21—Blower Speed Switch S24—4-Way Flasher Switch W30—G08 BLK Ground for Front Dash Components in Load Center

X1—Service ADVISOR System Connector X2—TCU Diagnostic and Programming Connector X3—Load Center Harness-to-Engine Frame Harness Connector X4—Load Center Harness-to-Engine Harness Connector X5—Load Center Harness-to-Cab Roof Harness 12-Pin Connector X6—Load Center Harness-to-Cab Roof Harness 4-Pin Connector X7—Load Center Harness-to-Heater and Air Conditioner Harness 3-Pin Connector X8—Load Center Harness-to-Heater and Air Conditioner Harness 2-Pin Connector X9—Load Center Harness-to-Heater and Air Conditioner Harness 4-Pin Connector X10—Vehicle Electrical Center 8-Pin BLK Connector X11—Vehicle Electrical Center 8-Pin GRY Connector

X12—Vehicle Electrical Center 8-Pin BLU Connector X13—Vehicle Electrical Center 8-Pin GRN Connector X14—Vehicle Electrical Center 2-Pin GRY Connector X15—Vehicle Electrical Center 2-Pin BLK Connector X17—Vehicle Electrical Center 8-Pin YEL Connector X18—Vehicle Electrical Center 8-Pin RED Connector X19—Load Center Harness Spare BAT Connector X20—Load Center Harness Spare IGN Connector X21—Load Center Harness Spare GND Connector X22—Load Center Harness-to-Transmission Harness Connector X23—Transmission Control Unit (TCU) Connector X27—Joystick Shifter Switch Connector 1 X30—Load Center Harness-to-Front Console Harness Connector X33—Load Center Harness-to-Air Adjust Seat Harness Connector

X34—Load Center Harness-to-Radio Harness Connector X35—Load Center Harness-to-Converter and Power Plug Harness Connector X40—Flex Load Controller Connector (J1) (RED) X41—Flex Load Controller Connector (J2) (RED) X42—Flex Load Controller Connector (J3) (RED) X53—Sealed Switch Module Connector X67—Load Center Harness-to-Loader Frame Harness Connector X71—Engine Control Unit (ECU) Connector X72—Engine Control Unit (ECU) Connector X75—Machine Information 4-Pin Connector X76—Machine Information 8-Pin Connector X77—Load Center Harness Spare 12Volt Connector

9015 10 39

WS68074,0001172 –19–25APR07–2/2

TM10229 (17MAR09)

9015-10-39

544J Loader (S.N. 611800— ) 032409

PN=553

System Diagrams

Load Center Harness (W3) Wiring Diagram TX1016327 –UN–15DEC06

Load Center Harness (W3) Wire Table (S.N. 611275—615705) WS68074,0001174 –19–01NOV07–1/26

TM10229 (17MAR09)

9015-10-40

544J Loader (S.N. 611800— ) 032409

PN=554

System Diagrams

9015 10 41

TM10229 (17MAR09)

9015-10-41

544J Loader (S.N. 611800— ) 032409

PN=555

System Diagrams TX1016330 –UN–15DEC06

Load Center Harness (W3) Wiring Diagram (1 of 6) (S.N. 611275—615705)

WS68074,0001174 –19–01NOV07–2/26

TM10229 (17MAR09)

9015-10-42

544J Loader (S.N. 611800— ) 032409

PN=556

System Diagrams K4—Ignition Relay X2—TCU Diagnostic and Programming Connector X3—Load Center Harness-to-Engine Frame Harness Connector X4—Load Center Harness-to-Engine Harness Connector X5—Load Center Harness-to-Cab Roof Harness 12-Pin Connector

X6—Load Center Harness-to-Cab Roof Harness 4-Pin Connector X7—Load Center Harness-to-Heater and Air Conditioner Harness 3-Pin Connector X8—Load Center Harness-to-Heater and Air Conditioner Harness 2-Pin Connector

X9—Load Center Harness-to-Heater and Air Conditioner Harness 4-Pin Connector X19—Load Center Harness Spare BAT Connector X20—Load Center Harness Spare IGN Connector X21—Load Center Harness Spare GND Connector

Continued on next page

X35—Load Center Harness-to-Converter and Power Plug Harness Connector X77—Load Center Harness Spare 12V Connector X109—Splice L06 BRN X177—Splice R12 BLK X178—Splice M13 GRN X179—Splice M12 YEL

WS68074,0001174 –19–01NOV07–3/26

9015 10 43

TM10229 (17MAR09)

9015-10-43

544J Loader (S.N. 611800— ) 032409

PN=557

System Diagrams TX1016332 –UN–15DEC06

Load Center Harness (W3) Wiring Diagram (2 of 6) (S.N. 611275—615705)

Continued on next page

TM10229 (17MAR09)

9015-10-44

WS68074,0001174 –19–01NOV07–4/26

544J Loader (S.N. 611800— ) 032409

PN=558

System Diagrams G5—12 V Power Plug G9—Power Plug S1—Key Switch S21—Blower Speed Switch S24—4-Way Flasher Switch X10—Vehicle Electrical Center 8-Pin BLK Connector X11—Vehicle Electrical Center 8-Pin GRY Connector

X17—Vehicle Electrical Center 8-Pin YEL Connector X18—Vehicle Electrical Center 8-Pin RED Connector X34—Load Center Harness-to-Radio Harness Connector X104—Splice A15 ORG

Continued on next page

X105—Splice B10 RED X106—Splice G04 BLK X108—Splice B02 RED X121—Splice P18 RED X133—Splice P11 RED X170—Splice P32 RED X202—Splice P83 RED X203—Splice G06 BLK

WS68074,0001174 –19–01NOV07–5/26

9015 10 45

TM10229 (17MAR09)

9015-10-45

544J Loader (S.N. 611800— ) 032409

PN=559

System Diagrams TX1016333 –UN–15DEC06

Load Center Harness (W3) Wiring Diagram (3 of 6) (S.N. 611275—615705)

Continued on next page

TM10229 (17MAR09)

9015-10-46

WS68074,0001174 –19–01NOV07–6/26

544J Loader (S.N. 611800— ) 032409

PN=560

System Diagrams X40—Flex Load Controller Connector (J1) (RED) X41—Flex Load Controller Connector (J2) (RED)

X42—Flex Load Controller Connector (J3) (BLU) X107—Splice L22 BRN

X110—Splice B17 RED X111—Splice B16 RED

Continued on next page

X112—Splice B15 RED X113—Splice A12 ORG

WS68074,0001174 –19–01NOV07–7/26

9015 10 47

TM10229 (17MAR09)

9015-10-47

544J Loader (S.N. 611800— ) 032409

PN=561

System Diagrams TX1016335 –UN–15DEC06

Load Center Harness (W3) Wiring Diagram (4 of 6) (S.N. 611275—615705)

Continued on next page

TM10229 (17MAR09)

9015-10-48

WS68074,0001174 –19–01NOV07–8/26

544J Loader (S.N. 611800— ) 032409

PN=562

System Diagrams K3—Start Relay K4—Ignition Relay X23—Transmission Control Unit (TCU) Connector

X33—Load Center Harness-to-Air Adjust Seat Harness Connector X122—Splice P78 RED

X123—Splice R09 BLK X124—Splice G01 BLK X171—Splice G04 BLK

Continued on next page

X187—Splice R12 BLK X188—Splice M13 GRN X189—Splice M12 YEL

WS68074,0001174 –19–01NOV07–9/26

9015 10 49

TM10229 (17MAR09)

9015-10-49

544J Loader (S.N. 611800— ) 032409

PN=563

System Diagrams TX1029448 –UN–18SEP07

Load Center Harness (W3) Wiring Diagram (5 of 6) (S.N. 611275—615705)

Continued on next page

TM10229 (17MAR09)

9015-10-50

WS68074,0001174 –19–01NOV07–10/26

544J Loader (S.N. 611800— ) 032409

PN=564

System Diagrams A4—Pilot Controller R1—CAN Termination Node X1—Service ADVISOR System Connector X22—Load Center Harness-to-Transmission Harness Connector X24—Engine Control Unit (ECU) Connector X27—Joystick Gear Select Connector

X53—Sealed Switch Module (SSM) Connector X71—Engine Control Unit (ECU) Connector X72—Engine Control Unit (ECU) Connector X75—Load Center Harness-to-Machine Information Gateway (MIG) Harness 4-Pin Connector

X76—Load Center Harness-to-Machine Information Gateway (MIG) Harness 8-Pin Connector X115—Splice M12 YEL X116—Splice M13 GRN X117—Splice R12 BLK X118—Splice G04 BLK X119—Splice P28 RED X120—Splice R20 BLK

Continued on next page

X167—Splice G11 BLK X168—Splice P03 RED X204—Splice R12 BLK X205—Splice G01 BLU X206—Splice M13 GRN X207—Splice M12 YEL X208—Splice M13 GRN X209—Splice R12 BLK X210—Splice M12 YEL X215—Splice T17 BLU

WS68074,0001174 –19–01NOV07–11/26

9015 10 51

TM10229 (17MAR09)

9015-10-51

544J Loader (S.N. 611800— ) 032409

PN=565

System Diagrams TX1027448 –UN–07AUG07

Load Center Harness (W3) Wiring Diagram (6 of 6) (S.N. 611275—615705)

Continued on next page

TM10229 (17MAR09)

9015-10-52

WS68074,0001174 –19–01NOV07–12/26

544J Loader (S.N. 611800— ) 032409

PN=566

System Diagrams B14—Analog Throttle Position Sensor B25—Steering System Pressure Switch (closes with high pressure) B27—Service Brake Accumulator Charge Pressure Switch (closes with high pressure) B33—Clutch Cut-Off Sensor B40—Brake Light Pressure Switch (closes with pressure)

B51—Not Used B52—Not Used M1—Starter Motor S13—Differential Lock Foot Switch V1—Starter Coil Suppression 5 A Diode W25—G01 BLK Ground for CMU, TCU, CCU at Starter W28—Ground at Cab Right Front

X30—Load Center Harness-to-Front Console Harness Connector X67—Load Center Harness-to-Loader Frame Harness Connector X127—Splice L09 BRN X130—Splice A08 ORG

Continued on next page

X134—Splice R68 BLK X135—Splice P23 RED X136—Splice N06 YEL X190—Splice P13 RED X191—Splice P79 RED X193—Splice R73 BLK X211—Splice L12 BRN X212—Splice E04 WHT X213—Splice P69 RED X214—Splice R69 BLK

WS68074,0001174 –19–01NOV07–13/26

9015 10 53

TM10229 (17MAR09)

9015-10-53

544J Loader (S.N. 611800— ) 032409

PN=567

System Diagrams TX1026567 –UN–18JUL07

TX1026567 Load Center Harness (W3) Wire Table (S.N. 615706— )

Continued on next page

TM10229 (17MAR09)

9015-10-54

WS68074,0001174 –19–01NOV07–14/26

544J Loader (S.N. 611800— ) 032409

PN=568

System Diagrams

9015 10 55

TM10229 (17MAR09)

9015-10-55

544J Loader (S.N. 611800— ) 032409

PN=569

System Diagrams TX1026568 –UN–18JUL07

TX1026568 Load Center Harness (W3) Wiring Diagram (1 of 6) (S.N. 615706— )

Continued on next page

TM10229 (17MAR09)

9015-10-56

WS68074,0001174 –19–01NOV07–15/26

544J Loader (S.N. 611800— ) 032409

PN=570

Continued on next page

WS68074,0001174 –19–01NOV07–16/26

9015 10 57

TM10229 (17MAR09)

9015-10-57

544J Loader (S.N. 611800— ) 032409

PN=571

System Diagrams TX1016332 –UN–15DEC06

Load Center Harness (W3) Wiring Diagram (2 of 6) (S.N. 615706— )

Continued on next page

TM10229 (17MAR09)

9015-10-58

WS68074,0001174 –19–01NOV07–17/26

544J Loader (S.N. 611800— ) 032409

PN=572

X17—Vehicle Electrical Center 8-Pin YEL Connector X18—Vehicle Electrical Center 8-Pin RED Connector X34—Load Center Harness-to-Radio Harness Connector X104—Splice A15 ORG

Continued on next page

X105—Splice B10 RED X106—Splice G04 BLK X108—Splice B02 RED X121—Splice P18 RED X133—Splice P11 RED X170—Splice P32 RED X202—Splice P83 RED X203—Splice G06 BLK

WS68074,0001174 –19–01NOV07–18/26

9015 10 59

TM10229 (17MAR09)

9015-10-59

544J Loader (S.N. 611800— ) 032409

PN=573

System Diagrams TX1016333 –UN–15DEC06

Load Center Harness (W3) Wiring Diagram (3 of 6) (S.N. 615706— )

Continued on next page

TM10229 (17MAR09)

9015-10-60

WS68074,0001174 –19–01NOV07–19/26

544J Loader (S.N. 611800— ) 032409

PN=574

System Diagrams X40—Flex Load Controller Connector (J1) (RED) X41—Flex Load Controller Connector (J2) (RED)

X42—Flex Load Controller Connector (J3) (BLU) X107—Splice L22 BRN

X110—Splice B17 RED X111—Splice B16 RED

Continued on next page

X112—Splice B15 RED X113—Splice A12 ORG

WS68074,0001174 –19–01NOV07–20/26

9015 10 61

TM10229 (17MAR09)

9015-10-61

544J Loader (S.N. 611800— ) 032409

PN=575

System Diagrams TX1016335 –UN–15DEC06

Load Center Harness (W3) Wiring Diagram (4 of 6) (S.N. 615706— )

Continued on next page

TM10229 (17MAR09)

9015-10-62

WS68074,0001174 –19–01NOV07–21/26

544J Loader (S.N. 611800— ) 032409

PN=576

System Diagrams K3—Start Relay K4—Ignition Relay X23—Transmission Control Unit (TCU) Connector

X33—Load Center Harness-to-Air Adjust Seat Harness Connector X122—Splice P78 RED

X123—Splice R09 BLK X124—Splice G01 BLK X171—Splice G04 BLK

Continued on next page

X187—Splice R12 BLK X188—Splice M13 GRN X189—Splice M12 YEL

WS68074,0001174 –19–01NOV07–22/26

9015 10 63

TM10229 (17MAR09)

9015-10-63

544J Loader (S.N. 611800— ) 032409

PN=577

System Diagrams TX1026569 –UN–18SEP07

Load Center Harness (W3) Wiring Diagram (5 of 6) (S.N. 615706— )

Continued on next page

TM10229 (17MAR09)

9015-10-64

WS68074,0001174 –19–01NOV07–23/26

544J Loader (S.N. 611800— ) 032409

PN=578

Continued on next page

WS68074,0001174 –19–01NOV07–24/26

9015 10 65

TM10229 (17MAR09)

9015-10-65

544J Loader (S.N. 611800— ) 032409

PN=579

System Diagrams TX1027448 –UN–07AUG07

Load Center Harness (W3) Wiring Diagram (6 of 6) (S.N. 615706— )

Continued on next page

TM10229 (17MAR09)

9015-10-66

WS68074,0001174 –19–01NOV07–25/26

544J Loader (S.N. 611800— ) 032409

PN=580

B51—Not Used B52—Not Used M1—Starter Motor S13—Differential Lock Foot Switch V1—Starter Coil Suppression 5 A Diode W25—G01 BLK Ground for CMU, TCU, FLC at Starter W28—Ground at Cab Right Front

X30—Load Center Harness-to-Front Console Harness Connector X67—Load Center Harness-to-Loader Frame Harness Connector X127—Splice L09 BRN X130—Splice A08 ORG

WS68074,0001174 –19–01NOV07–26/26

9015 10 67

TM10229 (17MAR09)

9015-10-67

544J Loader (S.N. 611800— ) 032409

PN=581

System Diagrams

Front Console Harness (W4) Component Location H2

X48

R2 9015 10 68

H1 S23

M3 S25 S3

X50

–UN–13OCT03

X51

T191951

X30

T191951 Front Console Harness (W4) Component Location Continued on next page

TM10229 (17MAR09)

9015-10-68

CS33148,00014BD –19–31OCT06–1/2

544J Loader (S.N. 611800— ) 032409

PN=582

System Diagrams H1—Monitor Alarm H2—CAN Monitor Unit (CMU) M3—Front Wiper Motor R2—CAN Termination Node S3—Start-Aid Switch

S8—Park Brake Release Switch S23—Horn Switch S25—Turn Switch

X30—Load Center Harness-to-Front Console Harness Connector

X48—CAN Monitor Unit Connector (CMU) X50—Shifter Switch Connector X51—Shifter Switch Connector

CS33148,00014BD –19–31OCT06–2/2

9015 10 69

TM10229 (17MAR09)

9015-10-69

544J Loader (S.N. 611800— ) 032409

PN=583

System Diagrams

Front Console Harness (W4) Wiring Diagram TX1016041 –UN–11DEC06

WS68074,0000780 –19–19JAN07–1/2

TM10229 (17MAR09)

9015-10-70

544J Loader (S.N. 611800— ) 032409

PN=584

System Diagrams H1—Monitor Alarm M3—Front Wiper Motor R2—CAN Termination Node S3—Start Aid Switch S8—Park Brake Release Switch

S23—Horn Switch S25—Turn Switch X30—Load Center Harness-to-Front Console Harness Connector

X48—CAN Monitor Unit Connector X50—Shifter Switch X51—Shifter Switch X137—Splice M12 YEL

X138—Splice M13 GRN X139—Splice R12 BLK X163—Splice P13 RED X164—Splice G08 BLK

WS68074,0000780 –19–19JAN07–2/2

9015 10 71

TM10229 (17MAR09)

9015-10-71

544J Loader (S.N. 611800— ) 032409

PN=585

System Diagrams

Engine Frame Harness (W5) Component Location

X39 X3

W26

X78 M2 M4

X86 F66

9015 10 72

X43

B17

B15 B21

X83

B8 Y14

TX1029547

–UN–19SEP07

Y15

TX1029547 Engine Frame Harness (W5) Component Location Continued on next page

TM10229 (17MAR09)

9015-10-72

AA95137,000099C –19–01NOV07–1/2

544J Loader (S.N. 611800— ) 032409

PN=586

System Diagrams B8—Hydraulic System Pressure Sensor (if equipped) B15—Hydraulic Oil Temperature Sensor B17—Fuel Level Sensor B21—Hydraulic Oil Filter Restriction Switch

F66—JDLink Ground 7.5-Amp Fuse (S.N. 615706— ) M2—Front Washer Pump M4—Rear Washer Pump W26—G02 BLK Ground for Engine Frame Components by Starter X3—Load Center Harness-to-Engine Frame Harness Connector

X39—Engine Frame Harness-to-Rear Frame Harness Connector X43—12 Volt Center Tap Battery Connector X78—Ether Start Solenoid Connector X83—2-Pin Connector (not used)

JDLink is a trademark of Deere & Company

X86—Engine Frame Harness-to-Negative Battery Cable 2-Pin Connector (S.N. 615706— ) Y14—Pilot Enable Solenoid Y15—Boom Down Accumulator Solenoid

AA95137,000099C –19–01NOV07–2/2

9015 10 73

TM10229 (17MAR09)

9015-10-73

544J Loader (S.N. 611800— ) 032409

PN=587

System Diagrams

Engine Frame Harness (W5) Wiring Diagram TX1015279 –UN–12DEC06

Engine Frame Harness (W5) Wiring Diagram (S.N. 611275—615705) WS68074,000116A –19–01NOV07–1/4

TM10229 (17MAR09)

9015-10-74

544J Loader (S.N. 611800— ) 032409

PN=588

System Diagrams B8—Hydraulic Pressure Sensor (if equipped) B15—Hydraulic Oil Temperature Sensor B17—Fuel Level Sensor B21—Hydraulic Oil Filter Restriction Switch M2—Front Washer Pump

M4—Rear Washer Pump W26—G02 BLK Ground for Engine Frame Components by Starter X3—Load Center Harness-to-Engine Frame Harness Connector

X39—Engine Frame Harness-to-Rear Frame Harness Connector X43—12V Center Tap Battery Connector X78—Ether Start Solenoid Connector

Continued on next page

X140—Splice G02 BLK X142—Splice H24 GRN Y14—Pilot Enable Solenoid Y15—Boom Down Accumulator Solenoid Y39—Power Management Solenoid (if equipped)

WS68074,000116A –19–01NOV07–2/4

9015 10 75

TM10229 (17MAR09)

9015-10-75

544J Loader (S.N. 611800— ) 032409

PN=589

System Diagrams TX1026676 –UN–20JUL07

Engine Frame Harness (W5) Wiring Diagram (S.N. 615706— )

Continued on next page

TM10229 (17MAR09)

9015-10-76

WS68074,000116A –19–01NOV07–3/4

544J Loader (S.N. 611800— ) 032409

PN=590

System Diagrams B8—Hydraulic Pressure Sensor (if equipped) B15—Hydraulic Oil Temperature Sensor B17—Fuel Level Sensor B21—Hydraulic Oil Filter Restriction Switch

F66—JDLink Ground 7.5-Amp Fuse M2—Front Washer Pump M4—Rear Washer Pump W26—G02 BLK Ground for Engine Frame Components by Starter X3—Load Center Harness-to-Engine Frame Harness Connector

X39—Engine Frame Harness-to-Rear Frame Harness Connector X43—12V Center Tap Battery Connector X78—Ether Start Solenoid Connector X86—Engine Frame Harness-to-Negative Battery Cable 2-Pin Connector

JDLink is a trademark of Deere & Company

X140—Splice G02 BLK X142—Splice H24 GRN Y14—Pilot Enable Solenoid Y15—Boom Down Accumulator Solenoid Y39—Power Management Solenoid (if equipped)

WS68074,000116A –19–01NOV07–4/4

9015 10 77

TM10229 (17MAR09)

9015-10-77

544J Loader (S.N. 611800— ) 032409

PN=591

System Diagrams

Engine Harness (W6) Component Location

9015 10 78

B19 B7

X81 B1

B48

–UN–12JAN07

X84

TX1017311

TX1017311 Continued on next page

TM10229 (17MAR09)

9015-10-78

WS68074,000091B –19–16JUL08–1/4

544J Loader (S.N. 611800— ) 032409

PN=592

System Diagrams B1—Engine Coolant Temperature Sensor B7—Manifold Air Temperature Sensor

B19—Engine Air Filter Restriction Switch (closed with restriction) B48—Water in Fuel Sensor

G4—24-Volt 80-Amp Alternator X4—Load Center Harness-to-Engine Harness Connector

Continued on next page

X81—Fuel Injector Harness Connector X84—Low Pressure Fuel Pump Connector (field option)

WS68074,000091B –19–16JUL08–2/4

9015 10 79

TM10229 (17MAR09)

9015-10-79

544J Loader (S.N. 611800— ) 032409

PN=593

System Diagrams

B10

9015 10 80

Y16

B3 B5

V11

B49

X79

B4 B23

TX1045675

–UN–21JUL08

X80

TX1045675 Engine Harness (W6) Component Location (2 of 2)

Continued on next page

TM10229 (17MAR09)

9015-10-80

WS68074,000091B –19–16JUL08–3/4

544J Loader (S.N. 611800— ) 032409

PN=594

System Diagrams B3—Camshaft Position Sensor B4—Crankshaft Position Sensor B5—Fuel Temperature Sensor B10—Ambient Air Temperature Sensor

B23—Engine Oil Pressure Sensor B49—Fuel Rail Pressure Sensor M1—Starter Motor V11—A/C Compressor Clutch 1 A Diode

X4—Load Center Harness-to-Engine Harness Connector X79—Engine Harness-to-Secondary Steering Motor Connector

X80—Not Used Y8—High Pressure Fuel Pump Solenoid Y16—A/C Compressor Clutch

WS68074,000091B –19–16JUL08–4/4

9015 10 81

TM10229 (17MAR09)

9015-10-81

544J Loader (S.N. 611800— ) 032409

PN=595

System Diagrams

Engine Harness (W6) Wiring Diagram TX1045638 –UN–18JUL08

WS68074,000091C –19–16JUL08–1/4

TM10229 (17MAR09)

9015-10-82

544J Loader (S.N. 611800— ) 032409

PN=596

System Diagrams B1—Engine Coolant Temperature Sensor B3—Camshaft Position Sensor B4—Crankshaft Position Sensor

B5—Fuel Temperature Sensor B23—Engine Oil Pressure Sensor B49—Fuel Rail Pressure Sensor

M1—Starter Motor V11—A/C Clutch 1 A Diode X4—Load Center Harness-to-Engine Harness Connector Continued on next page

X80—Not Used X193—Splice R73 BLK Y8—High Pressure Fuel Pump Solenoid Y16—A/C Compressor Clutch WS68074,000091C –19–16JUL08–2/4

9015 10 83

TM10229 (17MAR09)

9015-10-83

544J Loader (S.N. 611800— ) 032409

PN=597

System Diagrams TX1045639 –UN–21JUL08

Continued on next page

TM10229 (17MAR09)

9015-10-84

WS68074,000091C –19–16JUL08–3/4

544J Loader (S.N. 611800— ) 032409

PN=598

System Diagrams B7—Manifold Air Temperature Sensor B10—Ambient Air Temperature Sensor B19—Engine Air Filter Restriction Switch (closed with restriction)

B48—Water and Fuel Sensor G4—24V 80 A Alternator X79—Engine Frame Harness-to-Secondary Steering Motor Connector

X81—Fuel Injector Harness Connector X84—Low Pressure Fuel Pump Connector (field option)

X192—Splice P11 RED

WS68074,000091C –19–16JUL08–4/4

9015 10 85

TM10229 (17MAR09)

9015-10-85

544J Loader (S.N. 611800— ) 032409

PN=599

System Diagrams

Transmission Harness (W10) Component Location

X22

9015 10 86

B28 B30

B29

X36

B20

T191961

–UN–13OCT03

B31

T191961 Transmission Harness (W10) Component Location Continued on next page

TM10229 (17MAR09)

9015-10-86

CS33148,00014C7 –19–31OCT06–1/2

544J Loader (S.N. 611800— ) 032409

PN=600

System Diagrams B20—Transmission Oil Filter Restriction Switch B28—Torque Converter Input Speed Sensor B29—Torque Converter Output Speed Sensor

B30—Internal Clutch Speed Sensor B31—Transmission Output Speed Sensor

X22—Load Center Harness-to-Transmission Harness Connector

X36—Transmission Harness-to-Transmission Control Valve Harness Connector

CS33148,00014C7 –19–31OCT06–2/2

9015 10 87

TM10229 (17MAR09)

9015-10-87

544J Loader (S.N. 611800— ) 032409

PN=601

System Diagrams

Transmission Harness (W10) Wiring Diagram TX1016048 –UN–11DEC06

WS68074,000077D –19–11DEC06–1/2

TM10229 (17MAR09)

9015-10-88

544J Loader (S.N. 611800— ) 032409

PN=602

System Diagrams B20—Transmission Oil Filter Restriction Switch B28—Torque Converter Input Speed Sensor (Engine Speed)

B29—Torque Converter Output Speed Sensor B30—Internal Clutch Speed Sensor B31—Transmission Output Speed Sensor

X22—Load Center Harness-to-Transmission Harness Connector X36—Transmission Harness-to-Transmission Control Valve Harness Connector

X152—Splice R06 BLK

WS68074,000077D –19–11DEC06–2/2

9015 10 89

TM10229 (17MAR09)

9015-10-89

544J Loader (S.N. 611800— ) 032409

PN=603

System Diagrams

Rear Frame Harness (W13) Component Location

E8 E16

E9 E17 9015 10 90

E3 Y37 E10

E5 Y38 X39

TX1018426

–UN–01FEB07

TX1018426 Rear Frame Harness (W13) Component Location Continued on next page

TM10229 (17MAR09)

9015-10-90

AA95137,000059C –19–01FEB07–1/4

544J Loader (S.N. 611800— ) 032409

PN=604

System Diagrams E3—Left Rear Turn Light E5—Right Rear Turn light E8—Left Tail Light E9—Right Tail Light

E10—License Plate Light E16—Left Rear Brake Light E17—Right Rear Brake Light H3—Backup Alarm

X39—Engine Frame Harness-to-Rear Frame Harness Connector Y37—Proportional Fan Solenoid Continued on next page

Y38—Reverse Fan Solenoid (If Equipped)

AA95137,000059C –19–01FEB07–2/4

9015 10 91

TM10229 (17MAR09)

9015-10-91

544J Loader (S.N. 611800— ) 032409

PN=605

System Diagrams

E8 E16

E9 E17 E3

E10

Y37

E5 X39

–UN–08DEC06

Y38

TX1016298

9015 10 92

TX1016298 Rear Frame Harness (W13) Component Location (Fan Reverse Option)

Continued on next page

TM10229 (17MAR09)

9015-10-92

AA95137,000059C –19–01FEB07–3/4

544J Loader (S.N. 611800— ) 032409

PN=606

System Diagrams E3—Left Rear Turn Light E5—Right Rear Turn light E8—Left Tail Light E9—Right Tail Light

E10—License Plate Light E16—Left Rear Brake Light E17—Right Rear Brake Light H3—Backup Alarm

X39—Engine Frame Harness-to-Rear Frame Harness Connector

Y37—Proportional Fan Solenoid Y38—Reverse Fan Solenoid

AA95137,000059C –19–01FEB07–4/4

9015 10 93

TM10229 (17MAR09)

9015-10-93

544J Loader (S.N. 611800— ) 032409

PN=607

System Diagrams

Rear Frame Harness (W13) Wiring Diagram TX1015721 –UN–06DEC06

WS68074,000077C –19–15DEC06–1/2

TM10229 (17MAR09)

9015-10-94

544J Loader (S.N. 611800— ) 032409

PN=608

System Diagrams E3—Left Rear Turn Light E5—Right Rear Turn light E8—Left Tail Light E9—Right Tail Light E10—License Plate Light

E16—Left Rear Brake Light E17—Right Rear Brake Light H3—Backup Alarm Y37—Proportional Fan Solenoid

Y38—Reverse Fan Solenoid X39—Engine Frame Harness-to-Rear Frame Harness Connector

X199—Splice G02 BLK X200—Splice L06 BRN X201—Splice L04 BRN

WS68074,000077C –19–15DEC06–2/2

9015 10 95

TM10229 (17MAR09)

9015-10-95

544J Loader (S.N. 611800— ) 032409

PN=609

System Diagrams

Secondary Steering Harness (W17) Component Location

X79

9015 10 96

TX1016296

–UN–08DEC06

TX1016296 Secondary Steering Harness (W17) Component Location M1—Starter Motor

M8—Secondary Steering Pump

X79—Engine Harness-to-Secondary Steering Harness Connector

AA95137,000059D –19–11DEC06–1/1

TM10229 (17MAR09)

9015-10-96

544J Loader (S.N. 611800— ) 032409

PN=610

System Diagrams

9015 10 97

TM10229 (17MAR09)

9015-10-97

544J Loader (S.N. 611800— ) 032409

PN=611

System Diagrams

Secondary Steering Harness (W17) Wiring Diagram TX1016418 –UN–15DEC06

B09

H13

X79

G20

H13

B09

G20

G20A

TX1016418

AA95137,000059E –19–18DEC06–1/2

TM10229 (17MAR09)

9015-10-98

544J Loader (S.N. 611800— ) 032409

PN=612

System Diagrams M1—Starter Motor

M8—Secondary Steering Pump Motor

X79—Engine Harness-to-Secondary Steering Motor Connector

AA95137,000059E –19–18DEC06–2/2

9015 10 99

TM10229 (17MAR09)

9015-10-99

544J Loader (S.N. 611800— ) 032409

PN=613

System Diagrams

Cab Roof Harness (W19) Component Location

E20

E24 S29 S28 E25 E18 E15

M5 E21

E22 9015 10 ,100

E23

T209784

–UN–01AUG05

T209784 Cab Roof Harness (W19) Component Location Continued on next page

TM10229 (17MAR09)

9015-10-100

CS33148,00014CB –19–31OCT06–1/2

544J Loader (S.N. 611800— ) 032409

PN=614

System Diagrams E15—Beacon Light E18—Dome Light E20—Left Front Work Light E21—Right Front Work Light E22—Left Rear Work Light

E23—Right Rear Work Light E24—Left Front Auxiliary Light E25—Right Front Auxiliary Light M5—Rear Wiper Motor

S28—Dome Light Switch S29—Door Switch X5—Load Center Harness-to-Cab Roof Harness 12-Pin Connector

X6—Load Center Harness-to-Cab Roof Harness 4-Pin Connector

CS33148,00014CB –19–31OCT06–2/2

9015 10 ,101

TM10229 (17MAR09)

9015-10-101

544J Loader (S.N. 611800— ) 032409

PN=615

System Diagrams

Cab Roof Harness (W19) Wiring Diagram TX1016088 –UN–12DEC06

WS68074,000077B –19–04DEC06–1/2

TM10229 (17MAR09)

9015-10-102

544J Loader (S.N. 611800— ) 032409

PN=616

System Diagrams E15—Beacon Light E18—Dome Light E20—Left Front Work Light E21—Right Front Work Light E22—Left Rear Work Light E23—Right Rear Work Light

E24—Left Front Auxiliary Light E25—Right Front Auxiliary Light M5—Rear Wiper Motor S28—Dome Light Switch

S29—Door Switch X5—Load Center Harness-to-Cab Roof Harness 12-Pin Connector X6—Load Center Harness-to-Cab Roof Harness 4-Pin Connector

X157—Splice G04 BLK X158—Splice G04 BLK X215—Splice P49 RED

WS68074,000077B –19–04DEC06–2/2

9015 10 ,103

TM10229 (17MAR09)

9015-10-103

544J Loader (S.N. 611800— ) 032409

PN=617

System Diagrams

Heater and Air Conditioner Harness (W20) Component Location

9015 10 ,104

B35

X52

T192383

–UN–13OCT03

B50

T192383 Heater and Air Conditioner Harness (W20) Component Location Continued on next page

TM10229 (17MAR09)

9015-10-104

WS68074,000077A –19–08JAN07–1/2

544J Loader (S.N. 611800— ) 032409

PN=618

System Diagrams B35—Freeze Control Switch (opens with freeze condition) B50—A/C Binary Pressure Switch (opens with high and low pressures)

M6—Blower Motor M7—Pressurizer Motor R3—Blower Speed Resistor X7—Load Center Harness-to-Heater and Air Conditioner Harness 3-Pin Connector

X8—Load Center Harness-to-Heater and Air Conditioner Harness 2-Pin Connector X9—Load Center Harness-to-Heater and Air Conditioner Harness 4-Pin Connector

X52—A/C Pressure Switch Jumpered Connector

WS68074,000077A –19–08JAN07–2/2

9015 10 ,105

TM10229 (17MAR09)

9015-10-105

544J Loader (S.N. 611800— ) 032409

PN=619

System Diagrams

Heater and Air Conditioner Harness (W20) Wiring Diagram T192382 –UN–06OCT03

WS68074,0000779 –19–08JAN07–1/2

TM10229 (17MAR09)

9015-10-106

544J Loader (S.N. 611800— ) 032409

PN=620

System Diagrams B35—Freeze Control Switch (opens with freeze condition) B50—A/C Binary Pressure Switch (opens with high and low pressures)

M6—Blower Motor M7—Pressurizer Motor R3—Blower Speed Resistor X7—Load Center Harness-to-Heater and Air Conditioner Harness 3-Pin Connector

X8—Load Center Harness-to-Heater and Air Conditioner Harness 2-Pin Connector X9—Load Center Harness-to-Heater and Air Conditioner Harness 4-Pin Connector

X52—A/C Pressure Switch Jumpered Connector X161—W20 Splice S1

WS68074,0000779 –19–08JAN07–2/2

9015 10 ,107

TM10229 (17MAR09)

9015-10-107

544J Loader (S.N. 611800— ) 032409

PN=621

System Diagrams

JDLink System Harnesses (W29, and W30) Component Location—If Equipped (S. N. 615706— ) TX1027269 –UN–30JUL07

A10

A9 W40

W30

X227 X216 W41

X217 X75 X76

W29

X218 X223 X219

W36

TX1027269 AA95137,0000C92 –19–14JAN08–1/2

TM10229 (17MAR09)

9015-10-108

544J Loader (S.N. 611800— ) 032409

PN=622

System Diagrams A9—GlobalTRACS Terminal (GTT) Controller A10—Machine Information Gateway

W29—GlobalTRACS Terminal (GTT) Harness W30—Machine Information Gateway (MIG) Harness W36—GlobalTRACS Terminal (GTT) Controller Ground W40—GlobalTRACS Terminal (GTT) Antenna W41—GlobalTRACS Terminal (GTT) Chassis Ground X75—Load Center Harness-to-Machine Information Gateway (MIG) Harness 4-Pin Connector X76—Load Center Harness-to-Machine Information Gateway (MIG) Harness 8-Pin Connector

X216—GlobalTRACS Terminal (GTT) Controller 70-Pin Connector X217—GlobalTRACS Terminal (GTT) Harness-to-Machine Information Gateway (MIG) Harness 10-Pin Connector X218—GlobalTRACS (GTT) Harness-to-Machine Information Gateway (MIG) Harness 4-Pin Connector X219—GT Config Tool Adapter 6-Pin Connector (RS232)

X221—Machine Information Gateway (MIG) Connector 30-Pin (L1— Y3) Connector X222—Machine Information Gateway (MIG) Connector 30-Pin (A1— K3) Connector X223—JDLink MMS Direct Connector (ethernet) X227—2-Pin Connector (not used)

9015 10 ,109

JDLink is a trademark of Deere & Company GlobalTRACS is a registered trademark of Qualcomm Incorporated

TM10229 (17MAR09)

9015-10-109

AA95137,0000C92 –19–14JAN08–2/2

544J Loader (S.N. 611800— ) 032409

PN=623

System Diagrams

GlobalTRACS Terminal (GTT) Harness (W29) Wiring Diagram—If Equipped (S.N. 615706— ) TX1026934 –UN–25JUL07

X216

M18 M19 — — — G02 M05 M06 — — — —

— — — —

G02 BLK

— — — —

W36

M30 PUR

— — — — — — —

M31 PUR M32 PUR M33 PUR

— — — —

X218 1 2

4 3

P01 M17

1 2 3 4

G01 —

57 65 66 67 68 69 70

9 10 11 12 13

X216

— G01 M44 M08 — — —

X217

58 59 60 61 62 63

6 5 4 3 2

NUMBER G01 G02 J01 J03 M05 M06 M07 M08 M17 M18 M19 M20 M21 M30

COLOR BLK BLK TAN TAN PUR PUR PUR PUR PUR PUR PUR PUR PUR PUR

K J H G F

X220

— — —

END #2 X218 W36 X217 X217 X217 X217 X217 X217 X218 X217 X217 X217 X217 —

END #1 X216 X216 X216 X216 X216 X216 X216 X216 X216 X216 X217 X217 X217 X217

NUMBER M31 M32 M33 M40 M41 M42 M43 M44 P01 R01 SHLD 1 SHLD 2 SHLD 3 SHLD 4

COLOR PUR PUR PUR PUR PUR PUR PUR PUR RED BLK BLK BLK BLK BLK

END #2 — — — X219 X219 X219 X219 X219 X218 X220 X220 X220 X220 X220

J03 M18

A B C D E F G H J K

E D C B A

— M32 M33 J03 J01

END #1 X216 X216 X216 X216 X216 X216 X216 X216 X216 X216 X216 X216 X216 X216 TX1026934

— —

54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70

M42 M07 R01 —

M30 M31 M20 M21

— — — — — M17 P01

—

M43 — — —

37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53

M40 M41

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

SIDE A R01 SIDE B SHLD 1 SHLD 2 SHLD 3 SHLD 4

M19 M21 M20 M07 M08 M06 M05 J01

X219 6

1 2 3 4 5 6

M40 M41 M42 M43 M44 —

AA95137,0000C93 GlobalTRACS Terminal (GTT) Harness Wiring Diagram

TM10229 (17MAR09)

9015-10-110

–19–01NOV07–1/2

544J Loader (S.N. 611800— ) 032409

PN=624

System Diagrams W36—GlobalTRACS Terminal (GTT) Controller Ground X216—GlobalTRACS Terminal (GTT) Controller 70-Pin Connector X217—GlobalTRACS Terminal (GTT) Harness-to-Machine Information Gateway (MIG) Harness 10-Pin Connector

X218—GlobalTRACS Terminal (GTT) Harness-to-Machine Information Gateway (MIG) Harness 4-Pin Connector

X219—GT Config Tool Adapter 6-Pin Connector (RS232)

X220—R01 BLK Splice

AA95137,0000C93 –19–01NOV07–2/2

9015 10 ,111

TM10229 (17MAR09)

9015-10-111

544J Loader (S.N. 611800— ) 032409

PN=625

System Diagrams

Machine Information Gateway (MIG) Harness (W30) Wiring Diagram—If Equipped (S.N. 615706—619284 ) TX1026935 –UN–25JUL07

END #1 X226 X226 X226 X221 X221 X221 X221 X226 X221 X221 X222 X222 X222 X222 X221 X221 X221 X221 X221 X221 X221 X221 X221 X218 X222 X222 X222 X222 X225 X225 X221 X221 X221 X221 X221 X221 X221 X221 X221

NUMBER G01A G01B G01C G01E G01F G01G G01H G01J J01 J03 M01 M02 M03 M04 M05 M06 M07 M08 M09 M10 M11 M12 M16 M17 M18 M19 M20 M21 P01 P01A P01B P01C P02 R01 R02 SHLD 1 SHLD 2 SHLD 3 SHLD 4

COLOR BLK BLK BLK BLK BLK BLK BLK BLK TAN TAN PUR PUR PUR PUR PUR PUR PUR PUR PUR PUR PUR PUR PUR PUR PUR PUR PUR PUR RED RED RED RED RED RED RED BLK BLK BLK BLK

END #2 X75 X218 X227 X226 X226 X226 X226 X224 X217 X217 X223 X223 X223 X223 X217 X217 X217 X217 X76 X76 X76 X76 X75 X75 X217 X217 X217 X217 X75 X218 X225 X225 X227 X76 X76 X224 X224 X224 X224

X221

X227

1 2

P02 G01C

X223 1 2 3 4

1 2

X76

5 6

4 3

7 8

2 1

X226 SIDE A G01 G01 G01A G01B G01C G01J SIDE B G01E G01F G01G G01H

X225 SIDE A P01 P01A SIDE B P01B P01C

M09 M10

1 2 3 4 5 6 7 8

R01 — M11 M12 R02 —

X75 1 2

4 3

1 2 3 4

P01 M17

M01 M02 M03 M04

L1 L2 L3 M1 M2 M3 N1 N2 N3 P1 P2 P3 R1 R2 R3 S1 S2 S3 T1 T2 T3 W1 W2 W3 X1 X2 X3 Y1 Y2 Y3

— M07

X222

M08 — M05 M06 — G01E — — J03 — G01F

Y X W T S

R P N M L

K J H G F

3 2

E D C B A

— — P01C — M09 — — M10 — G01G M11 J01 M16 M12 P02

Y X W T S

R P N M L

K J H G F

E D C B A

R01 R02

P01B G01H

G01A M16

A1 A2 A3 B1 B2 B3 C1 C2 C3 D1 D2 D3 E1 E2 E3 F1 F2 F3 G1 G2 G3 H1 H2 H3 J1 J2 J3 K1 K2 K3

M04 M20 M18 M03 M21 M19 M01 — — M02 — — — — — — — — — — — — — — — — — — — —

X218

X224

4 3

1 2

SIDE A G01J SHLD 1 SHLD 2 SHLD 3 SHLD 4

1 2 3 4

P01A M17 G01B —

X217

A B C D E F GH J K

A B C D E F G H J K

J03 M18 M19 M21 M20 M07 M08 M06 M05 J01

TX1026935 –19–28MAY08–1/2 Machine Information Gateway (MIG) HarnessAA95137,0000C8F (W30) Wiring Diagram

TM10229 (17MAR09)

9015-10-112

544J Loader (S.N. 611800— ) 032409

PN=626

System Diagrams X75—Load Center Harness-to-Machine Information Gateway (MIG) Harness 4-Pin Connector

X76—Load Center Harness-to-Machine Information Gateway (MIG) Harness 8-Pin Connector X217—GlobalTRACS Terminal (GTT) Harness-to-Machine Information Gateway (MIG) Harness 10-Pin Connector

X218—GlobalTRACS (GTT) Harness-to-Machine Information Gateway (MIG) Harness 4-Pin Connector X221—Machine Information Gateway (MIG) Connector 30-Pin (L1— Y3) Connector X222—Machine Information Gateway (MIG) Connector 30-Pin (A1— K3) Connector

GlobalTRACS is a registered trademark of Qualcomm Incorporated JDLink is a trademark of Deere & Company

X223—JDLink MMS Direct Connector (Ethernet) X224—G01 BLK Splice X225—P01 RED Splice X226—G01 BLK Splice X227—2-Pin Connector (not used)

AA95137,0000C8F –19–28MAY08–2/2

9015 10 ,113

TM10229 (17MAR09)

9015-10-113

544J Loader (S.N. 611800— ) 032409

PN=627

System Diagrams

Machine Information Gateway (MIG) Harness (W30) Wiring Diagram—If Equipped (S.N. 619285— ) TX1042013 –UN–05JUN08

NUMBER G01A G01B G01G G01J G02 G02A G02B J01 J03 M01 M02 M03 M04 M05 M06 M07 M08 M09 M10 M11 M12 M16 M17 M18 M19 M20 M21 P01 P01A P01B P01C P02 R02 SHLD 1 SHLD 2 SHLD 3 SHLD 4

COLOR BLK BLK BLK BLK BLK BLK BLK TAN TAN PUR PUR PUR PUR PUR PUR PUR PUR PUR PUR PUR PUR PUR PUR PUR PUR PUR PUR RED RED RED RED RED RED BLK BLK BLK BLK

END #2 X75 X218 W37 X224 X229 X229 X229 X217 X217 X223 X223 X223 X223 X217 X217 X217 X217 X76 X76 X76 X76 X75 X75 X217 X217 X217 X217 X75 X218 X225 X225 X227 X76 X224 X224 X224 X224

X221

L1 L2 L3 M1 M2 M3 N1 N2 N3 P1 P2 P3 R1 R2 R3 S1 S2 S3 T1 T2 T3 W1 W2 W3 X1 X2 X3 Y1 Y2 Y3

X223 1 2 3 4

M01 M02 M03 M04

X75 1 2

1 2 3 4

4 3

P01 M17 G01A M16

X76 X225 SIDE A P01 P01A SIDE B P01B P01C

5 6

4 3

7 8

2 1

M09 M10

1 2 3 4 5 6 7 8

R01 — M11 M12

— M07

X222

M08 — M05 M06 — G02 — — J03 — —

Y X W T S

E D C B A

— — P01C — M09 — — M10

Y X W T S

R P N M L

SHLD 1

— G01G M11 J01 M16 M12 —

K J H G F

SHLD 2 SHLD 3

E D C B A

R01 R02

SHLD 4

P01B —

W37

X229 X228 X224 X226

X224

SIDE A G01J SHLD 1 SHLD 2 SHLD 3 SHLD 4

1 2

— G02A

A1 A2 A3 B1 B2 B3 C1 C2 C3 D1 D2 D3 E1 E2 E3 F1 F2 F3 G1 G2 G3 H1 H2 H3 J1 J2 J3 K1 K2 K3

M04 M20 M18 M03 M21 M19 M01 — — M02 — — — — — — — — — — — — — — — — — — — —

X230 X229

X226

K J H G F 3 2

R02 —

SIDE A G01B G01 G01J SIDE B G01A

R P N M L

3 2

G01G

END #1 X226 X226 X221 X226 X221 X221 X222 X221 X221 X222 X222 X222 X222 X221 X221 X221 X221 X221 X221 X221 X221 X221 X218 X222 X222 X222 X222 X225 X225 X221 X221 X221 X221 X221 X221 X221 X221

1 2

— G02B

X230

X228

SIDE A G02A G02B SIDE B G02

X218 4 3

1 2

1 2 3 4

P01A M17

X217

G01B —

A B C D E F GH J K

TX1042013

A B C D E F G H J K

J03 M18 M19 M21 M20 M07 M08 M06 M05 J01

–19–28MAY08–1/2 Machine Information Gateway (MIG) Harness TF44157,0000329 (W30) Wiring Diagram

TM10229 (17MAR09)

9015-10-114

544J Loader (S.N. 611800— ) 032409

PN=628

System Diagrams W37—Machine Information Gateway (MIG) Harness Ground X75—Load Center Harness-to-Machine Information Gateway (MIG) Harness 4-Pin Connector

X76—Load Center Harness-to-Machine Information Gateway (MIG) Harness 8-Pin Connector X217—GlobalTRACS Terminal (GTT) Harness-to-Machine Information Gateway (MIG) Harness 10-Pin Connector X218—GlobalTRACS (GTT) Harness-to-Machine Information Gateway (MIG) Harness 4-Pin Connector

GlobalTRACS is a registered trademark of Qualcomm Incorporated JDLink is a trademark of Deere & Company

X224—G01 BLK Splice X225—P01 RED Splice X226—G01 BLK Splice X228—2-Pin Connector (not used) X229—2-Pin Connector (not used) X230—G02 BLK Splice

TF44157,0000329 –19–28MAY08–2/2

9015 10 ,115

TM10229 (17MAR09)

9015-10-115

544J Loader (S.N. 611800— ) 032409

PN=629

System Diagrams

Radio Harness (W34) Component Location

T192814

–UN–12SEP03

9015 10 ,116

Harness Component Location Continued on next page

TM10229 (17MAR09)

9015-10-116

CS33148,00014CF –19–31OCT06–1/2

544J Loader (S.N. 611800— ) 032409

PN=630

System Diagrams A5—12 V Radio B43—Right Speaker B42—Left Speaker

G7—24 V to 12 V Voltage Converter

X34—Load Center Harness to Radio Harness Connector

W1—Antenna

CS33148,00014CF –19–31OCT06–2/2

9015 10 ,117

TM10229 (17MAR09)

9015-10-117

544J Loader (S.N. 611800— ) 032409

PN=631

System Diagrams

Radio Harness (W34) Wiring Diagram TX1015439 –UN–21DEC06

WS68074,0000778 –19–18DEC06–1/2

TM10229 (17MAR09)

9015-10-118

544J Loader (S.N. 611800— ) 032409

PN=632

System Diagrams A5—12V Radio B42—Left Speaker B43—Right Speaker

G7—24V to 12V Voltage Converter

X34—Load Center Harness-to-Radio Harness Connector

X165—Splice P81 RED

WS68074,0000778 –19–18DEC06–2/2

9015 10 ,119

TM10229 (17MAR09)

9015-10-119

544J Loader (S.N. 611800— ) 032409

PN=633

System Diagrams

9015 10 ,120

TM10229 (17MAR09)

9015-10-120

544J Loader (S.N. 611800— ) 032409

PN=634

Group 15

Sub-System Diagnostics Starting and Charging Circuit Theory of Operation TX1023320 –19–14MAY07

WS68074,000119E –19–17MAY07–1/3

TM10229 (17MAR09)

9015-15-1

544J Loader (S.N. 611800— ) 032409

PN=635

Sub-System Diagnostics • For more information concerning the CAN, see Controller Area Network (CAN) Theory of Operation. (Group 9015-15.)

Unswitched power is supplied to the following components: • Key Switch (S1) • Starter Motor (M1), • Start Relay (K3) • Alternator (G4) • Ignition Relay (K4) Starting Circuit—Turning key switch (S1) to the START position, sends current out key switch terminal ST to terminal E1 of connector X72 on the engine control unit (ECU) (A1). When the ECU detects current at terminal E1, and if no active diagnostic trouble codes (DTC) exist, the ECU will send current out terminal K4 of ECU connector X72, through fuse (F41) [located inside vehicle electrical center (VEC) (G8)], then to the coil of start relay (K3), energizing the relay. 9015 15 2

With the start relay energized, unswitched current from the battery flows to the starter motor solenoid, engaging the starter motor. Unswitched current from the battery also flows to terminal F1 of ECU connector X72 to inform the ECU that current to the coil of the starter motor solenoid is present. At the same time, current from fuse (F41) flows to terminal C2 of connector X40 on the flex load controller (FLC) (A2). The FLC then transmits a signal across the controller area network (CAN) to the transmission control unit (TCU) to inform the TCU that the engine is being started. When the TCU detects this signal, the TCU automatically puts the transmission in neutral, regardless of the position of the transmission control lever (TCL) or position of the shift switch (if equipped with joystick pilot controller). • For more information concerning the FLC, see Flex Load Controller (FLC) Circuit Theory of Operation. (Group 9015-15.) • For more information concerning the TCU, see Transmission Control Unit (TCU) Circuit Theory of Operation. (Group 9015-15.)

As the starter motor cranks the engine, the crankshaft position sensor (B4) sends a signal representing engine rpm to the ECU. When the ECU detects this signal, it knows the crankshaft is turning. The ECU then sends a signal to the high pressure fuel pump solenoid (Y8) to provide high pressure fuel to the electronic fuel injectors. At the same time, the ECU sends current to the electronic fuel injectors to start the fuel injection process, and thus start the engine. For more information on the ECU, high pressure fuel pump solenoid, and electronic fuel injectors, see Engine Control Unit (ECU) Circuit Theory of Operation. (Group 9015-15.) Diodes (V3 and V4) protect the start circuit by suppressing voltage spikes caused when the relays de-energize. Diode (V1) suppresses voltage spikes caused when the starter motor solenoid coil de-energizes. Charging Circuit—Alternator (G4) provides power to all machine circuits and charges the batteries when the engine is running. Terminal B+ of the alternator is connected to battery positive (+) at all times. When key switch (S1) is turned to the ON position, current from key switch terminal IGN flows through diode (V7) (located inside the VEC) to the coil of ignition relay (K4), energizing the relay. With the ignition relay energized, unswitched current from the battery is allowed to flow through fuse (F53) and diode (V5) (both located in the VEC) to the D+ (3) terminal of the alternator. The current then flows through the alternator field windings causing excitation of the windings. For more information, see Alternator Test Procedure. (Group 9015-20.) Diode (V7) prevents the ignition relay from energizing if the polarity on the system is reversed (batteries or starter installed incorrectly).

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TM10229 (17MAR09)

9015-15-2

WS68074,000119E –19–17MAY07–2/3

544J Loader (S.N. 611800— ) 032409

PN=636

Sub-System Diagnostics Diode (V5) prevents current feedback from the alternator if the alternator circuitry is improperly connected or if there is a major malfunction.

WS68074,000119E –19–17MAY07–3/3

9015 15 3

TM10229 (17MAR09)

9015-15-3

544J Loader (S.N. 611800— ) 032409

PN=637

Sub-System Diagnostics

Controller Area Network (CAN) Theory of Operation TX1016275 –19–20DEC06

Controller Area Network (CAN) Circuit Schematic OUO1010,000097C –19–26JAN07–1/2

TM10229 (17MAR09)

9015-15-4

544J Loader (S.N. 611800— ) 032409

PN=638

Sub-System Diagnostics This machine uses a controller area network (CAN) that allows the following devices to communicate with each other: • CAN Monitor Unit (CMU) • Engine Control Unit (ECU) • Transmission Control Unit (TCU) • Flex Load Controller (FLC) • Sealed Switch Module (SSM) Operations and functions of these individual devices are covered separately. • See CAN Monitor Unit (CMU) Circuit Theory of Operation. (Group 9015-15.) • See Engine Control Unit (ECU) Circuit Theory of Operation. (Group 9015-15.) • See Transmission Control Unit (TCU) Circuit Theory of Operation. (Group 9015-15.) • See Flex Load Controller (FLC) Circuit Theory of Operation. (Group 9015-15.) • See Switch Pad. (Operator’s Manual.) The CAN consists of two buses, CAN High and CAN Low. These two buses (wires) carry signals opposite to each other to overcome noise interference and minimize communication errors. The high and low buses, along with a ground wire, are weaved together forming what is called a twisted triple. The twisted triple provides an additional method of reducing

interference and thus help the devices communicate with minimal errors. The CAN is an arbitration based system. This means that a low priority message will always allow a high priority message to go first. Each CAN device checks to see if the bus is idle before it transmits a signal. Whichever device gets on the bus first will be 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 lowest ID will have higher priority to access the bus. The device that loses arbitration will immediately retransmit its signal when the device with the higher priority has completed its transmission. The CAN also includes the following components: • CAN Termination Node (R1) • CAN Termination Node (R2) • Service ADVISOR Diagnostic Connector (X1) The termination nodes are 120 ohm resistors that help prevent signal errors. These resistors are located at opposite ends of the CAN bus. The Service ADVISOR diagnostic connector provides an interface for connecting diagnostic equipment such as a laptop. See Service ADVISOR Connection Procedure. (Group 9015-20.)

Service ADVISOR is a trademark of Deere & Company

TM10229 (17MAR09)

OUO1010,000097C –19–26JAN07–2/2

9015-15-5

544J Loader (S.N. 611800— ) 032409

PN=639

9015 15 5

Sub-System Diagnostics

Engine Control Unit (ECU) Circuit Theory of Operation TX1056408 –19–11MAR09

Engine Control Unit (ECU) Circuit Schematic WS68074,0001183 –19–25FEB09–1/6

TM10229 (17MAR09)

9015-15-6

544J Loader (S.N. 611800— ) 032409

PN=640

Sub-System Diagnostics Engine Control Unit (ECU) (A1)— For component location, see Engine Harness (W6) Component Location. (Group 9015-10.) Unswitched battery power is available at terminals L1, L4, M1, and M4 of ECU connector X72, through fuse (F03). When key switch (S1) is turned to the ON or START position, current from fuse (F10) flows to terminal B2 of ECU connector X72, causing the ECU to power up. The ECU uses information received from various sensors to determine the correct amount of fuel and injection timing based on load, temperatures, and operator input. Some of the data calculated by the ECU is transmitted across the controller area network (CAN) to other controllers. For more information concerning the CAN, see Controller Area Network (CAN) Theory of Operation. (Group 9015-15.) The ECU also detects malfunctions in the sensors and sensor circuits, or abnormal operating conditions. When this happens, the ECU will generate a diagnostic trouble code (DTC). For a complete list of engine diagnostic trouble codes, See Diagnostic Trouble Codes (DTC) Quick Reference List. (Group 9015-20.) Whenever an engine DTC occurs, the information is captured or recorded. The information generated is called a Snapshot. The Snapshot information is categorized in two types; Snapshot Capture and Snapshot Recording. For more information, see Snapshot Information. (CTM502.) The ECU contains a barometric air pressure (BAP) sensor that is located inside the ECU. This sensor is used to determine the pressure of the ambient air at the mounting location of the ECU. The BAP sensor helps the ECU determine the air density for calculating the correct air/fuel ratio. This sensor cannot be repaired or replaced without replacing the entire ECU. The ECU also contains a temperature sensor that is located inside the ECU. This sensor is used to

determine the internal temperature of the ECU. If the ECU temperature exceeds specification, the ECU will limit the speed of the engine in an attempt to protect the ECU from permanent damage. This sensor cannot be repaired or replaced without replacing the entire ECU. Engine Coolant Temperature (ECT) Sensor (B1)— For component location, see Engine Harness (W6) Component Location. (Group 9015-10.) The ECU senses resistance from the engine coolant temperature sensor at terminals D2 and C4 of ECU connector X71. The ECU transmits the engine coolant temperature information across the CAN to the CAN monitor unit (CMU) (H2). The CMU uses this information to determine the position of the needle on the engine coolant temperature gauge and moves the needle accordingly. When the coolant temperature reaches 113—115°C (234.4—239°F), the indicator light on the coolant temperature gauge will flash. When the coolant temperature becomes greater than 115°C (239°F), both the indicator light on the coolant temperature gauge and the STOP indicator will flash. The audible alarm will also activate. The ECU uses the signal from the engine coolant temperature sensor to monitor the coolant temperature and apply derate conditions when needed. If the engine coolant temperature reaches 113°C (234.4°F), the ECU will derate fuel by 80% of full power. If the coolant temperature becomes greater than 115°C (239°F), the ECU will derate fuel by 40% of full power. The fuel delivery will recover to full power when the engine coolant temperature drops below the derate threshold temperature of 110°C (230°F). If the ECU senses a value that is out of valid range, the ECU will use the default temperature of 90°C (194°F). High ECT engine protection is disabled. For information on engine deration, see OEM Engines - Derate Specifications. (CTM502.)

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TM10229 (17MAR09)

9015-15-7

WS68074,0001183 –19–25FEB09–2/6

544J Loader (S.N. 611800— ) 032409

PN=641

9015 15 7

Sub-System Diagnostics The engine coolant temperature is also used by the FLC in calculating proportional fan speed. For more information on the proportional fan circuit, see Flex Load Controller (FLC) Circuit Theory of Operation. (Group 9015-15.)

For information on how speed sensors operate, see Measuring Speed. (CTM502.)

For more information on the monitor warning indicators and gauges, see Monitor Panel Functions. (Operator’s Manual.)

Fuel Temperature Sensor (B5)— For component location, see Engine Harness (W6) Component Location. (Group 9015-10.)

For information on how temperature sensors operate, see Measuring Temperature. (CTM502.)

The ECU senses resistance from the fuel temperature sensor at terminals D2 and F4 of ECU connector X71. The ECU transmits the signal representing fuel temperature across the CAN to the CMU and the FLC.

For sensor specifications, see Electrical Component Specifications. (Group 9015-20.)

For information on how speed sensors operate, see Measuring Speed. (CTM502.)

The ECU uses the signal from the fuel temperature sensor to monitor the fuel temperature and apply derate conditions when needed. If the ECU senses fuel temperature above 100°C (220°F), the ECU will derate the fuel delivery by 80% of full power. The fuel delivery will recover to full power when the fuel temperature drops below the derate threshold temperature. If the ECU senses a value that is out of valid range, the ECU will use the default temperature of 40°C (104°F). High fuel temperature engine protection is disabled. For information on engine deration, see OEM Engines - Derate Specifications. (CTM502.)

For sensor specifications, see Electrical Component Specifications. (Group 9015-20.)

For information on how temperature sensors operate, see Measuring Temperature. (CTM502.)

Crankshaft Position Sensor (B4)— For component location, see Engine Harness (W6) Component Location. (Group 9015-10.)

For sensor specifications, see Electrical Component Specifications. (Group 9015-20.)

Camshaft Position Sensor (B3)— For component location, see Engine Harness (W6) Component Location. (Group 9015-10.)

9015 15 8

For sensor specifications, see Electrical Component Specifications. (Group 9015-20.)

The ECU detects the signal from the camshaft position sensor at terminals A4 and E4 of ECU connector X71. The ECU uses this signal to determine which cylinder is approaching top dead center and to calculate camshaft speed.

The ECU detects the signal from the crankshaft position sensor at terminals B4 and D4 of ECU connector X71. The ECU uses this signal to determine when the number one cylinder is at top dead center. The ECU also uses this signal to calculate engine (crankshaft) speed and sends this information across the CAN to the CMU, where it appears in the monitor display window as engine rpm.

Manifold Air Temperature (MAT) Sensor (B7)—The ECU senses resistance from the MAT sensor at terminals C2 and D2 of ECU connector X71. The ECU transmits the signal representing manifold air temperature across the CAN to the CMU and the FLC. The MAT signal is used by the FLC in calculating proportional fan speed. For more information on the proportional fan circuit, see Flex Load Controller (FLC) Circuit Theory of Operation. (Group 9015-15.)

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TM10229 (17MAR09)

9015-15-8

WS68074,0001183 –19–25FEB09–3/6

544J Loader (S.N. 611800— ) 032409

PN=642

Sub-System Diagnostics The manifold air temperature can cause an engine fuel derate condition if it reaches 88°C (190°F). The ECU will derate fuel 2% per minute up to 20%. If the manifold air temperature falls below the derate temperature, the ECU will recovery fuel delivery 2% per minute until power is fully restored. For information on engine deration, see OEM Engines - Derate Specifications. (CTM502.) For information on how temperature sensors operate, see Measuring Temperature. (CTM502.) For sensor specifications, see electrical component specifications. (Group 9015-20.) Ambient Air Temperature Sensor (B10)—The ECU senses resistance from the ambient air temperature sensor at terminals B4 and C3 of ECU connector X72. The ECU transmits the signal representing ambient air temperature across the CAN to the CMU and the FLC. The FLC uses the ambient air temperature to calculate proportional fan speed. For more information on the proportional fan circuit, see Flex Load Controller (FLC) Circuit Theory of Operation. (Group 9015-15.) For information on how temperature sensors operate, see Measuring Temperature. (CTM502.) For sensor specifications, see electrical component specifications. (Group 9015-20.) Analog Throttle Position Sensor (B14)—For component location, see Load Center Harness (W3) Component Location. (Group 9015-10.) The ECU supplies a 5-volt reference voltage to the analog throttle position sensor at terminal A3 of ECU connector X72. The ECU provides a ground for the position sensor at terminal D2 of ECU connector X71. The analog throttle position sensor sends an analog signal representing throttle request to terminal A4 of ECU connector X72.

Engine Air Filter Restriction Switch (B19)—For component location, see Engine Harness (W6) Component Location. (Group 9015-10.) The engine air filter restriction switch is a normally open switch that closes when the engine air filter becomes restricted. When this happens, current from fuse (F11) is applied to terminal F2 of ECU connector X72. The ECU transmits the signal representing status of the air filter restriction switch across the CAN to the CMU, causing the engine air filter restriction light to come on. For more information on CMU warning indicators, see Monitor Panel Functions. (Operator’s Manual.) Engine Oil Pressure Sensor (B23)— For component location, see Engine Harness (W6) Component Location. (Group 9015-10.) The ECU supplies a 5-volt reference voltage to the engine oil pressure sensor at terminal F3 of ECU connector X71. The ECU provides a ground for the engine oil pressure sensor at terminal D2 of ECU connector X71. The engine oil pressure sensor sends an analog signal representing engine oil pressure to terminal A3 of ECU connector X71. The ECU transmits the signal representing engine oil pressure information across the CAN to the CAN monitor unit (CMU) (H2) and the flex load controller (FLC) (A2). The CMU uses this information to determine position of the needle on the engine oil pressure gauge and moves the needle accordingly. It also activates a warning indicator when oil pressure is too low. See Monitor Panel Functions. (Operator’s Manual.) The ECU uses the engine oil pressure sensor to monitor the oil pressure and apply derate conditions when needed. If the oil pressure is below threshold pressure, the ECU will derate the engine fuel delivery by as indicated in the following table:

The ECU transmits the signal representing throttle position across the CAN to the CAN monitor unit (CMU) (H2) and the flex load controller (FLC) (A2).

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TM10229 (17MAR09)

9015-15-9

WS68074,0001183 –19–25FEB09–4/6

544J Loader (S.N. 611800— ) 032409

PN=643

9015 15 9

Sub-System Diagnostics Oil Pressure

Engine Speed

Engine Derate

1 kPa (0.01 bar) (0.15 psi)

Less Than 700 rpm

40% of full power

146 kPa (1.46 bar) (21.2 psi)

More Than 700 rpm

40% of full power

202 kPa (2.02 bar) (29.3 psi)

More Than 700 rpm

80% of full power

284 kPa (2.84 bar) (41.2 psi)

More Than 2000 rpm

40% of full power

311 kPa (3.11 bar) (45.1 psi)

More Than 2000 rpm

80% of full power

If the ECU senses a value that is out of valid range, the ECU will use the default pressure of 500 kPa (5 bar) (72.5 psi). Low oil pressure engine protection is disabled. For information on engine deration, see OEM Engines - Derate Specifications. (CTM502.) For information on how pressure sensors operate, see Measuring Pressure. (CTM502.) 9015 15 10

For sensor specifications, see Electrical Component Specifications. (Group 9015-20.) Water In Fuel (WIF) Sensor (B48)— For component location, see Engine Harness (W6) Component Location. (Group 9015-10.) The WIF sensor measures the amount of resistance of the fluid in the water separator bowl. Since water is a better conductor of electricity than fuel, and if water is present in the separator bowl, the ECU senses a resistance drop between terminals B2 and D2 of ECU connector X71. If the ECU senses low resistance indicating water in fuel, the ECU will derate fuel delivery by 50% of full power. The fuel delivery will recover to full power when the problem is corrected. For information on engine deration, see OEM Engines - Derate Specifications. (CTM502.)

For sensor specifications, see Electrical Component Specifications. (Group 9015-20.) Fuel Rail Pressure Sensor (B49)— For component location, see Engine Harness (W6) Component Location. (Group 9015-10.) The ECU supplies a 5-volt reference voltage and ground to the fuel rail pressure sensor at terminals E2 and D3 of ECU connector X71. The fuel rail pressure sensor sends an analog signal representing fuel rail pressure to terminal E3 of ECU connector X71. The ECU uses this signal to monitor the high pressure side of the fuel system and apply derate conditions when needed. If the ECU senses a value that is out of valid range, the ECU will derate fuel delivery by 50%. The fuel delivery will recover to full power when the problem is corrected. For information on engine deration, see OEM Engines - Derate Specifications. (CTM502.) For information on how pressure sensors operate, see Measuring Pressure. (CTM502.) For sensor specifications, see Electrical Component Specifications. (Group 9015-20.) High Pressure Fuel Pump Solenoid (Y8)— For component location, see Engine Harness (W6) Component Location. (Group 9015-10.) The high pressure fuel pump solenoid regulates delivery of fuel to the high pressure common rail (HPCR). The ECU sends a signal out terminals H1 and H2 of ECU connector X71 to the pump control solenoid. When the solenoid is energized, fuel is allowed to discharge from the fuel outlet on the high-pressure fuel pump to the HPCR. For more information, see High Pressure Fuel Pump Operation. (CTM502.)

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9015-15-10

WS68074,0001183 –19–25FEB09–5/6

544J Loader (S.N. 611800— ) 032409

PN=644

Sub-System Diagnostics Electronic Injectors (Y21—Y24)—The ECU controls the injection timing and the amount of fuel injected by energizing and de-energizing the electronic injectors (Y21—Y24). For more information on the electronic injectors, see Electronic Injector (EI) Operation. (CTM502.)

Starting Circuit—The ECU provides an interlock for the engine start circuit at terminals E1 and K4 of ECU connector X72. For more information on the starting circuit, see Starting and Charging Circuit Theory of Operation. (Group 9015-15.)

WS68074,0001183 –19–25FEB09–6/6

9015 15 11

TM10229 (17MAR09)

9015-15-11

544J Loader (S.N. 611800— ) 032409

PN=645

Sub-System Diagnostics

Flex Load Controller (FLC) Circuit Theory of Operation TX1022564 –19–26APR07

Flex Load Controller (FLC) Circuit Schematic (1 of 4) (Power, Ground, SSM, Secondary Steering, a WS68074,000116B –19–24MAY07–1/16

TM10229 (17MAR09)

9015-15-12

544J Loader (S.N. 611800— ) 032409

PN=646

Sub-System Diagnostics Flex Load Controller (FLC) (A2)—The FLC controls and monitors the machine electrical systems and vehicle operations. The FLC also provides diagnostics in the form of diagnostic trouble codes (DTC) for the systems it controls. For a list of flex load controller diagnostic trouble codes, see Diagnostic Trouble Codes (DTC) Quick Reference List. (Group 9015-20.) For information on the operation of the FLC output drivers, see Flex Load Controller (FLC) Fault Exceptions. (Group 9015-20.) The FLC uses the controller area network (CAN) to communicate with the other controllers. For more information on the CAN, see Controller Area Network (CAN) Theory of Operation. (Group 9015-15.) The FLC provides outputs that control various solenoids, which in turn, control many of the hydraulic functions on the machine. The operator activates many of these functions using the sealed switch module (SSM) (A6). The SSM is a device that receives operator input through momentary switches (buttons). The SSM transmits the button selection across the controller area network (CAN) to the CAN monitor unit (CMU) and FLC. The CMU and FLC interpret the CAN signals and determine if the input is valid or not. If the input is not valid for the machine options available or machine state, the input is ignored. If the input is valid, the appropriate function is activated. The SSM then receives confirmation that the function is activated and causes the appropriate LED on the switch button to come on to indicate that the function has been activated. For more information on the SSM, see Switch Pad. (Operator’s Manual.) For more information on the CMU, see CAN Monitor Unit (CMU) Circuit Theory of Operation. (Group 9015-15.) The FLC controls the following systems:

• Ride Control • Pilot Enable • Pin Disconnect • Reverse Fan • Proportional Fan • Return-to-Carry • Boom Height Kickout • Return-to-Dig • Turn Signal Lights • 4-Way Flashers • Drive Lights • Marker/Tail Lights • Brake Lights • Work Lights • Beacon Light • Air Conditioning • Front Wiper Motor • Front Washer Pump • Rear Wiper Motor • Rear Washer Pump The FLC receives unswitched battery power from fuse (F21) at terminal L1 of FLC connector X41. Ground is provided at terminals L2 and M2 of FLC connector X41, and terminals H1 and H2 of FLC connector X42. Turning the key switch to the ON position sends current to the FLC at the following terminals/connectors: • G3, G4, H3, and H4 of connector X40 • L3, L4, M3, and M4 of connector X41 • G1, G2, H3, and H4 of connector X42 With the key switch in the ON position, current also flows through fuse (F15) to terminal M1 of FLC connector X41. Current also flows through fuse (F13) to terminal 1 of the SSM. Start Signal—The FLC determines if engine is being cranked by sensing the signal that energizes the start relay (K3) at terminal C1 of FLC connector X40. This signal comes from the ECU when the key switch is turned to the START position. For more information on the starting circuit, see Starting and Charging Circuit Theory of Operation. (Group 9015-15.)

• Secondary Steering

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WS68074,000116B –19–24MAY07–2/16

544J Loader (S.N. 611800— ) 032409

PN=647

9015 15 13

Sub-System Diagnostics 12-Volt Center Tap—The FLC measures the battery voltage of one battery at terminal F1 of FLC connector X40. The FLC transmits the single battery voltage, along with the 24-volt system voltage, across the CAN to the CAN monitor unit (CMU). The CMU uses the separate voltage values to calculate the voltage level of the two batteries. These values can be read in the battery monitor menu of the CMU menu structure. For more information on the CMU menu structure, See CAN Monitor Unit (CMU) Menu Structure—Service Mode. (Group 9015-20.) Service Brake Pressure Sensor (B27)—The FLC supplies a 5-volt reference voltage to the service brake pressure sensor at terminal K4 of FLC connector X41. The FLC provides a ground for the service brake pressure sensor at terminal K3 of FLC connector X41.

9015 15 14

The service brake pressure sensor sends an analog signal representing brake pressure to terminal G1 of FLC connector X41. The FLC then transmits the information representing service brake pressure across the CAN to the CAN monitor unit (CMU). When the sensor signal reaches a specified voltage, the CMU will cause the brake pressure light to come on. For more information on the monitor warning indicators and gauges, see Monitor Panel Functions. (Operator’s Manual.) For service brake pressure sensor specifications, see Electrical Component Specifications. (Group 9015-20.) Hydraulic Oil Filter Restriction Switch (B21)—The hydraulic oil filter restriction switch is a normally open switch that closes when hydraulic oil differential pressure at the hydraulic oil filter is greater than specification. For hydraulic oil filter restriction switch specifications, see Electrical Component Specifications. (Group 9015-20.) When closed, the switch provides a ground to terminal F2 of FLC connector X41. When the FLC detects this ground, it transmits the signal representing status of the hydraulic oil filter restriction switch across the CAN to the CAN monitor unit (CMU), causing the hydraulic

oil filter restriction light to come on. For more information on the monitor warning indicators and gauges, see Monitor Panel Functions. (Operator’s Manual.) Secondary Steering—The secondary steering circuit consists of steering system pressure switch (B25) and secondary steering pump motor (M8). The steering system pressure switch is a normally open switch that closes when normal operating steering system pressure is present. The closed switch sends current from fuse (F23) to terminal C1 of FLC connector X41. If a loss of steering system pressure occurs, the steering system pressure switch will open, stopping current flow to terminal C1. If this occurs while the engine is running, the FLC will send current out terminal F1 of FLC connector X42, activating the secondary steering pump motor. At the same time, the FLC will transmit a message across the CAN to the CAN monitor unit (CMU), causing the secondary steering light to come on. For more information on the monitor warning indicators and gauges, see Monitor Panel Functions. (Operator’s Manual.) For steering system pressure switch specifications, see Electrical Component Specifications. (Group 9015-20.) Hydraulic System Pressure Sensor (B8)—The FLC uses the hydraulic system pressure sensor to monitor the hydraulic pump output pressure and lower engine rpm as required by the spin control setting. The FLC supplies a 5-volt reference voltage to the hydraulic system pressure sensor at terminal K4 of FLC connector X41. The FLC provides a ground for the hydraulic system pressure sensor at terminal K3 of FLC connector X41. The hydraulic system pressure sensor sends an analog signal representing hydraulic system pressure to terminal D3 of FLC connector X41. For more information on the hydraulic system pressure sensor, see Electrical Component Specifications. (Group 9015-20.)

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WS68074,000116B –19–24MAY07–3/16

544J Loader (S.N. 611800— ) 032409

PN=648

Sub-System Diagnostics Spin control has four settings which can be selected by pressing the spin control switch on the SSM. Once the hydraulic system pressure reaches a predetermined value (determined by the setting), the FLC transmits a requested engine speed across the CAN to the ECU. The reduced engine speed reduces rim pulling force at the wheel rims, allowing the boom to lift easier. The required hydraulic system pressure and engine rpm for each setting are: Setting

Hydraulic System Pressure

Engine Speed

22 753 kPa 227.5 bar 3300 psi

1900 rpm

22 753 kPa 227.5 bar 3300 psi

1800 rpm

21 718 kPa 217.2 bar 3150 psi

1700 rpm

19 994 kPa 200 bar 2900 psi

1600 rpm

9015 15 15

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9015-15-15

WS68074,000116B –19–24MAY07–4/16

544J Loader (S.N. 611800— ) 032409

PN=649

Sub-System Diagnostics TX1022881 –19–09MAY07

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9015-15-16

WS68074,000116B –19–24MAY07–5/16

544J Loader (S.N. 611800— ) 032409

PN=650

Sub-System Diagnostics Hydraulic Oil Temperature Sensor (B15) (Spin Control Equipped Machines Only)—The FLC senses resistance from the hydraulic oil temperature sensor at terminal K2 of FLC connector X41 and terminal E4 of FLC connector X42. The FLC transmits the signal representing hydraulic oil temperature across the CAN to the CAN monitor unit (CMU). The CMU uses this information to determine position of the needle on the hydraulic oil temperature gauge and moves the needle accordingly. It also activates a warning light when oil temperature becomes too high. For more information on the monitor warning indicators and gauges, see Monitor Panel Functions. (Operator’s Manual.) The hydraulic oil temperature is also used in calculating proportional fan speed. For hydraulic oil temperature sensor specifications, see Electrical Component Specifications. (Group 9015-20.) Ride Control—The ride control circuit consists of the following components: • Ride Control Pressure Switch (B41) • Ride Control Boom Solenoid (Y17) • Ride Control On/Off Solenoid (Y18) • Ride Control On/Off Solenoid (Y34) When the ride control system is in manual mode or when active in auto mode, the FLC sends current out terminal G4 of FLC connector X41 to ride control on/off solenoids (Y18 and Y34). The FLC uses ignition power from VEC circuit B16 RED, available at terminals L3 and M3 of FLC connector X41, to provide the current to these solenoids. When the key switch is in the ON or START position, power from terminal E4 of FLC connector X41 is available at the normally open ride control pressure switch (B41). When bucket dump is actuated, the ride control pressure switch closes, allowing current from terminal E4 to flow to the ride control boom solenoid, energizing the solenoid. With the ride control boom solenoid energized, the oil in the boom cylinder head end cannot flow into the accumulator.

To enable manual mode, push the ride control switch on the SSM until only one LED is on. To enable auto mode, push the ride control switch again so two LEDs are on. While in auto mode, ride control will remain off until machine ground speed is at or above 6 km/h (3.7 MPH). For more information on the ride control system, see Ride Control Operation. (Group 9025-05.) Pilot Enable/Boom Down—When the key switch is in the ON position and the engine is running, the hydraulic pilot controls can be enabled or disabled by pushing the pilot enable/boom down switch on the SSM. When the switch LED is on, the hydraulic pilot controls are enabled allowing the hydraulic functions to be actuated. When the hydraulic pilot controls are enabled, the FLC sends current out terminal E1 at FLC connector X42 to pilot enable solenoid (Y14) and accumulator solenoid (Y15), energizing both solenoids. The FLC uses ignition power from VEC circuit B17 RED, available at terminals G1 and G2 of FLC connector X42, to provide the current to these solenoids. Turning the key switch to OFF to stop the engine will lock the hydraulic pilot control. When the engine is off, the boom down hydraulic function can be temporarily actuated to lower the boom. To do this, the key switch must be in the ON position and the pilot enable/boom down switch held down while operating the pilot controller. Doing this energizes both the pilot enable solenoid and the accumulator solenoid, allowing oil pressure from the boom down accumulators to be used for pilot control. For more information, see Pressure Reducing Valve Operation. (Group 9025-05.) Pilot Controller Detents—The pilot controller (A4) controls the boom and bucket hydraulic functions. The pilot controller contains electromagnetic detent coils for the boom height kickout, return-to-dig, and return-to-carry. The pilot enable must be on before any of the pilot controller detents will become active.

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TM10229 (17MAR09)

9015-15-17

WS68074,000116B –19–24MAY07–6/16

544J Loader (S.N. 611800— ) 032409

PN=651

9015 15 17

Sub-System Diagnostics Return-to-Dig (RTD)—Machines equipped with the Z-bar linkage use a magnetic position switch to detect return to dig position. Machines equipped with the Powerllel linkage use an analog sensor to detect return-to-dig position. RTD (Z-Bar Linkage): For Z-Bar linkage machines, the return-to-dig function is enabled (left LED on) by pushing the return-to-dig enable switch on the sealed switch module (SSM). If no return-to-dig switch LED’s are on, the return-to-dig is disabled. The right LED is used for Powerllel linkage only. The return-to-dig switch (S17) is a metal sensing proximity switch mounted at the rod end of the bucket cylinder. When the return-to-dig function is enabled and the bucket is in the dump position, the return-to-dig switch senses a metal bar mounted to the Z-bar linkage. The metal bar, which is adjustable, causes the switch to close, allowing current from fuse (F11) to flow to terminal C2 of FLC connector X41. 9015 15 18

When the FLC detects current at terminal C2, the FLC will send current out terminal H4 of FLC connector X41 to the return-to-dig detent coil, energizing the coil. The FLC uses ignition power from VEC circuit B15 RED, available at terminals L4 and M4 of FLC connector X41, to provide the current to the return-to-dig detent coil. When the pilot controller lever is moved fully to the bucket rollback position, the magnetic field created by the return-to-dig detent coil will hold the pilot controller in that position. The pilot controller will stay in that position until the return-to-dig switch no longer senses the metal rod. The FLC will then stop current flow to the return-to-dig detent coil, allowing the pilot controller to return to neutral. To set the return-to-dig position for machines with Z-Bar linkage, see Return-To-Dig Adjustment—Z-Bar Linkage. (Group 9015-20.) RTD (Powerllel Linkage): For Powerllel linkage machines, there are two set points. When the left LED

of the return-to-dig enable switch is on, the first set point is enabled. When the right LED is on, the second position set point is enabled. If no LED’s are on, the return-to-dig is disabled. The analog RTD position sensor (B37) provides the FLC with a variable voltage that corresponds to the bucket position. The FLC supplies a 5-volt reference voltage to the analog RTD position sensor at terminal K1 of FLC connector X41. The FLC provides a ground for the analog RTD position sensor at terminal K2 of FLC connector X41. The analog RTD position sensor sends an analog signal representing bucket position to terminal C3 of FLC connector X41. When return-to-dig is enabled and the FLC senses the bucket is in a dump position, the FLC sends current out terminal H4 of FLC connector X41 to the return-to-dig detent coil, energizing the coil. The FLC uses ignition power from VEC circuit B15 RED, available at terminals L4 and M4 of FLC connector X41, to provide the current to the return-to-dig detent coil. When the pilot controller lever is moved fully to the bucket rollback position, the magnetic field created by the return-to-dig detent coil will hold the pilot controller in that position. The pilot controller will stay in that position until the FLC senses that the analog signal from the RTD position sensor has reached the programmed set point. The FLC will then stop current flow to the return-to-dig detent coil, allowing the pilot controller to return to neutral. To set the return-to-dig position for machines with Powerllel linkage, see Return-To-Dig Adjustment— Powerllel Linkage. (Group 9015-20.) Boom Height Kickout (BHKO)/Return-to-Carry (RTC)—The BHKO/RTC sensor (B45) provides the FLC with a variable voltage that corresponds to the boom position.

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TM10229 (17MAR09)

9015-15-18

WS68074,000116B –19–24MAY07–7/16

544J Loader (S.N. 611800— ) 032409

PN=652

Sub-System Diagnostics The FLC supplies a 5-volt reference voltage to the BHKO/RTC sensor at terminal K1 of FLC connector X41. The FLC provides a ground for the BHKO/RTC sensor at terminal K2 of FLC connector X41. The BHKO/RTC sensor sends an analog signal representing boom position to terminal E3 of FLC connector X41. Boom Height Kickout: The boom height kickout function is enabled (switch LED on) by pushing the boom height kickout switch on the SSM. The FLC uses the analog BHKO/RTC sensor to detect the position of the boom. If the position is lower than the preset kickout position, the FLC will send current out terminal A2 of FLC connector X42 to the boom height kickout detent coil, energizing the coil. The FLC uses ignition power from VEC circuit B15 RED, available at terminals H3 and H4 of FLC connector X42, to provide the current to the boom height kickout detent coil. When the pilot controller lever is moved fully to the boom raise position, the magnetic field created by the boom height kickout detent coil will hold the pilot controller in that position. The pilot controller will stay in that position until the boom reaches the preset position as detected by the BHKO/RTC sensor. The FLC will then stop current flow to the boom height kickout detent coil, allowing the pilot controller to return to neutral. To set the boom height kickout position, see Boom Height Kickout/Return-to-Carry Adjustment. (Group 9015-20.) Return-to-Carry: The return-to-carry function can be enabled (switch LED on) by pushing the return-to-carry switch on the SSM. The FLC uses the analog BHKO/RTC sensor to detect the position of the boom. If the boom position is higher than the preset kickout position, the FLC will send current out terminal D4 of FLC connector X41 (J2) to

the return-to-carry/float detent coil, energizing the coil. The FLC uses ignition power from VEC circuit B16 RED, available at terminals L3 and M3 of FLC connector X41, to provide the current to the return-to-carry/float detent coil. When the pilot controller lever is moved fully to the boom lower (float) position, the magnetic field created by the return-to-carry/float detent coil will hold the pilot controller in that position. The pilot controller will stay in that position until the boom reaches the preset position as detected by the BHKO/RTC sensor. The FLC will then stop current flow to the return-to-carry/float detent coil, allowing the pilot controller to return to neutral. To set the return-to-carry position, see Boom Height Kickout/Return-to-Carry Adjustment. (Group 9015-20.) The float function also uses the return-to-carry/float detent coil. The energizing of the detent coil and actuation of the pilot controller is the same as described for the return-to-carry function. To use the float function, the return-to-carry function must be disabled. Pin Disconnect—If equipped with pin disconnect, the front attachment can be detached by pushing and holding down the pin disconnect switch on the SSM. When the LED is on, the FLC sends current out terminal F4 of FLC connector X41 to pin disconnect solenoid (Y20), energizing the solenoid. With the pin disconnect solenoid energized, hydraulic oil retracts the pins in the front coupling, disconnecting the attachment. Proportional Fan—The proportional fan controls the cooling capacity of the cooling package by varying the speed of the fan. The FLC automatically controls the speed of the fan by monitoring hydraulic oil temperature, engine coolant temperature, transmission oil temperature, ambient air temperature, manifold air temperature, and air conditioning state (on/off).

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9015 15 19

9015-15-19

WS68074,000116B –19–24MAY07–8/16

544J Loader (S.N. 611800— ) 032409

PN=653

Sub-System Diagnostics The hydraulic oil temperature sensor, ambient air temperature sensor, and A/C compressor clutch (Y16) are hard-wired to the FLC. The engine coolant temperature sensor (B1), manifold air temperature sensor (B7), and ambient air temperature (B10) are hard-wired to the engine control unit (ECU) (A1) and transmitted across the CAN to the FLC.

Once the above fan speed is selected, the FLC derates fan speed based on manifold air temperature. The percentages are based on temperatures between 50°C (122°F) and 60°C (140°F).

The transmission oil temperature sensor is hard-wired to the transmission control unit (TCU) (A3) and transmitted across CAN to the FLC. The FLC uses certain reference values for determining fan speed. The first set of values the FLC interprets is the hydraulic oil temperature, engine coolant temperature, and the transmission oil temperature. From the table below, the FLC selects the fastest fan speed at which all three temperatures are below the specified temperatures. Fan Speed 9015 15 20

Hydraulic Oil Temperature

Engine Coolant Temperature

Transmission Oil Temperature

500 rpm

62.8°C 145°F

90°C 194°F

82.2°C 180°F

1700 rpm

96.1°C 205°F

101.7°C 215°F

When the manifold air temperature is above 50°C (122°F), the FLC considers the differential temperature between manifold air temperature and ambient air temperature as another item to calculate fan speed with. From the table below, the FLC selects the fastest fan speed at which all four temperatures are below the specified temperatures. Fan Speed

% Speed

Manifold Air Temperature

50°C 122°F

50%

55°C 131°F

100%

60°C 140°F

If the manifold air temperature is 60°C (140°F) or higher, the fan will operate at 100% of the rated speed based on fluid and differential air temperature. When the air conditioner is on, the minimum fan speed is determined by the ambient air temperature. Fan Speed

Ambient Air Temperature

500 rpm

21°C 70°F

960 rpm

43°C 110°F

The proportional fan solenoid (Y37) is controlled by terminals C4 and D4 on FLC connector X42. Ignition power for the solenoid is supplied to the FLC at terminals H3 and H4 on connector X42. The amount of current the FLC drives the solenoid is inversely dependant on the calculated fan speed. The current supplied to the solenoid ranges from 600 mA (545 rpm) to 0 mA (1900 rpm). For more information, see Hydraulic Fan Drive Operation. (Group 9025-05.)

Hydraulic Engine Transmission Manifold Oil Coolant Oil Air Temperature Temperature Temperature Temperature - Ambient Air Temperature

500 rpm

62.8°C 145°F

90°C 194°F

82.2°C 180°F

3.3°C 38°F

1700 rpm

96.1°C 205°F

101.7°C 215°F

17.2°C 63°F

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TM10229 (17MAR09)

9015-15-20

WS68074,000116B –19–24MAY07–9/16

544J Loader (S.N. 611800— ) 032409

PN=654

Sub-System Diagnostics Reverse Fan—The reverse fan function reverses the fan direction to purge the cooling system of debris. The reverse fan function can be operated in manual and automatic mode. Automatic mode is the default mode and will automatically reverse directions every 30 minutes unless manual mode is activated. Pushing the reverse fan switch on the SSM activates manual mode (switch LED on). Once the manual reverse cycle is complete, the LED on the reverse fan switch will go off and the function will return to automatic mode. When the internal 30 minute timer in the FLC reaches full count or if manual mode is selected, the FLC will begin the reversing sequence. The reversing function works in conjunction with the proportional fan solenoid. The FLC ramps up the proportional fan solenoid current to slow the fan down to minimum fan speed (approximately 500 rpm). When the fan speed is at a minimum, the FLC will send current out terminal C4 of FLC connector X41 to the reverse fan solenoid (Y38), reversing the fan drive direction. When power is

applied to the reverse fan solenoid, the FLC will ramp down the current applied to the proportional fan solenoid until maximum fan speed (approximately 1900 rpm) is reached. The FLC will operate the fan at maximum speed for 15 seconds, then ramp up the proportional fan solenoid current until the fan is at minimum speed. Once the fan is slowed down to minimum speed, the FLC will remove power from the reverse fan solenoid then ramp current down to the normal current for the normal operating fan speed. The reverse fan sequence cannot be activated again for one minute after it was completed. If the reverse fan was in automatic mode prior to manual mode being activated, the 30 minute timer is stopped then started again after the reverse fan sequence is completed. For more information, see Hydraulic Fan Drive Operation. (Group 9025-05.) 9015 15 21

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TM10229 (17MAR09)

9015-15-21

WS68074,000116B –19–24MAY07–10/16

544J Loader (S.N. 611800— ) 032409

PN=655

Sub-System Diagnostics TX1022880 –19–09MAY07

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TM10229 (17MAR09)

9015-15-22

WS68074,000116B –19–24MAY07–11/16

544J Loader (S.N. 611800— ) 032409

PN=656

Sub-System Diagnostics Turn Lights and 4-Way Flashers—When the operator activates the turn signals, the CAN monitor unit (CMU) transmits the signal across the CAN to the FLC. The FLC interprets the signal and sends current to the appropriate turn lights. When the left turn signal is selected, the FLC sends intermittent current at a predetermined rate from terminal B2 of FLC connector X42 to left front turn light (E2) and left rear turn light (E3). When the right turn signal is selected, the FLC sends intermittent current at a predetermined rate from terminal C2 of FLC connector X42 to right front turn light (E4) and right rear turn light (E5). The FLC uses battery power from fuse 21 (circuit P21 RED), available at terminal L1 of connector X41, to provide the current to these lights. When the 4-way flasher switch (S24) is moved to the ON position, battery current from fuse (F01) flows to terminal D2 of FLC connector X41. The FLC will then send intermittent current at a predetermined rate out terminal B2 and terminal C2 of FLC connector X42 to the left and right front turn lights, and the left and right rear turn lights. The FLC also transmits the on/off state of the flashers across the CAN to the CMU. The CMU will flash the turn indicators on the CMU at the same rate as the flashing turn lights. The key switch does not have to be ON to activate the 4-way flashers. When the 4-way flasher switch in put in the ON position when the key switch is OFF, the FLC will power up and send intermittent current to the turn lights. Marker and Drive Lights—The drive light switch on the SSM has three modes: • OFF (no LEDs on) • Marker Lights (left LED on) • Marker/Drive Lights (all LEDs on)

Marker Lights: When the left LED is on, the FLC sends current out terminal D2 of FLC connector X42 to front marker lights (E6 and E7), tail lights (E8 and E9), and license plate light (E10). The FLC uses ignition power from VEC circuit B15 RED, available at terminals H3 and H4 on connector X42, to provide the current to the marker and drive lights. Marker/Drive Lights: When both LEDs are on, the FLC sends current out terminals A3 and A4 of FLC connector X40 to the front drive lights (E11 and E12), in addition to sending current to the marker, tail lights, and license plate light. The FLC uses ignition power from VEC circuit B15 RED, available at terminals L4 and M4, of connector X41 to provide the current to the front drive lights. Work Lights—The work light switch on the SSM has four modes: • OFF (no LEDs on) • Front (left LED on) • Front/Rear (left and center LEDs on) • Front/Rear/Docking (all LEDs on) Front Work Lights: When the left LED is on, the FLC sends current out terminals C3 and C4 of FLC connector X40 to left front work light (E20) and right front work light (E21). The FLC uses ignition power from VEC circuit B16 RED, available at terminals L3 and M3 of connector X41, to provide the current to the front work lights. Front/Rear Work Lights: When the left and center LEDs are on, the FLC sends current out terminals B3 and B4 of FLC connector X40 to left rear work light (E22) and right rear work light (E23), in addition to the front work lights. The FLC uses ignition power from VEC circuit B15 RED, available at terminals L4 and M4 of connector X41, to provide the current to the rear work lights.

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9015-15-23

WS68074,000116B –19–24MAY07–12/16

544J Loader (S.N. 611800— ) 032409

PN=657

Sub-System Diagnostics Front/Rear/Docking Lights: When all three LEDs are on, the FLC sends current out terminals F3 and F4 of FLC connector X40 to left docking light (E24) and right docking light (E25), in addition to the front and rear work lights. The FLC uses ignition power from VEC circuit B15 RED, available at terminals H3 and H4 of connector X40, to provide the current to the docking lights. Brake Lights—The brake light pressure switch (B40) is a normally open switch that closes when brake pressure is present. When the brake light pressure switch closes, battery current from fuse (F02) flows to terminal A4 of FLC connector X41. The FLC then sends current out terminal B4 of FLC connector X42 to left brake light (E16) and right brake light (E17).

The key switch does not have to be ON to activate the brake lights. The FLC uses battery power from fuse F21 (circuit P21 RED), available at terminal L1 of connector X41, to provide the current to the brake lights. Beacon Light—Pushing the beacon light switch on the SSM causes the switch LED to come on and the FLC to send current out terminals H1 and H2 of FLC connector X40 to activate beacon light (E15). The FLC uses ignition power from VEC circuit B15 RED, available at terminals H3 and H4 of connector X40, to provide the current to the beacon light.

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WS68074,000116B –19–24MAY07–13/16

9015 15 24

TM10229 (17MAR09)

9015-15-24

544J Loader (S.N. 611800— ) 032409

PN=658

Sub-System Diagnostics TX1022879 –19–09MAY07

Air Conditioning—The air conditioning system is enabled using the A/C (on/off) switch on the SSM. Continued on next page

TM10229 (17MAR09)

9015-15-25

WS68074,000116B –19–24MAY07–14/16

544J Loader (S.N. 611800— ) 032409

PN=659

Sub-System Diagnostics Before the A/C compressor clutch can be activated, the blower speed switch (S21) must turned to a position other than OFF. When the blower speed switch is at LOW, MED, HIGH, or PURGE position, current from fuse (F05) flows through fuse (F33), to terminal D1 of FLC connector X40 to inform the FLC that the blower motor (M6) and pressurizer motor (M7) have been activated. When the A/C system is enabled (switch LED on) and the FLC detects current at terminal D1, the FLC will send current out terminal E3 of FLC connector X42. If the freeze control switch (B35) and A/C binary pressure switch (B50) are closed, the A/C compressor clutch will energize. The FLC uses ignition power from VEC circuit B17 RED, available at terminals H3 and H4 of connector X42, to provide the current to the A/C compressor clutch.

9015 15 26

The freeze control switch will open if the system begins to freeze. The A/C binary pressure switch will open if refrigerant pressures are too high or too low. Diode (V11) suppresses voltage spikes created from the clutch energizing and de-energizing. Front Wiper—The front wiper switch on the SSM has four modes: • OFF (no LEDs on) • Intermittent (left LED on) • Low Speed (left and center LEDs on) • High Speed (all LEDs on) Intermittent Mode: When the left LED is on, the FLC sends a predetermined rate of intermittent current out terminals E3 and E4 of FLC connector X40 to the low speed input of front wiper motor (M3). The front wipers will operate intermittently at low speed. The FLC uses ignition power from VEC circuit B16 RED, available at terminals G3 and G4 of connector X40, to provide the current to the low speed motor input. Low Speed Mode: When the left and center LEDs are on, the FLC sends a continuous current out terminals E3 and E4 of FLC connector X40 to the low speed

input of the front wiper motor. The front wiper will operate continuously at low speed. The FLC uses ignition power from VEC circuit B16 RED, available at terminals G3 and G4 of connector X40, to provide the current to the low speed motor input. High Speed Mode: When all three LEDs are on, the FLC sends current out terminal C1 of FLC connector X42 to the high speed input of the front wiper motor. The front wiper motor will operate continuously at high speed. The FLC uses ignition power from VEC circuit B17 RED, available at terminals G1 and G2 of connector X42, to provide the current to the high speed motor input. OFF Mode: When the front wiper is turned off (no LEDs on), the FLC will continue sending current to the wiper motor until the wiper arm reaches the park position. When the wiper arm reaches the park position, the wiper motor sends a park signal to terminal E2 of FLC connector X41. The current for the park signal comes from fuse (F56). When the FLC receives the park signal, the FLC stops current flow to the wiper motor, and thus stops the wiper at the park position. Front Washer Pump—Pushing and holding down the front washer switch on the SSM causes the FLC to send current out terminal D1 of FLC connector X42 to front washer pump (M2), activating the pump. The FLC uses ignition power from VEC circuit B17 RED, available at terminals G1 and G2 of connector X42, to provide the current to the front washer pump. If the button is pushed when the front wiper is not active, the FLC will operate the front wiper at low speed through three complete cycles after the front washer switch is released. Rear Wiper—The rear wiper switch on the SSM has four modes: • OFF (no LEDs on)

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TM10229 (17MAR09)

9015-15-26

WS68074,000116B –19–24MAY07–15/16

544J Loader (S.N. 611800— ) 032409

PN=660

Sub-System Diagnostics • Intermittent (left LED on) • Low Speed (left and center LEDs on) • High Speed (all LEDs on)

The FLC uses ignition power from VEC circuit B17 RED, available at terminals G1 and G2 of connector X42, to provide the current to the high speed motor input.

Intermittent Mode: When the left LED is on, the FLC sends a predetermined rate of intermittent current out terminals D3 and D4 of FLC connector X40 to the low speed input of rear wiper motor (M5). The rear wiper will operate intermittently at low speed. The FLC uses ignition power from VEC circuit B16 RED, available at terminals G3 and G4 of connector X40, to provide the current to the low speed motor input. Low Speed Mode: When the left and center LEDs are on, the FLC sends a continuous current out terminals D3 and D4 of FLC connector X40 to the low speed input of the rear wiper motor. The rear wiper will operate continuously at low speed. The FLC uses ignition power from VEC circuit B16 RED, available at terminals G3 and G4 of connector X40, to provide the current to the low speed motor input. High Speed Mode: When all three LEDs are on, the FLC sends current out terminal A1 of FLC connector X42 to the high speed input of the rear wiper motor. The rear wiper will operate continuously at high speed.

OFF Mode: When the rear wiper is turned off (no LEDs on), the FLC will continue sending current to the wiper motor until the wiper arm reaches the park position. When the wiper arm reaches the park position, the wiper motor sends a park signal to terminal E1 of FLC connector X41. The current for the park signal comes from fuse (F55). When the FLC receives the park signal, the FLC stops current flow to the wiper motor and thus stops the wiper at the park position. Rear Washer Pump—Pushing and holding down the rear washer switch on the SSM causes the FLC to send current out terminal C1 of FLC connector X42 to rear washer pump (M4), activating the pump. The FLC uses ignition power from VEC circuit B17 RED, available at terminals G1 and G2 of connector X42, to provide the current to the rear washer pump. If the button is pushed when the rear wiper is not active, the FLC will operate the rear wiper at low speed through five complete cycles after the rear washer switch is released.

WS68074,000116B –19–24MAY07–16/16

TM10229 (17MAR09)

9015-15-27

544J Loader (S.N. 611800— ) 032409

PN=661

9015 15 27

Sub-System Diagnostics

Transmission Control Unit (TCU) Circuit Theory of Operation TX1023391 –19–10MAY07

Transmission Control Unit (TCU) Circuit Schematic WS68074,000117A –19–15MAY07–1/4

TM10229 (17MAR09)

9015-15-28

544J Loader (S.N. 611800— ) 032409

PN=662

Sub-System Diagnostics The transmission control unit (TCU) (A3) monitors gear speeds at several points in the transmission and controls the transmission control valve according to the monitored speeds and operator input. The TCU also controls the neutral start, park brake, and backup alarm functions. Unswitched battery power is supplied to the TCU through the TCU battery power 10 A fuse (F18) to TCU terminals 23 and 68. When the key switch (S1) is turned to the ON position, switched current flows through TCU ignition power 5 A fuse (F28) to TCU terminal 45, powering up the TCU. When the engine is started, the TCU keeps the transmission in neutral, regardless of shifter position. If the shifter is not in neutral, the TCU requires the shifter be put in neutral first before forward or reverse can be selected. NOTE: The shifter is available as the joystick gear select (S9) or the steering column shifter switch (S10). Each shifter is supplied ignition power through the TCU ignition power 5 A fuse (F28). The shifter will then supply power to the appropriate terminals on the TCU to identify the selected gear range and gear. The operation mode (manual or automatic) is controlled by the automatic transmission switch (S6) on the sealed switch module (SSM) (A6). For more information on the SSM, see Flex Load Controller (FLC) Circuit Theory of Operation. (Group 9015-15.)

• The internal clutch speed sensor (B30) applies a pulsed signal at TCU terminals 3 and 42, which the TCU can calculate the clutch pack speed. • The transmission output shaft speed sensor (B31) applies a pulsed signal to TCU terminals 4 and 62, which is used to compute the ground speed of the machine. The sensor receives power from the transmission output speed sensor 5 A fuse (F40). For sensor specifications, see Electrical Component Specifications. (Group 9015-20.) When the transmission is in automatic mode and either second, third, or fourth gear is selected, the TCU will start machine travel in second gear, unless the auto to 1st option is enabled in the CAN monitor unit service menu. For more information, see CAN Monitor Unit (CMU) Menu Structure—Service Mode. (Group 9015-20.) When the quick shift switch (S7) is pushed, power from the restriction switch/radio ignition power 10 A fuse (F11) is applied to TCU terminal 44. If the transmission is in manual mode, the TCU will shift the transmission down one gear. Pushing the switch again will either shift the transmission down another gear or back to the original gear, depending on the selected mode in the CMU menu. For more information, see CAN Monitor Unit (CMU) Menu Structure—Service Mode. (Group 9015-20.)

The TCU has four inductive-type speed sensors located at various places in the transmission.

The TCU controls the transmission’s gear selection by controlling the six proportional solenoids in the transmission control valve. The TCU modulates the current supplied to the solenoid to control the smoothness of the clutch pack engagement.

• The torque convertor input speed sensor (B28) applies a pulsed signal at TCU terminals 3 and 19, which the TCU can calculate the engine speed at the torque convertor output. • The torque convertor output speed sensor (B29) applies a pulsed signal at TCU terminals 3 and 41, which the TCU can calculate the output speed at the torque convertor.

• Transmission control solenoid 1 (Y1) controls the high-range forward clutch pack (K4) • Transmission control solenoid 2 (Y2) controls the reverse clutch pack (KR) • Transmission control solenoid 3 (Y3) controls the first speed clutch pack (K1) • Transmission control solenoid 4 (Y4) controls the third speed clutch pack (K3)

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9015-15-29

WS68074,000117A –19–15MAY07–2/4

544J Loader (S.N. 611800— ) 032409

PN=663

9015 15 29

Sub-System Diagnostics • Transmission control solenoid 5 (Y5) controls the low-range forward clutch pack (KV) • Transmission control solenoid 6 (Y6) controls the second speed clutch pack (K2) For more information on the clutch pack operation, see Transmission Clutch Engagement and Solenoids Activated. (Group 9020-05.) The transmission oil temperature sensor (B32) is a variable resistance temperature sensor. The TCU senses resistance of the sensor at terminals 39 and 46. The TCU transmits the transmission oil temperature across CAN to the flex load controller (FLC) and the CMU. The FLC uses the transmission oil temperature for the proportional fan drive speed calculation. The CMU displays the transmission oil temperature on the gauge.

9015 15 30

The transmission oil filter restriction switch (B20) is a normally open switch that is closed by filter bypass oil pressure. When the filter becomes clogged, the bypass valve opens oil pressure increases at the switch. The TCU transmits the switch state across CAN to the CMU, which causes the indicator to come on if a restriction occurs. Park Brake Operation—The park brake is a spring applied, hydraulically released device. The park brake operation is controlled by the TCU. The park brake circuit consists of the park brake release switch (S8), park brake pressure switch (B34), and park brake release solenoid (Y19). The park brake release switch (S8) is a three position switch. The ON and center positions are detented. The OFF position is a momentary position. It has springs to return the switch to the center position. The park brake release switch (S8) receives ignition power from the park brake release switch/back up alarm 5 A fuse (F32). The park brake pressure switch (B34) is a normally closed switch. It is closed when the transmission oil pressure is low. In the closed position, power is supplied to TCU terminal 30, causing the park brake light (located on the CMU) to come on.

Before the park brake can be released, the key switch (S1) must be ON and the engine running. The TCU receives the rpm signal from the torque converter input speed sensor (B28) at TCU terminal 19. The TCU software requires a minimum of 300 rpm input signal before it will allow the release of the park brake. The data from the torque converter input speed sensor can be viewed in the diagnostic menu of the CMU. See CAN Monitor Unit (CMU) Menu Structure—Service Mode. (Group 9015-20.) To release the park brake, push and hold the park brake release switch (S8) in the OFF (momentary) position. Current flows through the park brake release switch/backup alarm 5 A fuse (F32), across the park brake release switch (S8) to TCU terminals 21 and 31. When the TCU detects power at these terminals, the TCU provides a ground at terminal 33, energizing park brake release solenoid (Y19). With the solenoid energized, transmission oil flows through the park brake solenoid valve to the park brake, releasing the park brake. The transmission oil used to release the park brake also opens the contacts of park brake pressure switch (B34). This switch must open immediately after the park brake release solenoid (Y19) has been energized to inform the TCU that adequate oil pressure is present to release the park brake. When the TCU no longer senses power at TCU terminal 30, it transmits the park brake status across the CAN to the CMU, causing the park brake light to go off. When the park brake light goes off, the park brake pressure release switch (S8) can be released. The switch returns to its center position with power applied to only TCU terminal 21. The transmission can then be shifted into gear. If the park brake pressure switch (B34) is slow to open or does not open, the TCU will remove the ground at TCU terminal 33, de-energizing the park brake release solenoid (Y19).

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TM10229 (17MAR09)

9015-15-30

WS68074,000117A –19–15MAY07–3/4

544J Loader (S.N. 611800— ) 032409

PN=664

Sub-System Diagnostics To apply the park brake, turn the key switch to the OFF position or put the park brake release switch (S8) in the ON position.

TCU will demodulate only the solenoids of the directional clutch packs to put the transmission in neutral.

If the engine stops while the machine is being operated (key switch is still ON), the park brake may not set immediately because the park brake release solenoid (Y19) will remain energized.

The TCU software has programmed voltage thresholds to release and apply the directional clutch pack associated with the three settings. In the level slope (ground) setting (one LED on), either brake pedal only needs to be pushed slightly to reach the clutch cut-off point. As the settings increase from level ground to steep slope, the brake pedal must be pushed further before the clutch cut-off point is reached. In small slope (two LEDs on), the brake pedal must be pushed approximately halfway down for the TCU to put the transmission in neutral. When in steep slope (three LEDs on), the brake pedal needs to be pushed almost all of the way down to reach clutch cut-off point.

The TCU software determines that the engine is not running when data from the torque converter input speed sensor equals 50 rpm or less. The TCU software will look next at the data from the transmission output speed sensor (B31) for ground speed. If the machine is moving at a ground speed of approximately 1/2 mph or less, the TCU software will remove the ground at TCU terminal 33 and de-energize the park brake release solenoid (Y19). Backup Alarm (H3)—The backup alarm receives ignition power from the park brake release switch/backup alarm 5 A fuse (F32). When the reverse gear range is selected, the TCU activates the alarm by providing a ground at terminal 7. Clutch Cut-Off (B33)—The clutch cut-off sensor supplies the TCU with a variable resistance based on brake pedal position. The clutch cut-off sensor receives power from TCU terminal 37. The TCU senses changes in resistance at terminals 24 and 38. The clutch cut-off function has four settings indicated by status of three LEDs located on the clutch cut-off switch:

Specification Level Ground Set Point to Release Clutch—Voltage.............................................................. 1.20 Level Ground Set Point to Apply Clutch—Voltage .................................................................. 1.18 Small Slope Set Point to Release Clutch—Voltage.............................................................. 1.64 Small Slope Set Point to Apply Clutch—Voltage ............................................................................ 1.60 Steep Slope Set Point to Release Clutch—Voltage.............................................................. 2.00 Steep Slope Set Point to Apply Clutch—Voltage ............................................................................ 1.94

NOTE: The use of the service brake pedal to operate the clutch cut-off feature also applies the service brakes. Voltage for the clutch cut-off Sensor (B33) can be viewed in the Diagnostics / Transmission (3-3) of the CMU service menu. See CAN Monitor Unit (CMU) Menu Structure—Service Mode. (Group 9015-20.)

• Off—all LEDs off • Level Slope—one LED on • Small Slope—two LEDs on • Steep Slope—three LEDs on Regardless of which clutch cut-off setting is selected when set point to release the clutch is reached, the

WS68074,000117A –19–15MAY07–4/4

TM10229 (17MAR09)

9015-15-31

544J Loader (S.N. 611800— ) 032409

PN=665

9015 15 31

Sub-System Diagnostics

CAN Monitor Unit (CMU) Circuit Theory of Operation

TX1022883

–19–09MAY07

9015 15 32

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TM10229 (17MAR09)

9015-15-32

WS68074,000117B –19–10MAY07–1/2

544J Loader (S.N. 611800— ) 032409

PN=666

Sub-System Diagnostics CAN Monitor Unit (CMU) (H2)— The CMU receives unswitched battery power from fuse (F34) at terminal A. System ground is available at terminal P. When the key switch is in the OFF position, machine hours, battery voltage, and fuel level can be displayed by pushing and holding the SELECT button. As long as the SELECT button is pushed, the monitor will display machine hours, battery voltage, and fuel level. When the key switch is turned to the ON position, current flows through fuse (F13) to terminal L of the CMU, powering up the CMU. When powered-up, the CMU performs a self-test by activating all indicators: lights, gauges, and the monitor display window. For more information on the monitor warning indicators and gauges, see Monitor Panel Functions. (Operator’s Manual.) The CMU contains a menu structure designed for monitoring certain machine functions for operational and/or diagnostic purposes. It provides a means for viewing and clearing diagnostic trouble codes (DTC) and also provides a means for adjusting certain machine and monitor settings. For more information on the CMU menu structure, See CAN Monitor Unit (CMU) Menu Structure—Service Mode. (Group 9015-20.) The CMU uses the controller area network (CAN) to communicate with the engine control unit (ECU), transmission control unit (TCU), flex load controller (FLC), and sealed switch module (SSM). • For more information on the CAN, see Controller Area Network (CAN) Theory of Operation. (Group 9015-15.) • For more information on the ECU, see Engine Control Unit (ECU) Circuit Theory of Operation. (Group 9015-15.) • For more information on the FLC, see Flex Load Controller (FLC) Circuit Theory of Operation. (Group 9015-15.) • For more information on the TCU, see Transmission Control Unit (TCU) Circuit Theory of Operation. (Group 9015-15.)

• For more information on the SSM, see Switch Pad. (Operator’s Manual.) The following electrical components are hard wired directly to the CMU: • Fuel Level Sensor (B17) • Turn Signal Switch (S25) • Monitor Alarm (H1) Fuel Level Sensor (B17)—The fuel level sensor is a 14-stage reed switch type sensor. As the fuel level rises, the individual reed switches open, causing resistance in the circuit to decrease. When the fuel level lowers, the individual reed switches close, causing resistance in the circuit to increase. The total resistance is sensed by the CMU at terminals F and N. The CMU uses this information to determine the position of the needle on the fuel gauge and moves the needle accordingly. Turn Switch (S25)—The turn switch receives power from fuse (F13). When a left or right turn is selected, the turn switch sends current to the appropriate CMU terminal. The CMU transmits the turn signal status across CAN to the flex load controller (FLC). The FLC transmits the output flasher state (on or off) to the CMU. The CMU receives this signal and coordinates the flashing of the turn indicators to match the flashing of the turn lights. If the 4-way flashers are active when the turn switch is used, the lights of the direction chosen will continue to flash while the lights on the opposite side will be on steady until the turn switch is returned to neutral. Monitor Alarm (H1)—The monitor alarm is activated during the monitor self test, during certain monitor selections, and when the STOP light is on. The CMU activates the monitor alarm by providing power at terminal M and a ground at terminal D.

WS68074,000117B –19–10MAY07–2/2

TM10229 (17MAR09)

9015-15-33

544J Loader (S.N. 611800— ) 032409

PN=667

9015 15 33

Sub-System Diagnostics

9015 15 34

TM10229 (17MAR09)

9015-15-34

544J Loader (S.N. 611800— ) 032409

PN=668

Group 20

References Diagnostic Trouble Codes (DTC) Quick Reference List The diagnostic trouble code number is indicated by a suspect parameter number (SPN) and a failure mode indicator (FMI) number. In the example (000829.05), 000829 is the SPN and 05 is the FMI number. To view diagnostic trouble codes, use one of the following methods: • Service ADVISOR system. See Service ADVISOR Diagnostic Application. (Group 9015-20.) • CAN Monitor Unit (CMU). See CAN Monitor Unit (CMU) Menu Structure—Service Mode. (Group 9015-20.) CAN Monitor Unit (CMU) Diagnostic Trouble Codes • 000829.05—Fuel Level Open or Short. (Group 9001 -10.) • 002000.09—CAN Comm Lost For ECU. (Group 9001 -10.) • 002003.09—CAN Comm Lost For TCU. (Group 9001 -10.) • 002033.09—CAN Comm Lost For FLC. (Group 9001 -10.) • 002140.09—CAN Comm Lost For SSM. (Group 9001 -10.) • 002367.04—Left Turn Sw Short to Gnd. (Group 9001 -10.) • 002369.04—Right Turn Sw Short to Gnd. (Group 9001 -10.) • 524250.31—Inspect Park Brake. (Group 9001 -10.)

9015 20 1

Engine Control Unit (ECU) Diagnostic Trouble Codes • 000091.03—Eng Throttle Short to Power. (CTM502.) • 000091.04—Eng Throttle Open or Short. (CTM502.) • 000091.14—Eng Throttle Sensor Invalid. (CTM502.) • 000097.03—Water in Fuel Open or Short. (CTM502.) • 000097.04—Water in Fuel Short to Gnd. (CTM502.) • 000097.16—Water in Fuel. (CTM502.) • 000100.01—Engine Oil Pressure Low. (CTM502.) • 000100.03—Eng Oil Press Short to Power. (CTM502.) • 000100.04—Eng Oil Press Open or Short. (CTM502.)

Service ADVISOR is a trademark of Deere & Company

TM10229 (17MAR09)

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9015-20-1

WS68074,0001192 –19–18SEP07–1/12

544J Loader (S.N. 611800— ) 032409

PN=669

References

9015 20 2

• 000100.18—Engine Oil Pressure Low. (CTM502.) • 000100.31—Eng Oil Press Open or Short. (CTM502.) • 000105.00—Manifold Air High Temp. (CTM502.) • 000105.03—MAT Sensor Open or Short. (CTM502.) • 000105.04—MAT Sensor Short to Gnd. (CTM502.) • 000105.15—MAT Sensor High Temp. (CTM502.) • 000105.16—MAT Sensor High Temp. (CTM502.) • 000107.00—Eng Air Filter Restricted. (Group 9001-20.) • 000108.02—Barometric Calc Fault. (CTM502.) • 000110.00—Eng Coolant High Temp. (CTM502.) • 000110.03—Eng Coolant Open Circuit. (CTM502.) • 000110.04—Eng Coolant Short to Gnd. (CTM502.) • 000110.15—Eng Coolant High Temp. (CTM502.) • 000110.16—Eng Coolant High Temp. (CTM502.) • 000157.03—Rail Pressure Open or Short. (CTM502.) • 000157.04—Rail Pressure Short to Gnd. (CTM502.) • 000157.10—Rail Pressure Leak. (CTM502.) • 000157.17—Fuel System Not Primed. (CTM502.) • 000158.17—ECU Switched Power not 0V. (CTM502.) • 000171.03—Ambient Air Open Circuit. (Group 9001-20.) • 000171.04—Ambient Air Short to Gnd. (Group 9001-20.) • 000174.00—Fuel Temp High. (CTM502.) • 000174.03—Fuel Temp Open or Short. (CTM502.) • 000174.04—Fuel Temp Short to Gnd. (CTM502.) • 000174.16—Fuel Temp High. (CTM502.) • 000189.00—Engine Speed Derate Active. (CTM502.) • 000190.00—Engine Speed Too High. (CTM502.) • 000611.03—Injector Short to Power. (CTM502.) • 000611.04—Injector Short to Gnd. (CTM502.) • 000627.01—ECU Unswitch Short to GND. (Group 9001-20.) • 000629.13—ECU Failure. (CTM502.) • 000636.02—CAM Sensor Out of Sync. (CTM502.) • 000636.05—CAM Sensor Open or Short. (CTM502.) • 000636.06—CAM Sensor Short to Gnd. (CTM502.) • 000636.08—CAM Sensor No Signal. (CTM502.) • 000636.10—CAM Sensor Fault. (CTM502.) • 000637.02—Crank Sensor Out of Sync. (CTM502.) • 000637.05—Crank Sensor Open or Short. (CTM502.) • 000637.06—Crank Sensor Short to Gnd. (CTM502.) • 000637.07—Crank or CAM out of Sync. (CTM502.) • 000637.08—Crank Sensor No Signal. (CTM502.) • 000637.10—Crank Fault. (CTM502.) • 000651.00—Cyl 1 Injector Max Cal Error • 000651.01—Cyl 1 Injector Min Cal Error

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9015-20-2

WS68074,0001192 –19–18SEP07–2/12

544J Loader (S.N. 611800— ) 032409

PN=670

References • 000651.02—Cyl 1 Injector Invalid Pin. (CTM502.) • 000651.05—Cyl 1 Injector Open Circuit. (CTM502.) • 000651.06—Cyl 1 Injector Short. (CTM502.) • 000651.07—Cyl 1 Injector Bad. (CTM502.) • 000651.13—Cyl 1 Injector Fault. (CTM502.) • 000652.00—Cyl 2 Injector Max Cal Error • 000652.01—Cyl 2 Injector Min Cal Error • 000652.02—Cyl 2 Injector Invalid Pin. (CTM502.) • 000652.05—Cyl 2 Injector Open Circuit. (CTM502.) • 000652.06—Cyl 2 Injector Short. (CTM502.) • 000652.07—Cyl 2 Injector Bad. (CTM502.) • 000652.13—Cyl 2 Injector Fault. (CTM502.) • 000653.00—Cyl 3 Injector Max Cal Error • 000653.01—Cyl 3 Injector Min Cal Error • 000653.02—Cyl 3 Injector Invalid Pin. (CTM502.) • 000653.05—Cyl 3 Injector Open Circuit. (CTM502.) • 000653.06—Cyl 3 Injector Short. (CTM502.) • 000653.07—Cyl 3 Injector Bad. (CTM502.) • 000653.13—Cyl 3 Injector Fault. (CTM502.) • 000654.00—Cyl 4 Injector Max Cal Error • 000654.01—Cyl 4 Injector Min Cal Error • 000654.02—Cyl 4 Injector Invalid Pin. (CTM502.) • 000654.05—Cyl 4 Injector Open Circuit. (CTM502.) • 000654.06—Cyl 4 Injector Short. (CTM502.) • 000654.07—Cyl 4 Injector Bad. (CTM502.) • 000654.13—Cyl 4 Injector Fault. (CTM502.) • 000655.00—Cyl 5 Injector Max Cal Error • 000655.01—Cyl 5 Injector Min Cal Error • 000655.02—Cyl 5 Injector Invalid Pin. (CTM502.) • 000655.05—Cyl 5 Injector Open Circuit. (CTM502.) • 000655.06—Cyl 5 Injector Short. (CTM502.) • 000655.07—Cyl 5 Injector Bad. (CTM502.) • 000655.13—Cyl 5 Injector Fault. (CTM502.) • 000656.00—Cyl 6 Injector Max Cal Error • 000656.01—Cyl 6 Injector Min Cal Error • 000656.02—Cyl 6 Injector Invalid Pin. (CTM502.) • 000656.05—Cyl 6 Injector Open Circuit. (CTM502.) • 000656.06—Cyl 6 Injector Short. (CTM502.) • 000656.07—Cyl 6 Injector Bad. (CTM502.) • 000656.13—Cyl 6 Injector Fault. (CTM502.) • 001136.00—ECU Temp High. (CTM502.) • 001253.13—Injector Cal Required. (Group 9001-20.) • 001347.03—Pump Solenoid Short to Power. (CTM502.) • 001347.05—Fuel Pump Sol 1 Open Circuit. (CTM502.) • 001347.07—Fuel System Failure. (CTM502.) • 001569.31—Engine Derate Active. (CTM502.)

9015 20 3

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9015-20-3

WS68074,0001192 –19–18SEP07–3/12

544J Loader (S.N. 611800— ) 032409

PN=671

References • 002003.09—CAN Comm Lost for TCU. (Group 9001-20.) • 002033.09—CAN Comm Lost for FLC. (Group 9001-20.) • 003509.03—Sen Sup 1 Short to Power. (CTM502.) • 003509.04—Sen Sup 1 Short to Gnd. (CTM502.) • 003510.03—Sen Sup 2 Short to Power. (CTM502.) • 003510.04—Sen Sup 2 Short to Gnd. (CTM502.) • 003511.03—Sen Sup 3 Short to Power. (CTM502.) • 003511.04—Sen Sup 3 Short to Gnd. (CTM502.) Transmission Control Unit (TCU) Diagnostic Trouble Codes

9015 20 4

• 002023.09—CAN Comm Lost for CMU. (Group 9001 -30.) • 002033.09—CAN Comm Lost for FLC. (Group 9001 -30.) • 522344.00—Converter Overtemp. (Group 9001 -30.) • 522350.15—Input Torque Overload. (Group 9001 -30.) • 522364.07—Trans Clutch Calibr Failed. (Group 9001 -30.) • 522364.13—Trans Clutch Calibr Fault. (Group 9001 -30.) • 522365.13—Limp Home Mode. (Group 9001 -30.) • 522366.13—Application Invalid. (Group 9001 -30.) • 522367.13—TCU Configuration Invalid. (Group 9001 -30.) • 522368.02—Memory Failure. (Group 9001 -30.) • 522369.03—Remote Display Short to Power. (Group 9001 -30.) • 522369.04—Remote Display Short to Ground. (Group 9001 -30.) • 522370.02—TCU VP2 Short Circuit. (Group 9001 -30.) • 522371.02—TCU VP1 Short Circuit. (Group 9001 -30.) • 522373.03—Power Supply High Voltage. (Group 9001 -30.) • 522373.04—Power Supply Low Voltage. (Group 9001 -30.) • 522374.03—Sensor Supply Short to Power. (Group 9001 -30.) • 522374.04—Sensor Supply Short to Gnd. (Group 9001 -30.) • 522375.00—Trans Oil Filter Restricted. (Group 9001 -30.)

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TM10229 (17MAR09)

9015-20-4

WS68074,0001192 –19–18SEP07–4/12

544J Loader (S.N. 611800— ) 032409

PN=672

References • 522376.00—Trans Oil Temp Max Value. (Group 9001 -30.) • 522379.03—Park Brake Solenoid Short to Power. (Group 9001 -30.) • 522379.04—Park Brake Solenoid Short to Gnd. (Group 9001 -30.) • 522379.05—Park Brake Solenoid Open Circuit. (Group 9001 -30.) • 522382.03—Backup Alarm Short to Power. (Group 9001 -30.) • 522382.04—Backup Alarm Short to Gnd. (Group 9001 -30.) • 522382.05—Backup Alarm Open Circuit. (Group 9001 -30.) • 522383.02—Clutch KR Slippage. (Group 9001 -30.) • 522383.03—Clutch Rev Sol Short to Power. (Group 9001 -30.) • 522383.04—Clutch Rev Sol Short to Gnd. (Group 9001 -30.) • 522383.05—Clutch Rev Sol Open Circuit. (Group 9001 -30.) • 522386.02—Clutch KV Slippage. (Group 9001 -30.) • 522386.03—Clutch Fwd Sol Short to Power. (Group 9001 -30.) • 522386.04—Clutch Fwd Sol Short to Gnd. (Group 9001 -30.) • 522386.05—Clutch Fwd Sol Solenoid Open. (Group 9001 -30.) • 522389.02—Clutch K4 Slippage. (Group 9001 -30.) • 522389.03—Clutch K4 Sol Short to Power. (Group 9001 -30.) • 522389.04—Clutch K4 Sol Short to Gnd. (Group 9001 -30.) • 522389.05—Clutch K4 Sol Open Circuit. (Group 9001 -30.) • 522392.02—Clutch K3 Slippage. (Group 9001 -30.) • 522392.03—Clutch K3 Sol Short to Power. (Group 9001 -30.) • 522392.04—Clutch K3 Sol Short to Gnd. (Group 9001 -30.) • 522392.05—Clutch K3 Sol Open Circuit. (Group 9001 -30.) • 522395.02—Clutch K2 Slippage. (Group 9001 -30.) • 522395.03—Clutch K2 Sol Short to Power. (Group 9001 -30.)

9015 20 5

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9015-20-5

WS68074,0001192 –19–18SEP07–5/12

544J Loader (S.N. 611800— ) 032409

PN=673

References

9015 20 6

• 522395.04—Clutch K2 Sol Short to Gnd. (Group 9001 -30.) • 522395.05—Clutch K2 Sol Open Circuit. (Group 9001 -30.) • 522399.02—Clutch K1 Slippage. (Group 9001 -30.) • 522399.03—Clutch K1 Short to Power. (Group 9001 -30.) • 522399.04—Clutch K1 Short to Gnd. (Group 9001 -30.) • 522399.05—Clutch K1 Sol Open Circuit. (Group 9001 -30.) • 522401.02—Trans Speed Sensor Fault. (Group 9001 -30.) • 522401.03—Output Shaft Open or Short. (Group 9001 -30.) • 522401.04—Output Shaft Short to Gnd. (Group 9001 -30.) • 522401.12—Output Shaft Fault. (Group 9001 -30.) • 522401.15—Output shaft Overspeed. (Group 9001 -30.) • 522402.03—Clutch Speed Open or Short. (Group 9001 -30.) • 522402.04—Clutch Speed Sensor Short to Gnd. (Group 9001 -30.) • 522402.12—Clutch Speed Sensor Fault. (Group 9001 -30.) • 522403.03—Conv Output Spd Open or Short. (Group 9001 -30.) • 522403.04—Conv Output Spd Short to Gnd. (Group 9001 -30.) • 522403.12—Conv Output Spd Fault. (Group 9001 -30.) • 522404.03—Conv Input Spd Open or Short. (Group 9001 -30.) • 522404.04—Conv Input Spd Short to Gnd. (Group 9001 -30.) • 522404.12—Conv Input Spd Fault. (Group 9001 -30.) • 522406.03—Trans Oil Temp Open or Short. (Group 9001 -30.) • 522406.04—Trans Oil Temp Short to Gnd. (Group 9001 -30.) • 522407.03—Clutch Cutoff Short to Power. (Group 9001 -30.) • 522407.04—Clutch Cutoff Open or Short. (Group 9001 -30.) • 522409.05—2nd FNR Open Circuit. (Group 9001 -30.) • 522409.12—2nd FNR Mult Inputs. (Group 9001 -30.) • 522411.05—1st FNR Open Circuit. (Group 9001 -30.) • 522411.12—1st FNR Mult Inputs. (Group 9001 -30.)

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9015-20-6

WS68074,0001192 –19–18SEP07–6/12

544J Loader (S.N. 611800— ) 032409

PN=674

References • 522412.12—Gear Selection Error. (Group 9001 -30.) • 522419.02—Clutch Cutoff Disabled. (Group 9001 -30.) • 522420.02—Manual Downshift Disabled. (Group 9001 -30.) • 522421.02—Auto To 1st Disabled. (Group 9001 -30.) • 524048.00—Trans Output Torque Exceeded. (Group 9001 -30.) • 524049.00—Trans Input Torque Exceeded. (Group 9001 -30.) • 524287.00—Configure Machine Model. (Group 9001 -30.) Flex Load Controller (FLC) Diagnostic Trouble Codes • 000117.01—Brake Pressure Low. (Group 9001-40.) • 000167.16—Alternator High Voltage. (Group 9001-40.) • 000167.18—Alternator Low Voltage. (Group 9001-40.) • 000168.16—High Battery Voltage. (Group 9001-40.) • 000168.18—Low Battery Voltage. (Group 9001-40.) • 000444.05—12V Center Tap Open or Short. (Group 9001-40.) • 000444.18—Battery Voltage Imbalance. (Group 9001-40.) • 000544.19—Refer Torque Mis-Match. (Group 9001-40.) • 000628.12—Controller Not Programmed. (Group 9001-40.) • 000774.04—JS Upshift Short to Ground. (Group 9001-40.) • 000774.10—JS Upshift Button Stuck. (Group 9001-40.) • 000775.04—JS Downshift Short to Ground. (Group 9001-40.) • 000775.10—JS Downshift Button Stuck. (Group 9001-40.) • 000785.03—Pilot Solenoid Short to Power. (Group 9001-40.) • 000785.05—Pilot Solenoid Open Circuit. (Group 9001-40.) • 000785.06—Pilot Solenoid High Current. (Group 9001-40.) • 000880.03—Brake Lights Short to Power. (Group 9001-40.) • 000880.05—Brake Lights Open Circuit. (Group 9001-40.) • 000880.06—Brake Lights High Current. (Group 9001-40.)

9015 20 7

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WS68074,0001192 –19–18SEP07–7/12

544J Loader (S.N. 611800— ) 032409

PN=675

References

9015 20 8

• 000977.03—Rev Fan Solenoid Short to Power. (Group 9001-40.) • 000977.05—Rev Fan Sol Open Circuit. (Group 9001-40.) • 000977.06—Rev Fan Sol High Current. (Group 9001-40.) • 001045.04—Brake Lt Sw Shorted to Gnd. (Group 9001-40.) • 001069.02—Tire Size Incorrect. (Group 9001-40.) • 001071.31—Fan Speed Sol Circuit Fault. (Group 9001-40.) • 001075.00—Fuel Pump On Too Long. (Group 9001-40.) • 001079.04—FLC Sensor 1 Voltage Low. (Group 9001-40.) • 001080.04—FLC Sensor 2 Voltage Low. (Group 9001-40.) • 001638.00—Hydraulic Oil High Temp. (Group 9001-40.) • 001638.04—Hyd Oil Temp Circuit Short to Gnd. (Group 9001-40.) • 001713.01—Hyd Oil Filter Restricted. (Group 9001-40.) • 001762.03—Hyd Pressure Short to Power. (Group 9001-40.) • 001762.04—Hyd Pressure Open or Short. (Group 9001-40.) • 002000.09—CAN Communication Lost For ECU. (Group 9001-40.) • 002003.09—CAN Communication Lost For TCU. (Group 9001-40.) • 002023.09—CAN Communication Lost For CMU. (Group 9001-40.) • 002140.09—CAN Communication Lost For SSM. (Group 9001-40.) • 002350.05—Drive Lamps Open or Short. (Group 9001-40.) • 002350.06—Drive Lamps High Current. (Group 9001-40.) • 002355.05—Front Work Lights Open or Short. (Group 9001-40.) • 002355.06—Front Work Lights High Current. (Group 9001-40.) • 002356.05—Front Work Lights Open or Short. (Group 9001-40.) • 002356.06—Front Work Lights High Current. (Group 9001-40.) • 002362.05—Rear Work Lights Open or Short. (Group 9001-40.)

Continued on next page

TM10229 (17MAR09)

9015-20-8

WS68074,0001192 –19–18SEP07–8/12

544J Loader (S.N. 611800— ) 032409

PN=676

References • 002362.06—Rear Work Lights High Current. (Group 9001-40.) • 002368.03—Left Turn Lights Circuit Short to Power. (Group 9001-40.) • 002368.05—Left Turn Lights Open Circuit. (Group 9001-40.) • 002368.06—Left Turn Lights Circuit High Current. (Group 9001-40.) • 002370.03—Right Turn Lights Short to Power. (Group 9001-40.) • 002370.05—Right Turn Lights Open Circuit. (Group 9001-40.) • 002370.06—Right Turn Lights High Current. (Group 9001-40.) • 002378.03—Marker/Tail Lights Short to Power. (Group 9001-40.) • 002378.05—Marker/Tail Lights Open Circuit. (Group 9001-40.) • 002378.06—Marker/Tail Lights High Current. (Group 9001-40.) • 002386.06—Beacon Light High Current. (Group 9001-40.) • 002697.02—JS Mag Out of Range. (Group 9001-40.) • 002875.04—4-Way Flash Sw Short to Gnd. (Group 9001-40.) • 299261.02—Machine Configuration Invalid. (Group 9001-40.) • 522280.01—Brake Pressure Low. (Group 9001-40.) • 0522431.2—Memory Test Failure. (Group 9001-40.) • 522432.05—R Wiper High-Speed Open Circuit. (Group 9001-40.) • 522432.06—R Wiper High-Speed High Current. (Group 9001-40.) • 522433.05—R Wiper Low-Speed Open or Short. (Group 9001-40.) • 522433.06—R Wiper Low-Speed High Current. (Group 9001-40.) • 522434.05—F Wiper Low-Speed Open or Short. (Group 9001-40.) • 522434.06—F Wiper Low-Speed High Current. (Group 9001-40.) • 522435.05—F Wiper High-Speed Open Circuit. (Group 9001-40.) • 522435.06—F Wiper High-Speed High Current. (Group 9001-40.)

9015 20 9

Continued on next page

TM10229 (17MAR09)

9015-20-9

WS68074,0001192 –19–18SEP07–9/12

544J Loader (S.N. 611800— ) 032409

PN=677

References

9015 20 10

• 522436.03—Bucket Pos Short to Power. (Group 9001-40.) • 522436.04—Bucket Pos Open or Short. (Group 9001-40.) • 522437.04—RTDig Switch 1 Short to Gnd. (Group 9001-40.) • 522438.03—Pin Disc Sol Short To Power. (Group 9001-40.) • 522438.05—Pin Disc Sol Open circuit. (Group 9001-40.) • 522438.06—Pin Disc Sol High Current. (Group 9001-40.) • 522796.05—R Washer Pump Open Circuit. (Group 9001-40.) • 522796.06—R Washer Pump High Current. (Group 9001-40.) • 522797.05—F Washer Pump Open Circuit. (Group 9001-40.) • 522797.06—F Washer Pump High Current. (Group 9001-40.) • 523137.04—Steering Press Sw Shrt to Gnd. (Group 9001-40.) • 523214.05—No Voltage to FLC on VP6. (Group 9001-40.) • 523215.05—No Voltage to FLC on VP5. (Group 9001-40.) • 523216.05—No Voltage to FLC on VP4. (Group 9001-40.) • 523217.05—No Voltage to FLC on VP3. (Group 9001-40.) • 523218.05—No Voltage to FLC on VP2. (Group 9001-40.) • 523219.05—No Voltage to FLC on VP1. (Group 9001-40.) • 523436.17—FLC Watchdog Timed Out. (Group 9001-40.) • 523577.03—2nd Steer Pump Short to Power. (Group 9001-40.) • 523577.05—2nd Steer Pump Open Circuit. (Group 9001-40.) • 523577.06—2nd Steer Pump High Current. (Group 9001-40.) • 523786.03—Boom Position Short to Power. (Group 9001-40.) • 523786.04—Boom Position Open or Short. (Group 9001-40.)

Continued on next page

TM10229 (17MAR09)

9015-20-10

WS68074,0001192 –19–18SEP07–10/12

544J Loader (S.N. 611800— ) 032409

PN=678

References • 523840.01—Brake Pressure Low-Front. (Group 9001-40.) • 523840.03—Ft Brake Pressure Short to Power. (Group 9001-40.) • 523840.04—Ft Brake Pressure Open or Short. (Group 9001-40.) • 523948.03—Ride Contrl Sol Short to Power. (Group 9001-40.) • 523948.05—Ride Contrl Sol Open Circuit. (Group 9001-40.) • 523948.06—Ride Contrl Sol High Current. (Group 9001-40.) • 524265.19—Check sum Error. (Group 9001-40.) Sealed Switch Module (SSM) Unit Diagnostic Trouble Codes • 000628.12—Controller Not Programmed. (Group 9001-50.) • 000629.12—SSM Watchdog Time Out. (Group 9001-50.) • 000639.12—SSM Lost Message. (Group 9001-50.) • 000639.19—SSM Lost CAN Communications. (Group 9001-50.) • 002033.09—SSM Lost Communications. (Group 9001-50.) • 523523.10—Rear Wiper Keypad Stuck. (Group 9001-50.) • 523524.10—Front Wiper Keypad Stuck. (Group 9001-50.) • 523525.10—Front Washer Keypad Stuck. (Group 9001-50.) • 523526.10—Reverse Fan Keypad Stuck. (Group 9001-50.) • 523527.10—Pin Disconnect Keypad Stuck. (Group 9001-50.) • 523528.10—A/C Keypad Stuck. (Group 9001-50.) • 523529.10—Work Lights Keypad Stuck. (Group 9001-50.) • 523530.10—Beacon Light Keypad Stuck. (Group 9001-50.) • 523532.10—Spin Control Keypad Stuck. (Group 9001-50.) • 523533.10—Clutch Cut-Off Keypad Stuck. (Group 9001-50.)

9015 20 11

Continued on next page

TM10229 (17MAR09)

9015-20-11

WS68074,0001192 –19–18SEP07–11/12

544J Loader (S.N. 611800— ) 032409

PN=679

References • 523534.10—Pilot Enable Keypad Stuck. (Group 9001-50.) • 523535.10—Ride Control Keypad Stuck. (Group 9001-50.) • 523536.10—Auto Transmission Keypad Stuck. (Group 9001-50.) • 523537.10—Drive Lights Keypad Stuck. (Group 9001-50.) • 523538.10—Keypad Not Used. (Group 9001-50.) • 523607.10—Return to Dig Keypad Stuck. (Group 9001-50.) • 523608.10—BHKO Keypad Stuck. (Group 9001-50.) • 523609.10—RTCarry Keypad Stuck. (Group 9001-50.) • 523610.10—Rear Washer Keypad Stuck. (Group 9001-50.)

WS68074,0001192 –19–18SEP07–12/12

9015 20 12

TM10229 (17MAR09)

9015-20-12

544J Loader (S.N. 611800— ) 032409

PN=680

References

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. 9015 20 13

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 9015-20.) See Reading Diagnostic Trouble Codes with Service ADVISOR Diagnostic Application. (Group 9015-20.)

MH66O88,00003E3 –19–22JAN07–1/1

TM10229 (17MAR09)

9015-20-13

544J Loader (S.N. 611800— ) 032409

PN=681

References

Service ADVISOR Connection Procedure 1. Connect EDL (2) or PDM (5) to computer.

TX1011710A

–UN–30AUG06

1—USB Cable 2—Electronic Data Link (EDL) 3—Diagnostic 9-Pin Connector Cable 4—Parallel Port Cable 5—Parallel Port Data Module (PDM)

EDL and Cables

TX1011712A

–UN–30AUG06

9015 20 14

PDM and Cables

MH66O88,00003E4 –19–22JAN07–1/3

2. Remove connector cover (7) from Service ADVISOR diagnostic 9-pin connector located at lower right console. –UN–12DEC06

3. Connect diagnostic 9-pin connector cable (3) to diagnostic 9-pin connector.

TX1014646A

7—Connector Cover

Service ADVISOR is a trademark of Deere & Company

TM10229 (17MAR09)

Continued on next page

9015-20-14

MH66O88,00003E4 –19–22JAN07–2/3

544J Loader (S.N. 611800— ) 032409

PN=682

References

6. If computer cannot connect to the CAN and the CAN connection LED does not come on, check all cable connections to the machine and computer. Make sure the key switch is in the ON position and the power LED is on.

TX1011711A

5. The CAN connection LED (8) will come on when computer connects to the CAN. The CAN connection LED may flicker—this is normal. When the CAN connection LED is on, the CAN is active and data is being transmitted.

–UN–30AUG06

4. Turn key switch to ON position. Power LED (9) must come on.

TX1011713A

–UN–30AUG06

8—CAN Connection LED (red) 9—Power LED (green)

MH66O88,00003E4 –19–22JAN07–3/3

TM10229 (17MAR09)

9015-20-15

544J Loader (S.N. 611800— ) 032409

PN=683

9015 20 15

References

Reading Diagnostic Trouble Codes with Service ADVISOR Diagnostic Application

TX1002938A

–UN–26JAN06

9015 20 16

Service ADVISOR—Diagnostic Trouble Codes 1—Diagnostics Shortcut Bar

2—Connected Diagnostic Trouble Codes Folder

3—Readings Tab

4—Connected Diagnostic Trouble Codes Tab

1. Connect service laptop to machine. See Service ADVISOR Connection Procedure. (Group 9015-20.)

3. From the shortcut bar, click Diagnostics to open the Diagnostics shortcut bar (1).

2. Open Service ADVISOR and display appropriate model information.

4. Click the Connected Diagnostic Trouble Codes folder (2).

Service ADVISOR is a trademark of Deere & Company

Continued on next page

TM10229 (17MAR09)

9015-20-16

MH66O88,00003E5 –19–22JAN07–1/3

544J Loader (S.N. 611800— ) 032409

PN=684

References

TX1002997A

–UN–26JAN06

5. Select the Connect to Model(s) on the Connection Options dialog box, and click OK.

Connection Options Dialog Box

Continued on next page

MH66O88,00003E5 –19–22JAN07–2/3

9015 20 17

TM10229 (17MAR09)

9015-20-17

544J Loader (S.N. 611800— ) 032409

PN=685

TX1003001A

–UN–26JAN06

References

Select Readings Adapter Dialog Box

9015 20 18

5—Available Adaptors Drop-Down List

6—Selected Models List

7—Change Selected Models Button

6. On the Select Readings Adapter dialog box, make sure the appropriate adapter is displayed. If not, select correct adapter from drop-down list (5). Options include:

10. Double-click an underlined code on the Connected Diagnostic Trouble Codes tab to display a detailed description for servicing that diagnostic trouble code.

• 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

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.

7. Make sure the correct machine to connect to displays in the Selected Models list (6). If not, click the Change Selected Models button (7).

11. Click the Connected Diagnostic Trouble Codes tab (4) to select and view details for additional diagnostic trouble codes.

8. Click OK to connect to machine. 9. After Service ADVISOR connects to machine, both the Readings tab (3) and Connected Diagnostic Trouble Codes tab (4) display.

MH66O88,00003E5 –19–22JAN07–3/3

TM10229 (17MAR09)

9015-20-18

544J Loader (S.N. 611800— ) 032409

PN=686

References

JDLink Connection Procedure—If Equipped (S.N. 615706— ) Connect to Machine Information Gateway (MIG) Controller 1. Locate the JDLink MMS direct connector (1).

2. Connect one end of AT335476 JDLink MMS Direct Cable to the JDLink MMS direct connector (1), and connect the other end to an ethernet port on the computer.

1 2

Connect to the GlobalTRACS Terminal (GTT) Controller

TX1027311

For more information on connecting to the MIG, see Connect PC Laptop to MIG Controller. (CTM10006.)

–UN–30JUL07

NOTE: AT335476 JDLink MMS Direct Cable is included in the AT347680 JDLink MMS Direct Kit.

JDLink MIG and GTT Connector Location

1. Locate the GT config tool adapter connector (2).

9015 20 19

1—JDLink MMS Direct Connector 2—GT config Tool Adapter Connector

NOTE: CV90-J1006 PC Based JDLink Config Tool Serial Cable is included in the 65-J1115-11 PC based JDLink Config Tool Kit. 2. Connect one end of CV90-J1006 PC Based JDLink Config Tool Serial Cable to the GT config tool adapter connector (2), and connect the other end to a COM port on the computer. NOTE: If the computer is not equipped with COM ports, a USB-to-serial adapter cable will be required to simulate a COM port for use with the GT Configuration Tool software. For more information on connecting to the GTT, see Connect PC Laptop to GlobalTRACS Terminal (GTT). (CTM10006.)

JDLink is a trademark of Deere & Company GlobalTRACS is a registered trademark of Qualcomm Incorporated

TM10229 (17MAR09)

9015-20-19

AA95137,0000C95 –19–01NOV07–1/1

544J Loader (S.N. 611800— ) 032409

PN=687

References

CAN Monitor Unit (CMU) Menu Structure— Service Mode NOTE: The navigation buttons MENU, BACK, NEXT, and SELECT are located at the right side of the CMU display. There are two versions of the CAN monitor unit (CMU) main menu structure: Operator Mode and Service Mode. Operator Mode is used to change user preferences, view operational settings, and view diagnostic trouble codes (DTCs). To enter Operator Mode, turn key switch to the ON position, then push and immediately release the MENU button. Service Mode provides additional items not available in Operator Mode. This feature allows a service technician to change operational settings and clear DTCs. It also allows the technician to monitor functions for diagnostic and testing purposes. 9015 20 20

To enter Service Mode, turn the key switch to the ON position, then push and hold the MENU button down for approximately 5 seconds until a beep is heard and Service Mode temporarily appears on the Main Menu. NOTE: When Service Mode is accessed, the Main Menu will stay in Service Mode even if the CMU display is returned to the home screen. As long as the key switch is kept in the ON position, the MENU button only needs to be pushed once to re-enter Service Mode. Cycling the key switch to OFF, then back to ON resets the CMU menu mode. Pushing and releasing the MENU button after the key switch has been cycled, only allows access to the Operator Mode menus. To navigate through the menu structure, do the following: • Push the BACK button to go back one screen. • Push the NEXT button to scroll down the menu. • Push the SELECT button to select the highlighted item.

Continued on next page

TM10229 (17MAR09)

9015-20-20

CS33148,00023B2 –19–22MAY07–1/39

544J Loader (S.N. 611800— ) 032409

PN=688

References Selecting an item in the main menu will bring up the corresponding submenu. Selecting an item in the submenu will bring up the next corresponding submenu, if applicable. Continue navigating through the submenus until the appropriate submenu is obtained, then select the desired screen.

CS33148,00023B2 –19–22MAY07–2/39

1. Codes 2. Machine Settings 3. Diagnostics 4. Monitor Settings 5. Machine Config (service mode only)

1/5

–19–10NOV03

Main Menu 1-Codes 2-Machine Settings 3-Diagnostics 4-Monitor Settings 5-Machine Config

T196107

MAIN MENU—When in service mode, the main menu consists of the following submenus:

CS33148,00023B2 –19–22MAY07–3/39

1. Codes: The codes menu consists of the following submenus:

1/3

T196108

–19–10NOV03

Codes 1-Active Codes 2-Stored Codes 3-Clear Codes

1. Active Codes 2. Stored Codes 3. Clear Codes (service mode only)

Continued on next page

TM10229 (17MAR09)

9015-20-21

CS33148,00023B2 –19–22MAY07–4/39

544J Loader (S.N. 611800— ) 032409

PN=689

9015 20 21

References

1/3

Active Codes

1/3

–19–15DEC06

Active Codes Diff Lck Sol Open Circuit TCU 746.5

Wire P76 RED, T02 BLU Conn-Pin: X23-53, 57 Section: SE24

TX1016601

9015 20 22

–19–15DEC06

TX1016603

1. Active Codes: This menu displays the diagnostic trouble codes (DTCs) that are currently active on the machine. A detailed description of the code, the source controller (the controller that is reporting a problem), and the SPN.FMI number. a. Push NEXT to display the next code or BACK to go back to (1). b. Push SELECT to view more information about the DTC. The next screen will show information on what to check to fix the code.

Continued on next page

TM10229 (17MAR09)

9015-20-22

CS33148,00023B2 –19–22MAY07–5/39

544J Loader (S.N. 611800— ) 032409

PN=690

References

1/20

Stored Codes

1/20

–19–15DEC06

Stored Codes Diff Lck Sol Open Circuit TCU 746.5

TX1016600

2. Stored Codes: This menu displays the DTCs that are stored in memory. A detailed description of the code, the source controller (controller reporting the problem), and the SPN.FMI number. a. Push NEXT to display the next code or BACK to go back to (1). b. Push SELECT to view more information about the DTC. The next screen will show the number of occurrences, when the code first and last appeared, and the sensor reading at that time. c. Push SELECT to view information on what to check to fix the code. 3. Clear Codes: (service mode only) This menu will clear all stored DTCs on the machine. Push SELECT to clear the codes or push BACK to get back to (1).

Stored Codes

TX1016598

Last: 108.1 hrs

1/20

TX1016597

Wire P76 RED, T02 BLU Conn-Pin: X23-53, 57 Section: SE24

–19–15DEC06

First: 85.0 hrs

–19–15DEC06

Occurrences: 151

CS33148,00023B2 –19–22MAY07–6/39

1. Quick Shift 2. Auto to 1st 3. Job Timer 4. Stopwatch 5. Ride Control

Continued on next page

TM10229 (17MAR09)

9015-20-23

1/5 –19–30NOV06

Machine Settings 1-Quick Shift 2-Auto to 1st 3-Job Timer 4-Stopwatch 5-Ride Control

TX1015661

2. Machine Settings: The machine settings menu consists of the following submenus:

CS33148,00023B2 –19–22MAY07–7/39

544J Loader (S.N. 611800— ) 032409

PN=691

9015 20 23

References

1/2

T193358

Quick Shift Down/Up Down Only

–19–05AUG03

1. Quick Shift: This menu sets the mode for the quick shift switch (S7). Push SELECT to select the desired mode. a. Down/Up—The transmission will shift down one gear with one push and then shift up one gear with a second push. b. Down Only—The transmission will shift down one gear with each push.

CS33148,00023B2 –19–22MAY07–8/39

1/2

T193359

–19–05AUG03

Auto to 1st Off On

Job Timer SELECT to Reset BACK to Exit 0.0 hours

T193360

3. Job Timer: This menu controls a continually running job timer. a. Push SELECT to reset the job timer. b. Push BACK to get back to (2).

–19–05AUG03

CS33148,00023B2 –19–22MAY07–9/39

4. Stopwatch: This menu controls a stopwatch. a. Push SELECT to start and stop the stopwatch. b. Push NEXT to reset the stopwatch. c. Push BACK to get back to (2).

STOPWATCH SELECT on/off NEXT to reset BACK to Exit 00:00:00.0 Continued on next page

TM10229 (17MAR09)

9015-20-24

–19–30SEP03

CS33148,00023B2 –19–22MAY07–10/39

T193361

9015 20 24

2. Auto to 1st: This menu sets what gear the transmission will start in when automatic mode is selected. Push SELECT to select the desired mode. a. Off—The transmission will start out in second gear when automatic mode is selected. b. On—The transmission will start out in first gear when automatic mode is selected.

CS33148,00023B2 –19–22MAY07–11/39

544J Loader (S.N. 611800— ) 032409

PN=692

References 5. Ride Control: This menu selects the speed when ride control becomes active. a. Push BACK to decrease. b. Push NEXT to increase. c. Push SELECT to store. d. Push MENU to exit.

Ride Control –19–30NOV06

BACK to decrease NEXT to increase SELECT to Store

TX1015662

5.5 km/h

CS33148,00023B2 –19–22MAY07–12/39

3. Diagnostics: The diagnostics menu consists of the following submenus:

1/9

–19–08AUG08

9015 20 25

TX1015663

Diagnostics 1-Battery Monitor 2-Engine Sensors 3-Transmission 4-Hydraulic 5-Machine 6-Mach Switches 7-Switch Module 8-Machine ID 9-More Diagnostics

1. Battery Monitor 2. Engine Sensors 3. Transmission 4. Hydraulic 5. Machine 6. Machine Switches 7. Switch Module 8. Machine I.D. 9. More Diagnostics

CS33148,00023B2 –19–22MAY07–13/39

1. Battery Monitor: This menu displays the voltage level of both batteries. Push BACK to get back to (3). NOTE: If 12-volt center tap wire is not connected to the right battery, left battery will display system voltage and right battery will display 0.0.

13.7

Right Battery

T193363

13.7

–19–05AUG03

Battery Monitor Left Battery

Continued on next page

TM10229 (17MAR09)

9015-20-25

CS33148,00023B2 –19–22MAY07–14/39

544J Loader (S.N. 611800— ) 032409

PN=693

References

Engine Sensors 1-Temperatures 2-Pressure/Misc

TX1015666

• Temperatures—Displays current engine temperature sensor readings.

1/2 –19–30NOV06

2. Engine Sensors: The engine sensors menu consists of the following submenus. a. Temperatures b. Pressure/Misc

Temperatures 1-Display All 2-Coolant Temp 3-MAT 4-Fuel Temp 6-Comp Inlet Temp (not used) 5-CAC Output Temp (not used) 7-EGR Exhst Temp (not Used)

• Pressure/Misc—Displays current engine system pressures, throttle percentage, and turbo speed.

9015 20 26

Pressure/Misc 1-Display All 2-Oil Pressure 3-Throttle Sensor 4-Fuel Pressure (not used) 5-MAP (not used) 6-Exhaust (not used) 7-Turbo Speed (not used) 8-Engine Intercooler (not used)

Continued on next page

TM10229 (17MAR09)

9015-20-26

CS33148,00023B2 –19–22MAY07–15/39

544J Loader (S.N. 611800— ) 032409

PN=694

Transmission 1/7 1-Display All 2-Oil Temp 3-TC Input Speed 4-TC Output Speed 5-Clutch Speed 6-Output Shaft Spd 7-Clutch Cutoff V

TX1016596

3. Transmission: This menu shows the current readings of the sensors that are monitoring the transmission. • Display All—All of the transmission sensors will be displayed individually as the NEXT button is pushed. • Oil Temp—The transmission oil temperature as measured by the transmission oil temperature sensor (B32) is displayed. • TC Input Speed—The torque converter input speed (engine speed) as measured by the torque converter input speed sensor (B28) is displayed. • TC Output Speed—The torque converter output speed as measured by the torque converter output speed sensor (B29) is displayed. • Clutch Speed—The clutch speed as measured by the internal clutch speed sensor (B30) is displayed. • Output Shaft Spd—The output shaft speed sensor as measured by the transmission output speed sensor (B31) is displayed. • Clutch Cutoff V—The clutch cutoff sensor voltage as measured by the clutch cutoff sensor (B33) is displayed.

–19–15DEC06

References

9015 20 27

CS33148,00023B2 –19–22MAY07–16/39

Continued on next page

TM10229 (17MAR09)

9015-20-27

1/4 –19–30NOV06

Hydraulic 1-Display All 2-Oil Temp 3-Hyd Sys Press 4-Brake Accum

TX1015667

4. Hydraulic: This menu shows the current readings of the sensors that are monitoring the hydraulic system. • Display All—All of the hydraulic sensors will be displayed individually as the NEXT button is pushed. • Oil Temp—The hydraulic oil temperature as measured by the hydraulic oil temperature sensor (B15) is displayed. • Hyd Sys Press—The hydraulic system pressure as measured by the hydraulic system pressure sensor (B8) is displayed. • Brake Accum—The brake accumulator pressure is displayed.

CS33148,00023B2 –19–22MAY07–17/39

544J Loader (S.N. 611800— ) 032409

PN=695

References

1/6

–19–07DEC06

Machine 1-Display All 2-Boom Position 3-Bucket Position 4-Fuel Level 5-Entry Air Temp 6-Fan Speed %

TX1016249

5. Machine: This menu shows the current readings of various sensors on the machine. • Display All—All of the sensors will be displayed. • Boom Position—The boom position is displayed as the percentage of the total boom travel as measured by the analog BHKO/RTC position sensor (B45). • Bucket Position—The bucket position is displayed as the percentage of the total bucket travel as measured by the analog RTD position sensor (B37). • Fuel Level—The fuel level is displayed as the percentage of a full tank as measured by the fuel level sensor (B17). • Entry Air Temp—The entry air (ambient air) temperature is displayed as measured by the ambient air temperature sensor (B10). • Fan Speed %—The machine cooling fan speed is displayed as a percentage of maximum speed. 9015 20 28

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TM10229 (17MAR09)

9015-20-28

CS33148,00023B2 –19–22MAY07–18/39

544J Loader (S.N. 611800— ) 032409

PN=696

References

Mach Switches 1-Cab 2-Brakes 3-Transmission 4-Steering 5-Misc

TX1015670

• Cab Switches—Displays the state (ON/OFF) of switches in the cab.

1/5

–19–30NOV06

6. Mach Switches: The machine switches menu shows the state (ON/OFF) of the switches on the machine. The machine switches menu consists of the following submenus. a. Cab b. Brakes c. Transmission d. Steering e. Misc

Cab Switches 1-Start Signal 2-4 Way Flashers 3-Blower 4-Front Wiper Park 5-Rear Wiper Park 6-Left Turn 7-Right Turn

9015 20 29

• Brake Switches—Displays the state (ON/OFF) of brake switches. Brake Switches 1-Brake Accum Chg 2-Brake Light 3-Park Pressure 4-Park Rocker off 5-Park Rocker Cnt

• Transmission Switches—Displays the state (ON/OFF) of transmission switches. Transmission Switches 1-Kick Down 2-Joy Stick Gear Up 3-Joy Stick Gear Down 4-Trans Oil Filter Res

• Steer Switches—Displays the state (ON/OFF) of the steering pressure switch. Steer Switches 1-Steering Press

• Misc Switches—Displays the state (ON/OFF) of miscellaneous switches.

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TM10229 (17MAR09)

9015-20-29

CS33148,00023B2 –19–22MAY07–19/39

544J Loader (S.N. 611800— ) 032409

PN=697

References

Misc Switches 1-Hyd Oil Filter Res 2-Return to Dig 3-Fuel Pump switch CS33148,00023B2 –19–22MAY07–20/39

7. Switch Module: This menu tests the momentary switches in the sealed switch module (SSM). When you press the switch, the matching square on the monitor display will darken if the switch is working properly.

–19–22SEP03

SSM Test

T193389

Press any Button..

CS33148,00023B2 –19–22MAY07–21/39

Machine ID 1-CMU 2-FLC 3-SSM 4-TCU 5-ECU 6-Serial #

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TM10229 (17MAR09)

1/6

–19–30NOV06

8. Machine ID: This menu displays the serial numbers, part numbers, software numbers, and software versions for various devices on the machine. • CMU—The serial number, part number, software number, and software version are displayed for the CAN Monitor Unit (CMU) (H2). • FLC—The serial number, part number, software number, and software version are displayed for the flex load controller (FLC) (A2). • SSM—The part number, software number, and software version are displayed for the sealed switch module (SSM) (A6). • TCU—The machine model number, machine serial number, TCU part number, and software version are displayed for the transmission control unit (TCU) (A3). • ECU—The option code, ECU part number, software version, and software number are displayed for the (ECU) (A1). • Serial #—The serial number of the machine is displayed.

TX1015672

9015 20 30

9015-20-30

CS33148,00023B2 –19–22MAY07–22/39

544J Loader (S.N. 611800— ) 032409

PN=698

References 9. More Diagnostics: This menu displays the Forward, Neutral, Reverse (FNR) selector.

More Diagnostics 1-FNR Selector

TX1015664

–19–30NOV06

NOTE: The forward, neutral, reverse (FNR) selector, is also known as the Transmission Control Lever (TCL) or the shift switch (if equipped with joystick pilot controller).

1/1

• FNR Selector—Displays the status of the FNR selector (TCL) (shift switch).

CS33148,00023B2 –19–22MAY07–23/39

Monitor Settings 1-Units 2-Backlighting 3-LCD Contrast 4-Language 5-Hide Main Menu

1/5

TX1015676

1. Units 2. Backlighting 3. LCD Contrast 4. Language 5. Hide Main Menu

9015 20 31

–19–30NOV06

4. Monitor Settings: The monitor settings menu consists of the following submenus:

CS33148,00023B2 –19–22MAY07–24/39

1/2

T193395

Units English Metric

–19–05AUG03

1. Units: This menu sets the units for all functions of the CMU. Push SELECT to select the desired mode. a. English—All units will be English standard units. b. Metric—All units will be metric units.

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TM10229 (17MAR09)

9015-20-31

CS33148,00023B2 –19–22MAY07–25/39

544J Loader (S.N. 611800— ) 032409

PN=699

References 2. Backlighting: This menu sets the amount of backlighting for the CMU. The backlighting can be adjusted in increments of 1, from 0 (no light) to 10 (brightest). a. Push BACK to decrement the value. b. Push NEXT to increment the value. c. Push SELECT to store the current value. Once SELECT is pushed, the CMU will confirm that the value is stored. To exit, push MENU.

T193397

–19–15OCT03

Backlighting BACK to decrease NEXT to increase SELECT to store 10

CS33148,00023B2 –19–22MAY07–26/39

T193398

–19–22SEP03

LCD Contrast BACK to decrease NEXT to increase SELECT to store 9

CS33148,00023B2 –19–22MAY07–27/39

1/3

T194687

Language English Spanish French

–19–01OCT03

4. Language (service mode only): This menu sets the language for all functions of the CMU. Push SELECT to select the desired language. a. English—The menu language will be set to English. b. Spanish—The menu language will be set to Spanish. c. French—The menu language will be set to French.

5. Hide Main Menu: This menu sets the display mode for the main menu. Push SELECT to select the desired mode. a. Hide Main Menu—The main menu will not be available. The service menu will have to be entered to access any menus. b. Show Main Menu—The main menu will be available when the MENU button is pressed.

Hide Main Menu 1/2 Hide Main Menu Show Main Menu

–19–05AUG03

CS33148,00023B2 –19–22MAY07–28/39

T193396

9015 20 32

3. LCD Contrast: This menu sets the amount of contrast for the CMU LCD. The contrast can be adjusted in increments of 1, from 1 (lightest) to 10 (darkest). a. Push BACK to decrement the value. b. Push NEXT to increment the value. c. Push SELECT to store the current value. Once SELECT is pushed, the CMU will confirm that the value is stored. To exit, push MENU.

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TM10229 (17MAR09)

9015-20-32

CS33148,00023B2 –19–22MAY07–29/39

544J Loader (S.N. 611800— ) 032409

PN=700

Machine Config 1/8 1-Manufacturer 2-Machine Model 3-Tire Sizes 4-Enable Options 5-Max High Gear 6-Low Idle Adjust 7-Trans Clutch Cal 8-More Machine Config

1. Manufacturer 2. Machine Model 3. Tire Sizes 4. Enable Options 5. Max High Gear 6. Low Idle Adjust 7. Trans Clutch Cal 8. More Machine Config

TX1016595

5. Machine Config (service mode only): The machine configuration menu consists of the following submenus.

–19–15DEC06

References

CS33148,00023B2 –19–22MAY07–30/39

9015 20 33

1. Manufacturer: This menu shows the manufacturer of the machine (John Deere or Bell).

–19–04DEC06

1/2

TX1016003

Manufacturer John Deere Bell

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TM10229 (17MAR09)

9015-20-33

CS33148,00023B2 –19–22MAY07–31/39

544J Loader (S.N. 611800— ) 032409

PN=701

References

1/8

T194689

Machine Model 444 544 624 644 724 744 824 844

–19–18SEP03

2. Machine Model: This menu sets the machine model for the CMU menu system. Push SELECT to select the machine model. • 444—The machine model will set to 444. • 544—The machine model will set to 544. • 624—The machine model will set to 624. • 644—The machine model will set to 644. • 724—The machine model will set to 724. • 744—The machine model will set to 744. • 824—The machine model will set to 824. • 844—The machine model will set to 844.

9015 20 34

CS33148,00023B2 –19–22MAY07–32/39

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9015-20-34

1/13

–19–30NOV06

Tire Sizes 17.5 600/65 20.5 650/65 23.1 23.5 750/65 28 L More options 26.5 800/65 29.5 875/65

TX1015680

3. Tire Sizes: This menu displays the various tire options for the machine and allows the operator to select the proper tire size. Push NEXT until the machines tire size is highlighted; push SELECT to select the tire size. The CMU will confirm the change. • 17.5—The tire size will be set to 17.5. • 600/65—The tire size will be set to 600/65. • 20.5—The tire size will be set to 20.5. • 650/65—The tire size will be set to 650/65. • 23.1—The tire size will be set to 23.1. • 23.5—The tire size will be set to 23.5. • 750/65—The tire size will be set to 750/65. • 28 L—The tire size will be set to 28 L. • More options • 26.5—The tire size will be set to 26.5. • 800/65—The tire size will be set to 800/65. • 29.5—The tire size will be set to 29.5. • 875/65—The tire size will be set to 875/65.

CS33148,00023B2 –19–22MAY07–33/39

544J Loader (S.N. 611800— ) 032409

PN=702

Enable Options 1/16 Work Lights Aux Front Lights AC Engine PreHeat Ride Control Fan Drive Reverse Fan Beacon More Options Spin Control Pin Disconnect Axle Disconnect Sec. Steering Canopy Joystick Steer Rear Work Lights

NOTE: If the machine is equipped with a certain option, the option must be enabled in this menu for it to function. • Work Lights—The front and rear work lights will be enabled or disabled. • Aux Front Lights—The auxiliary front lights will be enabled or disabled. • AC—Air conditioning will be enabled or disabled. • Engine PreHeat—The engine preheaters will be enabled or disabled. • Ride Control—Ride control will be enabled or disabled. • Fan Drive—The proportional fan drive will be enabled or disabled. • Reverse Fan—The reverse fan drive will be enabled or disabled. • Beacon—The rotary beacon light will be enabled or disabled. • More Options—This will bring up the following options. • Spin Control—Spin control will be enabled or disabled. • Pin Disconnect—The pin disconnect feature will be enabled or disabled. • Axle Disconnect—The axle disconnect feature will be enabled or disabled. • Sec. Steering—The secondary steering system will be enabled or disabled. • Canopy—The wiper and washer systems will be enabled or disabled. • Joystick Steer—The joystick steer will be enabled or disabled. • Rear Work Lights—The rear work lights will be enabled or disabled.

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TM10229 (17MAR09)

9015-20-35

TX1015683

4. Enable Options: This menu enables and disables machine options.

–19–30NOV06

References

CS33148,00023B2 –19–22MAY07–34/39

544J Loader (S.N. 611800— ) 032409

PN=703

9015 20 35

References

1/3

TX1016004

Max High Gear 4 3 2

–19–04DEC06

5. Max High Gear: This menu sets the maximum high gear. Factory default is 4th gear. • 4—Maximum gear will be 4th. • 3—Maximum gear will be 3rd. • 2—Maximum gear will be 2nd.

Low Idle Adjust BACK to decrease NEXT to increase SELECT to Store 0

9015 20 36

TX1016002

6. Low Idle Adjust: This menu allows adjustment of the low idle. a. Push BACK to decrease the idle speed. b. Push NEXT to increase the idle speed c. Push SELECT to store the idle speed. d. To exit, push MENU.

–19–04DEC06

CS33148,00023B2 –19–22MAY07–35/39

CS33148,00023B2 –19–22MAY07–36/39

7. Trans Clutch Cal: This menu performs the transmission clutch calibration procedure. Before the procedure can be started, the following conditions must be satisfied: • Shifter in Neutral • Park Brake Applied • Engine Running and Below 1100 rpm • Transmission Oil Temperature at 77°C (170°F)

Press SELECT to Start BACK to Exit

Push SELECT to start the procedure. The CMU broadcasts the request across CAN to the TCU, and the TCU will initiate the procedure. If any errors occur during the procedure, they will be displayed on the CMU. Once the procedure is completed, the CMU will require the key switch to be cycled to off, then the engine restarted.

TX1015688

Warning Proceeding will Calibrate Transmission

–19–30NOV06

Trans Clutch Cal

For more information on this procedure, see Transmission Control Unit (TCU)—Electronic Clutch Calibration. (Group 9020-20.)

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9015-20-36

CS33148,00023B2 –19–22MAY07–37/39

544J Loader (S.N. 611800— ) 032409

PN=704

References 8. More Machine Config: This menu displays the Fan Speed % menu.

1/1

TX1015687

–19–30NOV06

More Mach Config 1-Fan Speed %

Fan Speed % BACK to decrease NEXT to increse SELECT to Store 90

T194694

9. Fan Speed %: This menu temporarily sets the proportional fan speed. The fan speed can be adjusted in increments of 10, from 0% (stopped) to 100% (full speed). a. Push BACK to decrement the value. b. Push NEXT to increment the value. c. Push SELECT to store the current value. Once SELECT is pushed, the fan will operate at the percentage selected until the key switch is cycled. To exit, push MENU.

–19–08AUG08

CS33148,00023B2 –19–22MAY07–38/39

CS33148,00023B2 –19–22MAY07–39/39

TM10229 (17MAR09)

9015-20-37

544J Loader (S.N. 611800— ) 032409

PN=705

9015 20 37

References

Flex Load Controller (FLC) Fault Exceptions The Flex Load Controller (FLC) controls the functions that are hardwired to the controller using three types of high current output drivers. The driver is a solid state device that acts like a relay, using the internal microcontroller’s low voltage outputs to control 24 volt, high current signals. The three different drivers are: • Dual Channel 3 A (per channel) Driver • Single Channel 6 A Driver • Single Channel 20 A Driver Dual Channel 3 A Driver Usage NOTE: Functions are paired on most of the dual channel drivers; however, some are paired with an unused output. These are labeled as “SPARE”.

9015 20 38

• Driver #1 and #2 – Left and Right Brake Lights (E16, E17) – SPARE • Driver #3 and #4 – Rear Washer Pump (M4) – Rear Wiper High Speed (M5) • Driver #5 and #6 – Front Washer Pump (M2) – Front Wiper High Speed (M3) • Driver #7 and #8 – Secondary Steering Pump (M8) – Pilot Enable Solenoid (Y14), Boom Down Accumulator Solenoid (Y15) • Driver #9 and #10 – Reverse Fan Solenoid (Y38) • Driver #11 and #12 – Pin Disconnect Solenoid (Y20) – Ride Control (On/Off) Solenoids (Y18, Y34) • Driver #13 and #14 – Float Detent Coil – Ride Control Boom Solenoid (Y17) • Driver #15 and #16 – Return-to-Dig Detent Coil – SPARE • Driver #17 and #18 – Right Turn Lights (E4, E5) – Left Turn Lights (E2, E3)

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TM10229 (17MAR09)

9015-20-38

MH66O88,00003E7 –19–08JAN07–1/3

544J Loader (S.N. 611800— ) 032409

PN=706

References • Driver #25 and #26 – Boom Height Kickout Detent Coil – A/C Compressor Clutch Solenoid (Y16) • Driver #27 and #28 – SPARE – Marker Lights, Tail Lights, License Plate Light (E6, E7, E8, E9, E10) 6 A Driver Usage NOTE: These drivers are one channel with two outputs. • Driver #19—Left and Right Drive Lights (E11, E12) • Driver #20—Left and Right Rear Work Lights (E22, E23) • Driver #21—Rear Wiper Low Speed (M5) • Driver #22—Front Wiper Low Speed (M3) • Driver #23—Left and Right Front Work Lights (E20, E21) • Driver #29—Left and Right Docking Lights (E24, E25) 20 A Driver Usage 9015 20 39

• Driver #24—Beacon Light (E15) The FLC has the capability to detect driver faults (open circuits, short circuits, etc.) and display diagnostic trouble codes (DTCs) for these faults. There are certain situations that the FLC does not have the ability to detect the proper fault. Following is a summary of the known exceptions. • On a single channel driver, the FLC cannot tell the difference between an open circuit and a short to power, or a short to ground and an overload. • When changing the model in the CMU, the monitor alarm will sound if the setting was stored correctly. If the monitor does not sound, the keyswitch must be cycled before changing options for them to be stored correctly. • If the beacon light (E15) output reaches a 20 A load, the driver will shut off and the function must be turned off then on to reset the driver. • A short to power for the reverse fan solenoid (Y38) cannot be detected if the brake lights (E16, E17) are on, regardless if the function is enabled or disabled. • Multiple faults on the same dual channel 3 A driver may result in an unexpected DTC for the circuits controlled by the driver.

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9015-20-39

MH66O88,00003E7 –19–08JAN07–2/3

544J Loader (S.N. 611800— ) 032409

PN=707

References

9015 20 40

• If the high speed and low speed wires are swapped on the front or rear wiper motor (M3 or M5), high speed will operate the wiper at low speed, low speed will operate like intermittent, and intermittent will not park correctly. • If both outputs on a dual channel 3 A driver are open circuit and one channel is turned one, the result is an open circuit fault for both channels. • On a dual channel 3 A or single channel 6 A driver, if one output is shorted to ground and the other output is an open circuit, the result is a high current fault for both outputs. • On a dual channel 3 A or single channel 6 A driver, if one output is shorted to power and the other output is an open circuit, no DTCs will be active as a result. • A short to power can only be detected on a dual channel 3 A driver output if the function is turned off. • A short to power can only be detected on a single channel 6 A driver output if the function is turned on. • On a dual channel 3 A driver, if one channel is spare or option that is not enabled and it is shorted to power, the resulting fault is a short to power on the other channel. • If a short to ground exists on a dual channel 3 A driver, the output will not reset every second. • If a short to ground exists on a single channel 6 A driver, the output will reset every 5 seconds up to 20 consecutive times. • If a short to ground exists on a single channel 20 A driver, the function must be turned off then on to reset the output. • If a fault exists for an output, that fault must be cleared by turning the function off then on before a different fault for the same output can exist. • If the FLC is not receiving the park signal from a wiper motor and the corresponding washer pump is activated, the wiper will cycle 6 times before stopping. • If a wiper is stalled and high speed is selected, a park signal fault will result. • If the wiper motor is disconnected or an open circuit in the park signal exists, the CMU will display the wiper in park position.

MH66O88,00003E7 –19–08JAN07–3/3

TM10229 (17MAR09)

9015-20-40

544J Loader (S.N. 611800— ) 032409

PN=708

References

TX1008899

–UN–05JUL06

CAN Circuit Test

Generic CAN Circuit Schematic 1—Controller 1 2—Controller 2

3—Service ADVISOR Connector 4—Termination Resistor 1

5—Termination Resistor 2 6—CAN Hi Wire (Yellow) 7—CAN Lo Wire (Green)

NOTE: This diagram and story are written using a generic 2-controller network. For networks with

Service ADVISOR is a trademark of Deere & Company

8—Grounded Shield Wire (Black)

more than two controllers, repeat last step for all controllers if necessary.

MH66O88,00003E8 –19–22JAN07–1/1

Controller Area Network (CAN) Diagnostics

– – –1/1

TM10229 (17MAR09)

9015-20-41

544J Loader (S.N. 611800— ) 032409

PN=709

9015 20 41

References 1 System Check

Turn key switch ON. Locate the Service ADVISOR connector and establish machine connection. Service ADVISOR System Computer Connection, Manual (TM133991). Do all controllers show up under connected controllers?

YES: Go to CAN Termination Resistor Check. (Group 9015-20.) NO: Not all controllers show up. Check fuses for the missing controller(s). See Fuse and Relay Specifications for fuse information. If OK, Perform Controller Check (Group 9015-20.) for missing controller. NO: A connection could not be established. Check fuse for the Service ADVISOR connector. See Fuse and Relay Specifications for fuse information. If OK, perform CAN Termination Resistor Check. (Group 9015-20.)

9015 20 42

Service ADVISOR is a trademark of Deere & Company

2 CAN Termination Resistor Check

– – –1/1

Turn key switch OFF. Locate, remove and label each CAN termination resistor. Using a multimeter, measure the resistance of each of the termination resistors (4 and 5). Are resistances between 110-130 ohm ?

YES: Install resistors and perform CAN Hi Wire Voltage Check. (Group 9015-20.) NO: Replace resistor. Install new resistor and perform CAN Hi Wire Voltage Check. (Group 9015-20.)

– – –1/1

TM10229 (17MAR09)

9015-20-42

544J Loader (S.N. 611800— ) 032409

PN=710

References 3 CAN Hi Wire Voltage Check

Turn key switch ON. Using a multimeter, measure the voltage from pin C (CAN Hi) to pin A (ground) of Service ADVISOR connector (3).

YES: Perform CAN Lo Wire Voltage Check. (Group 9015-10.)

Is voltage between 2.50—3.50 volts? NO: System voltage is measured. A short-to-power exists on the CAN Hi wire. Check CAN Hi voltage at one controller at a time to locate short circuit. Reference the System Functional Schematic, Wiring Diagram and Component Location Master Legend to locate wires. Repair or replace harness as necessary. NO: Zero volts are measured. Perform CAN Hi Wire Circuit Check. (Group 9015-10.) NO: Voltage is out of range but greater than 0 9015 and less than system 20 voltage. Remove one 43 controller at a time and recheck voltage. When voltage is in range, check harness of disconnected controller for short circuits. Repair or replace harness as necessary.

Service ADVISOR is a trademark of Deere & Company

TM10229 (17MAR09)

– – –1/1

9015-20-43

544J Loader (S.N. 611800— ) 032409

PN=711

References 4 CAN Lo Wire Voltage Check

Using a multimeter, measure voltage from pin D (CAN Lo) to pin A (ground) of Service ADVISOR connector (3).

YES: Perform CAN Hi Wire Circuit Check. (Group 9015-10.)

Is voltage between 1.50—2.50 volts? NO: System voltage is measured. A short-to-power exists on the CAN Lo wire. Check CAN Lo voltage at one controller at a time to locate the short circuit. Reference the System Functional Schematic, Wiring Diagram and Component Location Master Legend to locate wires. Repair or replace harness as necessary. NO: Zero volts are measured. Perform CAN Lo Wire Circuit Check. (Group 9015-10.) NO: Voltage is out of range but greater than 0 and less than system voltage. Remove one controller at a time and recheck voltage. When voltage is in range, check harness of disconnected controller for short circuits. Reference the System Functional Schematic, Wiring Diagram and Component Location Master Legend to locate wires. Repair or replace harness as necessary.

9015 20 44

Service ADVISOR is a trademark of Deere & Company

TM10229 (17MAR09)

– – –1/1

9015-20-44

544J Loader (S.N. 611800— ) 032409

PN=712

References 5 CAN Hi Wire Circuit Check

Using a multimeter, measure continuity between pin C (CAN Hi) and pin A (ground) of Service ADVISOR connector (3). Is continuity measured?

YES: A short-to-ground exists on the CAN Hi wire. Check CAN Hi voltage at one controller at a time to locate the short circuit. Reference the System Functional Schematic, Wiring Diagram and Component Location Master Legend) to locate wires. Repair or replace harness as necessary. NO: An open circuit exists on the CAN Hi wire. Reference the System Functional Schematic, Wiring Diagram and Component Location Master Legend to locate wires. Repair or replace harness as necessary. 9015 20 45

Service ADVISOR is a trademark of Deere & Company

6 CAN Lo Wire Circuit Check

– – –1/1

Using a multimeter, measure continuity between pin D (CAN Lo) and pin A (ground) of Service ADVISOR connector (3). Is continuity measured?

YES: A short-to-ground exists on the CAN Lo wire. Check CAN Lo voltage at one controller at a time to locate the trunk of the harness where the short is located. Reference the System Functional Schematic, Wiring Diagram and Component Location Master Legend to locate wires. Repair or replace harness as necessary. NO: An open circuit exists on the CAN Lo wire. Reference the System Functional Schematic, Wiring Diagram and Component Location Master Legend to locate wires. Repair or replace harness as necessary.

Service ADVISOR is a trademark of Deere & Company

TM10229 (17MAR09)

– – –1/1

9015-20-45

544J Loader (S.N. 611800— ) 032409

PN=713

References 7 Controller Check

Turn key switch OFF. Locate controller. Using the System Functional Schematic, Wiring Diagram and Component Location Master Legend locate the CAN wires and disconnect the appropriate connector. Using a multimeter, measure resistance between the CAN Hi and CAN Lo wires Is resistance between 55—65 ohms?

YES: Connect controller. Repeat Controller Check for all other controllers. NO: An open or short circuit exists in one of the CAN wires. Work from the controller back to the main harness checking the CAN Hi and Lo wires for open and short circuit

– – –1/1

9015 20 46

TM10229 (17MAR09)

9015-20-46

544J Loader (S.N. 611800— ) 032409

PN=714

References

Electrical Component Specifications Item

Measurement

Specification

B1—Engine Coolant Temperature Sensor

Resistance

120.6—147.4 [OHgr ] @ 60°C (140°F) 46.8—56.3 [OHgr ] @ 90°C (194°F) 34.6—42.35 [OHgr ] @ 100°C (212°F)

B3—Camshaft Position Sensor

Resistance

2.7—3.3 k[OHgr ]

B4—Crankshaft Position Sensor

Resistance

2.7—3.3 k[OHgr ]

B5—Fuel Temperature Sensor

Resistance

90—108 k[OHgr ] @ -40°C (-40°F) 26—31 k[OHgr ] @ -20°C (-4°F) 8.7—10.2 k[OHgr ] @ 0°C (32°F) 3.3—3.8 k[OHgr ] @ 20°C (68°F) 1.4—1.6 k[OHgr ] @ 40°C (104°F) 648—708 [OHgr ] @ 60°C (140°F) 317—350 [OHgr ] @ 80°C (176°F) 170—186 [OHgr ] @ 100°C (212°F) 97—105 [OHgr ] @ 120°C (248°F)

B7—Manifold Air Temperature Sensor

Resistance

B10—Ambient Air Temperature Sensor

Resistance

B14—Analog Throttle Position Sensor

Resistance between pins A and B

280—420 [OHgr ] Minimum Value 4.28—6.42 k[OHgr ] Maximum Value 4—6 k[OHgr ]

Resistance Between Pins A and C

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9015-20-47

MH66O88,00003EA –19–08JAN07–1/5

544J Loader (S.N. 611800— ) 032409

PN=715

9015 20 47

References

Item

Measurement

Specification

B15—Hydraulic Oil Temperature Sensor

Resistance

B17—Fuel level Sensor

Resistance

32.4 [OHgr ] @ 100% Fill (full) 42.4 [OHgr ] @ 93% Fill 52.4 [OHgr ] @ 86% Fill 62.4 [OHgr ] @ 79% Fill 72.4 [OHgr ] @ 71% Fill 85.4 [OHgr ] @ 63% Fill 103.6 [OHgr ] @ 50% Fill 119.8 [OHgr ] @ 40% Fill 138 [OHgr ] @ 31% Fill 153 [OHgr ] @ 25% Fill 167 [OHgr ] @ 20% Fill 180 [OHgr ] @ 16% Fill 190 [OHgr ] @ 12% Fill 239.9 [OHgr ] @ 0% Fill (Empty)

B19—Engine Air Filter Restriction Switch

Closing pressure

4.98—7.48 kPa 1.47—2.2 in. of Hg 20—30 in. of H2O

B20—Transmission Oil Filter Restriction Switch

Opening pressure

276—414 kPa 2.7—4.1 bar 40—60 psi

B21—Hydraulic Oil Filter Restriction Switch

Closing pressure

276—414 kPa 2.7—4.1 bar 40—60 psi

B23—Engine Oil Pressure Sensor

Operating pressure

0—2660 kPa 0—26.6 bar 0—385 psi

B25—Steering System Pressure Switch

Opening pressure

192—288 kPa 1.92—2.88 bar 27.9—41.8 psi

9015 20 48

Continued on next page

TM10229 (17MAR09)

9015-20-48

MH66O88,00003EA –19–08JAN07–2/5

544J Loader (S.N. 611800— ) 032409

PN=716

References

Item

Measurement

Specification

B28—Torque Convertor Input Speed Sensor

Resistance Gap

925—1155 [OHgr ] 0.5—0.8 mm 0.0197—0.0315 in. 4 pulses per revolution 0.45—7.03 V

Output Signal AC Voltage B29—Torque Convertor Output Speed Sensor

Resistance Gap

925—1155 [OHgr ] 0.5—0.8 mm 0.0197—0.0315 in. 59 pulses per revolution 0.45—7.03 V

Output Signal AC Voltage B30—Internal Clutch Speed Sensor

Resistance Gap

925—1155 [OHgr ] 0.5—0.8 mm 0.0197—0.0315 in. 91 pulses per revolution 0.45—7.03 V

Output Signal AC Voltage B31—Transmission Output Speed Sensor

Output Frequency Gap

2 Hz—5 kHz 1.0—1.5 mm 0.04—0.06 in. 60 pulses per revolution 20—30 V

Output Signal DC Voltage

9015 20 49

B32—Transmission Oil Temperature Sensor

Resistance

186—246 [OHgr ] @ 60°C (140°F) 71.2—91.2 [OHgr ] @ 90°C (194°F) 33—40 [OHgr ] @ 120°C (248°F) 16.6—20.8 [OHgr ] @ 150°C (302°F)

B33—Clutch Cut-Off Sensor

Resistance between pins A and B

280—420 [OHgr ] Minimum Value 4.28—6.42 k[OHgr ] Maximum Value 4—6 k[OHgr ]

Resistance between pins A and C B34—Park Brake Pressure Switch

Opening pressure (increasing)

Closing pressure (decreasing)

B35—Freeze Control Switch

Opening temperature (decreasing) Closing temperature (increasing)

Continued on next page

TM10229 (17MAR09)

9015-20-49

1172—1310 kPa 11.7—13.1 bar 170—190 psi 931—1137 kPa 9.3—11.4 bar 135—165 psi -1.4°C 29.5°F 2.2°C 36°F

MH66O88,00003EA –19–08JAN07–3/5

544J Loader (S.N. 611800— ) 032409

PN=717

References

Item

Measurement

Specification

B37—Analog Return-to-Dig Sensor (Powerllel linkage only)

Resistance

4—6 k[OHgr ]

B40—Brake Light Pressure Switch

Closing pressure (increasing)

414 kPa 4.1 bar 60 psi 276 kPa 2.7 bar 40 psi

Opening pressure (decreasing)

B41—Ride Control Pressure Switch

Closing pressure (increasing)

Opening pressure (decreasing)

9015 20 50

414 kPa 4.1 bar 60 psi 276 kPa 2.7 bar 40 psi

B45—Analog BHKO/RTC Position Sensor

Resistance

4—6 k[OHgr ]

B48—Water in Fuel Sensor

Resistance

209—231 k[OHgr ]

B49—Fuel Rail Pressure Sensor

Operating pressure

0—180 MPa 0—1800 bar 0—26 100 psi

B50—A/C Binary Pressure Switch

Opening pressure (high)

2620—2896 kPa 26.2—29 bar 380—420 psi 1379—2068 kPa 13.8—20.7 bar 200—300 psi 137.9—227.5 kPa 1.38—2.28 bar 20—33 psi 158.6—255.1 kPa 1.58—2.55 bar 23—37 psi

Closing pressure (high)

Opening pressure (low)

Closing pressure (low)

R1—CAN Termination Node

Resistance

120 [OHgr ]

R2—CAN Termination Node

Resistance

120 [OHgr ]

Continued on next page

TM10229 (17MAR09)

9015-20-50

MH66O88,00003EA –19–08JAN07–4/5

544J Loader (S.N. 611800— ) 032409

PN=718

References

Item

Measurement

Specification

R3—Blower Speed Resistor

Low speed resistance (wires A15 1.2 [OHgr ] and A18) Medium speed resistance (wires A16 0.6 [OHgr ] and A18) High speed resistance (wires A17 0.4 [OHgr ] and A18)

Y1—Trans. Control Solenoid 1

Resistance

17.1—20.9 [OHgr ]

Y2—Trans. Control Solenoid 2

Resistance

17.1—20.9 [OHgr ]

Y3—Trans. Control Solenoid 3

Resistance

17.1—20.9 [OHgr ]

Y4—Trans. Control Solenoid 4

Resistance

17.1—20.9 [OHgr ]

Y5—Trans. Control Solenoid 5

Resistance

17.1—20.9 [OHgr ]

Y6—Trans. Control Solenoid 6

Resistance

17.1—20.9 [OHgr ]

Y7—Start Aid Solenoid

Resistance

2.7—3.3 [OHgr ]

Y13—Differential Lock Solenoid

Resistance

25.65—31.35 [OHgr ]

Y14—Pilot Enable Solenoid

Resistance

25.65—31.35 [OHgr ]

Y15—Boom Down Accumulator Solenoid

Resistance

29.79—36.41 [OHgr ]

Y16—A/C Compressor Clutch

Resistance

12.6—15.4 [OHgr ]

Y17—Ride Control Boom Solenoid

Resistance

29.79—36.41 [OHgr ]

Y18—Ride Control (On/Off) Solenoid

Resistance

29.79—36.41 [OHgr ]

Y19—Park Brake Release Solenoid

Resistance

25.65—31.35 [OHgr ]

Y20—Pin Disconnect Solenoid

Resistance

25.65—31.35 [OHgr ]

Y34—Ride Control (On/Off) Solenoid

Resistance

29.79—36.41 [OHgr ]

Y37—Proportional Fan Solenoid

Resistance

21.6—26.4 [OHgr ]

Y38—Reverse Fan Solenoid

Resistance

29.79—36.41 [OHgr ]

9015 20 51

MH66O88,00003EA –19–08JAN07–5/5

TM10229 (17MAR09)

9015-20-51

544J Loader (S.N. 611800— ) 032409

PN=719

References

Transmission Control Valve Solenoid Check

T193571

–19–25NOV03

9015 20 52

Transmission Hydraulic Control Unit Solenoid Check Continued on next page

TM10229 (17MAR09)

9015-20-52

MH66O88,00003EB –19–14DEC06–1/2

544J Loader (S.N. 611800— ) 032409

PN=720

References Following is a simple test to check electrical operation of the transmission hydraulic control unit solenoids: 1. Disconnect the load center harness-to-transmission harness connector (X22). See Transmission Harness (W10) Component Location for machine location. (Group 9015-10.) 2. Using an ohmmeter, check the resistance between the common pin terminal (pin V) and each solenoid

terminal as shown. Specification Control Valve Solenoid— Resistance ...................................................................... 15—20 ohms

3. This check can also be done at the transmission control valve connector (X36).

MH66O88,00003EB –19–14DEC06–2/2

Clutch Cut-Off Sensor Check and Adjustment 1. Turn key switch to on. 2. Press MENU on the monitor to bring up the main menu. 9015 20 53

3. Press NEXT twice and then SELECT to enter the diagnostics menu. 4. Press NEXT twice and then SELECT to view the transmission sensors. 5. Press NEXT until 7—Clutch Cutoff V is highlighted and then press SELECT. 6. With the brake pedals in the up position (not depressed), verify the clutch cut-off voltage is within specification. Specification Clutch Cut-Off Sensor—Voltage— Pedal Up .................................................................................... 0.8—1.0 V

NOTE: The clutch cut-off sensor is located under cab on left brake pedal assembly. 7. If the voltage is not within specification, loosen the clutch cut-off sensor (B33) cap screws and turn the clutch cut-off sensor until specification is met. 8. Tighten cap screws.

MH66O88,00003EC –19–14DEC06–1/1

TM10229 (17MAR09)

9015-20-53

544J Loader (S.N. 611800— ) 032409

PN=721

References

Boom Height Kickout/Return-to-Carry Adjustment Boom height kickout position can be adjusted from cab using the following procedure: 1. Position boom at the desired height. 2. Push and hold the boom height kickout enable switch (S39) on the Sealed Switch Module (SSM). Hold until monitor beeps. 3. Lower boom. 4. Move loader control lever to boom raise detent position and release. Boom should raise to the set position. Return-to-carry kickout position can be adjusted from the cab using following procedure: 9015 20 54

1. Position boom at the desired height. 2. Push and hold the return-to-carry enable switch (S40) on the Sealed Switch Module (SSM). Hold until monitor beeps. 3. Raise boom. 4. Move loader control lever to boom lower detent position and release. Boom should lower to the set position.

MH66O88,00003ED –19–14DEC06–1/1

TM10229 (17MAR09)

9015-20-54

544J Loader (S.N. 611800— ) 032409

PN=722

References

T141829

–UN–30APR01

Return-To-Dig Adjustment—Z-Bar Linkage

9015 20 55

Return-to-Dig Adjustment

1. Raise boom adequately to allow clearance for full bucket dump position.

(medium strength) thread lock and sealer to cap screws.

IMPORTANT: The machine hydraulic system must be at operating temperature before making the adjustment. Cycle the cylinder through full travel at least 4 times to ensure oil in the cylinder is warm.

6. Install cap screws (C) but do not tighten. Adjust bar to align marks on switch bracket and end of bar. Tighten cap screws.

2. Move loader control lever to return-to-dig detent position and release. IMPORTANT: Perform this step with the engine operating between 1500 - 1700 rpm. 3. After control lever returns to neutral, scribe a mark (D) on the switch bracket and adjustable bar (B) to align with each other. 4. Position the boom and bucket in the desired return-to-dig position. Stop engine.

Specification Adjusting Bar Cap Screw— Torque.................................................................................... 121 N•m 89.0 lb-ft

7. Loosen hex nuts (E) to switch bracket. Adjust air gap (A) between switch and adjustable bar (B). Tighten hex nuts. Specification Air Gap Between Switch and Bar—Distance ........................................................................ 5—8 mm 0.197— 0.315 in. Hex Nut—Torque ..................................................................... 75 N•m 55 lb-ft

5. Remove cap screws (C), one at a time and remove old thread lock and sealer. Apply cure primer and

MH66O88,00003EE –19–26JAN07–1/1

TM10229 (17MAR09)

9015-20-55

544J Loader (S.N. 611800— ) 032409

PN=723

References

Return-To-Dig Adjustment—Powerllel Linkage

–UN–08SEP04

Return-to-Dig (RTD) position can be adjusted from cab using the following procedure:

T192456B

NOTE: The machine’s hydraulic system must be at operating temperatures and the boom and bucket cylinders should be cycled its full length 4 times before setting return-to-dig to assure there is warm hydraulic oil in the cylinders. Do not set return-to-dig with a cold hydraulic system! 1. With engine running, position bucket or attachment in the desired dig position. 2. Press the return-to-dig switch (1) until the desired position memory is illuminated.

9015 20 56

3. Press and hold the return-to-dig switch until the monitor alarm beeps. The monitor will display on-screen instructions. 4. Follow the four on-screen instruction displays.

Continued on next page

TM10229 (17MAR09)

9015-20-56

MH66O88,00003EF –19–26JAN07–1/2

544J Loader (S.N. 611800— ) 032409

PN=724

Return-To-Dig Calibration 1/4

Return-To-Dig Calibration 2/4

RTD Calibration

–19–26APR06

4/4

TX1006714

–19–26APR06

Complete

TX1006711

RTD Calibration 3/4 7-Do NOT move Bucket Lever 8-Lower Bucket/Fork until touches ground 9-Press RTD Button

TX1006710

–19–26APR06

RTD Calibration 2/4 4-Do NOT move Bucket Lever 5-Raise Boom to Max Height 6-Press RTD Button

TX1006707

RTD Calibration 1/4 1-Position Bucket or Forks 2-Lower Bucket/Forks until touches ground 3-Press RTD Button

–19–26APR06

References

Return-To-Dig Calibration 3/4

Return-To-Dig Calibration 4/4 MH66O88,00003EF –19–26JAN07–2/2

Sensor Circuitry Check This procedure checks if a failure of the wiring harness or the sensor is causing a diagnostic trouble code to be generated. Use the monitor or Service ADVISOR application to view codes. See Service ADVISOR Connection Procedure. (Group 9015-20.) This procedure will verify if the wiring harness and controllers are working correctly. This procedure does not check the sensor.

Service ADVISOR is a trademark of Deere & Company

TM10229 (17MAR09)

Continued on next page

9015-20-57

MH66O88,00003F0 –19–22JAN07–1/3

544J Loader (S.N. 611800— ) 032409

PN=725

9015 20 57

References Sensor With Two Wires Performing Two-Wire Sensor Check:

T104537

–19–21OCT96

1. Record and clear diagnostic trouble codes. See Diagnostic Trouble Codes Quick Reference List. (Group 9015-20.) 2. With key switch off, disconnect suspected sensor wiring harness connector. Connect a jumper wire between the wires in the harness connector. 3. Start engine and run for several seconds. Stop engine. 4. Record all diagnostic trouble codes as in Step 1 above. Results:If a new diagnostic trouble code (Short-to-Ground” or “Short-to-Power”) appears, a failed sensor is indicated. (The new diagnostic trouble code was created when the jumper wire was connected to the harness connector, proving the harness is OK.)

9015 20 58

If a new diagnostic trouble code does not appear, a failed harness or controller is indicated. (The harness cannot send the new diagnostic trouble code to the controller.)

Continued on next page

TM10229 (17MAR09)

9015-20-58

MH66O88,00003F0 –19–22JAN07–2/3

544J Loader (S.N. 611800— ) 032409

PN=726

References Sensor With Three Wires Performing Three Wire Sensor Check

–19–21OCT96

1. Record and clear diagnostic trouble codes. See Diagnostic Trouble Codes Quick Reference List. (Group 9015-20.)) 2. With key switch off, disconnect the suspected sensor wiring harness connector. If the original diagnostic trouble code was “Short to Power” connect a jumper wire between the sensing wire and the ground wire in the wiring harness connector. If the original diagnostic trouble code was “Short to Ground” connect a jumper wire between the sensing wire and the power wire in the wiring harness connector. 3. Start engine and run several seconds. Stop engine. 4. Turn key switch on. 5. Record all diagnostic trouble codes as in Step 1 above.

If a new diagnostic trouble code does not appear, a failed harness or controller is indicated. (The harness cannot send the new diagnostic trouble code to the controller.)

T104538

Results:If a new diagnostic trouble code (Short-to-Ground” or “Short-to-Power”) appears, a failed sensor is indicated. (The new diagnostic trouble code was created when the jumper wire was connected to the harness connector, proving the harness is OK.) Malfunctioning Three-Wire Sensor Test

MH66O88,00003F0 –19–22JAN07–3/3

TM10229 (17MAR09)

9015-20-59

544J Loader (S.N. 611800— ) 032409

PN=727

9015 20 59

References

Diagnostic Trouble Codes—After Machine Repair After repairing the machine, delete all diagnostic trouble codes from memory. Use one of the following methods to clear codes:

9015 20 60

• Service ADVISOR application. Delete codes by pushing the CLEAR button under the diagnostics tab. For more information, see Reading Diagnostic Trouble Codes with Service ADVISOR Diagnostic Application. (Group 9015-20.) • CAN Monitor Unit (CMU). Delete codes from the CMU as follows: a. Enter the service menu by holding down the MENU button for 5 seconds. b. Go to menu 1-3, by first selecting codes (1) then clear codes (3). c. Push SELECT to clear all stored codes. d. The CMU will verify the codes have been cleared. For more information, see CAN Monitor Unit (CMU) Menu Structure—Service Mode. (Group 9015-20.) e. Operate the machine, then check for DTCs to verify that the problem has been fixed.

Service ADVISOR is a trademark of Deere & Company

TM10229 (17MAR09)

MH66O88,00003F1 –19–22JAN07–1/1

9015-20-60

544J Loader (S.N. 611800— ) 032409

PN=728

References

Change Backup Alarm Volume NOTE: The backup warning alarm is set on high volume at the factory. It may be necessary to adjust the volume to meet local regulations.

1 2

4 5

TX1014619

2. To set to low volume, remove bar (4) and connect wire to low terminal (5).

3 –UN–09NOV06

1. Leave bar (4) connected to high volume (3) and low volume (5) terminals, connect wire to the high volume terminal (5) to maintain high volume.

1—Backup Alarm 2—Ground 3—High volume Terminal 4—Bar 5—Low Volume Terminal

9015 20 61

WS68074,00008FC –19–14DEC06–1/1

TM10229 (17MAR09)

9015-20-61

544J Loader (S.N. 611800— ) 032409

PN=729

References

Pressure Switches Remove and Install

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

9015 20 62

X9811

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

–UN–08DEC08

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

If an accident occurs, see a doctor immediately. Any fluid injected into the skin must be surgically removed within a few hours or gangrene may result. Doctors unfamiliar with this type of injury should reference a knowledgeable medical source. Such information is available from Deere & Company Medical Department in Moline, Illinois, U.S.A. Before removing any pressure switch, operate all hydraulic control valves to relieve hydraulic pressure. With boom raised slightly, turn key switch to on position. Cycle ride control from off to on. Boom will jump up unexpectedly if ride control accumulator is energized. Push and hold pilot enable/boom down switch while moving and holding the control lever in the boom down position for 5 seconds. Push brake pedal at least 40 times to discharge brake accumulators.

MH66O88,00003F3 –19–14DEC06–1/1

TM10229 (17MAR09)

9015-20-62

544J Loader (S.N. 611800— ) 032409

PN=730

References

T7751GM

–19–14SEP92

Alternator Test Procedure

12 V System—Perform the following test if equipped with a 12 V charging system. 1. With engine running at slow idle, check DC voltage between terminal D+ and ground. Voltage should be 13.5 VDC or greater1. 2. With engine running at fast idle, check DC voltage between terminal B+ and ground. Voltage should be 13.5 VDC or greater1. 3. If voltage from previous steps is below 13.5 VDC1, check excitation by placing a jumper wire between terminals D+ and B+ with the engine running. If output at terminals B+ and D+ rise to 13.5 VDC or greater, check for an open diode, wiring problem or blown fuse in the alternator excitation circuit (wire to D+ terminal).

4. With engine running, check AC voltage between terminal W (if equipped) and ground. Voltage should be 6—7 VAC. 5. Repeat above steps with lights on to load the alternator. 6. If alternator fails to produce specified voltage after testing, check for worn out brushes in the regulator/brush assembly. Replace brush/regulator assembly if necessary. See CTM77 for specific test and repair procedures. If alternator still fails, replace it. If alternator tests OK, check indicator light circuit. 24 V System—Perform the following test if equipped with a 24 V charging system.

Note: For 12 V systems with maintenance free batteries, D+ and B+ voltage should be 14.1 VDC or greater. Continued on next page

TM10229 (17MAR09)

9015-20-63

MH66O88,00003F4 –19–04JAN07–1/2

544J Loader (S.N. 611800— ) 032409

PN=731

9015 20 63

References 1. With engine running at slow idle, check DC voltage between terminal D+ and ground. Voltage should be 27.5 VDC or greater2.

4. With engine running, check AC voltage between terminal W (if equipped) and ground. Voltage should be 12—14 VAC.

2. With engine running at fast idle, check DC voltage between terminal B+ and ground. Voltage should be 27.5 VDC or greater2.

5. Repeat above steps with lights on to load the alternator.

3. If voltage from previous steps is below 27.5 VDC2, 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).

6. If alternator fails to produce specified voltage after testing, check for worn out brushes in the regulator/brush assembly. Replace brush/regulator assembly if necessary. See CTM77 for specific test and repair procedures. If alternator still fails, replace it. If alternator tests OK, check indicator light circuit.

9015 20 64 2 Note: For 24 V systems with maintenance free batteries, D+ and B+ voltage should be 28.2 VDC or greater.

MH66O88,00003F4 –19–04JAN07–2/2

TM10229 (17MAR09)

9015-20-64

544J Loader (S.N. 611800— ) 032409

PN=732

References

Replace (Push Type) Metri-Pack Connectors Disconnect the Metri-Pack1 connector. Remove the tie bands and tape. –UN–29JUN92

Remove the connector lock (A), and mark wire colors for identification.

RW21325

Identify wire color locations with connector terminal letters. Insert JDG776 or JDG7772 Terminal Extraction Tool (B) into connector body socket (C) pushing the terminal locking tab inward. NOTE: Use JDG776 Extraction Tool with 56, 280 and 630 series METRI-PACK terminals. Use JDG777 Extraction Tool with 150 series METRI-PACK terminals.

A—Connector Lock B—Extraction Tool JDG777 C—Connector Body Socket D—Terminal E—Locking Tab

Remove extraction tool and pull terminal (D) out of the socket. 9015 20 65

Replace terminal. Make sure locking tab (E) on the new terminal is in the outward position. Push terminal into connector body socket until terminal locks.

Metri-Pack is a trademark of Packard Electric

Included in JT07195A Electrical Repair Kit MH66O88,00003F5 –19–14DEC06–1/1

TM10229 (17MAR09)

9015-20-65

544J Loader (S.N. 611800— ) 032409

PN=733

References

Replace METRI-PACK Connectors

–UN–01NOV96

1. A small locking tab is located inside of the METRI-PACK connector. Use a small screwdriver (B) to move tab (A) outward to the first detent position; the tab will “click.”

T104764B

A—Tab B—Screwdriver

Metri-Pack is a trademark of Packard Electrical.

2. Slide JDG939 Metri-Pack Extractor Tool (B) into connector body until it is positioned over terminal contact.

–UN–01NOV96

3. Gently pull wire out of connector body.

T104763B

IMPORTANT: Install contact in proper location using correct size grommet. 4. Push contact straight into connector body until positive stop is felt. 5. Pull on wire slightly to be certain contact is locked in place.

A—Wire B—Extractor Tool

6. Transfer remaining wires to correct terminal in new connector.

MH66O88,00003F6 –19–14DEC06–2/3

7. Use a small screwdriver (B) to move tab (A) inward to the first detent position; the tab will “click” and lock the wires in the connector body.

–UN–01NOV96

A—Tab B—Screwdriver

T104764B

9015 20 66

MH66O88,00003F6 –19–14DEC06–1/3

MH66O88,00003F6 –19–14DEC06–3/3

TM10229 (17MAR09)

9015-20-66

544J Loader (S.N. 611800— ) 032409

PN=734

References

Install METRI-PACK Contact 1. Strip 6 mm (1/4 in.) insulation from wire.

–UN–23AUG88

2. Adjust selector (A) on JDG360 Crimper1 for correct wire size.

TS117

3. Loosen lock nut (B) and turn adjusting screw (C) in until it stops. A—Selector B—Lock Nut C—Adjusting Screw

Included in JDG359 Deutsch Electrical Repair Kit. MH66O88,00003F7 –19–14DEC06–1/3

9015 20 67

IMPORTANT: Select proper size contact “sleeve” or “pin” to fit connector body.

–UN–23AUG88

4. Insert METRI-PACK contact (A) and turn adjusting screw (D) until contact is flush with cover (B). 5. Tighten lock nut (C).

TS0134

IMPORTANT: Contact must remain centered between indenters while crimping. 6. Insert wire into contact and crimp until handle touches stop. A—Contact B—Cover C—Lock Nut D—Adjusting Screw

7. Release handle and remove contact.

Metri-Pack is a trademark of Packard Electric.

MH66O88,00003F7 –19–14DEC06–2/3

NOTE: Readjust crimping tool for each crimping procedure.

TS0135

8. Inspect contact to be certain all wires are in crimped barrel.

–UN–23AUG88

IMPORTANT: If all wire strands are not crimped into contact, cut off wire at contact and repeat contact installation procedures.

MH66O88,00003F7 –19–14DEC06–3/3

TM10229 (17MAR09)

9015-20-67

544J Loader (S.N. 611800— ) 032409

PN=735

References

Replace DEUTSCH Connectors 1. Select correct size extractor tool for size of wire to be removed: • JDG361 Extractor Tool1 for 12 to 14 gauge wire. • JDG362 Extractor Tool1 for 16 to 18 gauge wire. • JDG363 Extractor Tool1 for 20 gauge wire.

Included in JDG359 DEUTSCH Electrical Repair Kit. MH66O88,00003F8 –19–14DEC06–1/3

2. Start correct size extractor tool over wire at handle (A). 3. Slide extractor tool rearward along wire until tool tip snaps onto wire. –UN–23AUG88

IMPORTANT: Do NOT twist tool when inserting in connector.

TS0124

4. 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.

–UN–23AUG88

A—Extractor Tool Handle

TS120

9015 20 68

DEUTSCH is a trademark of the Deutsch Co.

TM10229 (17MAR09)

Continued on next page

9015-20-68

MH66O88,00003F8 –19–14DEC06–2/3

544J Loader (S.N. 611800— ) 032409

PN=736

References IMPORTANT: Install contact in proper location using correct size grommet.

–UN–23AUG88

6. Push contact straight into connector body until positive stop is felt. 7. Pull on wire slightly to be certain contact is locked in place.

TS122

8. Transfer remaining wires to correct terminal in new connector.

MH66O88,00003F8 –19–14DEC06–3/3

9015 20 69

Install DEUTSCH Contact 1. Strip 6 mm (1/4 in.) insulation from wire.

–UN–23AUG88

2. Adjust selector (A) on JDG360 Crimper1 for correct wire size.

TS117

3. Loosen lock nut (B) and turn adjusting screw (C) in until it stops. A—Crimper Selector B—Lock Nut C—Adjusting Screw

Included in JDG359 Deutsch Electrical Repair Kit. Continued on next page

TM10229 (17MAR09)

9015-20-69

MH66O88,00003F9 –19–14DEC06–1/4

544J Loader (S.N. 611800— ) 032409

PN=737

References IMPORTANT: Select proper size contact “sleeve” or “pin” to fit connector body.

–UN–23AUG88

4. Insert DEUTSCH contact (A) and turn adjusting screw (D) until contact is flush with cover (B). 5. Tighten lock nut (C).

TS0134

A—Contact B—Cover C—Lock Nut D—Adjusting Screw

DEUTSCH is a trademark of the Deutsch Co.

IMPORTANT: Contact must remain centered between indenters while crimping.

–UN–23AUG88

6. Insert wire in contact and crimp until handle touches stop.

TS118

7. Release handle and remove contact.

MH66O88,00003F9 –19–14DEC06–3/4

NOTE: Readjust crimping tool for each crimping procedure. 8. Inspect contact to be certain all wires are in crimped barrel.

–UN–23AUG88

IMPORTANT: If all wire strands are not crimped into contact, cut off wire at contact and repeat contact installation procedures.

TS0135

9015 20 70

MH66O88,00003F9 –19–14DEC06–2/4

MH66O88,00003F9 –19–14DEC06–4/4

TM10229 (17MAR09)

9015-20-70

544J Loader (S.N. 611800— ) 032409

PN=738

References

Replace WEATHER PACK Connector

2. Insert JDG364 Extraction Tool1 over terminal contact in connector body. 3. Hold extractor tool fully seated and pull wire from connector body.

TS0128

1. Open connector body.

–UN–23AUG88

IMPORTANT: Identify wire color locations with connector terminal letters.

NOTE: If terminal cannot be removed, insert wire or nail through extractor tool handle and push terminal contact from connector.

9015 20 71

Included in JT07195A Electrical Repair Kit. MH66O88,00003FA –19–14DEC06–1/2

IMPORTANT: Carefully spread contact lances to assure good seating on connector body.

5. Pull on wire slightly to be certain contact is locked in place.

TS0130

4. Push contact into new connector body until fully seated.

–UN–23AUG88

NOTE: Connector bodies are “keyed” for proper contact mating. Be sure contacts are in proper alignment.

6. Transfer remaining wires to correct terminal in new connector. 7. Close connector body.

MH66O88,00003FA –19–14DEC06–2/2

TM10229 (17MAR09)

9015-20-71

544J Loader (S.N. 611800— ) 032409

PN=739

References

Install WEATHER PACK Contact NOTE: Cable seals are color coded for three sizes of wire: –UN–23AUG88

• Green - 18 to 20 gauge wire • Gray - 14 to 16 gauge wire • Blue - 10 to 12 gauge wire

TS0136

1. Slip correct size cable seal on wire. 2. Strip insulation from wire to expose 6 mm (1/4 in.) and align cable seal with edge of insulation.

Correct Size Cable

NOTE: Contacts have numbered identification for two sizes of wire:

TS1623

3. Put proper size contact on wire and crimp in place with a “W” type crimp, using JDG783 Crimping Tool.

Strip Insulation MH66O88,00003FB –19–14DEC06–1/2

IMPORTANT: Proper contact installation for “sleeve” (A) and “pin” (B) is shown.

–UN–02DEC88

4. Fasten cable seal to contact using JDG783 Crimping Tool, as shown. A—Sleeve B—Pin

TS0139

9015 20 72

–UN–02NOV94

• #15 for 14 to 16 gauge wire • #19 for 18 to 20 gauge wire

Contact Installation

MH66O88,00003FB –19–14DEC06–2/2

TM10229 (17MAR09)

9015-20-72

544J Loader (S.N. 611800— ) 032409

PN=740

References

Replace CINCH Connectors 1. Remove extraction tool (1) from the loading side of connector. 2. Insert blade of extraction tool into locking tabs (2) of secondary lock (3). Rotate tool away from the CINCH connector to pry one side of the secondary lock out of the locked position. Repeat this step for the other locking tab.

–UN–29JUN00

NOTE: After unlocking one side of the secondary lock, a screw driver or similar device may need to be used to hold it in the unlocked position while unlocking the second locking tab.

T132105B

1—Extraction Tool 2—Secondary Lock Locking Tabs 3—Secondary Lock

9015 20 73

CINCH is a trademark of the Cinch Co.

MH66O88,00003FC –19–04JAN07–1/3

3. Remove secondary lock (3).

T132301B

–UN–29JUN00

3—Secondary Lock

Continued on next page

TM10229 (17MAR09)

9015-20-73

MH66O88,00003FC –19–04JAN07–2/3

544J Loader (S.N. 611800— ) 032409

PN=741

References

6. Repair/Replace terminals as necessary using procedure in this group. See Install CINCH Contact. (Group 9015-20.) 7. Insert contact and wire into connector until it clicks.

T132107B

5. Gently pull wire out of the connector.

–UN–29JUN00

4. Insert pointed side of extraction tool into the contact cavity so that the flat side of tool faces secondary lock cavity (4). This will release the primary contact locking tab.

8. Install secondary lock.

MH66O88,00003FC –19–04JAN07–3/3

9015 20 74

TM10229 (17MAR09)

9015-20-74

544J Loader (S.N. 611800— ) 032409

PN=742

References

T138057

–UN–14FEB01

Install CINCH Contact

A—Top of Tool B—Contact Support C—Locator

D—Wire E—Micro Timer Slot

F—Junior Timer Slot G—Contact

1. Hold JDG708 crimping tool so that the tool is facing you as shown (left side of graphic). Squeeze tool handles together and allow them to open fully. 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. 2. 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 the tool handles together until ratchet engages sufficiently to hold the contact in position. Do NOT deform wire and insulation tabs (I and J). 4. Insert stripped wire into contact insulation and wire tabs until it is against locator (C). 5. Hold the wire in place. Squeeze tool handles together until ratchet releases. Allow tool handles to open and remove crimped contact. 6. Install contact into connector. See Replace CINCH Connectors. (Group 9015-20.)

CINCH is a trademark of the Cinch Co.

TM10229 (17MAR09)

I—Wire Tab J—Insulation Tab

MH66O88,00003FD –19–14DEC06–1/1

9015-20-75

544J Loader (S.N. 611800— ) 032409

PN=743

9015 20 75

References

Repair 32 and 48 Way CINCH Connectors

–UN–10SEP03

1. Push tab (A) and rotate locking cam (B) 90° to disconnect connector from flexbox. 2. Move cover locks (C) slightly outward with a small screwdriver.

RXA0070459

3. Remove cover (D) away from wires.

–UN–10SEP03

A—Tab B—Locking Cam C—Cover Locks D—Cover

RXA0070463

–UN–10SEP03

RXA0070462

9015 20 76

MH66O88,00003FE –19–14DEC06–1/4

4. Pull terminal lock (A) out until it stops. Do not force its removal.

RXA0070464

–UN–10SEP03

A—Terminal Lock

Continued on next page

TM10229 (17MAR09)

9015-20-76

MH66O88,00003FE –19–14DEC06–2/4

544J Loader (S.N. 611800— ) 032409

PN=744

References NOTE: JDG1725 terminal extractor tool has two different sizes of pins: 0.6 for smaller 20 gauge holes (A) and 1.5 for larger 16 and 18 gauge holes (B). –UN–10SEP03

5. Insert JDG1725 Terminal Extractor Tool into holes (C) next to terminal opening (D) to unlock terminal.

RXA0070471

6. Pull wire and terminal (E) from connector body.

RXA0070473

–UN–10SEP03

RXA0070472

–UN–10SEP03

A—20 Gauge Holes B—16 and 18 Gauge Holes C—Holes D—Terminal Hole E—Terminal

Continued on next page

TM10229 (17MAR09)

9015-20-77

MH66O88,00003FE –19–14DEC06–3/4

544J Loader (S.N. 611800— ) 032409

PN=745

9015 20 77

References

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.

RXA0070479

8. Firmly grip JDG1727 terminal crimping tool (A). Squeeze ratcheting mechanism until it bottoms out, then allow it to open completely.

–UN–10SEP03

7. Remove old terminal and strip 4.85 mm (0.191 in.) of insulation from wire.

11. Close terminal receptacle (B).

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.

18. Install cover. 19. Install connector to controller and close connector body locking cam.

–UN–10SEP03

17. Push terminal lock closed.

RXA0070481

9015 20 78

RXA0070480

13. Insert stripped wire (D) into terminal.

–UN–10SEP03

12. Squeeze handle until two clicks are heard.

A—CINCH Terminal Crimping Tool B—Terminal Receptacle C—Terminal D—Wire

MH66O88,00003FE –19–14DEC06–4/4

TM10229 (17MAR09)

9015-20-78

544J Loader (S.N. 611800— ) 032409

PN=746

References

Remove Connector Body from Blade Terminals

–UN–23AUG88

1. Depress locking tang (A) on terminal, using a small screw driver. Slide connector body off.

RW4218

2. Be sure to bend locking tang back to its original position (B) before installing connector body. A—Locking Tang B—Original Position

MH66O88,00003FF –19–14DEC06–1/1

9015 20 79

Engine Control Unit (ECU) Remove and Install 1. Turn battery disconnect to the OFF position.

T194448A

–UN–27AUG03

2. Loosen cap screws (1) to gain access to the load center compartment. The ECU (2) is mounted to the top side of the compartment. 1—Load Center Cover Cap Screw (4 used) 2—Engine Control Unit (ECU)

T194449A

–UN–27AUG03

Load Center Compartment Access

ECU Location Continued on next page

TM10229 (17MAR09)

9015-20-79

MH66O88,0000400 –19–04JAN07–1/2

544J Loader (S.N. 611800— ) 032409

PN=747

References 3. Loosen cap screws (3) and remove ECU connectors. 4. Remove mounting screws (4) to remove control unit.

–UN–08SEP03

5. Install new controller and tighten mounting cap screws.

T194623A

IMPORTANT: The ECU connectors need to be torqued to specification to prevent connection problems and damage to the connector. 6. Install ECU connectors and tighten cap screws to specification. ECU Connectors Specification ECU Connector Screw—Torque ....................................... 1.69—2.26 N•m 14.96—20 lb-in.

7. Close load center doors and tighten cap screws.

9. Reset options in the monitor. See CAN Monitor Unit (CMU) Menu Structure—Service Mode. (Group 9015-20.) 3—ECU Connector Cap Screw (2 used) 4—Engine Control Unit (ECU) Mounting Screw (4 used)

T194451A

9015 20 80

–UN–08SEP03

8. Turn battery disconnect to the on position.

ECU Mounting Cap Screws

MH66O88,0000400 –19–04JAN07–2/2

TM10229 (17MAR09)

9015-20-80

544J Loader (S.N. 611800— ) 032409

PN=748

References

Flex Load Controller (FLC) Remove and Install

3. Remove connectors (3) by pressing in locking tab (4) and rotate retainer (5) counterclockwise to release.

T194448A

2. Loosen cap screws (1) to gain access to the load center compartment. The FLC (2) is mounted on the back wall of the compartment.

–UN–27AUG03

1. Turn battery disconnect to the OFF position.

4. Remove mounting cap screws (6) to remove control unit. 5. Install new controller and tighten mounting cap screws.

8. Turn battery disconnect to the ON position. 9. See Electronic Controller Reconfiguration. (Group 9015-20.)

T194481A

7. Close load center doors and tighten cap screws.

–UN–28AUG03

6. Install FLC connectors.

10. Reset options in the monitor. See CAN Monitor Unit (CMU) Menu Structure—Service Mode. (Group 9015-20.)

T194482A

–UN–28AUG03

1—Load Center Cover Cap Screw (4 used) 2—Flex Load Controller (FLC) 3—FLC Connector (3 used) 4—FLC Connector Locking Tab 5—FLC Connector Retainer 6—FLC Retaining Mounting Cap Screw (2 used)

MH66O88,0000401 –19–21DEC06–1/1

TM10229 (17MAR09)

9015-20-81

544J Loader (S.N. 611800— ) 032409

PN=749

9015 20 81

References

Transmission Control Unit (TCU) Remove and Install 1. Turn battery disconnect to the OFF position. –UN–27AUG03

2. Loosen cap screws (1) to gain access to the load center compartment. The TCU (2) is mounted to the back wall of the compartment.

T194448A

3. Pull up on connector lock (3) to remove TCU connector. 4. Remove mounting screws to remove control unit. 5. Install new controller and tighten mounting cap screws. 6. Install TCU connector by pushing connector lock down.

–UN–05SEP03

7. Close load center doors and tighten cap screws.

T194605A

8. Turn battery disconnect to the ON position. 9015 20 82

9. See Electronic Controller Reconfiguration. (Group 9015-20.) 10. Reset options in the monitor. See CAN Monitor Unit (CMU) Menu structure—Service Mode. (Group 9015-20.)

1—Load Center Cover Cap Screw (4 used) 2—Transmission Control Unit (TCU) 3—TCU Connector Lock

MH66O88,0000402 –19–21DEC06–1/1

TM10229 (17MAR09)

9015-20-82

544J Loader (S.N. 611800— ) 032409

PN=750

References

Sealed Switch Module (SSM) Remove and Install

2. Remove nuts (1) on backside of module. 3. Pull module up and disconnect harness connector (2).

T194491A

4. Install new module and tighten mounting nuts.

–UN–28AUG03

1. Turn battery disconnect to the OFF position.

T194492A

–UN–02SEP03

1—Sealed Switch Module (SSM) Mounting Nut (4 used) 2—SSM Connector

MH66O88,0000403 –19–14DEC06–1/1

TM10229 (17MAR09)

9015-20-83

544J Loader (S.N. 611800— ) 032409

PN=751

9015 20 83

References

CAN Monitor Unit (CMU) Remove and Install 1. Turn battery disconnect to the OFF position. 2. Remove monitor mounting screws (1). 3. Pull monitor forward and disconnect harness connector (2).

–UN–09OCT03

4. Install new monitor and tighten mounting screws. 5. Turn battery disconnect to the ON position.

T195499A

6. Reprogram CMU. See Reprogram CAN Monitor Unit (CMU). (Group 9015-20.) 1—CAN Monitor Unit (CMU) Mounting Screws (4 used) 2—CMU Connector

T195500A

–UN–09OCT03

9015 20 84

MH66O88,0000404 –19–14DEC06–1/1

Reprogram CAN Monitor Unit (CMU) The CAN Monitor Unit (CMU) must be reprogrammed whenever it is replaced. Reprogramming is done using the following procedure. NOTE: When the CMU is first powered up after replacement, the CMU will display 544 as the model. This is before the auto configuration has run. 1. Turn the key switch ON. After the CMU initially powers up, the CMU will compare information between the flex load controller (FLC) and the transmission control unit (TCU). If the information is valid, that information will be stored in the CMU memory.

Continued on next page

TM10229 (17MAR09)

9015-20-84

MH66O88,0000405 –19–22JAN07–1/3

544J Loader (S.N. 611800— ) 032409

PN=752

References

a. If NO is selected, the monitor will operate as normal. The monitor will start with the set hours screen a total of 5 times. If the hours are not set on the fifth time, the CMU will acquire the machine hours operated since the monitor was installed.

Set Hours 1-No 2-Yes

1/2

–19–04NOV03

2. The set hours screen will be displayed. Push NEXT to choose between NO or YES.

T196067

b. If YES is selected, the set hour meter screen will be displayed. If the hour meter was not set on the first attempt, the set hour meter screen will default with the hours accrued since the monitor installation.

MH66O88,0000405 –19–22JAN07–2/3

5. Verify that all settings are correct. NOTE: If the CMU is being replaced along with the TCU or FLC, the model number will have to be set using the Service Menu and the serial number will have to be set using Service ADVISOR.

Set Hour Meter BACK to left NEXT to increase SELECT to store 0 0 0 0 0.0

–19–04NOV03

4. Enter the service menu and verify the tire size is correct. See CAN Monitor Unit (CMU) Menu Structure—Service Mode. (Group 9015-20.)

9015 20 85

T196068

3. To set the hours, push the BACK button to select the next digit to the left, push NEXT to increase, then push MENU to exit. Push SELECT to store the hour meter reading.

6. After the CMU has been replaced and reprogrammed, see Electronic Controller Reconfiguration. (Group 9015-20.)

Service ADVISOR is a trademark of Deere & Company

TM10229 (17MAR09)

MH66O88,0000405 –19–22JAN07–3/3

9015-20-85

544J Loader (S.N. 611800— ) 032409

PN=753

References

Electronic Controller Reconfiguration Whenever a CAN monitor unit (CMU), flex load controller (FLC), or transmission control unit (TCU) is replaced, the controllers must be reconfigured. The reconfiguration procedure is performed in the CMU service menu. If the CMU is replaced, the CMU will request to be programmed the first time the key switch is turned to ON. Reprogram the CMU before proceeding with reconfiguration. See Reprogram CAN Monitor Unit (CMU). (Group 9015-20.) The TCL lever or the shift switch (if equipped with a joystick pilot controller) must be in neutral position and the park brake must be applied in order for the reconfiguration to be successful. NOTE: The park brake light on the CMU, when lit, indicates that the park brake is applied. 9015 20 86

1. Turn the key switch ON and allow the CMU to perform the bulb check. The bulb check will take 5 seconds to complete. 2. If the CMU was replaced, complete the CMU reprogramming before performing a reconfiguration. 3. To reconfigure the machine, access the CMU service menu by pushing and holding the MENU button for 5 seconds. For more information on accessing the CMU service menu, See CAN Monitor Unit (CMU) Menu Structure—Service Mode. (Group 9015-20.) 4. From the CMU main menu, select Machine Config (5) (Machine Configuration). NOTE: When reconfiguring a machine, the enabled options will be reset. Before proceeding with the reconfiguration procedure, record the current machine configuration from Enable Options menu, if possible.

NOTE: In some instances, the model number in the display will match the model number of the machine. If so, highlight the model number, then push and hold the SELECT button until an audible “beep” is heard. The “beep”, along with the check mark next to the model number, indicates the FLC has been properly configured to the current machine model. 6. Using the NEXT button, scroll through the model list until the correct machine model is highlighted, then push the SELECT button. An audible “beep” and a check mark will appear beside the machine model to confirm the reconfiguration was successful. 7. Push the BACK button to return to the Machine Config menu. 8. From the Machine Config menu, select Tire Size (5-2). Match the tire size of the machine with tire size option from the menu. NOTE: During reconfiguration, tire size will default to the base tire size associated with each machine model. 9. Push the BACK button to return to the Machine Config menu. 10. From the Machine Config menu, select Enable Options (5-3). Enable the options unique to that machine, if any. Use the NEXT button to highlight the option, then push the SELECT button to enable the feature. 11. Turn key switch to OFF. When the key switch is turned back to ON, the controllers will reboot to their correct configuration. NOTE: Turning the key switch to OFF will close the CMU service menu.

5. From the Machine Config menu option select Machine Model (5-1).

MH66O88,0000406 –19–23JAN07–1/1

TM10229 (17MAR09)

9015-20-86

544J Loader (S.N. 611800— ) 032409

PN=754

Section 9020

Power Train Contents Page

Page

Group 05—Theory of Operation TEAMMATE Axles . . . . . . . . . . . . . . . . . . .9020-05-1 Transmission Clutch Engagement and Solenoids Activated . . . . . . . . . . . . . . . . . .9020-05-1 Power Train Component Operation . . . . . . . .9020-05-2 Transmission Operation . . . . . . . . . . . . . . . .9020-05-4 Transmission Operation—First Gear Forward . . . . . . . . . . . . . . . . . . . . . . . . . . .9020-05-6 Transmission Filter Bypass Valve Operation. . . . . . . . . . . . . . . . . . . . . . . . . .9020-05-9 Transmission Control Valve Component Operation. . . . . . . . . . . . . . . . . . . . . . . . .9020-05-10 Transmission Clutch Modulation Operation. . . . . . . . . . . . . . . . . . . . . . . . .9020-05-13 Thermal Bypass Valve Operation . . . . . . . .9020-05-14 Standard Differential Operation . . . . . . . . . .9020-05-16 Differential Lock Operation . . . . . . . . . . . . .9020-05-17 Axle Circulation Dual Pump Operation . . . .9020-05-18 Park Brake Operation . . . . . . . . . . . . . . . . .9020-05-20

Transmission Hydraulic System Overheats Diagnostic Procedure. . . . . . . . . . . . . . . .9020-15-21 Transmission Excessive Noise Diagnostic Procedure . . . . . . . . . . . . . . . . . . . . . . . .9020-15-22 Oil Aerated Diagnostic Procedure . . . . . . . .9020-15-24 Oil Ejected from Dipstick Diagnostic Procedure . . . . . . . . . . . . . . . . . . . . . . . .9020-15-24 Machine Vibrates Diagnostic Procedure . . .9020-15-24 Machine Power and Acceleration Low Diagnostic Procedure. . . . . . . . . . . . . . . .9020-15-25 Torque Converter Stall RPM Diagnostic Procedure . . . . . . . . . . . . . . . . . . . . . . . .9020-15-27 Differential and Axle Diagnose Malfunctions . . . . . . . . . . . . . . . . . . . . . .9020-15-27 Differential Lock Will Not Engage Diagnostic Procedure . . . . . . . . . . . . . . . . . . . . . . . .9020-15-28 Differential Lock Slips and Chatters Diagnostic Procedure. . . . . . . . . . . . . . . .9020-15-28 Differential Lock Will Not Disengage Diagnostic Procedure. . . . . . . . . . . . . . . .9020-15-29 Differential Oil Level Rises Diagnostic Procedure . . . . . . . . . . . . . . . . . . . . . . . .9020-15-30 Differential Oil Level Low Diagnostic Procedure . . . . . . . . . . . . . . . . . . . . . . . .9020-15-30 Differential and Axle Noise Excessive Diagnostic Procedure. . . . . . . . . . . . . . . .9020-15-31 Axle Wheel Hub Face Seal Leaking Diagnostic Procedure. . . . . . . . . . . . . . . .9020-15-32 Axle Overheats Diagnostic Procedure . . . . .9020-15-33 Service Brake Diagnose Malfunctions . . . . .9020-15-34 Brakes Poor or Do Not Apply Diagnostic Procedure . . . . . . . . . . . . . . . . . . . . . . . .9020-15-34 Brakes Aggressive Diagnostic Procedure . . . . . . . . . . . . . . . . . . . . . . . .9020-15-35 Brakes Dragging Diagnostic Procedure . . . .9020-15-36 Brakes Lock Up Diagnostic Procedure . . . .9020-15-36 Brakes Chatter Diagnostic Procedure . . . . .9020-15-37 Brake Warning Light On Diagnostic Procedure . . . . . . . . . . . . . . . . . . . . . . . .9020-15-37 Driveline Diagnose Malfunctions . . . . . . . . .9020-15-38 Driveline Excessive Vibration or Noise Diagnostic Procedure. . . . . . . . . . . . . . . .9020-15-38 Park Brake Diagnose Malfunctions . . . . . . .9020-15-39

Group 15—Diagnostic Information Transmission Control Circuit—First Forward . . . . . . . . . . . . . . . . . . . . . . . . . . .9020-15-2 Transmission Control System . . . . . . . . . . . .9020-15-4 Power Train Component Location . . . . . . . . .9020-15-6 Transmission System Diagnose Malfunctions . . . . . . . . . . . . . . . . . . . . . . .9020-15-9 Transmission Clutch Slippage Diagnostic Procedure . . . . . . . . . . . . . . . . . . . . . . . . .9020-15-9 Machine Will Not Move in Either Direction Diagnostic Procedure. . . . . . . . . . . . . . . .9020-15-11 Machine Will Not Engage in Low Gear Diagnostic Procedure. . . . . . . . . . . . . . . .9020-15-14 Machine Will Not Shift Correctly Diagnostic Procedure . . . . . . . . . . . . . . . . . . . . . . . .9020-15-15 Transmission System Pressure Is Low in Neutral Diagnostic Procedure . . . . . . . . .9020-15-16 Transmission Pressure Is Low (One or Two Gear Ranges) Diagnostic Procedure . . . . . . . . . . . . . . . . . . . . . . . .9020-15-17 Transmission Shifts Too Slow Diagnostic Procedure . . . . . . . . . . . . . . . . . . . . . . . .9020-15-17 Transmission Shifts Too Fast Diagnostic Procedure . . . . . . . . . . . . . . . . . . . . . . . .9020-15-19 Machine Creeps in Neutral Diagnostic Procedure . . . . . . . . . . . . . . . . . . . . . . . .9020-15-20 TM10229 (17MAR09)

9020-1

Continued on next page

544J Loader (S.N. 611800— ) 032409

PN=1

9020

Contents

Page

Park Brake Will Not Hold Diagnostic Procedure . . . . . . . . . . . . . . . . . . . . . . . .9020-15-39 Park Brake Overheats Diagnostic Procedure . . . . . . . . . . . . . . . . . . . . . . . .9020-15-40 Park Brake Indicator Light Flashes when Shifting from Fwd to Rev Diagnostic Procedure . . . . . . . . . . . . . . . . . . . . . . . .9020-15-41 Park Brake Indicator Light Flashes During Each Shift Diagnostic Procedure . . . . . . .9020-15-41 Park Brake Indicator Light Will Not Go On Diagnostic Procedure. . . . . . . . . . . . . . . .9020-15-43 Park Brake Will Not Apply Diagnostic Procedure . . . . . . . . . . . . . . . . . . . . . . . .9020-15-43 Group 20—Adjustments Service Brake Bleeding Procedure . . . . . . . .9020-20-1 External Service Brake Inspection . . . . . . . . .9020-20-2 Transmission Control Unit (TCU)—Electronic Clutch Calibration . . . . . . . . . . . . . . . . . . .9020-20-5

9020

Group 25—Tests Transmission Oil Warmup Procedure . . . . . .9020-25-1 Park Brake Pressure Test . . . . . . . . . . . . . . .9020-25-2 Park Brake Drag Test . . . . . . . . . . . . . . . . . .9020-25-4 Transmission Pump Flow Test . . . . . . . . . . .9020-25-6 Transmission System Pressure Test . . . . . . .9020-25-8 Transmission Clutch Pressure Test . . . . . . .9020-25-10 Transmission Element Leakage Test. . . . . .9020-25-14 Transmission Lube Pressure Test . . . . . . . .9020-25-16 Differential Lock Pressure Test . . . . . . . . . .9020-25-18 Torque Converter-In Pressure Test . . . . . . .9020-25-20 Torque Converter-Out Pressure Test . . . . .9020-25-22 Torque Converter Relief Pressure Test . . . .9020-25-25 Torque Converter-Out Flow Test . . . . . . . . .9020-25-27 Torque Converter Stall Speed Test . . . . . . .9020-25-31 Transmission Oil Cooler Thermal Bypass Valve Temperature Test . . . . . . . . . . . . .9020-25-32 Transmission Oil Cooler Thermal Bypass Valve Pressure Test . . . . . . . . . . . . . . . .9020-25-35 Transmission Oil Cooler Restriction Test. . .9020-25-37 Axle Circulation Dual Pump Flow Test . . . .9020-25-39 Axle Breather Test . . . . . . . . . . . . . . . . . . .9020-25-41

TM10229 (17MAR09)

9020-2

544J Loader (S.N. 611800— ) 032409

PN=2

Group 05

Theory of Operation TEAMMATE Axles For additional information on TEAMMATE axles and components, see the following Component Technical Manual (CTM). • See TeamMate IV 1200, and 1400 Series Inboard Planetary Axles. (CTM442.)

TEAMMATE is a trademark of Deere & Company

MM61211,0001680 –19–05DEC06–1/1

Transmission Clutch Engagement and Solenoids Activated Transmission Clutch Engagement and Solenoids Activated Directional Pack Engaged Lo-Range Forward (KV)

Speed Pack Engaged

Hi-Range Forward (K4)

Reverse (KR)

1st (K1)

2nd (K2)

3rd (K3)

Gear N1 N2 N3 N4 F1

Solenoid Y5

9020 05 1

Solenoid Y3 Solenoid Y6 Solenoid Y4 Solenoid Y1

Solenoid Y4

Solenoid Y2

Solenoid Y3 Solenoid Y6 Solenoid Y4

For theory of operation, see Transmission Operation. (Group 9020-05.) This table shows the clutch packs that are engaged with their corresponding solenoids for a selected gear. For example, in first forward (F1) solenoids Y5 and Y3 are energized to engage low-range forward direction clutch pack (KV) and first speed clutch (K1). Notice in the neutral gears no clutch packs are engaged.

MM61211,0001681 –19–05DEC06–1/1

TM10229 (17MAR09)

9020-05-1

544J Loader (S.N. 611800— ) 032409

PN=757

Theory of Operation

Power Train Component Operation NOTE: For location of components, see Power Train Component Location. (Group 9020-15.) The power train consists of the following components: • Drive dampener • Drive shaft • Torque converter • Transmission • Front and rear drive shafts • Park brake • Differential Lock Operation • Front and rear axles Engine power is transmitted to the transmission torque converter by a drive dampener on the engine flywheel and a universal joint drive shaft. A single stage torque converter drives a hydraulically engaged four speed forward, three speed reverse, countershaft type power shift transmission.

9020 05 2

A multiple wet disk park brake is located in the front drive line. The park brake also functions as a bearing support for the front driveline. The transmission outputs through universal joints and through two telescoping drive shaft assemblies. The front axle is mounted directly to the loader frame. The front axle is equipped with an hydraulic differential lock axle. The rear axle is mounted on an oscillating pivot. The rear axle can be equipped with either the standard conventional type differential, or an optional differential lock axle.

MM61211,0001682 –19–05DEC06–1/1

TM10229 (17MAR09)

9020-05-2

544J Loader (S.N. 611800— ) 032409

PN=758

Theory of Operation

9020 05 3

TM10229 (17MAR09)

9020-05-3

544J Loader (S.N. 611800— ) 032409

PN=759

Theory of Operation

Transmission Operation

T106975

–19–19FEB97

9020 05 4

Continued on next page

TM10229 (17MAR09)

9020-05-4

MM61211,0001683 –19–05DEC06–1/3

544J Loader (S.N. 611800— ) 032409

PN=760

Theory of Operation A—Turbine B—Engine Speed Sensor C—Impeller D—Oil Seal

E—Transmission Pump F—Sealing Ring G—Impeller Shaft H—High Range Drive Gear

I—Low Range Drive Gear J—Turbine Shaft K—Vent

L—Stator M—Torque Converter Components

MM61211,0001683 –19–05DEC06–2/3

INPUT A REVERSE C LOW RANGE

J HIGH RANGE

D 2ND SPEED

L 1ST SPEED E 3RD SPEED

A—Reverse C—Low Range

D—Second Speed E—Third Speed

J—High Range L—First Speed

The transmission is a hydraulically engaged four speed forward, three speed reverse countershaft-type, powershift transmission. Six clutch packs provide four forward and three reverse speeds. Two clutch packs, have to be engaged for movement: One directional clutch pack, either low-range forward (KV), high-range forward (K4) or reverse and one speed clutch pack, either first (K1), second (K2) or third (K3). For information on solenoid/clutch pack combinations. See Transmission Clutch Engagement and Solenoids Activated. (Group 9020-05.) The torque converter supplies torque to two drive gears which are in constant mesh with the forward low-range (KV), reverse clutch (KR) and the

T106954

TRANSMISSION GEAR PATTERN (VIEWED FROM CONTROL VALVE SIDE)

T106954

9020 05 5

–19–19FEB97

OUTPUT

I—Output

high range froward clutch (K4) hubs. The reverse clutch (KR), high range forward clutch (K4) and second speed clutch (K2) output gears are in constant mesh. As are the first speed clutch (K1) hub gear and the third speed clutch (K3) output gear. The torque converter is a single stage, single phase torque converter. Main pressure oil is routed through a passage in the countershaft to engage the clutches. Lube oil is routed to each clutch shaft through a manifold plate mounted between the torque converter and the transmission case.

MM61211,0001683 –19–05DEC06–3/3

TM10229 (17MAR09)

9020-05-5

544J Loader (S.N. 611800— ) 032409

PN=761

Theory of Operation

Transmission Operation—First Gear Forward

T106951

–19–19FEB97

9020 05 6

Continued on next page

TM10229 (17MAR09)

9020-05-6

MM61211,0001684 –19–14DEC06–1/3

544J Loader (S.N. 611800— ) 032409

PN=762

Theory of Operation A—Reverse Clutch (KR) B—Hydraulic Pump Drive C—Low-Range (KV) FWD Clutch Engaged D—Second Speed (K2) Clutch E—Third Speed Clutch (K3)

F—Front Output Flange G—Rear Output Flange H—Transmission and Torque Converter—First Gear Forward

I—Output Shaft J—High-Range (K4) FWD Clutch K—Converter Relief Valve L—First Speed (K1) Clutch Engaged

Continued on next page

M—Transmission Pump N—Drive Flange O—Torque Converter P—Engine Speed Sensor

MM61211,0001684 –19–14DEC06–2/3

9020 05 7

TM10229 (17MAR09)

9020-05-7

544J Loader (S.N. 611800— ) 032409

PN=763

Theory of Operation INPUT A C LOW RANGE (ENGAGED)

REVERSE

HIGH RANGE

2ND SPEED

L E

1ST SPEED (ENGAGED)

3RD SPEED

9020 05 8

A—Reverse C—Low Range (engaged)

T106956

–19–19FEB97

OUTPUT

POWER FLOW - 1ST FORWARD D—Second Speed E—Third Speed

J—High Range L—First Speed (engaged)

With the transmission in first forward, the low-range forward clutch (C) and the first speed clutch (L) are engaged. Main pressure oil is routed through the drilled passage in the countershaft to the low-range-forward and first speed clutches. This causes the pistons to extend, compressing the plates and disks causing both clutches to rotate as a unit through the upper clutch drum.

I—Output

Power flow from the low range clutch output gear is connected through the second speed output gear, the high range forward output gears to the first speed clutch drum and gear. Power flow continues out the first speed hub gear to the third speed output gear and finally on to the output shaft gear.

The torque converter supplies torque to a drive gear which meshes with the gear on the low-range forward clutch hub (C).

MM61211,0001684 –19–14DEC06–3/3

TM10229 (17MAR09)

9020-05-8

544J Loader (S.N. 611800— ) 032409

PN=764

Theory of Operation

Transmission Filter Bypass Valve Operation

B C 9020 05 9

–UN–14JUL00

F TRANSMISSION PRESSURE OIL

T132539

G LUBE PRESSURE OIL T132539 A—Transmission Filter and Filter Base Mounting Area B—Inlet Oil from Transmission Pump

C—Indicator Switch D—Bypass Valve Spool

E—Lube Pressure Passage Port

The spin-on type transmission filter and filter base is mounted on front of the transmission (A). A pressure

differential type bypass valve (D) and an indicator switch (C) protects the filter. Continued on next page

TM10229 (17MAR09)

F—Transmission Pressure Oil G—Lube Pressure Oil

9020-05-9

MM61211,00016F9 –19–12DEC06–1/2

544J Loader (S.N. 611800— ) 032409

PN=765

Theory of Operation The bypass valve senses inlet oil from the transmission pump (B). The bypass valve is located in series with the system pressure passage. The bypass valve spool is held in the closed position by a spring and filtered downstream oil pressure entering the control valve. During normal operation, the inlet and outlet pressures of the filter are nearly equal, and the spool valve and

indicator remain seated. If the filter becomes plugged, or the oil is very cold, the inlet pressure becomes higher than the outlet pressure and spring tension. During relief operation, the spool is shifted overcoming spring tension causing the indicator switch to open and the filter restriction indicator light to illuminate on the monitor. The bypass valve allows unfiltered oil to the lube circuit (E).

MM61211,00016F9 –19–12DEC06–2/2

Transmission Control Valve Component Operation B PRESSURE REDUCING VALVE

A PRESSURE REGULATING VALVE SOLENOID (6) H

C CONNECTOR

9020 05 10

D COVER

E VALVE BLOCK

HOUSING F

T107153

A—Pressure Regulating Valve B—Pressure Reducing Valve C—Connector

TRANSMISSION CONTROL VALVE

D—Cover E—Valve Block

F—Housing G—Modulation Circuit

Continued on next page

TM10229 (17MAR09)

–19–19FEB97

T107153

G MODULATION CIRCUIT

9020-05-10

H—Solenoid (6 used) I—Transmission Control Valve

MM61211,0001685 –19–01FEB07–1/4

544J Loader (S.N. 611800— ) 032409

PN=766

Theory of Operation

B PRESSURE REGULATING VALVE

VALVE BODY A

C PRESSURE REDUCING VALVE

CONNECTOR D

E INTERMEDIATE PLATE

G PLATE J

I RETURN OIL

K CONVERTER PRESSURE OIL

T107151

L TRANSMISSION PRESSURE REGULATING CIRCUIT

A—Valve Body B—Pressure Regulating Valve C—Pressure Reducing Valve D—Connector

E—Intermediate Plate F—Channel Plate G—Plate

H—Main Pressure Oil I—Return Oil J—Reduced Pressure Oil

Continued on next page

TM10229 (17MAR09)

–19–19FEB97

REDUCED PRESSURE OIL

9020-05-11

T107151

H MAIN PRESSURE OIL

F CHANNEL PLATE

9020 05 11

K—Converter Pressure Oil L—Transmission Pressure Regulating Circuit

MM61211,0001685 –19–01FEB07–2/4

544J Loader (S.N. 611800— ) 032409

PN=767

Theory of Operation

B DAMPER VALVE PROPORTIONAL SOLENOID VALVE A C BOOSTER VALVE

D INTERMEDIATE PLATE E CHANNEL PLATE

PLATE H

F TO CLUTCH G TRANSMISSION CASE

9020 05 12

A—Proportional Solenoid Valve B—Damper Valve C—Booster Valve

M MODULATION CIRCUIT D—Intermediate Plate E—Channel Plate F—To Clutch G—Transmission Case

H—Plate I—Main Pressure Oil J—Modulated Pressure To Clutch

NOTE: For overall system operation, see Transmission Control Circuit—First Forward. (Group 9020-15.) The transmission control valve assembly regulates the hydraulic control circuit of the transmission. The control valve receives electrical signals from the transmission controller to energize the proportional solenoids which direct oil to move the booster valves. When the booster valves are shifted against the spring, oil pressure begins to start modulation and fill the oncoming pack. The transmission control valve contains:

T102739

J MODULATED PRESSURE TO CLUTCH K REDUCED PRESSURE FROM PROPORTIONAL VALVE L RETURN OIL

–19–28AUG96

I MAIN PRESSURE OIL

K—Reduced Pressure From Proportional Valve L—Return Oil M—Modulation Circuit

• Pressure reducing valve • Six dampening valves • Six booster valves • Six proportional solenoid valves The pressure regulating valve is a spring-loaded spool valve which regulates main pressure oil by controlling flow into the control circuit. Excess oil from the control circuit flows to the torque converter. Main pressure oil flows to the solenoid pressure reducing valve. The pressure reducing valve provides a constant oil pressure to the proportional solenoids and is not affected by shift modulation. The solenoid pressure reducing valve is not adjustable.

• Pressure regulating valve

Continued on next page

TM10229 (17MAR09)

9020-05-12

MM61211,0001685 –19–01FEB07–3/4

544J Loader (S.N. 611800— ) 032409

PN=768

Theory of Operation The six proportional solenoid valves direct oil to the booster valves to provide machine direction, speed selection and shift modulation. The transmission controller sends a varying electrical signal to the proportional solenoids which controls the speed of clutch engagement during a shift. All of the proportional solenoid valves are identical. • Y1 solenoid valve engages the high-range forward booster valve. • Y2 solenoid valve engages the reverse booster valve. • Y3 solenoid valve engages the first speed booster valve. • Y4 solenoid valve engages the third speed booster valve. • Y5 solenoid valve engages the low-range forward booster valve.

• Y6 solenoid valve engages the second speed forward booster valve. All booster valves and springs are identical. The dampening valves act as an accumulator in the control circuit. Any pressure spikes will be absorbed by the dampening valve which allows for smooth and quiet operation of the booster valves. All dampening valves and springs are identical. Two clutch packs have to be engaged for the machine to move. One directional clutch pack, either low-range forward, high-range forward or reverse and one speed clutch pack, either first, second or third.

MM61211,0001685 –19–01FEB07–4/4

Transmission Clutch Modulation Operation The transmission controller will vary the clutch modulation according to a number of speed and load factors. Therefore, if clutch modulation is checked in a test condition with the machine stopped and the transmission in stalled condition, the clutch modulation will be different than normal operation. The proportional solenoids control the rate of engagement and disengagement of clutches. This provides the optimum timing of the modulating clutches. This provides a smooth shift between each gear under all operating conditions. In neutral-to-first forward shift only, low range forward clutch is modulated. The same is true for the reverse shift, only the reverse clutch is modulated. In all of the speed changes in forward and reverse only the engaging clutch is modulated.

MM61211,0001686 –19–05DEC06–1/1

TM10229 (17MAR09)

9020-05-13

544J Loader (S.N. 611800— ) 032409

PN=769

9020 05 13

Theory of Operation

Thermal Bypass Valve Operation C D H

C TO LUBE

FROM COOLER

SEAT B

H SPRING

VALVE A

FROM CONVERTER

I BYPASS

THERMOSTAT G

TXC7799BX

J COOLING

F TO COOLER

F K LUBE/CONVERTER-OUT FLOW

M THERMAL BYPASS VALVE

Continued on next page

TM10229 (17MAR09)

–19–20JAN98

9020-05-14

L TO COOLER (VALVE CLOSED) FLOW

T7799BX

9020 05 14

MM61211,0001687 –19–05DEC06–1/2

544J Loader (S.N. 611800— ) 032409

PN=770

Theory of Operation A—Valve B—Seat C—To Lube D—From Cooler

E—From Converter F—To Cooler G—Thermostat H—Spring

I—Bypass J—Cooling K—Lube/Converter-Out Flow

L—To Cooler (valve closed) Flow M—Thermal Bypass Valve

The thermal bypass valve is used to maintain the transmission oil temperature at a level which provides optimum torque converter performance.

avoiding thermal shock. Converter outlet flow enters passage (E) and flows through the valve (A) to lube (C).

The valve contains a standard automotive-type thermostat element connected to a hollow valve spool.

At higher temperatures, the thermostat (G) begins to open, allowing flow out of passage (F) to the transmission oil cooler. The thermostat will go to the full open position, forcing the valve closed against the seat (B). The spring loaded seat will act as a pressure relief valve in the event cooler flow is blocked.

The valve is designed to bypass the transmission oil cooler at low temperatures. Passages in the valve allow a small amount of oil to flow to the cooler at low temperatures. This allows the cooler to warm slowly

MM61211,0001687 –19–05DEC06–2/2

9020 05 15

TM10229 (17MAR09)

9020-05-15

544J Loader (S.N. 611800— ) 032409

PN=771

Theory of Operation

Standard Differential Operation The differential allows independent rotation of the axles when the machine is steered. The axle planetary gear cases are attached to the axles. Their purpose is to reduce speed and increase torque through gear reduction. The input pinion shaft to differential ring gear also provides a reduction in speed and an increase to torque. Input torque from the drive shaft rotates the input bevel pinion shaft which meshes with the differential ring gear, causing it to turn. The ring gear is fastened to the differential housing which drives the bevel pinion shafts and bevel pinions. The bevel pinions located on the bevel pinion shaft are in mesh with the side gears which spline to the sun pinion shaft. The sun pinion shaft meshes with the planet pinion carrier assembly which rotates around the inside of the stationary planetary ring gear. Torque is transferred into the output shaft causing it to rotate at a reduced speed but with greater torque.

9020 05 16

As the machine is steered, the inside wheel slows down in relation to the outside wheel. This causes the side gear, attached to the inside wheel’s axle, to slow down. The rotating differential housing and bevel pinion shafts allow the differential bevel pinions to rotate around the slow moving side gear; this allows the opposite side gear to rotate at a faster speed. This rotation causes the outside wheel’s axle to rotate faster than the inside axle which prevents tire scuffing.

MM61211,0001688 –19–05DEC06–1/1

TM10229 (17MAR09)

9020-05-16

544J Loader (S.N. 611800— ) 032409

PN=772

Theory of Operation

–UN–28AUG06

Differential Lock Operation

YZ7335

9020 05 17

A—Bearing Quill B—Side Bevel Gear C—Bevel Pinion (4 Used) D—Bevel Pinion Shaft E—Differential Housing

F—Thrust Washer G—Thrust Bearing H—Thrust Washer J—Bearing Quill with Seal Rings

NOTE: The differential lock solenoid and the park brake solenoid share the same valve block. See Power Train Component Location. (Group 9020-15.) When the differential lock pedal/switch is applied, a solenoid valve energizes, causing pressure oil to flow to the differential. The oil pressure forces a differential lock clutch piston (L) against the thrust washer (H), and thrust bearing (differential lock piston) (G). This forces a thrust washer (F) against the differential lock actuator plate (M). The clutch plate (N) compresses

K—Side Bevel Gear with Clutch Hub L—Differential Lock Clutch Piston M—Differential Lock Actuator Plate

N—Clutch Disk P—Separator Plate Q—Differential Case

against the separator plates (P), and differential housing (E). The clutch plates (N) are splined to the side bevel gear with clutch hub (K) with separator plates (P), which are fastened to the differential housing (E), between the clutch plates (N). When oil pressure is applied, the side bevel gear with clutch hub (K) locks to the differential housing (E). The bevel pinion (C) then locks up the and prevents the bevel pinion (C) from “walking around” the bevel pinion shaft (D). Differential lock differentials require a hydraulic pressure system.

MM61211,0001689 –19–05DEC06–1/1

TM10229 (17MAR09)

9020-05-17

544J Loader (S.N. 611800— ) 032409

PN=773

Theory of Operation

Axle Circulation Dual Pump Operation The axle circulation system is designed to circulate lubrication oil from each axle over the wheel bearings and braking elements to help keep the components from overheating.

TX1003476

–UN–08FEB06

Two gear pumps (1 and 2) are mounted in tandem and are driven by the engine cooling fan pump (3). The axles are closed loop systems, so each axle requires a separate pump. The axle circulation pump draws oil from the differential housing and routes it to the axle oil cooler. The axle oil cooler cools the oil and delivers oil to each end of the axle housing. The oil cools the wheel bearings and brake elements and returns to the differential housing sump. For component location, see Power Train Component Location. (Group 9020-15.) 1—Gear Pump 2—Gear Pump 3—Cooling Fan Pump

MM61211,000168A –19–05DEC06–1/1

9020 05 18

TM10229 (17MAR09)

9020-05-18

544J Loader (S.N. 611800— ) 032409

PN=774

Theory of Operation

9020 05 19

TM10229 (17MAR09)

9020-05-19

544J Loader (S.N. 611800— ) 032409

PN=775

Theory of Operation

Park Brake Operation

3 4 2

9020 05 20

5 6 7

TX1013611

–UN–06DEC06

TX1013611

Continued on next page

TM10229 (17MAR09)

9020-05-20

MM61211,000168B –19–01FEB07–1/4

544J Loader (S.N. 611800— ) 032409

PN=776

Theory of Operation 1—Seal 2—Spring (36 used)

3—Breather 4—Piston

5—Transmission Pressure Oil 6—Lubrication Oil

The park brake (7) is a multiple wet disk type, spring applied hydraulically released mechanical device. The separator plates are held stationary with the brake housing. The brake disks are splined to the shaft. When the park brake is released the park brake

7—Park Brake

solenoid valve is energized and oil pressure from the transmission pump enters the cavity behind the piston (4) moving it against the spring retainer which compresses the springs (2). This will allow the disks to rotate with the shaft, and the drive line is free to turn.

Continued on next page

MM61211,000168B –19–01FEB07–2/4

9020 05 21

TM10229 (17MAR09)

9020-05-21

544J Loader (S.N. 611800— ) 032409

PN=777

Theory of Operation

9 8

16 12

–UN–04DEC06

TX1013768

13 TX1013768 15

18 10

The TCU controls the operation of the park brake (7). To release the park brake the engine must be running. The TCU receives confirmation the engine is running from the input signal off the torque converter input speed sensor. The TCU needs to read 300 RPM or more as confirmation the engine is running. This data is not displayed as the tachometer reading of the CMU. The RPM data from the torque converter input speed sensor can be viewed from the CMU menu.

17 16

MAIN PRESSURE

RETURN OIL

7—Park Brake 8—Park Brake Solenoid 9—Differential Lock Solenoid 10—Park Brake Pressure Switch 11—To Differential Lock 12—To Park Brake Assembly 13—Return To Transmission 14—Inlet from Transmission 15—Test Port 16—Valve Body 17—Differential Lock 18—Check Valve

Continued on next page

TM10229 (17MAR09)

–UN–04DEC06

NOTE: The park brake solenoid and differential lock solenoid share the same valve block. See Power Train Component Location. (Group 9020-15.)

TX1013782

9020 05 22

9020-05-22

MM61211,000168B –19–01FEB07–3/4

544J Loader (S.N. 611800— ) 032409

PN=778

Theory of Operation With the engine running move the park brake release switch to the momentary or OFF position. This will energize the park brake solenoid (8). The solenoid will block the return path to the transmission sump and direct the transmission oil to the park brake (7). At the same time the transmission oil must open park brake pressure switch (10) immediately. If the park brake pressure switch responds slowly or fails to open, the TCU will de-energize the park brake release solenoid (8) and route oil flow to the transmission sump. The park brake will remain applied. When the park brake is moved to the ON position or the machine is shut off the park brake solenoid (8) is de-energized. The park brake solenoid will move to open and allow oil inside the park brake piston cavity to return to the transmission. The springs force the spring retainer and piston to the left compressing the plates against the disks. This locks the drive line to the brake housing to apply the park brake. If the engine should stop running, as long as the key switch remains in the ON position the park brake solenoid will remain energized. A check valve (18) will seat to temporarily maintain oil pressure inside the park brake and keep the brake released. When the machine slows to a ground speed of approximately 1/2 mph, the TCU will de-energize the park brake solenoid and allow the oil in the park brake to be sent to the transmission sump. This will apply the park brake.

9020 05 23

The park brake can be released by using a hand-operated hydraulic pump in a machine down situation. For correct procedure see Towing Procedure. (Operator’s Manual.)

MM61211,000168B –19–01FEB07–4/4

TM10229 (17MAR09)

9020-05-23

544J Loader (S.N. 611800— ) 032409

PN=779

Theory of Operation

9020 05 24

TM10229 (17MAR09)

9020-05-24

544J Loader (S.N. 611800— ) 032409

PN=780

Group 15

Diagnostic Information

9020 15 1

TM10229 (17MAR09)

9020-15-1

544J Loader (S.N. 611800— ) 032409

PN=781

Diagnostic Information

Transmission Control Circuit—First Forward TX1003498 –UN–14FEB06

13 31

15 18

21 20

24 23 25

29 26

32 MAIN PRESSURE

33 REDUCED PRESSURE 34 CONVERTER PRESSURE

35 RETURN OIL TX1003498 Transmission Control Circuit—First Forward, Park Brake Off, Bypass Closed MM61211,00016E2 –19–05DEC06–1/2

TM10229 (17MAR09)

9020-15-2

544J Loader (S.N. 611800— ) 032409

PN=782

Diagnostic Information 1—Reverse Clutch (KR) 2—High-Range Forward Clutch (K4) 3—First Speed Clutch (K1) 4—Third Speed Clutch (K3) 5—Low-Range Forward Clutch (KV) 6—Second Speed Clutch (K2) 7—Proportional Solenoid Valve (Y2) 8—Proportional Solenoid Valve (Y1) 9—Proportional Solenoid Valve (Y3)

10—Proportional Solenoid Valve (Y4) 11—Proportional Solenoid Valve (Y5) 12—Proportional Solenoid Valve (Y6) 13—Park Brake 14—Park Brake Switch 15—Park Brake/Differential Lock Solenoid 16—Transmission Control Valve 17—System Pressure Regulating Valve

18—Transmission Temperature Sensor 19—System Pressure Test Port 20—Filter Relief Valve 21—Torque Converter Inlet Pressure Test Port 22—Torque Converter Relief Valve 23—Torque Converter 24—Torque Converter Outlet Pressure Test Port 25—Torque Converter Back Pressure Valve

26—Thermal Relief Bypass Valve 27—Oil Cooler 28—System Pressure Relief Valve 29—Transmission Pump 30—Suction Screen 31—Differential Lock 32—Main Pressure 33—Reduced Pressure 34—Converter Pressure 35—Return Oil

MM61211,00016E2 –19–05DEC06–2/2

9020 15 3

TM10229 (17MAR09)

9020-15-3

544J Loader (S.N. 611800— ) 032409

PN=783

Diagnostic Information

Transmission Control System T194701 –19–19SEP03

MM61211,00016E3 –19–05DEC06–1/1

TM10229 (17MAR09)

9020-15-4

544J Loader (S.N. 611800— ) 032409

PN=784

Diagnostic Information

9020 15 5

TM10229 (17MAR09)

9020-15-5

544J Loader (S.N. 611800— ) 032409

PN=785

Diagnostic Information

Power Train Component Location TX1013940 –UN–01DEC06

27 26

28 34

37 24

30 35

15 23

36 20

9 13 35

14 11

21 34

8 33 4

1 TX1013940 Power Train Component Location MM61211,00016E4 –19–05DEC06–1/4

TM10229 (17MAR09)

9020-15-6

544J Loader (S.N. 611800— ) 032409

PN=786

Diagnostic Information 1—Front Axle Dipstick 2—Brake Valve-to-Front Axle Service Brake Hydraulic Hose 3—Differential Lock Hydraulic Hose 4—Park Brake 5—Park Brake Valve-to-Park Brake Hydraulic Hose 6—Park Brake/Differential Lock Valve Body 7—Transmission-to-Park Brake Valve Hydraulic Hose 8—Transmission Fill Tube 9—Transmission Filter

10—Park Brake-to-Transmission Hydraulic Hose 11—Park Brake Solenoid 12—Differential Lock Solenoid 13—Axle Breather (2 used) 14—Park Brake Breather 15—Torque Converter Housing 16—Thermal Bypass Valve 17—Brake Valve 18—Transmission 19—Transmission Control Valve 20—Service Brake Inspection Port

21—Rear Axle Dipstick 22—Sight Gauge 23—Brake Valve-to-Rear Axle Service Brake Hydraulic Hose 24—Thermal Bypass Valve-to-Transmission Oil Cooler Hydraulic Hose 25—Transmission Oil Cooler-to-Thermal Bypass Valve Hydraulic Hose 26—Transmission Oil Cooler 27—Front Axle Oil Cooler 28—Cooling Fan Drive Pump

Continued on next page

29—Rear Gear Drive Pump 30—Front Gear Drive Pump 31—Front Axle Oil Cooler Line 32—Rear Axle Oil Cooler 33—Rear Axle Oil Cooler Line 34—Rear Sump-to-Gear Drive Pump Inlet 35—Front Sump-to-Gear Drive Pump Inlet 36—Rear Output Gear Drive Pump-to-Oil Cooler Line 37—Front Output Gear Drive Pump-to-Oil Cooler Line

MM61211,00016E4 –19–05DEC06–2/4

9020 15 7

TM10229 (17MAR09)

9020-15-7

544J Loader (S.N. 611800— ) 032409

PN=787

Diagnostic Information

9 10 7

9020 15 8

5 1 1 4

3 4 7 8 TX1014101

Continued on next page

TM10229 (17MAR09)

9020-15-8

–UN–02NOV06

TX1014101

MM61211,00016E4 –19–05DEC06–3/4

544J Loader (S.N. 611800— ) 032409

PN=788

Diagnostic Information 1—Front Axle Oil Cooler Line 2—Rear Axle Oil Cooler Line 3—Rear Output Gear Drive Pump-to-Oil Cooler Line

4—Front Output Gear Drive Pump-to-Oil Cooler Line 5—Front Oil Cooler

6—Rear Oil Cooler 7—Rear Axle Sump-to-Input Gear Drive Pump

8—Front Axle Sump-to-Input Gear Drive Pump 9—Cooling Fan Drive Pump

MM61211,00016E4 –19–05DEC06–4/4

Transmission System Diagnose Malfunctions

OUO1020,0001650 –19–06JUN07–1/1

Transmission Clutch Slippage Diagnostic Procedure

– – –1/1

1 Oil Level Check

Check oil level. See Check Transmission Oil. (Operator’s Manual.)

YES: Go to Oil Type or Viscosity Check.

Is oil level to specification? NO: Add recommended oil. See Transmission, Park Brake, and Axle Oil. (Operator’s Manual.) 9020 15 9

– – –1/1

2 Oil Type or Viscosity Check

Check transmission oil. See Transmission, Park Brake, and Axle Oil. (Operator’s Manual.)

YES: Go to Transmission Pump Suction Screen Check.

Is correct oil used? NO: Replace transmission oil with correct oil.

– – –1/1

3 Transmission Pump Suction Screen Check

Remove and clean suction screen.

YES: Remove and clean suction screen.

Is suction screen restricted? NO: Go to Transmission Control Valve Orifice Check. – – –1/1

TM10229 (17MAR09)

9020-15-9

544J Loader (S.N. 611800— ) 032409

PN=789

Diagnostic Information 4 Transmission Control Valve Orifice Check

Inspect and clean control valve orifices. See Transmission Control Valve Disassemble and Assemble. (Group 0360.)

YES: Remove and clean orifice.

Is control valve orifice plugged?

NO: Go to Transmission Control Valve Check. – – –1/1

5 Transmission Control Valve Check

Inspect transmission control valve for wear or damage. See Transmission Control Valve Disassemble and Assemble. (Group 0360.)

YES: Repair or replace transmission control valve.

Is control valve worn or damaged? NO: Go to Transmission Pump Flow Check. – – –1/1

6 Transmission Pump Flow Check

9020 15 10

Check transmission pump flow. Perform Transmission Pump Flow Test. (Group 9020-25.)

YES: Go to Pressure Regulating Valve Check.

Is pump flow within specification?

NO: Repair or replace transmission pump. See Transmission Pump Remove and Install. (Group 0360.)

– – –1/1

7 Pressure Regulating Valve Check

Check pressure regulating valve. Perform Transmission System Pressure Test. (Group 9020-25.)

YES: Go to Transmission Control Valve Check.

Is transmission system pressure within specification?

NO: Repair or replace transmission regulating valve. – – –1/1

8 Transmission Control Valve Check

Check control valve. Perform Transmission Clutch Pressure Test. (Group 9020-25.) Is clutch pressure to specification?

YES: Go to Transmission Control Valve Solenoid Valve Check. NO: Repair or replace leaking clutch pack. – – –1/1

9 Transmission Control Valve Solenoid Valve Check

Check solenoid valve. Perform Transmission Control Valve Solenoid Check. (Group 9015-15.)

YES: Go to Clutch Sealing Rings Check.

Check solenoid valve for wear or damage. See Transmission Control Valve Disassemble and Assemble

NO: Replace solenoid valve.

Is solenoid valve working properly?

– – –1/1

TM10229 (17MAR09)

9020-15-10

544J Loader (S.N. 611800— ) 032409

PN=790

Diagnostic Information 10 Clutch Sealing Rings Check

Inspect clutch sealing rings and cover for wear or damage. See Clutches, Input and Output Shafts Remove and Install. (Group 0350.)

YES: Replace sealing rings and cover as needed.

Are sealing rings or cover worn or damaged? NO: Go to Clutch Pack Check. – – –1/1

11 Clutch Pack Check

Check clutch pack leakage. Perform Transmission Element Leakage Test. (Group 9020-25.)

YES: Checks complete. NO: Repair or replace clutch pack. See Transmission Remove and Install. (Group 0300.)

Is leakage within specification?

– – –1/1

Machine Will Not Move in Either Direction Diagnostic Procedure

– – –1/1

1 Diagnostic Trouble Code Check

Check diagnostic trouble codes to define problem. Are diagnostic trouble codes displayed?

YES: See Diagnostic Trouble Codes (DTC) Quick Reference List. (Group 9015-20.) NO: Go to Park Brake Check.

9020 15 11

– – –1/1

2 Park Brake Check

Check park brake fuse. See Fuse and Relay Specifications. (Group 9015-10.)

YES: Go to next check.

Is park brake fuse good?

NO: Replace fuse.

Check park brake sensor. See Sensor Circuitry Check. (Group 9015-20.)

YES: Go to Transmission Oil Level Check.

Is park brake sensor good? NO: Replace park brake sensor.

– – –1/1

TM10229 (17MAR09)

9020-15-11

544J Loader (S.N. 611800— ) 032409

PN=791

Diagnostic Information 3 Transmission Oil Level Check

Check oil level. See Check Transmission Oil. (Operator’s Manual.)

YES: Go to Clutch Cut-off Check.

Is oil level to specification? NO: Add recommended oil. See Transmission, Park Brake, and Axle Oil. (Operator’s Manual.)

– – –1/1

4 Clutch Cut-off Check

Check brake pedal.

YES: Go to TCU Power Check.

Is brake pedal fully released? NO: Repair or replace as necessary to fully release brake pedal. – – –1/1

5 TCU Power Check

Check transmission controller switched 5A fuse. See Fuse and Relay Specifications. (Group 9015-10.)

YES: Go to next check. NO: Replace fuse.

Is transmission controller fuse good?

Check monitor and transmission controller unswitched fuse. See Fuse and Relay Specifications. (Group 9015-10.)

9020 15 12

YES: Go to next check. NO: Replace fuse.

Is monitor and transmission controller fuse good?

Check load center harness (W3). See Load Center Harness (W3) Component Location. (Group 9015-10.)

YES: Repair or replace harness.

Is load center harness (W3) worn or damaged?

NO: Go to Park Brake Check (Park Brake Light On).

– – –1/1

6 Park Brake Check (Park Brake Light On)

Check park brake pressure. Perform Park Brake Pressure Test. (Group 9020-25.) Is park brake pressure to specification?

YES: Go to Park Brake Check (Park Brake Light Off). NO: Complete test recommendations. – – –1/1

7 Park Brake Check (Park Brake Light Off)

Inspect park brake. See Park Brake Remove and Install. (Group 1111.)

YES: Repair or replace park brake.

Is park brake worn or damaged? NO: Go to Park Brake Solenoid Valve Check. – – –1/1

TM10229 (17MAR09)

9020-15-12

544J Loader (S.N. 611800— ) 032409

PN=792

Diagnostic Information 8 Park Brake Solenoid Valve Check

Remove and inspect solenoid valve.

YES: Replace solenoid valve.

Is solenoid valve worn or damaged? NO: Go to Shift Switch Check. – – –1/1

9 Shift Switch Check

Check that basic display window shows correct gear when shift switch is moved. See Monitor Display Unit—Normal Display. (Operator’s Manual.)

YES: Go to Clutch Pack Check.

Is correct gear shown on display?

NO: Replace shift switch.

– – –1/1

10 Clutch Pack Check

Check clutch pack leakage. Perform Transmission Element Leakage Test. (Group 9020-25.)

YES: Go to Transmission Pressure Check.

Is leakage within specification?

NO: Repair or replace clutch pack. See Transmission Remove and Install. (Group 0300.)

– – –1/1

11 Transmission Pressure Check

Check transmission pressure. Perform Transmission System Pressure Test. (Group 9020-25.)

YES: Complete test recommendations.

Is transmission system pressure low?

NO: Go to Torque Converter Check. – – –1/1

12 Torque Converter Check

Check torque converter output speed in neutral.

YES: Go to Internal Shaft and Gear Check.

Does output speed equal engine rpm? NO: Access the Diagnostic/Transmission menu in the CMU main menu. See CAN Monitor Unit (CMU) Menu Structure—Service Mode. (Group 9015-20.)

– – –1/1

TM10229 (17MAR09)

9020-15-13

544J Loader (S.N. 611800— ) 032409

PN=793

9020 15 13

Diagnostic Information 13 Internal Shaft and Gear Check

Remove drain plug and check for large pieces of metal contamination in drained oil. Is drain oil contaminated with metal?

YES: Inspect shafts and gears for wear or damage. See Clutches, Input, and Output Shafts Remove. (Group 0350.) NO: Go to Drive Shaft and Universal Joint Check.

– – –1/1

14 Drive Shaft and Universal Joint Check

Check external drive shafts and universal joints for wear or damage.

YES: Repair or replace shafts or joints as needed. See Universal Joint and Drive Shaft Remove and Install. (Group 0225.)

Are drive shafts or universal joints worn or damaged?

NO: Go to Ring and Pinion Gear Check.

9020 15 14

– – –1/1

15 Ring and Pinion Gear Check

Check differential for wear or damage. See Differential Disassemble. (Group 0250.)

YES: Repair or replace differential as necessary.

Is differential worn or damaged? NO: Checks complete.

– – –1/1

Machine Will Not Engage in Low Gear Diagnostic Procedure

– – –1/1

1 Clutch Cut-Off Check

Check brake pedal.

YES: Go to Shift Switch Check.

Is brake pedal fully released? NO: Repair or replace as necessary to fully release brake pedal. – – –1/1

2 Shift Switch Check

Check that basic display window shows correct gear when shift switch is moved. See Monitor Display Unit—Normal Display. (Operator’s Manual.)

YES: Go to Transmission Control Valve Solenoid Valve Check

Is correct gear shown on display? NO: Replace shift switch. – – –1/1

TM10229 (17MAR09)

9020-15-14

544J Loader (S.N. 611800— ) 032409

PN=794

Diagnostic Information 3 Transmission Control Valve Solenoid Valve Check

Check solenoid valve. Perform Transmission Control Valve Solenoid Check. (Group 9015-15.)

YES: Go to Transmission Control Valve Check.

Check solenoid valve for wear or damage. See Transmission Control Valve Disassemble and Assemble. (Group 0360.)

NO: Replace solenoid valve.

Is solenoid valve working properly?

– – –1/1

4 Transmission Control Valve Check

Inspect transmission control valve for wear or damage. See Transmission Control Valve Disassemble and Assemble. (Group 0360.)

YES: Repair or replace transmission control valve.

Is control valve worn or damaged? NO: Go to Transmission Control Valve Orifice Check.

– – –1/1

5 Transmission Control Valve Office Check

Inspect and clean control valve orifices. See Transmission Control Valve Disassemble and Assemble. (Group 0360.)

YES: Remove and clean orifice.

Is control valve orifice plugged?

NO: Go to Clutch Sealing Rings Check. – – –1/1

6 Clutch Sealing Rings Check

Inspect clutch sealing rings and cover for wear or damage. See Clutches, Input and Output Shafts Remove and Install. (Group 0350.)

YES: Replace sealing rings and cover as needed.

Are sealing rings or cover worn or damaged? NO: Checks complete. – – –1/1

Machine Will Not Shift Correctly Diagnostic Procedure

– – –1/1

1 Transmission Control Unit Model Check

Check that correct control unit is installed for machine model number.

YES: Go to Speed Sensor Check.

Is correct control unit installed? NO: Install correct control unit. – – –1/1

TM10229 (17MAR09)

9020-15-15

544J Loader (S.N. 611800— ) 032409

PN=795

9020 15 15

Diagnostic Information 2 Speed Sensor Check

Access the Diagnostics/Transmission menu in the CMU main menu. See CAN Monitor Unit (CMU) Menu Structure—Service Mode. (Group 9015-20.)

YES: Go to Transmission Control Unit Check.

Is speed sensor working correctly?

NO: Replace speed sensor. – – –1/1

3 Transmission Control Unit Check

Check transmission control unit. Perform CAN Circuit Test. (Group 9015-20.) and see Transmission Control Unit (TCU) Circuit Theory of Operation. (Group 9015-15.) Is transmission control unit working correctly?

YES: Checks complete. NO: Replace transmission control unit.

– – –1/1

Transmission System Pressure Is Low in Neutral Diagnostic Procedure

– – –1/1

1 Transmission Oil Level Check

Check oil level. See Check Transmission Oil. (Operator’s Manual.)

YES: Go to Transmission Filter Check.

Is oil level to specification? NO: Add recommended oil. See Transmission, Park Brake, and Axle Oil. (Operator’s Manual.)

9020 15 16

– – –1/1

2 Transmission Filter Check

Check transmission filter for contamination.

YES: Replace transmission filter.

Is transmission filter plugged with contamination? NO: Go to Transmission Pump Suction Screen Check. – – –1/1

3 Transmission Pump Suction Screen Check

Check if transmission pump suction screen is clogged. Is suction screen clogged?

YES: Clean transmission pump suction screen. See Transmission Pump Remove and Install. (Group 0360.) NO: Go to Transmission System Pressure Check.

– – –1/1

TM10229 (17MAR09)

9020-15-16

544J Loader (S.N. 611800— ) 032409

PN=796

Diagnostic Information 4 Transmission System Pressure Check

Check transmission system pressure. Perform Transmission System Pressure Test. (Group 9020-25.)

YES: Check complete. NO: Replace transmission pressure regulator.

Is transmission system pressure to specification?

– – –1/1

Transmission Pressure Is Low (One or Two Gear Ranges) Diagnostic Procedure

– – –1/1

1 Transmission Control Valve Check

Check control valve gasket for damage. See Transmission Control Valve Remove and Install. (Group 0360.)

YES: Replace transmission control valve gasket.

Is transmission control valve gasket damaged? NO: Go to Clutch Pack Piston Seal Leakage Check.

– – –1/1

2 Clutch Pack Piston Seal Leakage Check

Check clutch packs for leakage.

YES: Replace clutch pack piston seal.

Is clutch pack piston seal leaking? NO: Go to Transmission Control Valve Solenoid Check. – – –1/1

3 Transmission Control Valve Solenoid Check

Check for transmission diagnostic trouble code by accessing the codes menu on the CMU main menu. See CAN Monitor Unit (CMU) Menu Structure—Service Mode. (Group 9015-20.)

YES: Check solenoid. See Transmission Control Valve Solenoid Check. (Group 9015-20.)

Is trouble code displayed? NO: Check complete. – – –1/1

Transmission Shifts Too Slow Diagnostic Procedure

– – –1/1

TM10229 (17MAR09)

9020-15-17

544J Loader (S.N. 611800— ) 032409

PN=797

9020 15 17

Diagnostic Information 1 Transmission Oil Level Check

Check oil level. See Check Transmission Oil. (Operator’s Manual.)

YES: Go to Transmission Pump Suction Screen Check.

Is oil level to specification?

NO: Add recommended oil. See Transmission, Park Brake, and Axle Oil. (Operator’s Manual.)

– – –1/1

2 Transmission Pump Suction Screen Check

Check if transmission pump suction screen is clogged.

YES: Clean transmission pump suction screen. See Transmission Pump Remove and Install. (Group 0360.)

Is suction screen clogged?

NO: Go to Transmission Pump Flow Check.

9020 15 18

– – –1/1

3 Transmission Pump Flow Check

Check transmission pump flow. Perform Transmission Pump Flow Test. (Group 9020-25.)

YES: Go to Transmission System Pressure Check.

Is pump flow within specification?

NO: Repair or replace transmission pump. See Transmission Pump Remove and Install. (Group 0360.)

– – –1/1

4 Transmission System Pressure Check

Check transmission system pressure. Perform Transmission System Pressure Test. (Group 9020-25.)

YES: Go to Clutch Pack Leakage Check.

Is transmission system pressure to specification?

NO: Replace transmission pressure regulator. – – –1/1

TM10229 (17MAR09)

9020-15-18

544J Loader (S.N. 611800— ) 032409

PN=798

Diagnostic Information 5 Clutch Pack Leakage Check

Check clutch pack leakage. Perform Transmission Element Leakage Test. (Group 9020-25.)

YES: Go to Transmission Control Unit Program Check.

Is leakage within specification? NO: Repair or replace clutch pack. See Transmission Remove and Install. (Group 0300.)

– – –1/1

6 Transmission Control Unit Program Check

Program TCU. See Transmission Control Unit (TCU)—Electronic Clutch Calibration. (Group 9020-20.) And see CAN Monitor Unit (CMU) Circuit Theory of Operation. (Group 9015-15.)

YES: Go to Transmission Control Valve Orifice Check.

Is TCU programed correctly?

NO: Program TCU to correct specifications. – – –1/1

7 Transmission Control Valve Orifice Check

Inspect and clean transmission control valve orifices. See Transmission Control Valve Disassemble and Assemble. (Group 0360.)

YES: Clean and install orifice or replace orifice.

Is orifice plugged?

NO: Go to Transmission Control Valve Oil Passage Check. – – –1/1

8 Transmission Control Valve Oil Passage Check

Inspect oil passages between control valve and transmission restrictions. See Transmission Control Valve Remove and Install. (Group 0360.)

YES: Clean oil passages. NO: Checks complete.

Are oil passages plugged or restricted?

– – –1/1

Transmission Shifts Too Fast Diagnostic Procedure

– – –1/1

1 Speed Sensor Check

Check for active transmission speed sensor codes. See CAN Monitor Unit (CMU) Menu Structure—Service Mode. (Group 9015-20.) Are speed sensor codes present?

YES: See Diagnostic Trouble Codes (DTC) Quick Reference List. (Group 9015-20.) NO: Go to Transmission System Pressure Check.

– – –1/1

TM10229 (17MAR09)

9020-15-19

544J Loader (S.N. 611800— ) 032409

PN=799

9020 15 19

Diagnostic Information 2 Transmission System Pressure Check

Check transmission system pressure. Perform Transmission System Pressure Test. (Group 9020-25.)

YES: Go to Transmission Clutch Pack Check.

Is transmission system pressure to specification?

NO: Replace transmission pressure regulator. – – –1/1

3 Transmission Clutch Pack Check

Check transmission clutch packs for wear or damage. See Clutches, Input and Output Shafts Remove. (Group 0350.)

YES: Repair or replace as necessary.

Is clutch pack worn or damaged?

NO: Go to Transmission Control Unit (TCU) Check. – – –1/1

4 Transmission Control Unit (TCU) Check

Check TCU operation. See CAN Circuit Test. (Group 9015-20.) And see Transmission Control Unit (TCU) Circuit Theory of Operation. (Group 9015-15.)

YES: Checks complete. NO: Replace TCU.

Is TCU working correctly?

– – –1/1

Machine Creeps in Neutral Diagnostic Procedure

9020 15 20

– – –1/1

1 Transmission Clutch Pack Check

Check transmission clutch packs for warped disks and plates. See Clutches, Input and Output Shafts Remove. (Group 0350.)

YES: Replace clutch packs as needed.

Are clutch pack disks and plates warped or damaged?

NO: Go to Transmission Control Valve Check. – – –1/1

2 Transmission Control Valve Check

Check control valve gasket for damage. See Transmission Control Valve Remove and Install. (Group 0360.)

YES: Replace transmission control valve gasket.

Is transmission control valve gasket damaged? NO: Go to Transmission Control Valve Solenoid Check.

– – –1/1

TM10229 (17MAR09)

9020-15-20

544J Loader (S.N. 611800— ) 032409

PN=800

Diagnostic Information 3 Transmission Control Valve Solenoid Check

Remove solenoid valve and check for plugged screen.

YES: Clean or replace screen. See Transmission Control Valve Disassemble. (Group 0360.)

Is screen plugged with debris?

NO: Checks complete.

– – –1/1

Transmission Hydraulic System Overheats Diagnostic Procedure

– – –1/1

1 Transmission Oil Level Check

Check oil level. See Check Transmission Oil. (Operator’s Manual.)

YES: Go to Hydraulic Line Check.

Is oil level to specification? NO: Bring oil to correct level using recommended oil. See Transmission, Park Brake, and Axle Oil. 9020 (Operator’s Manual.) 15 21

– – –1/1

2 Hydraulic Line Check

Check hydraulic lines. See Power Train Component Location. (Group 9020-15.)

YES: Replace damaged lines.

Are hydraulic lines pinched or damaged? NO: Go to Transmission Oil Cooler Check. – – –1/1

3 Transmission Oil Cooler Check

Check oil cooler for debris and bent fins. Are oil cooler fins clean and straight?

YES: Go to Transmission Oil Cooler Bypass Valve Check. NO: Clean and straighten oil cooler fins. – – –1/1

4 Transmission Oil Cooler Bypass Valve Check

Check oil cooler bypass valve. See Power Train Component Location. (Group 9020-15.)

YES: Replace oil cooler bypass valve.

Is oil cooler bypass valve damaged?

NO: Go to Thermal Bypass Valve Check. – – –1/1

TM10229 (17MAR09)

9020-15-21

544J Loader (S.N. 611800— ) 032409

PN=801

Diagnostic Information 5 Thermal Bypass Valve Check

Check thermal bypass valve. Perform Transmission Oil Cooler Thermal Bypass Valve Temperature Test. (Group 9020-25.)

YES: Go to Oil Cooler Restriction Check.

Is thermal bypass valve working correctly?

NO: Repair or replace thermal bypass valve. – – –1/1

6 Oil Cooler Restriction Check

Check oil cooler restriction. Perform Transmission Oil Cooler Restriction Test. (Group 9020-25.)

YES: Go to Transmission System Pressure Check.

Is oil cooler within specification?

NO: Repair or replace oil cooler. – – –1/1

7 Transmission System Pressure Check

Check transmission system pressure. Perform Transmission System Pressure Test. (Group 9020-25.)

YES: Go to Torque Converter-Out Pressure Check.

Is system pressure to specification? NO: Repair or replace system pressure relief valve.

9020 15 22

– – –1/1

8 Torque Converter-Out Pressure Check

Check torque converter-out pressure. Perform Torque Converter-Out Pressure Test. (Group 9020-25.)

YES: Go to Transmission Pump Output Check.

Is torque converter-out pressure to specification?

NO: Perform Torque Converter Relief Valve Test. (Group 9020-25.) – – –1/1

9 Transmission Pump Output Check

Check transmission pump output. Perform Transmission Pump Flow Test. (Group 9020-25.) Is pump flow within specification?

YES: Checks complete. NO: Repair or replace transmission pump.

– – –1/1

Transmission Excessive Noise Diagnostic Procedure

– – –1/1

TM10229 (17MAR09)

9020-15-22

544J Loader (S.N. 611800— ) 032409

PN=802

Diagnostic Information 1 Transmission Wear Check

Check suction screen for metal contamination. See Transmission Remove and Install. (Group 0300.) Is suction screen contaminated with metal particles?

YES: Repair transmission as necessary. See Transmission Remove and Install. (Group 0300.) NO: Go to Flywheel Output Dampener Check.

– – –1/1

2 Flywheel Output Dampener Check

Check output dampener for damage. See Engine Remove and Install. (Group 0400.) Is output dampener damaged?

YES: Replace output dampener. See Output Dampener Remove and Install. (Group 0752.) NO: Go to Converter Bearing Check.

– – –1/1

3 Converter Bearing Check

Check converter bearing for wear or damage. See Torque Converter and Housing Remove. (Group 0350.)

YES: Repair or replace converter.

Is converter bearing worn or damaged?

NO: Go to Transmission Lube Check. – – –1/1

4 Transmission Lube Check

Check transmission lube pressure. Perform Transmission Lube Pressure Test. (Group 9020-25.) Is lube pressure low?

YES: Perform Transmission Lube Pressure Test. (Group 9020-25.) NO: Go to Driveline Check.

– – –1/1

5 Driveline Check

Check driveline for wear or damage. See Universal Joints and Drive Shafts Remove and Install. (Group 0225.) Is driveline worn or damaged?

YES: Repair or replace worn or damaged driveline parts as necessary. NO: Checks complete. – – –1/1

TM10229 (17MAR09)

9020-15-23

544J Loader (S.N. 611800— ) 032409

PN=803

9020 15 23

Diagnostic Information Oil Aerated Diagnostic Procedure

– – –1/1

1 Oil Type or Viscosity Check

Check transmission oil. See Transmission, Park Brake, and Axle Oil. (Operator’s Manual.)

YES: Go to Oil Level Check.

Is correct oil used?

NO: Replace transmission oil with correct oil. – – –1/1

2 Oil Level Check

Check oil level. See Check Transmission Oil. (Operator’s Manual.) Is oil level to specification?

YES: Go to Transmission Pump Suction Tube Check. NO: Add recommended oil. See Transmission, Park Brake, and Axle Oil. (Operator’s Manual.)

9020 15 24

– – –1/1

3 Transmission Pump Suction Tube Check

Check transmission pump suction tube for air leak.

YES: Repair suction tube air leak.

Is suction tube leaking? NO: Checks complete.

– – –1/1

Oil Ejected from Dipstick Diagnostic Procedure

– – –1/1

1 Transmission Breather Check

Check transmission breather. Is transmission housing breather plugged?

YES: Remove and clean transmission housing breather. NO: Check complete. – – –1/1

Machine Vibrates Diagnostic Procedure

– – –1/1

TM10229 (17MAR09)

9020-15-24

544J Loader (S.N. 611800— ) 032409

PN=804

Diagnostic Information 1 Aerated Oil Check

Check oil level. See Check Transmission Oil. (Operator’s Manual.)

YES: Go to Driveline Check.

Is oil level to specification? NO: Add recommended oil. See Transmission, Park Brake, and Axle Oil. (Operator’s Manual.)

– – –1/1

2 Driveline Check

Check driveline for wear or damage. See Universal Joints and Drive Shafts Remove and Install. (Group 0225.) Is driveline worn or damaged?

YES: Repair or replace worn or damaged driveline parts as necessary. NO: Go to Flywheel Output Dampener Check.

– – –1/1

3 Flywheel Output Dampener Check

Check output dampener for damage. See Engine Remove and Install. (Group 0400.) Is output dampener damaged?

YES: Replace output dampener. See Output Dampener Remove and Install. (Group 0752.) NO: Checks complete. – – –1/1

Machine Power and Acceleration Low Diagnostic Procedure

– – –1/1

1 Oil Type or Viscosity Check

Check transmission oil. See Transmission, Park Brake, and Axle Oil. (Operator’s Manual.)

YES: Go to Aerated Oil Check.

Is correct oil used?

NO: Replace transmission oil with correct oil. – – –1/1

TM10229 (17MAR09)

9020-15-25

544J Loader (S.N. 611800— ) 032409

PN=805

9020 15 25

Diagnostic Information 2 Aerated Oil Check

Check oil level. See Check Transmission Oil. (Operator’s Manual.)

YES: Go to Transmission Clutch Pack Check.

Is oil level to specification? NO: Add recommended oil. See Transmission, Park Brake, and Axle Oil. (Operator’s Manual.)

– – –1/1

3 Transmission Clutch Pack Check

Check transmission clutch packs for warped disks and plates. See Clutches, Input and Output Shafts Remove. (Group 0350.)

YES: Replace clutch packs as needed.

Are clutch pack disks and plates warped or damaged?

NO: Go to Transmission Control Valve Check. – – –1/1

4 Transmission Control Valve Check

Check control valve gasket for damage. See Transmission Control Valve Remove and Install. (Group 0360.)

YES: Replace transmission control valve gasket.

Is transmission control valve gasket damaged? NO: Go to Torque Converter Check. 9020 15 26

– – –1/1

5 Torque Converter Check

Check torque converter performance. Perform Torque Converter Stall Speed Test. (Group 9020-25.)

YES: Go to Engine Low Power Check.

Is torque converter performance within specification?

NO: Perform remaining test checks. – – –1/1

6 Engine Low Power Check

Check engine speed. See Engine Speed Check and Adjust. (Group 9010-25.)

YES: Go to Torque Converter Relief Valve Check.

Is engine speed within specification?

NO: Perform Intake Manifold Pressure Test— Turbocharger Boost. (Group 9010-25.)

– – –1/1

7 Torque Converter Relief Valve Check

Check torque converter relief valve. See Torque Converter Relief Valve Remove, Disassemble and Install. (Group 0360.)

YES: Repair or replace torque converter relief valve.

Is torque converter relief valve damaged? NO: Checks complete. – – –1/1

TM10229 (17MAR09)

9020-15-26

544J Loader (S.N. 611800— ) 032409

PN=806

Diagnostic Information Torque Converter Stall RPM Diagnostic Procedure

– – –1/1

1 Oil Aerated Check

Check oil for aeration. See Oil Aerated Diagnostic Procedure. (Group 9020-15.) Is air present in oil?

YES: Follow diagnostic procedure to remove cause of aeration. NO: Go to Torque Converter Relief Valve Check.

– – –1/1

2 Torque Converter Relief Valve Check

Check torque converter relief valve. See Torque Converter Relief Valve Remove, Disassemble and Install. (Group 0360.)

YES: Repair or replace torque converter relief valve.

Is torque converter relief valve damaged? NO: Go to Torque Converter Stall Speed Check.

9020 15 27

– – –1/1

3 Torque Converter Stall Speed Check

Check torque converter stall speed. Perform Torque Converter Stall Speed Test. (Group 9020-25.) Are stall speeds within specification?

YES: Checks complete. NO: Remove and replace torque converter: See Torque Converter and Housing Remove and Install. (Group 0300.)

– – –1/1

Differential and Axle Diagnose Malfunctions

OUO1020,0001655 –19–01JUN07–1/1

TM10229 (17MAR09)

9020-15-27

544J Loader (S.N. 611800— ) 032409

PN=807

Diagnostic Information Differential Lock Will Not Engage Diagnostic Procedure

– – –1/1

1 Differential Lock Solenoid Circuit Check

Check differential lock electrical circuit. See System Functional Schematic and Section Legend. (Group 9015-10.)

YES: Go to Differential Lock Solenoid Valve Check.

Is there power to the differential lock solenoid? NO: Repair differential lock circuit as needed. – – –1/1

2 Differential Lock Solenoid Valve Check

Check differential lock solenoid valve.

YES: Repair or replace differential lock solenoid valve.

Is differential lock solenoid valve worn or damaged?

NO: Go to Differential Lock Leakage Check. – – –1/1

3 Differential Lock Leakage Check

Check differential lock pressure. Perform Differential Lock Pressure Test. (Group 9020-25.)

YES: Go to Differential Lock Disks and Plates Check.

Is pressure within specification? NO: Repair or replace leaking differential lock seal. See Differential Disassemble. (Group 0250.)

9020 15 28

– – –1/1

4 Differential Lock Disks and Plates Check

Check differential lock disks and plates. See Differential Disassemble. (Group 0250.)

YES: Repair differential lock as necessary.

Are differential lock disks and plates worn or damaged? NO: Checks complete.

– – –1/1

Differential Lock Slips and Chatters Diagnostic Procedure

– – –1/1

TM10229 (17MAR09)

9020-15-28

544J Loader (S.N. 611800— ) 032409

PN=808

Diagnostic Information 1 Axle Oil Check

Check axle oil. See Change Front and Rear Axle Oil. (Operator’s Manual.)

YES: Go to Differential Lock Leakage Check.

IMPORTANT: Perform this service at the first 250 hours of operation and at 2000 hour intervals thereafter. Has axle oil been changed as recommended?

NO: Change axle oil. See Transmission, Park Brake, and Axle Oil. (Operator’s Manual.)

– – –1/1

2 Differential Lock Leakage Check

Check differential lock pressure. Perform Differential Lock Pressure Test. (Group 9020-25.)

YES: Go to Differential Lock Disks and Plates Check.

Is pressure within specification? NO: Repair or replace leaking differential lock seal. See Differential Disassemble. (Group 0250.)

– – –1/1

3 Differential Lock Disks and Plates Check

Check differential lock disks and plates. See Differential Disassemble. (Group 0250.)

YES: Repair differential lock as necessary.

Are differential lock disks and plates worn or damaged? NO: Checks complete.

– – –1/1

Differential Lock Will Not Disengage Diagnostic Procedure

– – –1/1

1 Foot Switch Check

Check foot switch operation.

YES: Go to Differential Lock Solenoid Circuit Check.

Is foot switch free to return to disengage position?

NO: Repair or replace foot switch. – – –1/1

2 Differential Lock Solenoid Circuit Check

Check differential lock electrical circuit. See System Functional Schematic and Section Legend. (Group 9015-10.)

YES: Go to Differential Lock Solenoid Valve Check.

Is there power to the differential lock solenoid? NO: Repair differential lock circuit as needed. – – –1/1

TM10229 (17MAR09)

9020-15-29

544J Loader (S.N. 611800— ) 032409

PN=809

9020 15 29

Diagnostic Information 3 Differential Lock Solenoid Valve Check

Check differential lock solenoid valve.

YES: Repair or replace differential lock solenoid valve.

Is differential lock solenoid valve worn or damaged?

NO: Go to Differential Lock Piston Check. – – –1/1

4 Differential Lock Piston Check

Check differential lock piston. See Differential Disassemble. (Group 0250.)

YES: Go to Differential Lock Disks and Plates Check.

Is piston able to move in bore without binding?

NO: Repair or replace piston as necessary. – – –1/1

5 Differential Lock Disks and Plates Check

Check differential lock disks and plates. See Differential Disassemble. (Group 0250.)

YES: Repair differential lock as necessary.

Are differential lock disks and plates worn or damaged? NO: Checks complete.

– – –1/1

Differential Oil Level Rises Diagnostic Procedure

9020 15 30

– – –1/1

1 Differential Line Routing Check

Check line routing to axle. See Power Train Component Location. (Group 9020-15.)

YES: Go to Differential Lock Piston Check.

Are lines connected to the correct axle ports? NO: Connect lines to correct axle ports. – – –1/1

2 Differential Lock Piston Check

Check differential lock piston. See Differential Disassemble. (Group 0250.)

YES: Replace differential lock piston seal.

Is differential lock piston seal worn or damaged? NO: Go to Brake Piston Check. – – –1/1

3 Brake Piston Check

Check brake piston. See Service Brake Assembly Remove and Install. (Group 1000.)

YES: Replace brake piston seal.

Is brake piston seal worn or damaged? NO: Checks complete.

– – –1/1

Differential Oil Level Low Diagnostic Procedure

– – –1/1

TM10229 (17MAR09)

9020-15-30

544J Loader (S.N. 611800— ) 032409

PN=810

Diagnostic Information 1 Axle External Leakage Check

Check axle and differential for external leakage.

YES: Repair axle and differential leaks as necessary. See Disassemble and Assemble Differential and see Axle End and Final Drive Assembly. (CTM442.)

Is axle or differential leaking?

NO: Check complete.

– – –1/1

Differential and Axle Noise Excessive Diagnostic Procedure

– – –1/1

1 Axle Oil Check

Check axle oil. See Change Front and Rear Axle Oil. (Operator’s Manual.)

YES: Go to Foot Switch Check.

IMPORTANT: Perform this service at the first 250 hours of operation and at 2000 hour intervals thereafter. Has axle oil been changed as recommended?

NO: Change axle oil. See Transmission, Park Brake, and Axle Oil. (Operator’s Manual.) 9020 15 31

– – –1/1

2 Foot Switch Check

Check foot switch operation. Is foot switch free to return to disengage position?

YES: Go to Differential Lock Solenoid Valve Check. NO: Repair or replace foot switch. – – –1/1

3 Differential Lock Solenoid Valve Check

Check differential lock solenoid valve. Is differential lock solenoid valve sticking?

YES: Repair or replace differential lock solenoid valve. NO: Go to Service Brakes Check. – – –1/1

TM10229 (17MAR09)

9020-15-31

544J Loader (S.N. 611800— ) 032409

PN=811

Diagnostic Information 4 Service Brakes Check

Check service brakes. See External Service Brake Inspection. (Group 9020-20.) Are brakes worn or damaged?

YES: Replace service brakes. See Service Brake Assembly Remove and Install. (Group 1011.) NO: Go to Differential Check.

– – –1/1

5 Differential Check

Check differential. See Disassemble and Assemble Differential. (CTM442.)

YES: Replace differential.

Are differential parts worn or damaged?

NO: Go to Axle Bearing Check.

– – –1/1

6 Axle Bearing Check

Check axle bearings. See Disassemble and Assemble Differential. (CTM442.)

YES: Replace axle bearings.

Are axle bearings worn or damaged? NO: Go to Axle Planetary Check. 9020 15 32

– – –1/1

7 Axle Planetary Check

Check axle planetary. See Disassemble Planet Pinion Carrier. (CTM442.) Is axle planetary worn or damaged?

YES: Repair or replace axle planetary as necessary. NO: Go to Axle Circulation Pumps Check. – – –1/1

8 Axle Circulation Pumps Check

Check axle circulation pumps. Perform Axle Circulation Dual Pump Flow and Temperature Tests. (Group 9020-25.) Is pump flow within specification for both circulation pumps?

YES: Checks complete. NO: Clean pump suction screens and perform Axle Circulation Dual Pump Flow and Temperature Tests. (Group 9020-25.) If pump flow is still not within specification, replace both pumps.

– – –1/1

Axle Wheel Hub Face Seal Leaking Diagnostic Procedure

– – –1/1

TM10229 (17MAR09)

9020-15-32

544J Loader (S.N. 611800— ) 032409

PN=812

Diagnostic Information 1 Face Seal Check

Check face seals for wear or damage. See Disassemble Planet Pinion Carrier. (CTM442.)

YES: Replace face seal. NO: Go to Axle Bearing Check.

Is face seal worn or damaged?

– – –1/1

2 Axle Bearing Check

Check axle bearing for wear or damage. See Disassemble Planet Pinion Carrier. (CTM442.). (Group 0250.)

YES: Replace axle bearings.

Are axle bearings worn or damaged?

NO: Go to Axle Breather Check. – – –1/1

3 Axle Breather Check

Check axle breather. Perform Axle Breather Test. (Group 9020-25.)

YES: Clean or replace breathers.

Are axle breathers plugged? NO: Checks complete.

– – –1/1

Axle Overheats Diagnostic Procedure

– – –1/1

1 Axle Oil Check

Check axle oil. See Change Front and Rear Axle Oil. (Operator’s Manual.)

YES: Go to Axle Oil Level Check.

IMPORTANT: Perform this service at the first 250 hours of operation and at 2000 hour intervals thereafter. Has axle oil been changed as recommended?

NO: Change axle oil. See Transmission, Park Brake, and Axle Oil. (Operator’s Manual.)

– – –1/1

2 Axle Oil Level Check

Check axle oil level. See Differential Oil Level Rises Diagnostic Procedure in this malfunction diagnosis.

YES: Go to Service Brake Drag Check.

Is axle oil at correct level?

NO: Correct oil level rise using diagnostic procedure. See Differential Oil Level Rises Diagnostic Procedure in this malfunction diagnosis.

– – –1/1

TM10229 (17MAR09)

9020-15-33

544J Loader (S.N. 611800— ) 032409

PN=813

9020 15 33

Diagnostic Information 3 Service Brake Drag Check

Check service brakes. See Service Brake Diagnose Malfunctions. (Group 9020-15.)

YES: Repair or replace service brake.

Is service brake dragging? NO: Go to Axle Circulation Pumps Check. – – –1/1

4 Axle Circulation Pumps Check

Check axle circulation pumps. Perform Axle Circulation Dual Pump Flow and Temperature Tests. (Group 9020-25.)

YES: Checks complete. NO: Clean pump suction screens and perform Axle Circulation Dual Pump Flow and Temperature Tests. (Group 9020-25.)

Is pump flow within specification for both circulation pumps?

If pump flow is still not within specification, replace both pumps.

– – –1/1

Service Brake Diagnose Malfunctions

9020 15 34

OUO1020,000165B –19–06JUN07–1/1

Brakes Poor or Do Not Apply Diagnostic Procedure

– – –1/1

1 Axle Breather Check

Check axle breather. Perform Axle Breather Test. (Group 9020-25.)

YES: Clean or replace breathers.

Are axle breathers plugged? NO: Go to Air in Brake System Check. – – –1/1

2 Air in Brake System Check

Check brake system for air.

YES: Bleed air out of brake system.

Is air in brake system? NO: Go to Brake Accumulator Check. – – –1/1

3 Brake Accumulator Check

Check brake accumulators. Perform Brake Accumulator Precharge Test. (Group 9025-25.)

YES: Go to Pump Standby Pressure Check.

Is accumulator precharge pressure to specification?

NO: Replace accumulator. – – –1/1

TM10229 (17MAR09)

9020-15-34

544J Loader (S.N. 611800— ) 032409

PN=814

Diagnostic Information 4 Pump Standby Pressure Check

Check pump standby pressure. Perform Pump Load Sense Differential and Standby Pressure Test. (Group 9025-25.)

YES: Go to Brake Valve Check.

Is pump standby pressure within specification?

NO: Adjust pump standby pressure to specification. – – –1/1

5 Brake Valve Check

Check brake valve pressure. Perform Brake Valve Pressure Test. (Group 9025-25.)

YES: Go to Brake Disk Check.

Is brake pressure to specification? NO: Repair or replace brake valve. – – –1/1

6 Brake Disk Check

Check brake disk wear. See External Service Brake Inspection. (Group 9020-20.)

YES: Replace brake pack.

Is brake disk thickness less than specification? NO: Go to Brake Piston Seal Check. – – –1/1

7 Brake Piston Seal Check

Check brake piston seal. See Disassemble and Assemble Brakes. (CTM442.)

YES: Replace brake piston seal.

Is brake piston seal worn or damaged? NO: Go to Brake Line Blocked or Restricted Check. – – –1/1

8 Brake Line Blocked or Restricted Check

Check brake lines for blockage or restrictions. See Hydraulic System Component Location. (Group 9025-25.)

YES: Repair or replace lines as necessary.

Is brake line blocked or restricted?

NO: Checks complete.

– – –1/1

Brakes Aggressive Diagnostic Procedure

– – –1/1

1 Clutch Cut-Off Switch Check

Check clutch cut-off switch. Is clutch cut-off switch in the ON position?

YES: Move clutch cut-off switch to the OFF position. NO: Go to Hydraulic Oil Level Check. – – –1/1

2 Hydraulic Oil Level Check

Check hydraulic oil level. See Check Hydraulic Oil Level. (Operator’s Manual.)

YES: Fill hydraulic reservoir to proper level.

Is hydraulic oil level low? NO: Go to Air in Brake System Check. – – –1/1

TM10229 (17MAR09)

9020-15-35

544J Loader (S.N. 611800— ) 032409

PN=815

9020 15 35

Diagnostic Information 3 Air in Brake System Check

Check brake system for air.

YES: Bleed air out of brake system.

Is air in brake system? NO: Go to Brake Valve Check. – – –1/1

4 Brake Valve Check

Check brake valve pressure. Perform Brake Valve Pressure Test. (Group 9025-25.)

YES: Checks complete.

Is brake pressure to specification?

NO: Repair or replace brake valve.

– – –1/1

Brakes Dragging Diagnostic Procedure

– – –1/1

1 Brake Pedal Check

Check brake pedal for debris preventing pedal from returning fully.

YES: Go to Brake Valve Check.

Is brake pedal able to return fully? NO: Remove debris from around pedal. 9020 15 36

– – –1/1

2 Brake Valve Check

Check brake valve pressure. Perform Brake Valve Pressure Test. (Group 9025-25.)

YES: Go to Brake Disk Check.

Is brake released pressure to specification? NO: Remove debris from around brake valve. – – –1/1

3 Brake Disk Check

Check for warped brake disks. See External Service Brake Inspection. (Group 9020-20.)

YES: Replace brake pack.

Are brake disks warped?

NO: Go to Brake Piston Check. – – –1/1

4 Brake Piston Check

Check brake piston for wear or damage. See Service Brake Assembly Remove and Install. (Group 1011.)

YES: Replace brake piston.

Is brake piston worn or damaged?

NO: Checks complete.

– – –1/1

Brakes Lock Up Diagnostic Procedure

– – –1/1

TM10229 (17MAR09)

9020-15-36

544J Loader (S.N. 611800— ) 032409

PN=816

Diagnostic Information 1 Brake Valve Wear Check

Check brake valve for wear or damage. See Brake Valve Remove and Install. (Group 1060.)

YES: Repair or replace brake valve as necessary.

Is brake valve worn or damaged?

NO: Go to Brake Valve Pressure Check. – – –1/1

2 Brake Valve Pressure Check

Check brake valve pressures. Perform Brake Valve Pressure Test. (Group 9025-25.)

YES: Checks complete.

Are brake applied and released pressures to specification?

NO: Remove debris from around brake valve to ensure unrestricted operation. – – –1/1

Brakes Chatter Diagnostic Procedure

– – –1/1

1 Air in Brake System Check

Check brake system for air.

YES: Bleed air out of brake system.

Is air in brake system? NO: Go to Brake Disk Check. – – –1/1

2 Brake Disk Check

Check for worn brake disks. See External Service Brake Inspection. (Group 9020-20.)

YES: Replace brake pack.

Are brake disks worn? NO: Go to Axle Cooling Oil Check. – – –1/1

3 Axle Cooling Oil Check

Check axle cooling oil. See Hydraulic Reservoir Oil. (Operator’s Manual.)

YES: Checks complete.

Is correct oil used in reservoir?

NO: Drain incorrect oil and fill reservoir to proper level with correct oil. See Hydraulic Reservoir Oil. (Operator’s Manual.)

– – –1/1

Brake Warning Light On Diagnostic Procedure

– – –1/1

TM10229 (17MAR09)

9020-15-37

544J Loader (S.N. 611800— ) 032409

PN=817

9020 15 37

Diagnostic Information 1 Brake Accumulator Check

Check brake accumulators. Perform Brake Accumulator Precharge Test. (Group 9025-25.)

YES: Go to Pump Standby Pressure Check.

Is accumulator precharge pressure to specification?

NO: Replace accumulator. – – –1/1

2 Pump Standby Pressure Check

Check pump standby pressure. Perform Pump Load Sense Differential and Standby Pressure Test. (Group 9025-25.)

YES: Go to Brake Valve Check.

Is pump standby pressure within specification?

NO: Adjust pump standby pressure to specification. – – –1/1

3 Brake Valve Check

Check brake valve pressure. Perform Brake Valve Pressure Test. (Group 9025-25.)

YES: Go to Brake Valve Leakage Check.

Is brake pressure to specification? NO: Repair or replace brake valve. – – –1/1

4 Brake Valve Leakage Check

9020 15 38

Check brake valve leakage. See Brake Valve Leakage Test. (Group 9025-25.)

YES: Checks complete.

Is brake valve leakage within specification?

NO: Replace brake valve.

– – –1/1

Driveline Diagnose Malfunctions

OUO1020,000165C –19–14MAY07–1/1

Driveline Excessive Vibration or Noise Diagnostic Procedure

– – –1/1

1 Drive Shaft Yoke Alignment Check

Check drive shaft yokes for alignment. See Universal Joint and Drive Shaft Remove and Install. (Group 0225.)

YES: Go to Park Brake Bearing Check.

Are drive shaft yokes aligned?

NO: Align yokes and install drive shafts. – – –1/1

2 Park Brake Bearing Check

Check park brake bearings for wear or damage. See Park Brake Disassemble and Assemble. (Group 1111.)

YES: Replace park brake bearings.

Are park brake bearings worn or damaged?

NO: Go to Park Brake Oil Check. – – –1/1

TM10229 (17MAR09)

9020-15-38

544J Loader (S.N. 611800— ) 032409

PN=818

Diagnostic Information 3 Park Brake Oil Check

Check park brake oil level. See Check Park Brake Oil Level. (Operator’s Manual.)

YES: Go to Drive Shaft Check.

Is park brake oil at proper level? NO: Adjust park brake oil to proper level. – – –1/1

4 Drive Shaft Check

Check drive shafts for wear or damage. See Universal Joint and Drive Shaft Remove and Install. (Group 0225.)

YES: Replace drive shafts as necessary.

Are drive shafts damaged?

NO: Go to Universal Joint Retaining Nut Check. – – –1/1

5 Universal Joint Retaining Nut Check

Check for loose or missing universal joint retaining nuts. See Universal Joint and Drive Shaft Remove and Install. (Group 0225.)

YES: Install new retaining nuts as needed.

Are retaining nuts loose or missing?

NO: Go to Rear Axle Oscillating Support Check . – – –1/1

6 Rear Axle Oscillating Support Check

Check rear axle oscillating support for wear or damage. See Axle Oscillating Supports Disassemble and Assemble. (Group 0200.)

YES: Repair or replace parts as necessary.

Are axle oscillating supports worn or damaged?

NO: Go to Driveline Lubrication Check. – – –1/1

7 Driveline Lubrication Check

Check driveline lubrication.

YES: Checks complete.

Are all driveline components lubricated properly?

NO: Lubricate components as necessary. See Grease. (Operator’s Manual.) – – –1/1

Park Brake Diagnose Malfunctions

OUO1020,0001663 –19–06JUN07–1/1

Park Brake Will Not Hold Diagnostic Procedure

– – –1/1

1 Piston Seal Check

Check piston seals. See Park Brake Disassemble and Assemble. (Group 1111.)

YES: Replace piston seals.

Are piston seals worn or damaged? NO: Go to Park Brake Breather Check. – – –1/1

TM10229 (17MAR09)

9020-15-39

544J Loader (S.N. 611800— ) 032409

PN=819

9020 15 39

Diagnostic Information 2 Park Brake Breather Check

Check park brake breather.

YES: Clean or replace breather as necessary.

Is park brake breather plugged or damaged? NO: Go to Park Brake Solenoid Valve Check. – – –1/1

3 Park Brake Solenoid Valve Check

Check park brake solenoid valve.

YES: Repair or replace park brake solenoid valve.

Is park brake solenoid valve worn or damaged?

NO: Go to Park Brake Disk Check. – – –1/1

4 Park Brake Disk Check

Check park brake disks for wear or damage. See Park Brake Disassemble and Assemble. (Group 1111.)

YES: Replace park brake pack.

Are park brake disks worn or damaged?

NO: Go to Park Brake Spring Check. – – –1/1

5 Park Brake Spring Check

Check park brake springs. See Park Brake Disassemble and Assemble. (Group 1111.)

YES: Replace springs as needed.

Are any park brake springs worn or damaged? NO: Checks complete.

9020 15 40

– – –1/1

Park Brake Overheats Diagnostic Procedure

– – –1/1

1 Park Brake Oil Level Check

Check park brake oil level. See Check Park Brake Oil Level. (Operator’s Manual.)

YES: Go to Park Brake Pressure Check.

Is park brake oil to the proper level? NO: Adjust park brake oil to proper level. – – –1/1

2 Park Brake Pressure Check

Check park brake pressure. Perform Park Brake Pressure Test. (Group 9020-25.)

YES: Go to Park Brake Disk Check.

Is park brake pressure within specification? NO: Perform Transmission System Pressure Test. (Group 9020-25.)

– – –1/1

TM10229 (17MAR09)

9020-15-40

544J Loader (S.N. 611800— ) 032409

PN=820

Diagnostic Information 3 Park Brake Disk Check

Check park brake disks for wear or damage. See Park Brake Disassemble and Assemble. (Group 1111.)

YES: Replace park brake pack.

Are park brake disks worn or damaged?

NO: Go to Park Brake Bearing Check. – – –1/1

4 Park Brake Bearing Check

Check park brake bearings for wear or damage. See Park Brake Disassemble and Assemble. (Group 1111.)

YES: Replace bearings. NO: Checks complete.

Are park brake bearings worn or damaged?

– – –1/1

Park Brake Indicator Light Flashes when Shifting from Fwd to Rev Diagnostic Procedure

– – –1/1

1 Park Brake Oil Level Check

Check park brake oil level. See Check Park Brake Oil Level. (Operator’s Manual.)

YES: Go to Oil Temperature Check.

Is park brake oil to the proper level? NO: Adjust park brake oil to proper level. – – –1/1

2 Oil Temperature Check

Check oil temperature. Is oil temperature below normal operating temperature?

YES: Warm oil to specification. Perform Transmission Oil Warmup Procedure. (Group 9020-20.) NO: Go to Park Brake Solenoid Valve Check.

– – –1/1

3 Park Brake Solenoid Valve Check

Check park brake solenoid valve. Is park brake solenoid valve worn or damaged?

YES: Repair or replace park brake solenoid valve. NO: Checks complete. – – –1/1

Park Brake Indicator Light Flashes During Each Shift Diagnostic Procedure

– – –1/1

TM10229 (17MAR09)

9020-15-41

544J Loader (S.N. 611800— ) 032409

PN=821

9020 15 41

Diagnostic Information 1 Oil Temperature Check

Check oil temperature.

YES: Warm oil to specification. Perform Transmission Oil Warmup Procedure. (Group 9020-20.)

Is oil temperature below normal operating temperature?

NO: Go to Park Brake Oil Level Check.

– – –1/1

2 Park Brake Oil Level Check

Check park brake oil level. See Check Park Brake Oil Level. (Operator’s Manual.)

YES: Go to Park Brake Pressure Check.

Is park brake oil to the proper level? NO: Adjust park brake oil to proper level. – – –1/1

3 Park Brake Pressure Check

Check park brake pressure. Perform Park Brake Pressure Test. (Group 9020-25.)

YES: Go to Transmission Pump Flow Check.

Is park brake pressure within specification? NO: Perform Transmission System Pressure Test. (Group 9020-25.)

9020 15 42

– – –1/1

4 Transmission Pump Flow Check

Check transmission pump flow. Perform Transmission Pump Flow Test. (Group 9020-25.)

YES: Go to Park Brake Solenoid Valve Check.

Is transmission pump flow within specification?

NO: Repair or replace transmission pump. See Transmission Pump Remove and Install. (Group 0360.)

– – –1/1

5 Park Brake Solenoid Valve Check

Check park brake solenoid valve. Is park brake solenoid valve worn or damaged?

YES: Repair or replace park brake solenoid valve. NO: Checks complete. – – –1/1

TM10229 (17MAR09)

9020-15-42

544J Loader (S.N. 611800— ) 032409

PN=822

Diagnostic Information Park Brake Indicator Light Will Not Go On Diagnostic Procedure

– – –1/1

1 Park Brake Electrical Circuit Check

Check electrical circuit for damage. See System Functional Schematic and Section Legend. (Group 9015-10.)

YES: Repair or replace electrical circuit as necessary.

Is park brake electrical circuit damaged? NO: Check complete. – – –1/1

Park Brake Will Not Apply Diagnostic Procedure

– – –1/1

1 Park Brake Electrical Circuit Check

Check electrical circuit for damage. See System Functional Schematic and Section Legend. (Group 9015-10.)

YES: Repair or replace electrical circuit as necessary.

Is park brake electrical circuit damaged? NO: Go to Hydraulic Line Check. – – –1/1

2 Hydraulic Line Check

Check hydraulic line from transmission to park brake valve. See Power Train Component Location. (Group 9020-15.)

YES: Replace as necessary.

Is hydraulic line restricted or damaged?

NO: Checks complete.

– – –1/1

TM10229 (17MAR09)

9020-15-43

544J Loader (S.N. 611800— ) 032409

PN=823

9020 15 43

Diagnostic Information

9020 15 44

TM10229 (17MAR09)

9020-15-44

544J Loader (S.N. 611800— ) 032409

PN=824

Group 20

Adjustments Service Brake Bleeding Procedure 1. Install articulation locking bar, and engage park brake. 2. Remove front and rear axle bottom guard (if equipped) to access bleed screw (5). 3. Install clear plastic hose on differential bleed screw (5) to route oil flow to container. DO NOT reuse oil, dispose of waste oil properly.

TX1025001

4. Place a flat washer as wedge between the brake pedal and brake valve plunger to activate brakes.

–UN–03JUL07

5. Start engine and run at slow idle with park brake on. CAUTION: To avoid injury from escaping fluid under pressure, secure bleed hose on bleed screw then slowly open bleed screw to start oil flow. Tighten all connections after air bubbles have stopped flowing.

Bleed Screw 4—Container 5—Bleed Screw 6—Bleed Hose

6. Slowly open bleed plug until hydraulic oil starts to flow. Close bleed plug when oil is free of air bubbles. Repeat the bleed procedure for the other axle. Release brake pedal by removing washer. 9020 20 1

7. Stop engine and wait 15 minutes to allow air to migrate in brake system. 8. Place a flat washer between the brake pedal and plunger to activate brakes. Start engine and run at slow idle with park brake on. 9. Slowly open bleed plug until hydraulic oil starts to flow. Close bleed plug when oil is free of air bubbles. Repeat the bleed procedure for the other axle. Stop bleeding procedure if air bubbles continue for more than 3 minutes. Check for loose line connections. See Power Train Component Location. (Group 9020-15.) See Service Brake Diagnose Malfunctions. (Group 9020-15.)

Continued on next page

TM10229 (17MAR09)

9020-20-1

MR50960,0000247 –19–18SEP07–1/2

544J Loader (S.N. 611800— ) 032409

PN=825

Adjustments 10. Release brake pedal by removing washer. Remove bleed hose and dispose of waste oil properly. Install front and rear axle guards, if equipped. 11. Check hydraulic oil level. See Check Hydraulic Oil Level. (Operator’s Manual.)

MR50960,0000247 –19–18SEP07–2/2

External Service Brake Inspection SPECIFICATIONS Oil Groove Depth

0.99 mm 0.039 in.

New Service Brake Disk Thickness

7.57 mm 0.298 in.

SERVICE EQUIPMENT AND TOOLS Feeler Gauge

9020 20 2

Continued on next page

TM10229 (17MAR09)

9020-20-2

MM61211,00016E0 –19–05DEC06–1/3

544J Loader (S.N. 611800— ) 032409

PN=826

Adjustments

CAUTION: Prevent possible injury from hot spraying oil. Slowly loosen plug to relieve any pressure. NOTE: For rear axle brake inspection, remove oscillating support. See Rear Axle Remove and Install. (Group 0200.) 1. Remove plug (1) from brake inspection port.

–UN–08NOV06

2. Inspect the brake linings (2) on each side of the brake disk (4).

TX1014610

–UN–08NOV06

TX1014605A

–UN–08NOV06

TX1014606A

1—Inspection Plug (2 used) 2—Brake Lining (2 per disk) 3—Oil Groove 4—Brake Disk

Continued on next page

TM10229 (17MAR09)

9020-20-3

MM61211,00016E0 –19–05DEC06–2/3

544J Loader (S.N. 611800— ) 032409

PN=827

9020 20 3

Adjustments 3. If the oil grooves (3) are no longer visible or do not meet the minimum specification, replace brake disks. Specification Oil Groove—Minimum—Depth ..................................................... 0.99 mm 0.039 in. Specification New Service Brake Disk— Thickness...................................................................................... 7.57 mm 0.298 in.

TX1014608

–UN–08NOV06

3—Oil Groove

MM61211,00016E0 –19–05DEC06–3/3

9020 20 4

TM10229 (17MAR09)

9020-20-4

544J Loader (S.N. 611800— ) 032409

PN=828

Adjustments

Transmission Control Unit (TCU)—Electronic Clutch Calibration NOTE: This adjustment is required after a machine has the transmission 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 new machine or transmission. The adjustment will optimize the clutch pack shift operation by electronically adjusting the TCU for the exact transmission used in the machine. 1. The following criteria must be met and maintained for transmission clutch calibration to start and complete successfully: • Engine must be ON • TCL (Transmission Control Lever) must be in neutral • Park brake must be ON • Engine rpm must be lower than 1100 rpm • Transmission oil temperature must be 74—86°C (166—186°F) 2. Perform Transmission Oil Warmup Procedure. (Group 9020-25.) 9020 20 5

3. Begin transmission clutch calibration by accessing Trans Clutch Cal under Machine Config in the CAN Monitor Unit (CMU). See Transmission Control Unit (TCU) Circuit Theory of Operation. (Group 9015-15.) NOTE: While clutch calibration is in process, “Trans Clutch Cal” will be displayed at the top of the CMU and “Working” will be flashing on the bottom of the CMU. 4. Clutches will be calibrated and displayed on CMU as follows: • Adjusting K1 • Adjusting K2 • Adjusting K3 • Adjusting K4 • Adjusting KV • Adjusting KR

Continued on next page

TM10229 (17MAR09)

9020-20-5

MM61211,00016E1 –19–04JAN07–1/2

544J Loader (S.N. 611800— ) 032409

PN=829

Adjustments 5. If CMU displays the following during calibration, cycle key switch and start procedure again: • Shift Not in Neutral • Park Brake Not ON • Output Speed Not Zero If CMU displays the following during calibration, make required adjustments and continue with procedure: • Trans Temp too High • Trans Temp too Low • Engine RPM too Low • Engine RPM too High 6. If CMU displays “Cancelled” or “Aborted” during calibration, cycle key switch and start procedure again. If procedure cancels or aborts again, check for DTCs on CMU. See Diagnostic Trouble Codes (DTC) Quick Reference List—Transmission Control Unit (TCU). (Group 9001-30.) If no DTCs exist, diagnose transmission. See Diagnose Transmission System Malfunctions. (Group 9020-15.) 9020 20 6

7. With successful transmission calibration, one of the following will be displayed on the CMU: • Adjustment Complete Please Restart Engine • Fault Present Adjustment Complete Please Restart Engine

MM61211,00016E1 –19–04JAN07–2/2

TM10229 (17MAR09)

9020-20-6

544J Loader (S.N. 611800— ) 032409

PN=830

Group 25

Tests Transmission Oil Warmup Procedure SPECIFICATIONS Transmission Oil Temperature

2. Fully apply service brakes.

74—86°C 166—186°F

3. Release park brake by pushing the park brake switch to OFF position.

NOTE: The Service ADVISOR application or CAN monitor unit (CMU) may be used to indicate transmission oil temperature. Temperature sensor is located in transmission control valve. 1. To display transmission oil temperature using the CMU, access the Diagnostics / Transmission menu in the CMU main menu. See CAN Monitor Unit (CMU) Menu Structure—Service Mode. (Group 9015-20.) NOTE: Transmission auto mode and clutch cut-off must be turned off.

4. Shift to third gear forward. 5. Run engine at fast idle until test specification is met or for 30 seconds (whichever comes first). Specification Transmission Oil—Temperature ........................................... 74—86°C 166—186°F

6. Reduce speed, then shift to neutral and run for 15 seconds. 7. Repeat process until oil is to test specification. 8. Push MENU once to return to home screen.

Service ADVISOR is a trademark of Deere & Company

TM10229 (17MAR09)

MM61211,0001693 –19–24JAN07–1/1

9020-25-1

544J Loader (S.N. 611800— ) 032409

PN=831

9020 25 1

Tests

Park Brake Pressure Test The purpose of this test is to check that correct pressures are available to set and release the park brake. SPECIFICATIONS Transmission Oil Temperature

74—86°C 166—186°F

Engine Speed

Slow Idle

Transmission Position

Neutral

Park Brake—OFF Pressure

1500—1800 kPa 15—18 bar 218—261 psi

Park Brake—ON Pressure

0 kPa 0 bar 0 psi

ESSENTIAL TOOLS JT02156A Digital Pressure and Temperature Analyzer JT02161 Transducer 3447 kPa (34.5 bar) (500 psi) SERVICE EQUIPMENT AND TOOLS 38H1030 Tee Fitting (-6 M ORFS x -6 F ORFS x -6 M ORFS)

The purpose of this test is to check that correct pressures are available to set and release the park brake. 9020 25 2

1. Install frame articulation lock bar.

Continued on next page

TM10229 (17MAR09)

9020-25-2

MM61211,0001694 –19–04JAN07–1/3

544J Loader (S.N. 611800— ) 032409

PN=832

Tests 2. Park and prepare for service safely. See Park and Prepare For Service Safely. (Operator’s Manual.) 3. Install tee fitting and quick coupler (1 and 2) at park brake (3). 4. Connect JT02161 Transducer (4) and JT02156A Digital Pressure and Temperature Analyzer to quick coupler. See Digital Pressure and Temperature Analyzer Installation. (Group 9025-25.)

–UN–03MAY05

5. Warm transmission oil to specification. Perform Transmission Oil Warmup Procedure. (Group 9020-25.)

T211090A

Specification Transmission Oil—Temperature.................................................. 74—86°C 166—186°F

CAUTION: Prevent possible injury from unexpected machine movement. Keep bystanders clear of machine.

Park Brake Pressure Test 1—Tee Fitting 2—Quick Coupler 3—Park Brake 4—Transducer 5—Hydraulic Line (from park brake solenoid valve)

6. Operate engine at slow idle with transmission in neutral. Specification Engine—Speed ............................................................................ Slow Idle Transmission—Position ................................................................... Neutral

9020 25 3

7. Apply service brakes. 8. Turn park brake OFF. 9. Record park brake pressure. 10. Turn park brake ON. 11. Record park brake pressure. 12. Compare recorded pressure to specifications. Specification Park Brake—OFF—Pressure .......................................... 1500—1800 kPa 15—18 bar 218—261 psi Park Brake—ON—Pressure .............................................................. 0 kPa 0 bar 0 psi

Continued on next page

TM10229 (17MAR09)

9020-25-3

MM61211,0001694 –19–04JAN07–2/3

544J Loader (S.N. 611800— ) 032409

PN=833

Tests If pressure does not meet specification, perform Transmission System Pressure Test. (Group 9020-25.) If pressure does not drop to zero when park brake is ON, remove and inspect park brake valve. See Park Brake Operation. (Group 9020-05.) And see Park Brake Release Solenoid Valve Remove and Install. (Group 1160.)

MM61211,0001694 –19–04JAN07–3/3

Park Brake Drag Test The purpose of this test is to check for excessive brake drag due to internal damage or wear. This test should be performed only after Park Brake Pressure Test is completed. SPECIFICATIONS Park Brake Drag Resistance

Turn Freely with Hand

Drive Shaft Universal Joint Cap Screw—Torque

78 N•m 58 lb-ft

9020 25 4

Continued on next page

TM10229 (17MAR09)

9020-25-4

MM61211,0001695 –19–12DEC06–1/3

544J Loader (S.N. 611800— ) 032409

PN=834

Tests

TX1016116 1—Breather 2—Park Brake Solenoid

TX1016116

–UN–06DEC06

3—Drive Shaft (transmission-to-park brake)

4—Park Brake

CAUTION: Prevent possible injury from unexpected machine movement. Place blocks in front and rear of tires to prevent machine from rolling. 1. Park machine on level surface. Place blocks in front and rear of tires to prevent machine from rolling.

9020 25 5

5—Drive Shaft (front axle-to-park brake)

For machines with a joystick transmission control switch (TCS), it must be must be in the neutral position. 4. Remove drive shafts (3 and 5) from park brake (4) only. See Universal Joint and Universal Drive Shaft Remove and Install. (Group 0200.) 5. Start machine and turn park brake switch OFF.

CAUTION: Prevent possible injury from unexpected machine movement. Connect frame locking bar to both frames before working in frame pivot area.

6. Turn park brake yoke by hand. Yoke should turn freely with hand. Specification Park Brake Drag—Resistance......................... Turn Freely with Hand

2. Install frame articulation lock bar. 3. For machines with a column transmission control lever (TCL), move neutral lock to the locked position.

7. Turn park brake switch ON and turn machine off.

Continued on next page

TM10229 (17MAR09)

9020-25-5

MM61211,0001695 –19–12DEC06–2/3

544J Loader (S.N. 611800— ) 032409

PN=835

Tests IMPORTANT: Do not reuse drive shaft universal joint cap screws. Replace cap screws to avoid machine damage.

If park brake does not rotate by hand—remove park brake and inspect for worn or damaged parts. See Park Brake Remove and Install. (Group 1111.)

8. Install drive shafts with new cap screws. Tighten to specification. Specification Drive Shaft Universal Joint Cap Screw—Torque ........................................................................ 78 N•m 58 lb-ft

MM61211,0001695 –19–12DEC06–3/3

Transmission Pump Flow Test The purpose of this test is to determine transmission pump flow rate and performance. SPECIFICATIONS

9020 25 6

Transmission Oil Temperature

74—86°C 166—186°F

Engine Speed

1500 rpm

Transmission Position

Neutral

New Pump—Minimum Flow

74 L/min 16 gpm

Used Pump—Minimum Flow

67 L/min 14 gpm

ESSENTIAL TOOLS JDG596 Filter Adaptor JT0148 Flowmeter JDG596A1 Spacer and Sealing Washer Kit

1. Install frame articulation lock bar.

Continued on next page

TM10229 (17MAR09)

9020-25-6

MM61211,0001696 –19–11DEC06–1/2

544J Loader (S.N. 611800— ) 032409

PN=836

Tests 2. Remove transmission filter and install JDG596 Filter Adapter (1).

–UN–24OCT03

NOTE: It may be necessary to install one washer on each side of spacer when installing filter adapter. 3. Install JT0148 Flowmeter (2) to the filter adapter.

4. Perform Transmission Oil Warmup Procedure. (Group 9020-25.)

T195718B

IMPORTANT: Before starting engine, check that flowmeter loading valve is open. Pump can be damaged if engine is started with loading valve closed. 1—Filter Adapter 2—Flowmeter

Specification Transmission Oil—Temperature.................................................. 74—86°C 166—186°F

5. Operate engine at specified speed with transmission in neutral. Specification Engine—Speed ........................................................................... 1500 rpm Transmission—Position ................................................................... Neutral

6. Measure pump flow.

9020 25 7

Specification New Pump—Minimum—Flow....................................................... 60 L/min 16 gpm Used Pump—Minimum—Flow ..................................................... 54 L/min 14 gpm

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.

MM61211,0001696 –19–11DEC06–2/2

TM10229 (17MAR09)

9020-25-7

544J Loader (S.N. 611800— ) 032409

PN=837

Tests

Transmission System Pressure Test The purpose of this test is to check transmission pump output before it gets routed through the control valve to a clutch pack. This test can also indicate a malfunctioning pressure regulating valve or an oil leak before the control valve. SPECIFICATIONS Transmission Oil Temperature

74—86°C 166—186°F

Engine Speed

1500 rpm

Transmission Position

Neutral

Transmission System Pressure

1500—1800 kPa 15—18 bar 218—260 psi

ESSENTIAL TOOLS JT02156A Digital Pressure and Temperature Analyzer JT02161 Transducer 3447 kPa (34.5 bar) (500 psi)

NOTE: Four quick couplers are supplied to points on the transmission for checking pressure. Additional quick couplers may be purchased through John Deere Parts, or existing couplers may be removed and installed into points being tested. 1. Install frame articulation lock bar.

Continued on next page

MM61211,0001697 –19–25JAN07–1/3

9020 25 8

TM10229 (17MAR09)

9020-25-8

544J Loader (S.N. 611800— ) 032409

PN=838

Tests

T107136

–19–19FEB97

9020 25 9

1—System Pressure 2—Torque Converter-In Pressure 3—Reduced Pressure 4—Transmission Harness Connector

5—Clutch Forward High Range K4 6—Reverse Clutch KR (with quick coupler) 7—Clutch K1 (with quick coupler)

2. Connect transducer and digital pressure and temperature analyzer to transmission system pressure (1) test port using quick coupler. See

8—Clutch K3 9—Clutch Forward Low Range KV (with quick coupler) 10—Clutch K2 (with quick coupler)

Digital Pressure And Temperature Analyzer Installation. (Group 9025-25.)

Continued on next page

TM10229 (17MAR09)

11—Connection from Oil Cooler 12—Connection to Oil Cooler 13—Torque Converter-Out Pressure

9020-25-9

MM61211,0001697 –19–25JAN07–2/3

544J Loader (S.N. 611800— ) 032409

PN=839

Tests NOTE: The Service ADVISOR application or CAN monitor unit (CMU) may be used to read engine rpm and transmission oil temperature. 3. To display transmission oil temperature using the CMU, access the Diagnostics / Transmission menu in the CMU main menu. See CAN Monitor Unit (CMU) Menu Structure—Service Mode. (Group 9015-20.) If using Service ADVISOR application, access the Transmission System Pressure Test template. For information on connecting Service ADVISOR, see Service ADVISOR Connection Procedure. (Group 9015-20.) 4. Perform Transmission Oil Warmup Procedure. (Group 9020-25). Specification Transmission Oil—Temperature ........................................... 74—86°C 166—186°F

5. Operate engine at test specification with transmission in neutral. Specification Engine—Speed ..................................................................... 1500 rpm Transmission Position............................................................... Neutral

6. Record pressure with transmission in neutral. 7. Compare pressure to specifications. Specification Transmission System— Pressure.................................................................... 1500—1800 kPa 15—18 bar 218—260 psi

8. If pressure is low, perform Transmission Pump Flow Test. (Group 9020-25.) If flow is within specification, inspect pressure regulating valve spring in control valve.

9020 25 10

Service ADVISOR is a trademark of Deere & Company

MM61211,0001697 –19–25JAN07–3/3

Transmission Clutch Pressure Test SPECIFICATIONS Transmission Oil Temperature

74—86°C 166—186°F

Engine Speed

Slow Idle 1500 rpm

Transmission Clutch Pressure

1500—1800 kPa 15—18 bar 218—260 psi

This test is performed to test modulation circuits that electronically control clutch pressure in each clutch. NOTE: Four AT202955 Quick Couplers are supplied to points on the transmission for checking pressure. Additional quick couplers may be purchased through John Deere Parts, or existing couplers may be removed and installed into points being tested.

SERVICE EQUIPMENT AND TOOLS AT202955 Quick Coupler (1/8 x M10 - 1.5 M ORB) Gauge 2000 kPa (20 bar) (300 psi)

This test can be performed with one gauge, but the test time will be longer. Use six gauges if available. 1. Install frame articulation lock bar.

Continued on next page

TM10229 (17MAR09)

9020-25-10

MM61211,0001698 –19–25JAN07–1/4

544J Loader (S.N. 611800— ) 032409

PN=840

Tests

T107136

–19–19FEB97

9020 25 11

1—System Pressure 2—Torque Converter-In Pressure 3—Reduced Pressure 4—Transmission Harness Connector

5—Clutch Forward High Range K4 6—Reverse Clutch KR (with quick coupler) 7—Clutch K1 (with quick coupler)

8—Clutch K3 9—Clutch Forward Low Range KV (with quick coupler) 10—Clutch K2 (with quick coupler)

11—Connection from Oil Cooler 12—Connection to Oil Cooler 13—Torque Converter-Out Pressure

2. Connect gauges to transmission clutch points (5— 10).

Continued on next page

TM10229 (17MAR09)

9020-25-11

MM61211,0001698 –19–25JAN07–2/4

544J Loader (S.N. 611800— ) 032409

PN=841

Tests NOTE: The Service ADVISOR application or CAN monitor unit (CMU) may be used to read engine rpm and transmission oil temperature. 3. To display transmission oil temperature using the CMU, access the Diagnostics / Transmission menu in the CMU main menu. See CAN Monitor Unit (CMU) Menu Structure—Service Mode. (Group 9015-20.) If using Service ADVISOR application, access the Transmission Clutch Pressure Test template. For information on connecting Service ADVISOR, see Service ADVISOR Connection Procedure. (Group 9015-20.) 4. Perform Transmission Oil Warmup Procedure. (Group 9020-25.) Specification Transmission Oil—Temperature ........................................... 74—86°C 166—186°F

NOTE: Record pressures at both engine speeds. 5. Operate engine at engine speed test specifications. Pressure may be slightly lower at slow idle. 9020 25 12

Specification Engine—Speed ...................................................................... Slow Idle Engine—Speed ..................................................................... 1500 rpm

NOTE: Transmission auto mode and clutch cut-off must be turned off. 6. Apply service brakes and shift through all forward and reverse gears. The engagement pressure for each clutch should be the same. If pressure is low at slow idle and not at 1500 rpm, the clutch is leaking. If it is low at both test speeds, a control valve problem could exist.

Service ADVISOR is a trademark of Deere & Company

TM10229 (17MAR09)

Specification Transmission Clutch—Pressure ............................... 1500—1800 kPa 15—18 bar 218—260 psi

7. Repeat test for all remaining clutch packs at points (5—10) in neutral. Pressure should be zero in neutral. NOTE: Main transmission pressure is used to engage the clutch packs. If clutch engagement pressure is below specification, it does not always mean a clutch pack is leaking. Low voltage to a proportional solenoid or a plugged orifice in the modulation circuit can also cause low pressure. The modulation circuit uses reduced main pressure and is not affected by clutch leakage. 8. Compare pressures to specifications. Analyze test results as follows: • There will be some modulation when shifting gears, but since the transmission control unit varies the clutch modulation according to a number of load and speed factors, there is no specified modulation of the clutches. • If a given clutch pressure is much lower than the other clutch pressures and system pressure, probable cause is the modulation circuit for that particular clutch. See Electrical Component Specifications. (Group 9015-20.) • If pressure is low at both speeds, check for control valve problem. See Transmission Control Valve Remove and Install. (Group 0360.) • If pressure is low at slow idle and not at 1500 rpm, the clutch is leaking. Replace clutch pack. See Transmission Remove and Install. (Group 0300.)

Continued on next page

9020-25-12

MM61211,0001698 –19–25JAN07–3/4

544J Loader (S.N. 611800— ) 032409

PN=842

Tests TEST RESULTS Gear

Test Points

1 Forward

Pressure

7 2 Forward

10 3 Forward

8 4 Forward

8 1 Reverse

7 2 Reverse

10 3 Reverse

MM61211,0001698 –19–25JAN07–4/4

TM10229 (17MAR09)

9020-25-13

544J Loader (S.N. 611800— ) 032409

PN=843

9020 25 13

Tests

Transmission Element Leakage Test SPECIFICATIONS Engine Speed

1500 rpm

Transmission Oil Temperature

74—86°C 166—186°F

Transmission Position

Neutral

Torque Converter-Out— Maximum—Pressure Difference

28 kPa 0.28 bar 4 psi

ESSENTIAL TOOLS JT05491 Quick Coupler (7/16 - 20 M 37° x 14 M x 1.5 ORB) SERVICE EQUIPMENT AND TOOLS Gauge 690 kPa (7 bar) (100 psi)

The purpose of this test is to help isolate leakage in an element as compared to other elements (clutch packs). The pressure created by the torque converter-out lube flow through the cooler is measured. Changes in cooler pressure are a direct result of changes in lube flow. 1. Install frame articulation lock bar.

9020 25 14

Continued on next page

TM10229 (17MAR09)

9020-25-14

MM61211,0001699 –19–25JAN07–1/3

544J Loader (S.N. 611800— ) 032409

PN=844

Tests

T107136

–19–19FEB97

9020 25 15

1—System Pressure 2—Torque Converter-In Pressure 3—Reduced Pressure 4—Transmission Harness Connector

5—Clutch Forward High Range K4 6—Reverse Clutch KR (with quick coupler) 7—Clutch K1 (with quick coupler)

NOTE: Four JT05491 Quick Couplers are supplied to points on the transmission for checking pressure. Additional quick couplers may be purchased through John Deere Parts, or

8—Clutch K3 9—Clutch Forward Low Range KV (with quick coupler) 10—Clutch K2 (with quick coupler)

existing couplers may be removed and installed into points being tested. 2. Connect gauge to test port (13).

Continued on next page

TM10229 (17MAR09)

11—Connection from Oil Cooler 12—Connection to Oil Cooler 13—Torque Converter-Out Pressure

9020-25-15

MM61211,0001699 –19–25JAN07–2/3

544J Loader (S.N. 611800— ) 032409

PN=845

Tests NOTE: The Service ADVISOR application or CAN monitor unit (CMU) may be used to read engine rpm and transmission oil temperature.

engaged. This is due to the normal leakage that occurs in the transmission control valve when all the elements are disengaged.

3. To display transmission oil temperature using the CMU, access the Diagnostics / Transmission menu in the CMU main menu. See CAN Monitor Unit (CMU) Menu Structure—Service Mode. (Group 9015-20.)

6. Maintain specified engine speed and temperature.

If using Service ADVISOR application, access the Transmission Element Leakage Test template. For information on connecting Service ADVISOR, see Service ADVISOR Connection Procedure. (Group 9015-20.) 4. Perform Transmission Oil Warmup Procedure. (Group 9020-25.)

7. With clutch cut-off turned off and service brakes applied, shift through all forward and reverse gears. Record torque converter-out pressure for each gear. Analyze test results as follows:

Specification Transmission Oil—Temperature ........................................... 74—86°C 166—186°F

5. Operate engine at test specification with transmission in neutral.

9020 25 16

Specification Torque Converter-Out— Maximum—Pressure Difference ............................................... 28 kPa 0.28 bar 4 psi

Specification Engine—Speed ..................................................................... 1500 rpm Transmission—Position ............................................................ Neutral

• There should be little or no pressure difference between gears if there is no leakage in the elements that are engaged. • If there is a pressure drop in one or more gears, element leakage is indicated. See Transmission Clutch Engagement and Solenoids Activated. (Group 9020-05.) Identify the element that is common to gears showing a pressure drop. If the pressure difference is greater than specified, repair the transmission.

NOTE: Torque converter-out pressure will be less with transmission in neutral, than with the elements

Service ADVISOR is a trademark of Deere & Company

MM61211,0001699 –19–25JAN07–3/3

Transmission Lube Pressure Test SPECIFICATIONS

SERVICE EQUIPMENT AND TOOLS

Transmission Oil Temperature

74—86°C 166—186°F

Barb Tee Fitting (1 in.)

Engine Speed

Fast Idle

Gauge 414 kPa (4 bar) (60 psi)

Transmission Position

Neutral

Transmission Lube Pressure

20.7—103 kPa 0.20—1.03 bar 3—15 psi

Test Hose (1 in. x 4 in.)

1. Install frame articulation lock bar.

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TM10229 (17MAR09)

9020-25-16

MM61211,000169A –19–25JAN07–1/3

544J Loader (S.N. 611800— ) 032409

PN=846

Tests 2. Remove return hose (2) from thermal bypass valve (1). Make connections to gauge using test hose (3) and barb tee fitting. NOTE: The Service ADVISOR application or CAN monitor unit (CMU) may be used to read engine rpm and transmission oil temperature.

T195753C

–UN–27OCT03

3. To display transmission oil temperature using the CMU, access the Diagnostics / Transmission menu in the CMU main menu. See CAN Monitor Unit (CMU) Menu Structure—Service Mode. (Group 9015-20.) If using Service ADVISOR application, access the Transmission Lube Pressure Test template. For information on connecting Service ADVISOR, see Service ADVISOR Connection Procedure. (Group 9015-20.)

1—Thermal Bypass Valve 2—Return Hose 3—Test Hose

4. Perform Transmission Oil Warmup Procedure. (Group 9020-25.) Specification Transmission Oil—Temperature.................................................. 74—86°C 166—186°F

5. Operate engine at fast idle with transmission in neutral. 9020 25 17

Specification Engine—Speed ............................................................................ Fast Idle Transmission—Position ................................................................... Neutral

6. Record transmission lube pressure. Specification Transmission Lube—Pressure ........................................... 20.7—103 kPa 0.20—1.03 bar 3—15 psi

Low lube pressure can be caused by: • Hose pinched or restricted. Inspect hoses. See Power Train Component Location. (Group 9020-15.) • Torque converter relief valve stuck open. Perform Torque Converter Relief Pressure Test. (Group 9020-25.) • Thermal bypass valve restriction. Disassemble and inspect components.

Service ADVISOR is a trademark of Deere & Company

TM10229 (17MAR09)

Continued on next page

9020-25-17

MM61211,000169A –19–25JAN07–2/3

544J Loader (S.N. 611800— ) 032409

PN=847

Tests • Transmission pump worn. Perform Transmission Pump Flow Test. (Group 9020-25.) • Suction screen plugged. Check condition of transmission filter. Transmission pump may be noisy if transmission suction screen is clogged. Drain transmission. Clean transmission pump suction screen. See Transmission Remove and Install. (Group 0300.)

MM61211,000169A –19–25JAN07–3/3

Differential Lock Pressure Test SPECIFICATIONS

ESSENTIAL TOOLS

Transmission Oil Temperature

74.0—86.0°C 166—186°F

38H1273 Union (-4 M ORFS)

Engine Speed

Fast Idle

38H1414 Cap (-4 Parker No. 4FNL-S)

Differential Lock Pressure

1896—2068 kPa 19—21 bar 275—300 psi

JTO3455 Adapter (7/16-20 M JIC X -4 F ORFS)

SERVICE EQUIPMENT AND TOOLS Gauge 6900 kPa (69 bar) (1000 psi)

Continued on next page

9020 25 18

TM10229 (17MAR09)

9020-25-18

MM61211,00016EC –19–25JAN07–1/3

544J Loader (S.N. 611800— ) 032409

PN=848

Tests

4 1000 500

1500

2000 0

2 1 3

TX1015061

–UN–22NOV06

TX1015061 Differential Lock Pressure Test 1—38H1273 Union 2—JT03455 Adapter

3—38H1414 Cap

4—JT03117 Gauge

1. Install JT03117 Gauge (4), 38H1273 Union (1) and JT03455 Adapter (2) fitting to differential lock line. Install 38H1414 Cap (3) to the axle differential lock. NOTE: The Service ADVISOR application or CAN monitor unit (CMU) may be used to read engine rpm and transmission oil temperature. 2. To display transmission oil temperature using the CMU, access the Diagnostics / Transmission menu in the CMU main menu. See CAN Monitor Unit (CMU) Menu Structure—Service Mode. (Group 9015-20.) If using Service ADVISOR application, access the Differential Lock Pressure Test template. For information on connecting Service ADVISOR, See

Service ADVISOR is a trademark of Deere & Company

TM10229 (17MAR09)

9020 25 19

5—Differential Lock Line

Service ADVISOR Connection Procedure. (Group 9015-20.) 3. Warm transmission oil to specification. Perform Transmission Oil Warmup Procedure. (Group 9020-25.) Specification Transmission Oil—Temperature ........................................... 74—86°C 166—186°F

4. Start engine and operate at fast idle. Specification Engine—Speed ...................................................................... Fast Idle

5. Push differential lock switch.

Continued on next page

9020-25-19

MM61211,00016EC –19–25JAN07–2/3

544J Loader (S.N. 611800— ) 032409

PN=849

Tests 6. Pressure must reach test specification. Specification Differential Lock—Pressure ...................................... 1896—2068 kPa 19—21 bar 275—300 psi

• If pressure is within specification and differential lock is not working correctly, perform differential lock air test. See Air Test Differential Lock (Dif-Lok) and Air Test Axle Assembly. (CTM442.)

• If pressure is not within specification and machine is equipped with dual differential locks, remove and close-off differential lock not being tested. – Repeat steps 3—6 to determine if differential lock not being tested is leaking. – If pressure is then within specification, differential lock not being tested is leaking. Repair as necessary.

MM61211,00016EC –19–25JAN07–3/3

Torque Converter-In Pressure Test SPECIFICATIONS

ESSENTIAL TOOLS

Transmission Oil Temperature

74—86°C 166—186°F

JT03220 Male Quick Coupler (7/16 M 37° x M10 x 1) (Parker No. 4-M10x1 F80X-S)

Engine Speed

1500 rpm

JT03115 Gauge 1000 kPa (10 bar) (150 psi)

Transmission Position

Neutral

Torque Converter-In—Minimum Pressure

276 kPa 2.8 bar 40 psi

1. Install frame articulation lock bar.

Continued on next page

9020 25 20

TM10229 (17MAR09)

9020-25-20

MM61211,000169C –19–25JAN07–1/3

544J Loader (S.N. 611800— ) 032409

PN=850

Tests

T107136

–19–19FEB97

9020 25 21

1—System Pressure 2—Torque Converter-In Pressure 3—Reduced Pressure 4—Transmission Harness Connector

5—Clutch Forward High Range K4 6—Reverse Clutch KR (with quick coupler) 7—Clutch K1 (with quick coupler)

8—Clutch K3 9—Clutch Forward Low Range KV (with quick coupler) 10—Clutch K2 (with quick coupler)

11—Connection from Oil Cooler 12—Connection to Oil Cooler 13—Torque Converter-Out Pressure

2. Remove transmission control valve test plug and install JT03220 Male Quick Coupler and JT03115 Gauge to torque converter-in pressure (2).

Continued on next page

TM10229 (17MAR09)

9020-25-21

MM61211,000169C –19–25JAN07–2/3

544J Loader (S.N. 611800— ) 032409

PN=851

pressure. Specification Engine—Speed ..................................................................... 1500 rpm Transmission—Position ............................................................ Neutral Torque Converter-In— Minimum—Pressure .............................................................. 276 kPa 2.8 bar 40 psi

Low torque converter-in pressure can be caused by: If using Service ADVISOR application, access the Torque Converter-In Pressure Test template. For information on connecting Service ADVISOR, see Service ADVISOR Connection Procedure. (Group 9015-20.) 4. Perform Transmission Oil Warmup Procedure. (Group 9020-25.) Specification Transmission Oil—Temperature ........................................... 74—86°C 166—186°F

• 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. Perform Torque Converter Relief Pressure Test. (Group 9020-25.)

5. Run engine at specified test speed with transmission in neutral. Record converter-in

9020 25 22

Service ADVISOR is a trademark of Deere & Company

MM61211,000169C –19–25JAN07–3/3

Torque Converter-Out Pressure Test SPECIFICATIONS

ESSENTIAL TOOLS

Transmission Oil Temperature

74—86°C 166—186°F

JT05491 Quick Coupler (7/16 M 37° x 14 M - 1.5 ORB)

Engine Speed

1500 rpm

Transmission Position

Neutral

JT05474 Gauge 2069 kPa (21 bar) (300 psi)

Torque Converter-Out Pressure

250—600 kPa 2.5—6.0 bar 36—86 psi

1. Install frame articulation lock bar.

SERVICE EQUIPMENT AND TOOLS

Continued on next page

TM10229 (17MAR09)

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544J Loader (S.N. 611800— ) 032409

PN=852

Tests

T107136

–19–19FEB97

9020 25 23

1—System Pressure 2—Torque Converter-In Pressure 3—Reduced Pressure 4—Transmission Harness Connector

5—Clutch Forward High Range K4 6—Reverse Clutch KR (with quick coupler) 7—Clutch K1 (with quick coupler)

8—Clutch K3 9—Clutch Forward Low Range KV (with quick coupler) 10—Clutch K2 (with quick coupler)

11—Connection from Oil Cooler 12—Connection to Oil Cooler 13—Torque Converter-Out Pressure

2. Install JT05474 Gauge, and JT05491 Quick Coupler to torque converter-out pressure (13).

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TM10229 (17MAR09)

9020-25-23

MM61211,000169D –19–25JAN07–2/3

544J Loader (S.N. 611800— ) 032409

PN=853

Tests NOTE: The Service ADVISOR application or CAN monitor unit (CMU) may be used to read engine rpm and transmission oil temperature. 3. To display transmission oil temperature using the CMU, access the Diagnostics / Transmission menu in the CMU main menu. See CAN Monitor Unit (CMU) Menu Structure—Service Mode. (Group 9015-20.) If using Service ADVISOR application, access the Torque Converter-Out Pressure Test template. For information on connecting Service ADVISOR, see Service ADVISOR Connection Procedure. (Group 9015-20.) 4. Perform Transmission Oil Warmup Procedure. (Group 9020-25.). Specification Transmission Oil—Temperature ........................................... 74—86°C 166—186°F

5. Operate engine at specified speed with transmission in neutral.

9020 25 24

Specification Engine—Speed ..................................................................... 1500 rpm Transmission Position............................................................... Neutral

Low torque converter-out pressure can be caused by: • 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. Perform Torque Converter Relief Pressure Test. (Group 9020-25.) • Transmission pump worn. Perform Transmission Pump Flow Test. (Group 9020-25.) • Torque converter leakage. Disassemble and inspect. Perform Torque Converter and Housing Remove and Install. (Group 0350.) • Suction screen plugged. Check condition of transmission filter. Transmission pump may be noisy if transmission suction screen is clogged. Drain transmission. Clean transmission pump suction screen. See Transmission Remove and Install. (Group 0300.) High torque converter-out pressure can be caused by: • Hose pinched or restricted. Inspect hoses. See Power Train Component Location. (Group 9020-15.) • Thermal bypass valve restriction. Disassemble and inspect components.

6. Record torque converter-out pressure. Specification Torque Converter-Out— Pressure........................................................................ 250—600 kPa 2.5—6.0 bar 36—86 psi

Service ADVISOR is a trademark of Deere & Company

TM10229 (17MAR09)

MM61211,000169D –19–25JAN07–3/3

9020-25-24

544J Loader (S.N. 611800— ) 032409

PN=854

Tests

Torque Converter Relief Pressure Test SPECIFICATIONS Engine Speed

Slow Idle

Transmission Oil Temperature

74—86°C 166—186°F

Torque Converter Relief Pressure

850—1050 kPa 8.5—10.5 bar 125—155 psi

IMPORTANT: Do not heat transmission with cooler flow deadheaded to gauge. Transmission damage can occur from overheating. NOTE: Perform this test only if machine fails Torque Converter-Out Pressure Test. (Group 9020-25.)

SERVICE EQUIPMENT AND TOOLS 38H1150 Plug (-16 ORFS) Adapter (7/16 M 37° x -16 ORFS) Quick Coupler (7/16 F 37°) JT05474 Gauge 2000 kPa (20 bar) (300 psi)

2. Perform Transmission Oil Warmup Procedure. (Group 9020-25.) Specification Transmission Oil—Temperature ........................................... 74—86°C 166—186°F

1. Install frame articulation lock bar.

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PN=855

9020 25 25

Tests 3. Remove thermal bypass valve from elbow (1). 4. Install 38H1150 Plug (4), adapter (2), and quick coupler (3) with JT05474 Gauge as shown.

–UN–28OCT03

NOTE: The Service ADVISOR application or CAN monitor unit (CMU) may be used to read engine rpm and transmission oil temperature.

If using Service ADVISOR application, access the Torque Converter Relief Pressure Test template. For information on connecting Service ADVISOR, see Service ADVISOR Connection Procedure. (Group 9015-20.)

T195782B

6. Operate engine at slow idle. Specification Engine—Speed ............................................................................ Slow Idle

7. Record converter relief pressure. 9020 25 26

Specification Torque Converter Relief— Pressure ............................................................................ 850—1050 kPa 8.5—10.5 bar 125—155 psi

Low converter relief valve pressure can be caused by: • Transmission control valve or gasket leakage. See Transmission Control Valve Remove and Install. (Group 0360.) • Torque converter leakage. Disassemble and inspect. Perform Torque Converter and Housing Remove and Install. (Group 0350.) • Torque converter relief valve stuck open, or spring broken or weak. Remove transmission control valve and manifold plate for access. See Transmission Control Valve Remove and Install. (Group 0360.)

Service ADVISOR is a trademark of Deere & Company

TM10229 (17MAR09)

MM61211,000169E –19–25JAN07–2/2

9020-25-26

544J Loader (S.N. 611800— ) 032409

PN=856

Tests

Torque Converter-Out Flow Test SPECIFICATIONS Engine Speed

1500 rpm

Transmission Oil Temperature

74—86°C 166—186°F

Torque Converter-Out— Minimum Flow

45 L/min 12 gpm

SERVICE EQUIPMENT AND TOOLS 38H1281 Union (-16 M ORFS x -16 M ORFS) (Parker No. 16HLO-S) JT7148 Flowmeter

1. Install frame articulation lock bar.

Continued on next page

MM61211,000169F –19–25JAN07–1/4

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TM10229 (17MAR09)

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544J Loader (S.N. 611800— ) 032409

PN=857

Tests 2. Remove thermal bypass valve (4) from elbow (1). 3. Install 38H1281 Union (3) and test hose (2). 4. Install test hose (5).

–UN–04NOV03

NOTE: The Service ADVISOR application or CAN monitor unit (CMU) may be used to read engine rpm and transmission oil temperature.

T196090B

5. To display transmission oil temperature using the CMU, access the Diagnostics / Transmission menu in the CMU main menu. See CAN Monitor Unit (CMU) Menu Structure—Service Mode. (Group 9015-20.) If using Service ADVISOR application, access the Torque Converter-Out Flow Test template. For information on connecting Service ADVISOR, see Service ADVISOR Connection Procedure. (Group 9015-20.)

1—Elbow (to bypass valve) 2—Thermal Bypass Valve-to-Flowmeter Test Hose 3—Union 4—Thermal Bypass Valve 5—Flowmeter-to-Elbow Test Hose

IMPORTANT: Before starting engine, check that JT7148 Loading Valve is open. Pump can be damaged if engine is started with loading valve closed. 9020 25 28

6. Perform Transmission Oil Warmup Procedure. (Group 9020-25.) Specification Transmission Oil—Temperature.................................................. 74—86°C 166—186°F

7. Operate engine at test specification. Specification Engine—Speed ........................................................................... 1500 rpm

Service ADVISOR is a trademark of Deere & Company

TM10229 (17MAR09)

Continued on next page

9020-25-28

MM61211,000169F –19–25JAN07–2/4

544J Loader (S.N. 611800— ) 032409

PN=858

Tests NOTE: New machine minimum flow will be higher than the minimum specification. If torque converter-out flow is low in one gear, check for piston or sealing ring leakage in the elements for that gear. 8. Measure torque converter-out flow in each gear. Specification Torque Converter-Out— Minimum—Flow ............................................................................ 45 L/min 12 gpm

If torque converter-out flow is low in all gears, check the following: • Low oil level in transmission. • Cold transmission oil. • Air leak in pump suction tube. • Plugged thermal bypass valve or lube passage. See Transmission Lube Pressure Test. (Group 9020-25.) • Low transmission pump flow. Perform Transmission Pump Flow Test. (Group 9020-25.) • Torque converter relief valve stuck open, or spring weak or broken. Perform Torque Converter Relief Pressure Test. (Group 9020-25.) • 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 and Housing Remove and Install. (Group 0350.)

9020 25 29

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PN=859

Tests TEST RESULTS Gear

Flow

1st Forward 2nd Forward 3rd Forward 4th Forward 1st Reverse 2nd Reverse 3rd Reverse

MM61211,000169F –19–25JAN07–4/4

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PN=860

Tests

Torque Converter Stall Speed Test SPECIFICATIONS Transmission Oil Temperature

74—86°C 166—186°F

Transmission Gear

Third Forward.

Torque Converter Stall No. 1 Fuel Speed

2100—2200 rpm

Torque Converter Stall No. 2 Fuel Speed

2145—2210 rpm

NOTE: Transmission auto mode and clutch cut-off must be turned off. 5. Apply service brakes and release park brake. 6. Operate engine at fast idle with transmission in third forward.

NOTE: Number 2 (No. 2) fuel produces more power than number 1 (No. 1) and will impact engine performance. 1. Determine what type of fuel is in fuel tank. NOTE: The Service ADVISOR application or CAN monitor unit (CMU) may be used to read engine rpm and transmission oil temperature. 2. To display transmission oil temperature using the CMU, access the Diagnostics / Transmission menu in the CMU main menu. See CAN Monitor Unit (CMU) Menu Structure—Service Mode. (Group 9015-20.) If using Service ADVISOR application, access the Torque Converter Stall Speed Test template. For information on connecting Service ADVISOR, see Service ADVISOR Connection Procedure. (Group 9015-20.) 3. Perform Transmission Oil Warmup Procedure and Hydraulic Oil Warmup Procedure. (Group 9025-25.) Specification Transmission Oil—Temperature ........................................... 74—86°C 166—186°F

4. Set fan speed to 100% by accessing Machine Config menu in the CMU main menu. See CAN Monitor Unit (CMU) Menu Structure—Service Mode. (Group 9015-20.)

Specification Transmission—Gear ...................................................... Third Forward

7. Record engine speed while stalling torque converter. Check recorded speed against specification. Specification Torque Converter Stall No. 1 Fuel—Speed ............................................................. 2100—2200 rpm Torque Converter Stall No. 2 Fuel—Speed ............................................................. 2145—2210 rpm

If engine rpm is excessively low: • If input shaft speed reads zero rpm when torque converter is in stalled condition, the connectors for torque converter input speed sensor and torque converter output speed sensor may be reversed. Switch sensor connectors and verify engine speed with torque converter stalled. • If low engine horsepower is suspected, perform Intake Manifold Pressure Test—Turbocharger Boost. (Group 9010-25.) • Incorrect torque converter-in and or converter-out pressures: Perform Torque Converter-In Pressure Test and Torque Converter-Out Pressure Test. (Group 9010-25.) • Incorrect torque converter or torque converter malfunction. Remove and replace torque converter: See Torque Converter and Housing Remove and Install. (Group 0300.) If engine rpm is excessively high: • Clutch slippage may be indicated.

Service ADVISOR is a trademark of Deere & Company

TM10229 (17MAR09)

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MM61211,00016A0 –19–25JAN07–1/2

544J Loader (S.N. 611800— ) 032409

PN=861

9020 25 31

Tests View TC Output Speed on the CMU by accessing the Diagnostics / Transmission menu in the Main Menu. See CAN Monitor Unit (CMU) Menu Structure— Service Mode. (Group 9015-20.) Torque converter output speed should be approximately engine speed when in neutral. It must go to zero rpm when torque converter is stalled. If output speed reads anything above zero rpm, the transmission is slipping. See Diagnose Transmission System Malfunctions. (Group 9020-15.)

Test and Torque Converter-Out Pressure Test. (Group 9010-25.) • Incorrect torque converter or torque converter malfunction. Remove and replace torque converter: See Torque Converter and Housing Remove and Install. (Group 0300.) 8. After testing torque converter stall, cycle key switch to restart engine. This will activate proportional fan drive.

• Incorrect torque converter-in and or converter-out pressures: Perform Torque Converter-In Pressure

MM61211,00016A0 –19–25JAN07–2/2

Transmission Oil Cooler Thermal Bypass Valve Temperature Test SPECIFICATIONS

9020 25 32

Engine Speed

1500 rpm

Thermal Bypass Valve Start to Open Temperature

79—85°C 175—185°F

Thermal Bypass Valve Fully Open Temperature

96°C 205°F

This test measures the operating temperature of the thermal bypass valve to ensure that it is working properly. 1. Install frame articulation lock bar.

SERVICE EQUIPMENT AND TOOLS Test Hose (1 in. x 2 ft) Barb Fitting—Straight (1 in.) JT7148 Flowmeter JT07253 Noncontact Temperature Measuring Gun

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544J Loader (S.N. 611800— ) 032409

PN=862

Tests

T196597

–UN–25NOV03

T196597 1—Thermal Bypass Valve-to-Oil Cooler Hydraulic Hose

9020 25 33

2—Elbow

NOTE: If an oil cooler bypass valve malfunction is suspected, the thermal bypass valve can be removed and inspected in less time than it takes to perform a test.

5. Start engine.

2. Disconnect hose (1) at elbow (2).

6. Perform Transmission Oil Warmup Procedure and observe temperature at which flowmeter reading starts to increase. Compare temperature to specification.

3. Connect JT7148 Flowmeter in-line with test hose and barb fitting.

Specification Engine—Speed ..................................................................... 1500 rpm

4. Install JT07253 Noncontact Temperature Measuring Gun at flowmeter.

Specification Thermal Bypass Valve Start to Open—Temperature ............................................................. 79—85°C 175—185°F

IMPORTANT: Before starting engine, check that flowmeter loading valve is open. Pump can be damaged if engine is started with loading valve closed.

7. Observe temperature at which flowmeter reading is at maximum flow.

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MM61211,00016A1 –19–08DEC06–2/3

544J Loader (S.N. 611800— ) 032409

PN=863

Tests Specification Thermal Bypass Valve Fully Open—Temperature .................................................................... 96°C 205°F

8. If valve does not meet specifications, remove and repair valve. Repeat test after repairing valve.

MM61211,00016A1 –19–08DEC06–3/3

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TM10229 (17MAR09)

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PN=864

Tests

Transmission Oil Cooler Thermal Bypass Valve Pressure Test

T196598

–UN–25NOV03

T196598 1—Thermal Bypass Valve-to-Oil Cooler Hydraulic Hose

2—Thermal Bypass Valve Hydraulic Hose

SPECIFICATIONS Engine Speed

Slow Idle

Transmission Oil Temperature

74—86°C 166—186°F

Transmission Position

Neutral

Transmission Oil Cooler Thermal Bypass Valve Differential Pressure

530—650 kPa 5.3—6.5 bar 77—93 psi

The purpose of this test is to check restriction beyond the thermal bypass valve to and through the oil cooler. NOTE: If an oil cooler bypass valve malfunction is suspected, the thermal bypass valve can be removed and inspected in less time than it takes to perform a test. 1. Install frame articulation lock bar.

SERVICE EQUIPMENT AND TOOLS

2. Disconnect and install 38H1418 Cap to the thermal bypass valve-to-oil cooler hydraulic hose (1) to cooler. Connect pressure gauge to bypass valve with test hose and barb fitting.

JT03103 Adapter (7/16 M 37° x 1-1/16 F 37°) (2 used) JT05690 Adapter (1-1/16 M 37° x -12 M ORFS) JT05687 Adapter (-6 F ORFS x 1-1/16 M 37°) 38H1278 Union (-6 M ORFS x -6 M ORFS) (Parker No. 6HLO-S) 38H1418 Cap (-12 F ORFS) (Parker No. 12FNL-S) JT05753 Hydraulic Switch Box Gauge 700 kPa (7 bar) (100 psi) (2 used)

3. Disconnect thermal bypass valve hydraulic hose (2). Connect pressure gauge in-line with return hose using test hose and barb tee fitting.

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TM10229 (17MAR09)

9020-25-35

MM61211,00016A2 –19–25JAN07–1/2

544J Loader (S.N. 611800— ) 032409

PN=865

9020 25 35

Tests NOTE: The Service ADVISOR application or CAN monitor unit (CMU) may be used to read engine rpm and transmission oil temperature.

6. When oil temperature reaches specification, put transmission in neutral and operate engine at slow idle.

4. To display transmission oil temperature using the CMU, access the Diagnostics / Transmission menu in the CMU main menu. See CAN Monitor Unit (CMU) Menu Structure—Service Mode. (Group 9015-20.)

Specification Engine—Speed ...................................................................... Slow Idle Transmission—Position ............................................................ Neutral

If using Service ADVISOR application, access the Transmission Oil Cooler Thermal Bypass Valve Pressure Test template. For information on connecting Service ADVISOR, see Service ADVISOR Connection Procedure. (Group 9015-20.) NOTE: Pressure differential should start out low. When thermal bypass valve opens, pressure differential will increase. Observe pressure gauges during warmup. 5. See Transmission Oil Warmup Procedure. (Group 9020-25.)

9020 25 36

7. Record differential pressure and compare to specification. Specification Transmission Oil Cooler Thermal Bypass Valve Differential—Pressure ................................................... 530—650 kPa 5.3—6.5 bar 77—93 psi

NOTE: The bypass valve is not adjustable. If bypass valve pressure is higher than specification, replace valve. 8. If pressure is low: • Remove, inspect and clean valve. • Replace valve.

Specification Transmission Oil—Temperature ........................................... 74—86°C 166—186°F

Service ADVISOR is a trademark of Deere & Company

TM10229 (17MAR09)

MM61211,00016A2 –19–25JAN07–2/2

9020-25-36

544J Loader (S.N. 611800— ) 032409

PN=866

Tests

Transmission Oil Cooler Restriction Test SPECIFICATIONS Transmission Oil Temperature

74—86°C 166—186°F

Engine Speed

Fast Idle

Maximum Differential (Inlet-to-Outlet) Pressure

276 kPa 2.8 bar 40 psi

The purpose of this test is to check for restriction internal to the transmission oil cooler, which can cause transmission overheating. 1. Install frame articulation lock bar.

SERVICE EQUIPMENT AND TOOLS 38H1419 Cap (-16 F ORFS) (Parker No. 16 FNL-S) Barb Tee Fitting (1 in.) (2 used) Test Hose (1 in. x 2 ft) (2 used) JT03460 Quick Coupler (7/16 -20 M 37° x -16 F ORFS) (2 used) JT02156A Digital Pressure and Temperature Analyzer Pressure Transducer 6895 kPa (69 bar) (1000 psi) JT05746 Portable Filter Caddy

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544J Loader (S.N. 611800— ) 032409

PN=867

9020 25 37

Tests

–UN–12DEC03

T196871

T196871 9020 25 38

1—Elbow

2—Bypass Valve-to-Oil Cooler Hydraulic Hose

NOTE: If an internally restricted oil cooler is suspected, the cooler can be back flushed in less time than it takes to run this test. Use filter caddy to back flush.

3—Oil Cooler-to-Bypass Valve Hydraulic Hose

7. Connect in-line between bypass valve-to-oil cooler hydraulic hose (2) and elbow (1) using barb tee fitting and test hose.

3. Remove oil cooler-to-bypass valve hydraulic hose (3) at bypass valve.

8. Install JT02156A Digital Pressure and Temperature Analyzer with a 6895 kPa (69 bar) (1000 psi) pressure transducers to both tees to read pressure differential. See Digital Pressure and Temperature Analyzer Installation. (Group 9025-25.)

4. Connect barb tee fitting and test hose in-line of the oil cooler-to-bypass valve hydraulic hose (3) and valve.

NOTE: The Service ADVISOR application or CAN monitor unit (CMU) may be used to read engine rpm and transmission oil temperature.

5. Remove bypass valve-to-oil cooler hydraulic hose (2) from valve. 6. Install 38H1419 Cap to port on valve where hose (2) was removed.

9. To display transmission oil temperature using the CMU, access the Diagnostics / Transmission menu in the CMU main menu. See CAN Monitor Unit (CMU) Menu Structure—Service Mode. (Group 9015-20.)

Service ADVISOR is a trademark of Deere & Company

Continued on next page

2. Remove bypass valve from elbow (1).

TM10229 (17MAR09)

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MM61211,00016A3 –19–25JAN07–2/3

544J Loader (S.N. 611800— ) 032409

PN=868

Tests If using Service ADVISOR application, access the Transmission Oil Cooler Restriction Test template. For information on connecting Service ADVISOR, see Service ADVISOR Connection Procedure. (Group 9015-20.) 10. Perform Transmission Oil Warmup Procedure. (Group 9020-25.) Specification Transmission Oil—Temperature ........................................... 74—86°C 166—186°F

12. Read pressure on inlet and outlet sides of oil cooler and compare to specification. Specification Maximum Differential (Inlet-to-Outlet)—Pressure ...................................................... 276 kPa 2.8 bar 40 psi

• If difference is greater than specification, back flush oil cooler using JT05746 Filter Caddy. • If cooler does not meet specifications after back flushing, replace cooler.

11. Operate engine at fast idle. Specification Engine—Speed ...................................................................... Fast Idle

MM61211,00016A3 –19–25JAN07–3/3

Axle Circulation Dual Pump Flow Test The purpose of this test is to verify that the axle circulation dual pump assembly is functioning properly to keep axle oil temperatures within normal operating range. For fan pump tests, see Hydraulic Fan Pump Flow Test. (Group 9025-25.) And see Hydraulic Fan Pump Pressure Test. (Group 9025-25.)

9020 25 39

SPECIFICATIONS Engine Speed

Fast Idle

Axle Oil Temperature (Minimum)

21°C 70°F

Axle Circulation Pump Flow Rate (one pump—typical new minimum)

4.9 L/min 1.3 gpm

Axle Circulation Pump Flow Rate (one pump—used minimum)

3.8 L/min 1.0 gpm

SERVICE EQUIPMENT AND TOOLS JT02156A Digital Pressure and Temperature Analyzer -6 Test Hose with -6 ORFS End

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9020-25-39

MM61211,00016A4 –19–07JUN07–1/2

544J Loader (S.N. 611800— ) 032409

PN=869

TX1003758

–UN–13FEB06

Tests

9020 25 40

1—Fan Drive Pump 2—Axle Inlet Pump

3—Axle Outlet Pump 4—Axle Inlet Pump

5—Axle Outlet Pump 6—Rear Axle Pump

NOTE: Before performing Axle Circulation Dual Pump Flow Test. Check for seal damage. Repair or replace as needed. If oil leak is coming from the pump weep holes, replace pumps. 1. Perform Digital Pressure Analyzer Installation procedure. (Group 9025-25.) Specification Axle Oil—Temperature (Minimum) .................................................................................... 21°C 70°F

7—Front Axle Pump

pumps individually. Compare rate to specification. Specification Engine—Speed ...................................................................... Fast Idle Axle Circulation Pump—Flow Rate (one pump—typical new minimum) .............................................................................. 4.9 L/min 1.3 gpm Axle Circulation Pump—Flow Rate (one pump—used minimum) .............................................................................. 3.8 L/min 1.0 gpm

4. If flow rate is less than specification, clean axle suction screens and perform test again.

Warm axle oil to test temperature if required. 2. Install test hose between one axle circulation pump outlet (3 or 5) and collect oil in a clean 5 gallon container.

NOTE: Replace both pumps together. 5. If flow rate is still under specification after running test again, replace pumps (6 and 7).

3. Operate engine at fast idle and record circulation dual pump flow rate. Check flow rate on both

MM61211,00016A4 –19–07JUN07–2/2

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544J Loader (S.N. 611800— ) 032409

PN=870

Tests

Axle Breather Test SPECIFICATIONS Axle Oil Operating Temperature

49°C 120°F

Axle Breather Pressure Rating

35—49 kPa 0.35—0.49 bar 5—7 psi

The purpose of this test is to check that the axle breather opens, allowing pressure relief within the axle housing.

MM61211,00016F1 –19–25JAN07–1/2

NOTE: If axle level is low and/or leaking from outer axle seals, cause could be a plugged breather. 1. Make sure that correct breather is in axle. Pressure rating is stamped on top of the breather. 9020 25 41 –UN–09NOV06

2. Measure axle internal pressure by installing a gauge in the fill port.

Specification Axle Oil Operating—Temperature ...................................................... 49°C 120°F Axle Breather—Pressure Rating ............................................. 35—49 kPa 0.35—0.49 bar 5—7 psi

TX1014676A

3. Operate machine and warm axle oil to normal operating temperature.

1—Front Axle Breather

NOTE: Pressure may exceed specification by 14 kPa (0.14 bar) (2 psi) and not be excessive. • If pressure is within specification, breather is OK. Inspect and repair outer axle seals. • If pressure is greater than specification, clean or replace breather.

MM61211,00016F1 –19–25JAN07–2/2

TM10229 (17MAR09)

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544J Loader (S.N. 611800— ) 032409

PN=871

Tests

9020 25 42

TM10229 (17MAR09)

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PN=872

Section 9025

Hydraulic System Contents Page

Page

Group 05—Theory of Operation Loader Hydraulic System Operation . . . . . . .9025-05-1 Hydraulic Pump Operation . . . . . . . . . . . . . .9025-05-2 Hydraulic Fan Drive Operation . . . . . . . . . . .9025-05-4 Steering System Component Operation . . . .9025-05-9 Steering Valve Operation . . . . . . . . . . . . . .9025-05-10 Steering System Component Operation . . .9025-05-11 Secondary Steering Inlet Manifold Operation. . . . . . . . . . . . . . . . . . . . . . . . .9025-05-12 Pressure Reducing Valve Operation . . . . . .9025-05-14 Service Brake Hydraulic System Operation. . . . . . . . . . . . . . . . . . . . . . . . .9025-05-15 Service Brake Accumulator Operation . . . . .9025-05-16 Service Brake Valve Operation . . . . . . . . . .9025-05-18 Pin Disconnect Operation . . . . . . . . . . . . . .9025-05-20 Pilot Control Lever Operation . . . . . . . . . . .9025-05-22 Control Valve Pilot Orifice Check Valve Operation. . . . . . . . . . . . . . . . . . . . . . . . .9025-05-24 Loader Control Valve Operation . . . . . . . . .9025-05-25 Boom Section Operation—Boom Down and Steering . . . . . . . . . . . . . . . . . . . . . . . . . .9025-05-26 Boom Section Operation—Boom Raise and Bucket Dump . . . . . . . . . . . . . . . . . . . . . .9025-05-28 Bucket Section Operation—Boom Raise and Bucket Dump . . . . . . . . . . . . . . . . . . . . . .9025-05-30 Auxiliary Sections—Stroke Adjusters Operation. . . . . . . . . . . . . . . . . . . . . . . . .9025-05-31 Outlet Section Operation . . . . . . . . . . . . . . .9025-05-32 Load Sense Circuit Operation—Neutral. . . .9025-05-34 Load Sense Circuit Operation—Steering . . .9025-05-35 Load Sense Circuit Operation—Steering and Boom Down . . . . . . . . . . . . . . . . . . . . . . .9025-05-36 Load Sense Circuit Operation—Boom Raise and Bucket Dump . . . . . . . . . . . . .9025-05-37 Relief Valve Operation . . . . . . . . . . . . . . . .9025-05-38 Load Sense Relief Valve Operation. . . . . . .9025-05-40 Circuit Relief Valve Operation . . . . . . . . . . .9025-05-41 Anticavitation Valve Operation. . . . . . . . . . .9025-05-48 Return Filter Operation . . . . . . . . . . . . . . . .9025-05-49 Ride Control Operation . . . . . . . . . . . . . . . .9025-05-53

No Hydraulic Functions Diagnostic Procedure . . . . . . . . . . . . . . . . . . . . . . . . .9025-15-9 Hydraulic Functions Slow Diagnostic Procedure . . . . . . . . . . . . . . . . . . . . . . . .9025-15-10 Hydraulic Pump Noisy Diagnostic Procedure . . . . . . . . . . . . . . . . . . . . . . . .9025-15-13 No Steering Functions Diagnostic Procedure . . . . . . . . . . . . . . . . . . . . . . . .9025-15-15 Boom Float Function Not Working Diagnostic Procedure . . . . . . . . . . . . . . . . . . . . . . . .9025-15-16 One Hydraulic Function Not Working Diagnostic Procedure. . . . . . . . . . . . . . . .9025-15-17 Hydraulic Function Drifts Down Diagnostic Procedure . . . . . . . . . . . . . . . . . . . . . . . .9025-15-18 Boom Down Does Not Work (Engine Off) Diagnostic Procedure. . . . . . . . . . . . . . . .9025-15-19 Oil Overheats Diagnostic Procedure . . . . . .9025-15-20 Hydraulic Oil Foams Diagnostic Procedure . . . . . . . . . . . . . . . . . . . . . . . .9025-15-21 Pin Disconnect Cylinders Will Not Retract Diagnostic Procedure. . . . . . . . . . . . . . . .9025-15-22 Constant Steering Required to Maintain Straight Travel Diagnostic Procedure. . . .9025-15-22 Slow Steering Wheel Movement Will Not Cause Frame Movement Diagnostic Procedure . . . . . . . . . . . . . . . . . . . . . . . .9025-15-23 Steering Wheel Turns without Resistance and Causes No Frame Movement Diagnostic Procedure . . . . . . . . . . . . . . . . . . . . . . . .9025-15-24 Steering Erratic Diagnostic Procedure . . . . .9025-15-25 Steering Wheel Free Play Diagnostic Procedure . . . . . . . . . . . . . . . . . . . . . . . .9025-15-25 Steering Valve Binds or Locks Up Diagnostic Procedure . . . . . . . . . . . . . . . . . . . . . . . .9025-15-26 Steering Wheel Turns by Itself Diagnostic Procedure . . . . . . . . . . . . . . . . . . . . . . . .9025-15-27 Machine Turns in Opposite Direction as Steering Wheel Diagnostic Procedure . . .9025-15-27 Steering Wheel Kickback Diagnostic Procedure . . . . . . . . . . . . . . . . . . . . . . . .9025-15-27 Steering Jerky Diagnostic Procedure. . . . . .9025-15-28 Secondary Steering Motor Will Not Operate Diagnostic Procedure. . . . . . . . . . . . . . . .9025-15-28

Group 15—Diagnostic Information Hydraulic System Schematic . . . . . . . . . . . . .9025-15-2 Hydraulic System Component Location . . . . .9025-15-4 Hydraulic System Diagnose Malfunctions . . .9025-15-9 TM10229 (17MAR09)

9025-1

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544J Loader (S.N. 611800— ) 032409

PN=1

9025

Contents

Page

Secondary Steering Pump Runs but Will Not Steer Machine Diagnostic Procedure . . . . . . . . . . . . . . . . . . . . . . . .9025-15-28

Boom Down Accumulator Precharge Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9025-25-49 Brake Valve Pressure Test. . . . . . . . . . . . .9025-25-52 Brake Valve Leakage Test . . . . . . . . . . . . .9025-25-55 Brake Accumulator Inlet Check Valve Leakage Test. . . . . . . . . . . . . . . . . . . . . .9025-25-58 Pin Disconnect Pressure Test . . . . . . . . . . .9025-25-58 Hydraulic Fan Pump Pressure Test. . . . . . .9025-25-60 Hydraulic Fan Motor Speed Test. . . . . . . . .9025-25-61 Hydraulic Fan Pump Flow Test . . . . . . . . . .9025-25-62 Hydraulic Fan Motor Case Drain Test . . . . .9025-25-64 Hydraulic Oil Filter Inspection Procedure. . .9025-25-66

Group 20—Adjustments Hydraulic Oil Clean-Up Procedure Using Portable Filter Caddy . . . . . . . . . . . . . . . . .9025-20-1 Return-to-Dig Adjustment . . . . . . . . . . . . . . .9025-20-1 Return-to-Carry and Boom Height Kickout Adjustment. . . . . . . . . . . . . . . . . . . . . . . . .9025-20-1 Pump Load Sense Differential and Standby Pressure Adjustment . . . . . . . . . . . . . . . . .9025-20-1 Pilot Controller Adjustment—Two Lever Pilot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9025-20-2 Ride Control Accumulator Hydraulic Discharge Procedure . . . . . . . . . . . . . . . . .9025-20-3 Ride Control Accumulator Charge Procedure . . . . . . . . . . . . . . . . . . . . . . . . .9025-20-6 Adjustments Auxiliary Valve Section—Stroke Adjustment (If Equipped) . . . . . . . . . . . . . . . . . . . . .9025-20-9

9025

Group 25—Test Hydraulic Oil Warmup Procedure . . . . . . . . .9025-25-1 Hydraulic System Pressure and Accumulators Discharge . . . . . . . . . . . . . . . . . . . . . . . . .9025-25-2 Digital Pressure and Temperature Analyzer Installation . . . . . . . . . . . . . . . . . . . . . . . . .9025-25-4 Pump Load Sense Differential and Standby Pressure Test . . . . . . . . . . . . . . . . . . . . . .9025-25-5 Maximum System Pressure Test. . . . . . . . . .9025-25-9 Hydraulic Pump Flow Test . . . . . . . . . . . . .9025-25-12 Hydraulic Pump Case Drain Test . . . . . . . .9025-25-14 Loader System Relief and Circuit Relief Valve Pressure Test . . . . . . . . . . . . . . . . . . . . .9025-25-16 Loader Cylinder Drift Test . . . . . . . . . . . . . .9025-25-20 Boom, Bucket and Steering Cylinder Leakage Test. . . . . . . . . . . . . . . . . . . . . .9025-25-22 Steering Valve Leakage Test . . . . . . . . . . .9025-25-24 Steering Valve Drift Test . . . . . . . . . . . . . . .9025-25-28 Secondary Steering Pump Relief Valve Pressure Test . . . . . . . . . . . . . . . . . . . . .9025-25-30 Secondary Steering Manifold Primary Check Valve Leakage Test . . . . . . . . . . .9025-25-32 Secondary Steering Manifold Secondary Check Valve Leakage Test . . . . . . . . . . .9025-25-34 Pilot Control Valve Pressure Test—Single Lever . . . . . . . . . . . . . . . . . . . . . . . . . . . .9025-25-35 Pilot Control Valve Pressure Test—Two Lever . . . . . . . . . . . . . . . . . . . . . . . . . . . .9025-25-40 Pressure Reducing Valve Pressure Test . . .9025-25-45 Cycle Time Test . . . . . . . . . . . . . . . . . . . . .9025-25-46 Brake Accumulator Precharge Test . . . . . . .9025-25-47 TM10229 (17MAR09)

9025-2

544J Loader (S.N. 611800— ) 032409

PN=2

Group 05

Theory of Operation Loader Hydraulic System Operation All hydraulic functions are incorporated into one system utilizing a singe axial piston pump that includes:

essentially no flow. With the pilot enable/boom down switch in the center (on) position, both the boom down and the pilot enable solenoid provides low regulated pressure to the pilot controller. All load sense lines and passages are bled to return. The pin disconnect is shown in the disconnected position.

1. Loader. 2. Steering and service brake functions. 3. Pin disconnect. 4. Ride control. 5. Oil cooler functions. These components are tied together by a pressure flow compensating load sense system. The major components include: 1. A variable displacement axial piston pump with load sense flow and pressure control. 2. An orbital steering valve. 3. A loader control valve with load sense, individual work port flow compensation, and a circuit providing priority for steering and loader pilot control valve. 4. A pressure reducing valve module that provides low regulated pressure for the pilot controller and pin disconnect. 5. A low pressure brake valve, pressure limiting and modulation. Design features include: 1. All closed center control valves. 2. Improved system efficiency with minimal relief flow loss. 3. Metering independent of load. 4. A single load sense circuit controlling pump flow, providing priority to steering and proportional and pressure flow compensation to all loader functions. NOTE: For overall system operation, See Hydraulic System Schematic (Group 9025-15.) and see Hydraulic System Component Location. (Group 9025-15.) In Neutral—the hydraulic pump supplies low standby pressure to all closed center control valves. There is

Steering Operation—a valve is rotated and steering is started, the pressure to the steering cylinders is also picked up in the valve and sent out as a load sense. It is directed to both ends of the loader control valve. One path is to a shuttle check valve, through a 0.055 in. orifice and then back to the pump. The pump goes into stroke and starts suppling pressure oil to the steering valve maintaining the differential pressure difference between load sense and output pressure. The other path for load sense in the loader valve is to the spring end of each compensator valve. This will have no effect on the steering circuit until one of the loader functions is operated. Steering and Boom Down—functions are being operated at the same time. Without some type of flow control to the boom cylinder rod ends, all the pump flow would go to the boom circuit because little or no oil pressure is required for lowering the boom. With relatively high pressures required for steering, there would be little or no steering with this condition. To provide priority for the steering circuit in this situation, compensators are used in each valve section. Load sense pressure, which will be relatively high, from the steering valve is directed to the spring side of each compensator, restricting or blocking flow through the compensator to the boom down circuit with very low pressures, allowing the steering circuit to always have priority when any of the loader functions are at a low pressure. Boom Raise and Bucket Dump—functions are being operated at the same time, without flow control to the bucket dump circuit all of the pump flow would go to that function and there would be no boom raise.

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9025-05-1

MH66O88,00002E3 –19–01FEB07–1/2

544J Loader (S.N. 611800— ) 032409

PN=875

9025 05 1

Theory of Operation To provide equal flow to both functions, compensators are used in both circuits. The metered load sense pressure from boom raise will be much higher than that from bucket dump. It will flow through the boom C1 check and on through C4, the orifice and then to the hydraulic pump and isolation valve. The metered load sense from the bucket will be blocked at its C1 check because of the much higher load sense pressure on the other side.

at low pressure will be blocked at the boom C2 check. The regulated boom load sense will control the isolation valve output so that it is equal to the boom regulated load sense. This pressure, which is essentially the boom raise work load, is sent through all C3 checks to all the compensators. Since the pump will be working against equal pressures at the compensators, the flow will be equal to both functions, though the bucket work load pressure is much less than that for the boom.

The boom regulated load will flow through C2 to the isolation valve end. The bucket regulated load sense

MH66O88,00002E3 –19–01FEB07–2/2

Hydraulic Pump Operation

T196366

–UN–17NOV03

9025 05 2

Hydraulic Pump Cross Section 1—Bias Spring 2—Push Rod

3—Displacement Piston 4—Drive Shaft

5—Roller Bearing 6—Swash Plate

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TM10229 (17MAR09)

9025-05-2

7—Rotate Group

MH66O88,00002E4 –19–04DEC06–1/2

544J Loader (S.N. 611800— ) 032409

PN=876

T196412

–UN–18NOV03

Theory of Operation

Hydraulic Pump Control Valve 8—Pump Control Valve 9—Load Sense Spool 10—Load Sense System Port 11—Load Sense Spring

12—Load Sense Differential Pressure Adjustment Screw 13—Pump Outlet Port

The pump has one displacement piston (3). With engine off, spring force acting on swash plate (6) holds pump at maximum displacement. As engine is started, transmission begins to rotate turning the pump drive shaft (4). Pump outlet pressure acts with spring force as result of the offset rotate group (7). With all hydraulic functions in neutral, pump outlet pressure acts against the head end of the low pressure standby

14—Low Pressure Standby Spool 15—Case Return Port 16—Low Pressure Standby Spring

17—Low Pressure Standby Adjustment Screw

spool (13) and LS spool (12). When pump outlet pressure is great enough to overcome spring pressure of the LS and low pressure spool, the spools shift making a connection to the displacement piston. Displacement piston shifts rotating swash plate (6) to minimum displacement but allowing a small amount of displacement for internal leakage. This condition is known as low pressure standby.

MH66O88,00002E4 –19–04DEC06–2/2

TM10229 (17MAR09)

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544J Loader (S.N. 611800— ) 032409

PN=877

9025 05 3

Theory of Operation

Hydraulic Fan Drive Operation NOTE: Fan reversing valve is a factory option. Not all machines may be equipped with reversing option. The hydraulic fan drive system consists of: • Gear type pump • Gear type motor • Fan reversing valve • Fan proportional solenoid • Fan reverse solenoid

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TM10229 (17MAR09)

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544J Loader (S.N. 611800— ) 032409

PN=878

Theory of Operation

2 3

–UN–01NOV06

9 5

TX1014082

7 TX1014082 Fan Drive Components 1—Fan Pump Inlet From Reservoir 2—Fan Pump 3—Fan Motor

4—Fan Proportional Solenoid 5—Reverse Fan Solenoid 6—Fan Reversing Valve

7—Fan Pump Outlet-to-Fan Reversing Valve Hose 8—Fan Reversing Valve Return-to-Filter Hose

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TM10229 (17MAR09)

9025-05-5

9—Fan Motor Return-to-Filter Hose

OUO1020,0001674 –19–23MAY07–2/5

544J Loader (S.N. 611800— ) 032409

PN=879

9025 05 5

Theory of Operation

A B

PUMP 9025 05 6

–UN–22FEB05

TANK

T208416

4 T208416 Fan Reversing Valve 4—Fan Proportional Solenoid

5—Reverse Fan Solenoid

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OUO1020,0001674 –19–23MAY07–3/5

544J Loader (S.N. 611800— ) 032409

PN=880

Theory of Operation The fan pump (2) is powered by a gear on the front of the engine. Pump output is directed to the fan reversing valve (6) and fan motor (3) inlet. The fan proportional solenoid (4) is used to control fan speed and act as an adjustable relief valve.

–UN–01MAR05

T204687

Proportional fan speed is controlled by the Flex Load Controller (FLC) based upon machine fluid and air temperatures. Fan speed may be manually set from 0% to 100% in increments of 10% if desired. With fan speed is set at 100% in the CAN Monitor Unit (CMU), the fan proportional solenoid allows a small amount of oil from the fan pump to return to reservoir. With fan speed is set at 0%, the fan proportional solenoid allows a larger amount of oil to return to reservoir. As fan speed setting increases to 100%, the fan proportional solenoid allows less oil to return to reservoir and more oil to flow to fan motor (3). An electrical malfunction will default fan speed to 100% to avoid overheating.

Fan Motor with Proportional Solenoid without Reverse Fan Option 3—Fan Motor 4—Fan Proportional Solenoid

When equipped with the reverse fan valve, reversing the fan direction is controlled by the FLC. The fan direction can be reversed in either an automatic or manual mode. In the automatic mode the FLC will reverse the fan direction every thirty minutes. To reverse the fan direction manually, the operator must press and hold the reverse fan switch on the SSM.

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OUO1020,0001674 –19–23MAY07–4/5

544J Loader (S.N. 611800— ) 032409

PN=881

9025 05 7

Theory of Operation To reverse the fan rotation, the FLC begins by energizing the reverse fan solenoid (5) to shift the proportional solenoid valve. With the valve shifted, most of the oil flow supplied to the fan motor from the fan pump is diverted to the reservoir. This will reduce the fan speed to approximately 500 rpm. With the fan motor rotating at the minimum rpm, the FLC will energize the reverse fan solenoid. This shifts the reverse solenoid valve to change the oil flow to the fan motor from the fan pump. With the fan rotation reversed the FLC de-energizes the fan proportional solenoid (4). The proportional solenoid valve minimizes the oil flow to the reservoir to produce the maximum fan speed. The reverse cycle will operate for 30 seconds with the fan rotating at the maximum rpm. At the end of the reverse cycle, the FLC energizes the proportional solenoid and the proportional solenoid valve once again routes the majority of the oil supplied from the fan pump to the reservoir. The fan motor slows to its minimum rpm. Then the FLC de-energizes the reverse solenoid . The reverse solenoid valve is shifted to return the oil flow from the fan pump to the fan motor for normal rotation. Fan pump and fan motor operation returns to the control of the FLC based on the machine fluid and air temperatures. For access to fan speed settings, see CAN Monitor Unit (CMU) Circuit Theory of Operation. (Group 9015-15.) For more electrical fan drive information, see Flex Load Controller (FLC) Circuit Theory of Operation. (Group 9015-15.) 9025 05 8

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TM10229 (17MAR09)

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544J Loader (S.N. 611800— ) 032409

PN=882

Theory of Operation

Steering System Component Operation NOTE: For location of steering components, see Hydraulic System Component Location. (Group 9025-15.) The steering hydraulic system consists of a variable-displacement pump supplying a closed center steering and loader system. The components of the steering system are: • Variable Displacement Axial Piston Pump • Steering valve • Steering cylinders The hydraulic pump draws oil from the reservoir and outlet pressure flows to the steering valve. When the machine is steered, the steering valve routes flow to the steering cylinders to articulate the machine. Steering load sense pressure is directed to the pump

control valve signaling the hydraulic pump to increase displacement. The steering load sense signal in the pump control valve provides priority to steering by utilizing compensator valves in each loader function. The compensator will restrict flow to any loader function that has a work load pressure less than the steering work load pressure. An optional secondary steering system is used to provide temporary steering flow in the event of a flow loss in the steering hydraulic system. The secondary steering is a gear type pump driven by an electric motor. The secondary steering inlet manifold is a valve connected to the steering valve inlet. The manifold contains two check valves which isolate secondary steering flow and a pressure switch which controls operation of the secondary steering motor.

MH66O88,00002E6 –19–29NOV06–1/1

9025 05 9

TM10229 (17MAR09)

9025-05-9

544J Loader (S.N. 611800— ) 032409

PN=883

Theory of Operation

Steering Valve Operation A NEUTRAL B STEERING CYLINDERS

C ANTI-CAVITATION VALVES LOAD SENSE PORT TO LOADER D CONTROL VALVE E GEROTOR

T106786

L WORK PRESSURE OIL G RETURN

F FROM HYDRAULIC PUMP

M TRAPPED OIL N RETURN PRESSURE OIL

T106786

G RETURN SLEEVE H J STEERING SHAFT

–19–05AUG98

K SYSTEM PRESSURE OIL

SPOOL I

O STEERING VALVE OPERATION Steering Valve Operation

9025 05 10

A—Neutral B—Steering Cylinders C—Anti-Cavitation Valves D—Load Sense Port to Loader Control Valve

E—Gerotor F—From Hydraulic Pump G—Return H—Sleeve

The steering valve (O) consists of a spool (I) inside a sleeve (H) within a housing. When the steering wheel is not moving, the valve is in the neutral (A) position. In neutral, the spool and sleeve are aligned so that oil flow through the valve is blocked. The steering cylinders (B) are held stationary by trapped oil in the left and right work ports. When the steering valve is turned to the right, the spool rotates relative to the sleeve, and opens passages that allow pump flow through the spool and sleeve assembly. Oil flows to the gerotor (E), causing the gerotor gear to rotate. Oil flow from the gerotor flows back into the valve, where it is directed out the right work port to the respective ends of the steering cylinders.

I—Spool J—Steering Shaft K—System Pressure Oil L—Work Pressure Oil

A bypass orifice is machined into the spool and sleeve assembly. It is a variable orifice that introduces a small leak into the pressure side of the steering valve. Its purpose is to dampen the initial pressure surge when the steering wheel is partially turned. When the steering wheel is fully turned, the leak is closed off. Return oil flows back through the left work port, through the spool and sleeve assembly to return. The load-sensing orifice is located between the sleeve and the gerotor. This orifice feeds the load-sensing pressure to the loader control valve.

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TM10229 (17MAR09)

M—Trapped Oil N—Return Pressure Oil O—Steering Valve

9025-05-10

MH66O88,00002E7 –19–29NOV06–1/2

544J Loader (S.N. 611800— ) 032409

PN=884

Theory of Operation When the rotation of the steering wheel stops, the gerotor gear continues to move, turning the sleeve, until the sleeve stops the flow to the gerotor. At this point, the valve is back in the neutral position and will remain there until the steering wheel is moved again.

A variable orifice bypasses oil around the gerotor. Turning the steering wheel slowly takes approximately seven turns (variable orifice small) stop-to-stop versus three turns (variable orifice large) when turning the steering wheel quickly.

The valve has a variable steering rate that is proportional to the speed the steering wheel is rotated.

Four anti-cavitation balls are located inside the spool (not shown).

MH66O88,00002E7 –19–29NOV06–2/2

Steering System Component Operation NOTE: For location of steering components, See Hydraulic System Component Location. (Group 9025-15.) The steering hydraulic system consists of a variable-displacement pump supplying a closed center steering and loader system. The components of the steering system are: • Variable Displacement Axial Piston Pump • Steering valve • Steering cylinders • Compensator Valve Manifold The hydraulic pump draws oil from the reservoir and outlet pressure flows to the steering valve. When machine is steered, the steering valve routes flow to the steering cylinders to articulate the machine. Steering load sense pressure is directed to the pump control valve signaling the hydraulic pump to increase displacement. The hydraulic system uses the steering pre-compensator valve in conjunction with the loader control valve post-compensators to give steering priority. The post-compensator will restrict flow to any loader function that has a work load pressure less than the steering work load pressure.

The steering compensator valve manifold contains a compensator valve cartridge . The compensator valve function is to maintain a constant differential pressure between the steering work port pressure and steering inlet pressure. This valve meters oil to a more open/closed position to maintain this differential, which is set by the spring. In the event that the pump becomes saturated and can no longer maintain this margin, the steering compensator valve will be shifted to the fully open position to give hydraulic priority to the steering valve. An optional secondary steering system is used to provide temporary steering flow in the event of a flow loss in the steering hydraulic system. The secondary steering pump and motor is a small gear pump driven by an electric motor. The secondary steering inlet manifold is a valve connected to the steering valve inlet. The manifold contains two check valves which isolate secondary steering flow and a pressure switch which controls operation of the secondary steering motor.

MH66O88,00002F7 –19–03APR08–1/1

TM10229 (17MAR09)

9025-05-11

544J Loader (S.N. 611800— ) 032409

PN=885

9025 05 11

Theory of Operation

Secondary Steering Inlet Manifold Operation

J E G B C

SWITCH E

LEVER H

LS-PORT I SECONDARY CHECK VALVE J

PISTON D

MAGNET G

SPRING C ORIFICE B A INLET

OUTLET F

L STEERING PRESSURE –19–07NOV97

PRIMARY CHECK VALVE K

M LS PRESSURE O INLET MANIFOLD

N RETURN PRESSURE

T6567OL

9025 05 12

T6567OL Secondary Steering Inlet Manifold Operation A—Inlet B—Orifice C—Spring D—Piston

E—Switch F—Outlet G—Magnet H—Lever

I—LS-Port J—Secondary Check Valve K—Primary Check Valve L—Steering Pressure

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TM10229 (17MAR09)

9025-05-12

M—LS Pressure N—Return Pressure O—Inlet Manifold

MH66O88,00002E9 –19–07DEC06–1/2

544J Loader (S.N. 611800— ) 032409

PN=886

Theory of Operation The secondary steering inlet manifold isolates the main steering system and provides a signal to the controller to warn of low steering pressure. During normal steering operation, pump flow enters from the hydraulic pump through the inlet (A), unseats the primary check valve (K), and flows to the steering valve through the outlet (F). Inlet pressure is sensed on the top of the piston (D) through the orifice (B), to move the piston down against the spring (C) and load-sensing pressure. With the main hydraulic pump supplying flow, the steering inlet pressure is higher than load-sensing pressure. This pressure difference keeps the switch (E) in the closed position.

If main pump flow is lost, the primary check valve seats. The pilot pressure in the loader control valve drops, causing pressure through the orifice to drop. This causes the spring, plus load-sensing pressure through the LS-port (I), to move the piston up. The magnet (G) pulls the lever (H), which opens the switch. When the switch opens, the Flex Load Controller (FLC) energizes the secondary steering relay. The relay energizes the secondary steering motor which, drives the pump. Pump flow unseats the secondary check valve (J), providing temporary steering flow.

MH66O88,00002E9 –19–07DEC06–2/2

9025 05 13

TM10229 (17MAR09)

9025-05-13

544J Loader (S.N. 611800— ) 032409

PN=887

Theory of Operation

Pressure Reducing Valve Operation 4 The PRV manifold contains:

• Pressure reducing valve (PRV) • Pilot enable solenoid • Boom down accumulator solenoid • Boom down accumulator

7 6

For hydraulic system operation, see Hydraulic System Schematic. (Group 9025-15.)

The PRV regulates pressure to the pilot controls by bleeding excess pressure to reservoir. Pilot control pressure and accumulator charge should be within specification with engine running. See Pressure Reducing Valve Pressure Test. (Group 9025-25.) With pilot enable solenoid valve de-energized, a bias spring holds pilot enable spool up, venting oil in the pilot controls to reservoir. With the pilot enable solenoid energized, the spool shifts down, connecting regulated pilot pressure to the pilot controls.

9025 05 14

11 –UN–05DEC06

10 9

TX1015567

The pressure reducing valve manifold (4) receives system pressure directly from the pump outlet. System pressure oil flows through a check valve (7) to the boom down solenoid valve (9) and adjustable pressure reducing valve (10). Oil then flows to the pilot enable solenoid valve (8) and allows oil to flow to the pilot control valve.

1—Low Pressure Oil 2—Regulated Pressure Oil 3—Return Oil 4—Pressure Reducing Valve Manifold 5—Pump Pressure Test Port 6—Boom Down Accumulator 7—Check Valve 8—Pilot Enable Solenoid Valve 9—Boom Down Solenoid Valve 10—Pressure Reducing Valve (PRV) 11—Regulated Pressure Test Port

Boom or Bucket Down Operation—Oil can flow to the boom down accumulator (6) in either boom down solenoid valve (9) spool position. With engine off, key on, and pilot enable/boom down switch depressed, the boom down accumulator solenoid valve shifts the spool down. The check valve (7) closes and directs accumulator high-pressure oil to the pressure regulating valve (10) to supply regulated pressure oil to the pilot functions. The accumulator can only be discharged with the engine in the OFF position. Turn the key to the ON position, depress and hold the pilot enable/boom down switch, and move a pilot function. Using this procedure the operator can continue to cycle the pilot control lever, allowing the accumulator pilot pressure to lower the boom or bucket until the accumulator is discharged.

MH66O88,00002EA –19–04JAN07–1/1

TM10229 (17MAR09)

9025-05-14

544J Loader (S.N. 611800— ) 032409

PN=888

Theory of Operation

Service Brake Hydraulic System Operation NOTE: For brake system operation, see Hydraulic System Schematic. (Group 9025-15.) Loader service brakes are operated by a load sensing pressure compensated, closed center hydraulic system. Flow is supplied by a variable displacement, axial piston hydraulic pump. Pressure to the brake system varies from low standby to the maximum pressure where the load sense relief valve in the loader control valve limits extreme pressure. The hydraulic pump supplies oil flow to the accumulators. The accumulators have a gas pre-charge and inlet check valves to maintain a pressurized volume of oil for reserve brake applications.

a warning signal to the Flex Load Controller (FLC) and monitor. See Flex Load Controller (FLC) Circuit Theory of Operation. (Group 9015-15.) The shuttle valve is used to isolate the accumulators. The brake valve is a closed center design and can be operated by pressing on either the left or right pedal. The single brake valve operates both the front and rear brakes. Brake outlet pressure flows through orifice check valves to ensure that if either brake line is damaged, brakes on the remaining axle will still function. Brakes are self-bleeding during operation. A brake light pressure switch is used to sense brake outlet pressure for activating the brake lights.

Oil from the accumulators flows through a shuttle valve to the single brake valve. A pressure sensor senses pressure at the brake valve inlet. Low pressure triggers

Clutch cut-off is controlled through the Transmission Control Unit (TCU) by a potentiometer signal activated by the brake pedal linkage. See Transmission Control Unit (TCU) Circuit Theory of Operation. (Group 9015-15.)

MH66O88,00002EC –19–04JAN07–1/1

9025 05 15

TM10229 (17MAR09)

9025-05-15

544J Loader (S.N. 611800— ) 032409

PN=889

Theory of Operation

T196150

–19–19NOV03

Service Brake Accumulator Operation

A—Inlet Check Valve C—Piston 9025 05 16

D—Outlet E—Brake Circuit Pressure

NOTE: Brake accumulators are not repairable and are serviced as a complete unit. The accumulator is used to store pressurized oil for reserve brake application. The top of the accumulator is charged with dry nitrogen gas. When the hydraulic system pressure exceeds the charge pressure, oil flows through the inlet (E) and inlet check valve (A). The piston (C) moves upward until gas pressure is equal to hydraulic circuit pressure.

G—Precharge Pressure

H—Brake Accumulator

If pump flow stops, the inlet check valve will close against the inlet fitting, which is machined to provide a check valve seat, keeping the accumulator charged. The accumulator will remain pressurized until the brakes are applied. The volume of the accumulator will allow several brake applications in the event of a loss of brake pump flow.

MH66O88,00002ED –19–01FEB07–1/1

TM10229 (17MAR09)

9025-05-16

544J Loader (S.N. 611800— ) 032409

PN=890

Theory of Operation

9025 05 17

TM10229 (17MAR09)

9025-05-17

544J Loader (S.N. 611800— ) 032409

PN=891

Theory of Operation

Service Brake Valve Operation B

B INLET

SERVICE A BRAKE PRESSURE SWITCH

C RETURN D

ONE-WAY N ORIFICES

M BRAKE LIGHT PRESSURE SWITCH

D WORKPORTS E BRAKE SHUTTLE VALVE

FROM BRAKE L ACCUMULATOR

F FROM BRAKE/PRV ACCUMULATOR G SPOOL

9025 05 18

H PLUNGER

SNAP K RING

O INLET PRESSURE P METERED PRESSURE

T116212

R BRAKE VALVE OPERATION

Q RETURN PRESSURE

T116212

TO REAR J BRAKES

–19–09JUL98

D I TO FRONT BRAKES

Brake Valve Continued on next page

TM10229 (17MAR09)

9025-05-18

MH66O88,00002EF –19–29NOV06–1/2

544J Loader (S.N. 611800— ) 032409

PN=892

Theory of Operation A—Service Brake Pressure Switch B—Inlet C—Return Passage D—Work ports E—Brake Shuttle Valve

F—From Brake/PRV Accumulator G—Spool H—Plunger I—To Front Brakes

J—To Rear Brakes K—Snap Ring L—From Brake Accumulator M—Brake Light Pressure Switch

The brake valve is a closed center, manually operated spool-type valve. One valve is used to actuate both the front and rear brakes. Orifice check valves are used in the brake lines so that if either brake line is damaged, the remaining axle brake will still function. Brake pressure oil from the accumulators enters the inlet (B). When the valve is in neutral, oil in the work ports is routed to return through return passage (C). When the brakes are partially engaged, the brake pedal pushes the plunger (H) against a spring which contacts the guide. The spool has a metering notch which begins to trap the work port oil from the return passage. As the brake pedal is further depressed, the plunger (H) compresses the spring against the guide, which moves the spool (G) further to the left. As the spool, moves to the left, the return passage (C) is blocked. A

N—One-Way Orifices O—Inlet Pressure P—Metered Pressure Q—Return Pressure R—Brake Valve Operation

metering notch on the spool starts to open, allowing brake pressure oil from the inlet (B) to the work ports (D). The brakes in the front and rear axles begin to engage. When the brakes are fully engaged, the spool is moved to the far left position against the spring. Full inlet flow at a regulated pressure is available to the work ports to engage the brakes. The brake valve regulates brake application pressure based on brake pedal travel. When the inlet is opened to pressurize the work ports, the one-way orifice (N) allows work port pressure on the left end of the spool. The work port pressure, plus spring force on the left end of the spool, balance against the compressed spring force on the right end of the spool. This meters the inlet pressure oil to prevent aggressive braking or brake lock-up.

MH66O88,00002EF –19–29NOV06–2/2

TM10229 (17MAR09)

9025-05-19

544J Loader (S.N. 611800— ) 032409

PN=893

9025 05 19

Theory of Operation

Pin Disconnect Operation 1

Pin disconnect solenoid (5) is housed in the pin disconnect manifold valve (1). The pump outlet pressure line (2) supplies oil to the pin disconnect pressure reducing valve (3), reducing system pressure to specification.

Specification Pin Disconnect—Regulated Pressure ...................................................................................... 7584 kPa 76 bar 1100 psi

9025 05 20

5 6

TX1015747

During pin disconnect operation, the pin disconnect solenoid (5) energizes allowing pressure oil to shift the pin disconnect spool and flow to the end of the pin disconnect cylinder (6) to retract the pins. With the pin disconnect solenoid de-energized, pressure oil flows to the center of the pin disconnect cylinder, holding the pins in the extended position. Cylinder rod ends are joined by a common return line to reservoir (4).

–UN–05DEC06

For additional information on the hydraulic system operation, see Hydraulic System Component Location. (Group 9025-15.)

Pin Disconnect Schematic 1—Pin Disconnect Manifold Valve 2—Pump Outlet Pressure Line 3—Pin Disconnect Pressure Reducing Valve 4—Return Line to Reservoir 5—Pin Disconnect Solenoid 6—Pin Disconnect Cylinder

MH66O88,00002F1 –19–07DEC06–1/1

TM10229 (17MAR09)

9025-05-20

544J Loader (S.N. 611800— ) 032409

PN=894

Theory of Operation

9025 05 21

TM10229 (17MAR09)

9025-05-21

544J Loader (S.N. 611800— ) 032409

PN=895

Theory of Operation

Pilot Control Lever Operation

A 3 10

11 P

9025 05 22

5 C

TX1012036

–UN–20SEP06

TX1012036 Pilot Control Lever—Single Lever Control Continued on next page

TM10229 (17MAR09)

9025-05-22

SJ25320,000031A –19–07DEC06–1/2

544J Loader (S.N. 611800— ) 032409

PN=896

Theory of Operation 1—Wobble Plate 2—Push Rod 3—Pull Plate 4—Extra Centering Spring 5—Metering Spring

6—Return Spring 7—Spool Assembly 8—Work Port A 9—Work Port C

10—Plunger Assembly 11—Spring Guide A—Boom Lower Port B—Bucket Dump Port

Single lever pilot control levers moves fore and aft as well as side to side and consists of four, two position, two way, lever operated valves. Fingertip pilot control levers have a pair of levers that move fore and aft consisting of two, two way, two position, lever operated valves. Both pilot controllers operate the same way. In neutral, the return spring (6) and extra centering spring (4) hold spool assembly (7) closed blocking flow from the pressure port to connect to work ports and allowing oil to return to reservoir. During operation, pilot pressure oil from the pressure reducing valve enters the pilot controller housing at the pressure port.

C—Boom Raise Port D—Bucket Rollback Port P—Pressure Oil Port T—Return Oil (Tank) Port

With the control lever pushed activated in either direction, the push rod (2) pushes plunger (10) down contacting spring guide (11). Spring guide (11) compresses both return spring (6) and metering spring (5) moving spool assembly (7) down into a metering position and allowing oil to flow out the work port. With the spool assembly moved to maximum travel, full pilot pressure will be available to shift the control valve spool. Boom float and raise functions use an electromagnetic detent.

SJ25320,000031A –19–07DEC06–2/2

9025 05 23

TM10229 (17MAR09)

9025-05-23

544J Loader (S.N. 611800— ) 032409

PN=897

Theory of Operation

Control Valve Pilot Orifice Check Valve Operation

A ORIFICE CHECK PLATE

TOP VIEW

C RESTRICTED RETURN OIL D RETURN OIL

A—Orifice Check Plate B—Control Valve End Cap 9025 05 24

T102095

–19–28AUG96

CONTROL B VALVE END CAP

E PILOT OIL RETURN RESTRICTED

C—Restricted Return Oil

D—Return Oil

Orifice check plate is installed in control valve pilot cap of bucket and auxiliary control valve sections. Orifice (A) dampens the control valve spool movement to stop unwanted bucket or auxiliary function movement when

E—Pilot Oil Return Restricted

the pilot controller lever is centering itself. It also stops unwanted correction in opposite direction as the lever kicks out of bucket return-to-dig.

SJ25320,000032F –19–11DEC06–1/1

TM10229 (17MAR09)

9025-05-24

544J Loader (S.N. 611800— ) 032409

PN=898

Theory of Operation

Loader Control Valve Operation X

C B I

J W N

–UN–15JUL04

S R

T201490

P Q

Loader Control Valve Operation A—Auxiliary Work Port “B” B—Circuit Relief C—Auxiliary Pilot D—Bucket Rollback Pilot E—Boom Raise Pilot F—Bucket Rollback Work Port G—Boom Raise Work Port

H—Load Sense Relief Valve— Maximum System Pressure I—Load Sense to Pump J—C1 and C2 Check Valves K—Return L—Return from Ride Control M—Boom Lower Work Port

N—Bucket Dump Work Port O—Anticavitation Valve P—Boom Lower Pilot Q—Bucket Dump Pilot R—Auxiliary Pilot S—Circuit Relief

T—Auxiliary Work Port “A” U—Relief Valve (clipper) V—Inlet from Pump W—Load Sense from Steering X—Stroke Adjuster (if equipped)

9025 05 25

SJ25320,0000319 –19–11DEC06–1/1

TM10229 (17MAR09)

9025-05-25

544J Loader (S.N. 611800— ) 032409

PN=899

Theory of Operation

Boom Section Operation—Boom Down and Steering 2

1 8

5 6 10 –UN–13AUG04

11 12 1

9025 05 26

T201431

14 T201431 Boom Section—Boom Down and Steering 1—Anticavitation Check 2—Boom Down Work Port 3—C2 Check 4—Load Check

5—Compensator 6—C1 Check 7—Boom Up Work Port 8—Boom Up Pilot

9—Boom Down Pilot 10—High Pressure 11—Medium Pressure (load sense)

NOTE: An external orifice check valve is located in a fitting between the pilot port and hose. The boom lower work port has an anticavitation check (1), the boom raise is plugged. There are no circuit relief valves. Two load sense pressures are generated. One pressure is from the metered pump flow past C1 check

(6). The other pressure exists past the compensator and C2 check (3). When the system is below maximum pressure, the pressure from past C2 check (compensated load sense) is used to close the compensator. When the system is at maximum pressure, the pressure from C1 check (metered load sense) is reduced by the load sense relief valve and is used to close the compensator. The steering load sense can feed both of these signals.

Continued on next page

TM10229 (17MAR09)

12—Low Pressure (load sense) 13—Pilot Pressure 14—Return Pressure

9025-05-26

SJ25320,0000318 –19–01FEB07–1/2

544J Loader (S.N. 611800— ) 032409

PN=900

Theory of Operation During a boom down and steering operation the following will occur. Pilot oil shifts the spool to the right. Oil flow from the pump is directed to the spool center. Metered load sense flows past C1 check (6) and it also exerts a force to open the compensator (5). Steering load sense comes from the steering valve through the outlet section to the load sense shuttle spool. This load sense pressure is then directed to the spring area of each compensator.

Since the steering load sense pressure is much greater than the boom work port load sense pressure, the compensator restricts oil flow to boom down. This provides priority to steering. The reduced pressure opens the load check (4) and flows to the work port. The work port pressure also flows past C2 check (3).

SJ25320,0000318 –19–01FEB07–2/2

9025 05 27

TM10229 (17MAR09)

9025-05-27

544J Loader (S.N. 611800— ) 032409

PN=901

Theory of Operation

Boom Section Operation—Boom Raise and Bucket Dump

5 6

3 10

5 4

11 12 13 –UN–29JUL04

9025 05 28

T201432

T201432 Boom Section—Boom Raise and Bucket Dump 1—Anticavitation Check 2—Boom Down Work Port 3—C2 Check 4—Load Check

5—Compensator 6—C1 Check 7—Boom Up Work Port 8—Boom Up Pilot

9—Boom Down Pilot 10—High Pressure 11—Medium Pressure (load sense)

NOTE: An external orifice check valve is located in a fitting between the pilot port and hose. During boom raise and bucket dump oil flow to these two functions will be equal even though there is a large difference in work port pressures. This is accomplished by the load sense pressure control of the boom and bucket compensators.

During boom raise the work port and load sense pressures will be high. Metered load sense flows past C1 check (6) to the outlet section and back to the hydraulic pump. Metered load sense oil flows to the compensator center and past C1 check back to the outlet section and to the pump.

Continued on next page

TM10229 (17MAR09)

12—Low Pressure (load sense) 13—Pilot Pressure 14—Return Pressure

9025-05-28

SJ25320,0000317 –19–01FEB07–1/2

544J Loader (S.N. 611800— ) 032409

PN=902

Theory of Operation The highest work port pressure unseats the C2 check and flows to the outlet section. The load sense shuttle spool directs the highest work port pressure to the spring area of the compensator. This identical high load sense pressure is also directed to the bucket compensator spring area. With both compensators

having the same spring pressure, the same hydraulic force will be required to open both compensators. Thus the flow to both functions will be the same, even though the bucket work port pressure is lower than the boom work port pressure.

SJ25320,0000317 –19–01FEB07–2/2

9025 05 29

TM10229 (17MAR09)

9025-05-29

544J Loader (S.N. 611800— ) 032409

PN=903

Theory of Operation

Bucket Section Operation—Boom Raise and Bucket Dump 6

2 1

4 6 5

11 –UN–23JUL04

12 13

2 9025 05 30

T201858

15 T201858 Bucket Section—Boom Raise and Bucket Dump 1—Auxiliary Pilot (Work Port A) 2—Circuit Relief and Anticavitation Valve 3—Work Port A

4—Shuttle Check C2 5—Load Check 6—Compensator 7—Shuttle Check C1 8—Work Port B

9—Auxiliary Pilot (Work Port B) 10—Stroke Adjuster Plunger Assembly (Work Port B) 11—High Pressure

In combined operation with the boom valve some of the pressure conditions will be determined by what’s happening in the boom valve. The metered load sense is essentially blocked at C1 check (6) by the metered load sense from the boom valve. The metered load sense flows up through the compensator and is blocked by the C2 check, but flows past the load check.

The pressure on the spring side of the compensator is essentially boom load sense pressure, the same pressure that is acting on the boom compensator. Therefore, the flow to bucket dump which requires very little pressure will be the same as the boom which requires high pressure.

Continued on next page

TM10229 (17MAR09)

12—Medium Pressure (load sense) 13—Low Pressure (load sense) 14—Pilot Pressure 15—Return Pressure

9025-05-30

OUO1020,0001671 –19–24MAY07–1/2

544J Loader (S.N. 611800— ) 032409

PN=904

Theory of Operation NOTE: Stroke adjuster assembly (10) is factory set to control flow to help maintain rollback characteristics.

OUO1020,0001671 –19–24MAY07–2/2

T121124

–UN–14APR99

Auxiliary Sections—Stroke Adjusters Operation

A—Set Screw (2 used) B—Cartridge (2 used) C—End Cap (2 used) D—Pilot Ports E—Spool

F—“A” Work Port G—“B” Work Port H—Stripper Bolt I—Plunger— “B” Work Port J—Locking Hex Nut (2 used)

The auxiliary section of the loader control valve is equipped with spool stroke adjuster assembly (Q) in each end cap. The adjusters allow the maximum auxiliary section flow to be set anywhere from a few gallons per minute (gpm) to full pump flow. This is accomplished by controlling the maximum travel of the spool (E) by

K—Back-Up Ring (2 used) L—O-Ring (2 used) M—O-Ring (2 used) N—O-Ring (2 used)

O—Plunger— “A” Work Port P—Cap Screw (4 used) Q—Auxiliary Section—Stroke Adjuster Assembly

adjusting the plunger position in the end cap assembly with setscrew (A) and hex nut (J). Adjusting the spool travel regulates the amount of flow area opened by the spool. Since the hydraulic system is load sensing, there is a set differential pressure across the opened inlet area. As a result, a flow proportional to this area will be delivered to the implement. The stroke adjusters are set at full flow at the factory.

SJ25320,0000314 –19–07DEC06–1/1

TM10229 (17MAR09)

9025-05-31

544J Loader (S.N. 611800— ) 032409

PN=905

9025 05 31

Theory of Operation

Outlet Section Operation

3 14 1

7 8

13 8 13 15

12 2

10 11 9

1 6

3 –UN–29JUL04

9025 05 32

4 15

T201637

12 T201637 Outlet Section—Steering 1—Load Sense Shuttle Spool 2—Load Sense From C2 Checks 3—Shuttle 4—Load Sense From Steering 5—Load Sense to Compensators

6—Shuttle 7—Load Sense to Relief Valve 8—Load Sense From C1 Checks 9—Load Sense Signal to Pump

10—Tank Pressure Reducing Valve Spool 11—Tank In (from ride control) 12—Tank Out 13—Pump Output Pressure

14—Load Sense Relief Valve 15—High Pressure 16—Medium (load sense) Pressure 17—Return Pressure

The outlet section functions as a control center for the load sense system. It also provides an outlet for the loader system return oil.

Continued on next page

TM10229 (17MAR09)

9025-05-32

SJ25320,0000313 –19–07DEC06–1/2

544J Loader (S.N. 611800— ) 032409

PN=906

Theory of Operation The load sense shuttle spool assembly contains two shuttles (3 and 6) and itself moves also. Load sense from the steering valve enters the outlet section and is applied to each shuttle where the pressure from the C1 checks is applied to one shuttle and the pressure from the C2 checks is applied to the other. Since no loader functions are actuated, the steering load sense is greater and seats both shuttles. Load sense oil from shuttle (6) flows through an orifice to the load sense signal to pump (9) and to the one end of the load sense shuttle spool (1). This oil also flows through another orifice to the load sense relief valve (14). Load sense oil from the other shuttle (3) is applied to other side of the load sense shuttle spool (1). This oil also flows through an orifice and then to the spring side of compensators. The load sense relief valve limits load sense pressure thereby limiting maximum hydraulic system pressure. When the pressure setting is reached, there is oil flow

through the relief valve to return. The flow through the orifice causes a pressure difference between the load sense port (9) to the pump and the steering load sense (4) or C1 load sense (8) coming from work load pressure. This pressure difference is sensed at the pump control assembly relief valve. When the difference reaches the margin pressure of the load sense valve the pump destrokes to a point that maintains maximum system pressure. The maximum hydraulic system is set by the load sense relief valve (14) adjustment. The tank pressure reducing valve spool (10), ensures that a constant pressure to the control valve return circuit is maintained. If pressure in the return circuit is too high, it will shift the spool against the spring to allow the oil to flow to return. If the pressure is lower than tank plus the spring pressure, the spool will shift and allow pump output pressure (13) into the return circuit and raise the pressure.

SJ25320,0000313 –19–07DEC06–2/2

9025 05 33

TM10229 (17MAR09)

9025-05-33

544J Loader (S.N. 611800— ) 032409

PN=907

Theory of Operation

Load Sense Circuit Operation—Neutral 3

–UN–15JUL04

5 6

T201607

7 8 T201607 Load Sense Circuit Operation—Neutral 1—Pump Inlet 2—Load Sense In (from steering) 9025 05 34

3—Tank In (from ride control) 4—Tank Out

5—Load Sense Out (to pump) 6—Standby Pressure

7—Trapped Pressure 8—Return Pressure

The function of the load sense circuit is to:

• Hydraulic pump control assembly

• Control pump output • Limit maximum system pressure • Provide priority to the steering circuit • Provide proportional flow to all functions with varying pressures

In neutral it is very important that the entire load sense circuit be pressure free. This is accomplished by a number of bleed orifices and passages. In the steering valve there is a small passage directly to return. In the inlet section of the control valve, the load sense signals bleed back to return through triple orifice fittings. With all of the load sense circuit bled to return the hydraulic pump will maintain the specified standby pressure. Any residual pressure build-up in load sense would affect low pressure standby.

The load sense circuit consists of: • All loader control valve sections • Steering valve

SJ25320,0000312 –19–07DEC06–1/1

TM10229 (17MAR09)

9025-05-34

544J Loader (S.N. 611800— ) 032409

PN=908

Theory of Operation

Load Sense Circuit Operation—Steering 3

–UN–15JUL04

5 6 7

T201608

8 9

T201608 Load Sense Circuit—Steering 1—Pump Inlet 2—Load Sense In (from steering)

3—Tank In (from ride control) 4—Tank Out 5—Load Sense Out (to pump)

The load sense pressure signal enters the loader control at load sense in port (2) of the outlet section. With loader functions being in neutral, the steering pressure seats both shuttle checks. Steering load

6—High Pressure 7—Medium (load sense) Pressure

8—Trapped Pressure 9—Return Pressure

sense oil then flows through an orifice to the hydraulic pump control valve through the outlet port (5). Steering load sense oil also flows through the load sense shuttle spool to the spring side of the compensators.

SJ25320,0000311 –19–07DEC06–1/1

TM10229 (17MAR09)

9025-05-35

544J Loader (S.N. 611800— ) 032409

PN=909

9025 05 35

Theory of Operation

Load Sense Circuit Operation—Steering and Boom Down 3

T201609

–UN–15JUL04

T201609 Load Sense Circuit—Steering and Boom Down

9025 05 36

1—Pump Inlet 2—Load Sense In (from steering) 3—Tank In (from ride control)

4—Tank Out 5—Load Sense Out (to pump) 6—High Pressure

The steering load sense signal enters the control valve in the same way as with steering only activated. Steering load sense pressure is present at spring area of the boom compensator. The boom compensator will now restrict oil flow out of the boom down work port, thereby providing priority oil flow to steering.

7—Medium (load sense) Pressure 8—Low (load sense) Pressure

9—Pilot Pressure 10—Trapped Pressure 11—Return Pressure

boom load sense pressure would seat the shuttle check to the right and the higher load sense pressure will be used. The highest load sense pressure will be utilized by both the hydraulic pump control unit and the compensator valves.

If for example, boom raise was operated while steering and boom pressures were higher than steering, then

SJ25320,0000310 –19–07DEC06–1/1

TM10229 (17MAR09)

9025-05-36

544J Loader (S.N. 611800— ) 032409

PN=910

Theory of Operation

Load Sense Circuit Operation—Boom Raise and Bucket Dump 3

T201609

–UN–15JUL04

T201609 Load Sense Circuit—Boom Raise and Bucket Dump 1—Pump Inlet 2—Load Sense In (from steering) 3—Tank In (from ride control)

4—Tank Out 5—Load Sense Out (to pump) 6—High Pressure

Without any flow control when operating boom raise and bucket dump, all of the pump output would go to the bucket dump circuit. With compensators in the loader circuits, the bucket compensator will restrict flow so that equal flow will go to boom raise and bucket dump. This is accomplished by sending the higher

7—Medium (load sense) Pressure 8—Low (load sense) Pressure

9—Pilot Pressure 10—Trapped Pressure 11—Return Pressure 9025 05 37

boom load sense pressure to the top side of the bucket compensator. Now both bucket and boom compensators have the same spring side pressure. Flow past each compensator is the same though the bucket dump work port pressure is very low.

SJ25320,000030F –19–07DEC06–1/1

TM10229 (17MAR09)

9025-05-37

544J Loader (S.N. 611800— ) 032409

PN=911

Theory of Operation

Relief Valve Operation 1

–UN–22JUL04

2 4

T201681

5 T201681 Relief Valve Operation 1—Return 2—Pump Inlet 9025 05 38

3—Poppet

4—Relief Pressure

The loader hydraulic system uses a direct-acting relief valve located in the inlet section of the loader control valve assembly. Its function is to relieve pressures spikes that result from abrupt flow changes. During normal operation, loader pressures are below the relief pressure of the relief valve. The poppet (3)

remains closed against the floating seat to seal the pump inlet (2) from the return passage (1). When a pressure spike occurs and exceeds the relief setting, pressure oil in the inlet forces the poppet open and allows oil to flow to return.

Continued on next page

TM10229 (17MAR09)

5—Return Pressure

9025-05-38

SJ25320,000030E –19–07DEC06–1/2

544J Loader (S.N. 611800— ) 032409

PN=912

Theory of Operation

–UN–09OCT06

TX1013137

5 TX1013137 Relief Valve Anticavitation Operation 1—Return 2—Pump Inlet

3—Floating Seat

4—Return Pressure

If the pump inlet pressure in the circuit drops below return pressure, the anti-cavitation feature of the relief valve activates.

5—No Pressure (cavitation)

If cavitation occurs, the oil pressure in the pump inlet and in the spring area of the poppet drops below return pressure. Return pressure oil works against the poppet to force it open against the spring.

During normal operation , the floating seat (3) remains closed against the housing causing the pump inlet (2) to be sealed from the return (1) passage.

SJ25320,000030E –19–07DEC06–2/2

TM10229 (17MAR09)

9025-05-39

544J Loader (S.N. 611800— ) 032409

PN=913

9025 05 39

Theory of Operation

Load Sense Relief Valve Operation

1 2

2 1

1 2

–UN–22JUL04

5 6 4

T201683

T201683 Load Sense Relief Valve Operation 1—Return 2—Work Port 9025 05 40

3—Poppet 4—Adjusting Screw

5—Relief Pressure 6—Operating Pressure

The load sense relief valve is a direct acting poppet (3) type design located in the loader control valve outlet section. Its function is to limit the maximum pressure in the hydraulic system. It actually senses and limits load sense pressure. Setting a limit on load sense pressure also sets a limit on pump output or system pressure.

7—Return Pressure

This pressure level will normally be margin pressure plus the setting of the load sense relief valve. To adjust, a hydraulic function is bottomed, the pump output pressure is monitored and the adjustment screw (4) is turned to set the pressure reading to the specified maximum value. Turn adjustment screw in to increase and out to decrease pressure.

SJ25320,000030D –19–07DEC06–1/1

TM10229 (17MAR09)

9025-05-40

544J Loader (S.N. 611800— ) 032409

PN=914

Theory of Operation

Circuit Relief Valve Operation

B RETURN B

A D

WORKPORT A G POPPET D B RETURN

C SEAT

H NORMAL OPERATION

WORKPORT

B RETURN

G PILOT POPPET

F PIN I

D POPPET J RELIEF OPERATION

PILOT OPERATION

L OPERATING PRESSURE M RETURN PRESSURE

T6567OU

N CIRCUIT RELIEF VALVE

–19–09OCT97

K RELIEF PRESSURE

(WITH ANTI-CAVITATION) Circuit Relief Valve Operation (1 of 2)

A—Work Port B—Return C—Seat D—Poppet

E—Return Passage F—Pin G—Pilot Poppet H—Normal Operation

I—Pilot Operation J—Relief Operation K—Relief Pressure L—Operating Pressure

Type 1—the bucket rollback and dump, and both auxiliary work ports of the loader control valve use a pilot-operated circuit relief with an anticavitation feature.

M—Return Pressure N—Circuit Relief Valve (with anticavitation)

As the circuit pressures approach the relief pressure setting, the pin (F) forces the pilot poppet (G) off its seat. Grooves cut into the pin, bleed oil on the right side of the poppet to return through the pilot poppet.

During normal operation (H), the poppet (D) is positioned against the seat (C) to seal the work port (A) oil from the return (B) passage.

Continued on next page

TM10229 (17MAR09)

9025-05-41

SJ25320,000030C –19–02FEB07–1/7

544J Loader (S.N. 611800— ) 032409

PN=915

9025 05 41

Theory of Operation During relief operation (J), oil on the right side of the poppet is drained to return causing pressure in the work port to overcome the poppet spring force. Relief

pressure oil flows from the work port to return across the poppet.

Continued on next page

SJ25320,000030C –19–02FEB07–2/7

9025 05 42

TM10229 (17MAR09)

9025-05-42

544J Loader (S.N. 611800— ) 032409

PN=916

Theory of Operation

B RETURN

WORKPORT A

C POPPET F NORMAL OPERATION

B RETURN

WORKPORT A

D PIN

E SPRING

9025 05 43

–19–09OCT06

G ANTI-CAVITATION OPERATION H RETURN PRESSURE

CIRCUIT RELIEF VALVE (WITH ANTI-CAVITATION)

I LOW PRESSURE C RETURN PRESSURE

TX1013135

TX1013135 A—Work Port B—Return C—Poppet

D—Pin E—Spring F—Anticavitation Operation

If the work port pressure in the circuit drops below return pressure, the anticavitation feature of the circuit relief valve activates.

G—Circuit Relief Valve (with anticavitation) H—Return pressure

During normal operation (F), the poppet (C) remains closed against its seat causing the work port (A) to be sealed from the return (B) passage.

Continued on next page

TM10229 (17MAR09)

I—No Pressure (cavitation) J—Low Pressure

9025-05-43

SJ25320,000030C –19–02FEB07–3/7

544J Loader (S.N. 611800— ) 032409

PN=917

Theory of Operation If cavitation occurs, the oil pressure in the work port and in the spring (E) area of the poppet drops below return pressure. Return pressure oil works against the

shoulder of the poppet to force it open against the spring.

Continued on next page

SJ25320,000030C –19–02FEB07–4/7

9025 05 44

TM10229 (17MAR09)

9025-05-44

544J Loader (S.N. 611800— ) 032409

PN=918

Theory of Operation

3 4

9025 05 45

3 –UN–22JUL04

5 6

T201663

7 T201663 1—Work Port 2—Return

3—Poppet 4—Pilot Poppet

5—Relief Pressure 6—Load Sense Pressure Continued on next page

TM10229 (17MAR09)

9025-05-45

7—Return Pressure SJ25320,000030C –19–02FEB07–5/7

544J Loader (S.N. 611800— ) 032409

PN=919

Theory of Operation Type 2—the bucket rollback and dump, and both auxiliary work ports of the loader control valve use a pilot-operated circuit relief with an anticavitation feature. During normal operation, the poppet (3) is positioned against the seat to seal the work port (1) oil from the return (2) passage.

Grooves cut into the pin, bleed oil on the right side of the poppet to return through the pilot poppet. During relief operation, oil on the right side of the poppet is drained to return causing pressure in the work port to overcome the poppet spring force. Relief pressure oil flows from the work port to return across the poppet.

As the circuit pressures approach the relief pressure setting, the pin forces the pilot poppet (4) off its seat.

Continued on next page

SJ25320,000030C –19–02FEB07–6/7

9025 05 46

TM10229 (17MAR09)

9025-05-46

544J Loader (S.N. 611800— ) 032409

PN=920

Theory of Operation

2 1 2

1 4

TX1013134

–UN–09OCT06

6 Circuit Relief Valve Anticavitation Operation

1—Low Pressure 2—Return

3—Poppet

4—Return Pressure

If the work port pressure in the circuit drops below return pressure, the anticavitation feature of the circuit relief valve activates. During normal operation, the poppet (3) remains closed against its seat causing the work port (1) to be sealed from the return (2) passage.

5—No Pressure (cavitation)

If cavitation occurs, the oil pressure in the work port and in the spring area of the poppet drops below return pressure. Return pressure oil works against the shoulder of the poppet to force it open against the spring.

SJ25320,000030C –19–02FEB07–7/7

TM10229 (17MAR09)

9025-05-47

544J Loader (S.N. 611800— ) 032409

PN=921

9025 05 47

Theory of Operation

Anticavitation Valve Operation RETURN A

WORKPORT B

POPPET C

NORMAL OPERATION

RETURN A

T121234

A—Return B—Work Port 9025 05 48

G ANTI-CAVITATION VALVE OPERATION C—Poppet D—Pressure Oil

E—Return Oil F—Cavitation Pressure Oil

The boom section of the loader control valve contains an anticavitation valve in boom down and a plug in the boom raise work port. If work port pressure in the circuit drops below return pressure, the anticavitation valve will open and return pressure oil will flow into the work port.

E RETURN OIL F CAVITATION PRESSURE OIL

T121234

ANTI-CAVITATION OPERATION

–19–21APR99

D PRESSURE OIL

G—Anticavitation Valve Operation

If cavitation occurs, the oil pressure in the work port (B) and in the spring area on the backside of the poppet will drop. With work port pressure below return pressure, the return pressure works against the shoulder area of the poppet (C) causing it to open against the spring. Return pressure oil flows into the work port to prevent cylinder cavitation.

During normal operation, the poppet (C) is held against the seat by spring force plus work port pressure acting on the backside of the poppet. With the poppet seated, the work port (B) is sealed from the return passage.

SJ25320,000030B –19–01FEB07–1/1

TM10229 (17MAR09)

9025-05-48

544J Loader (S.N. 611800— ) 032409

PN=922

Theory of Operation

Return Filter Operation INLET CHECK VALVE 2

BYPASS VALVE 3

A OUTLET 5 CHECK VALVE

BYPASS 4 VALVE SPRING

1 MAIN INLET

6 OUTLET

FILTER 7 A COOLER OUTLET 8

SWITCH 9

10 RETURN OIL

1—Main Inlet 2—Inlet Check Valve (Optional) 3—Bypass Valve

SECTION A-A 11 HYDRAULIC FILTER - NORMAL OPERATION 4—Bypass Valve Spring 5—Outlet Check Valve 6—Outlet

7—Filter 8—Cooler Outlet 9—Switch

Continued on next page

TM10229 (17MAR09)

T195407

–19–08OCT03

9025 05 49

9025-05-49

10—Return Oil 11—Hydraulic Filter—Normal Operation

SJ25320,0000308 –19–02FEB07–1/4

544J Loader (S.N. 611800— ) 032409

PN=923

Theory of Operation Normal Return Filter Operation—the hydraulic filter assembly removes contaminants from the hydraulic system return oil (10), produces inlet back-pressure, and regulates outlet back-pressure, which forces flow through the hydraulic oil cooler. The filter housing contains an (optional) inlet check valve (2), a bypass valve (3), a filter restriction switch (9), and an outlet pressure check valve (5). Return oil (10) flows from the loader valve and steering valve return into the main and auxiliary inlet (1). The oil then flows through the inlet check valve (2), the filter element (7), and the auxiliary outlet (8) to the cooler or through the outlet check valve (5), and then through the main outlet (6) to the reservoir. Pressure on the inlet side of the filter assembly is sensed on the left side of the inlet valve (2). The valve opens when the pressure increases

enough to overcome the force of the inlet check valve spring. The oil flows into the filter element (7), then to the outlet pressure check valve (5). The outlet pressure check valve forces flow through the cooler outlet (8) port to the oil cooler. When the restriction in the oil cooler becomes high enough to overcome outlet pressure plus the set spring force of the outlet check valve (5), the outlet valve opens and allows oil to return to the reservoir. Pressure on the inlet side of the filter element is sensed on the left side of the bypass valve (3). Any pressure at the filter outlet due to line restriction is sensed on the right side of the bypass valve (3). Pressure in the outlet passage and plus bypass spring (4) force hold the bypass valve closed unless the oil filter is clogged.

Continued on next page

SJ25320,0000308 –19–02FEB07–2/4

9025 05 50

TM10229 (17MAR09)

9025-05-50

544J Loader (S.N. 611800— ) 032409

PN=924

Theory of Operation

HIGH PRESSURE PASSAGE 5

A BYPASS VALVE 4

BYPASS 6 VALVE SPRING

TO RESERVOIR

1 MAIN INLET

7 OUTLET 2

FILTER 3

8 LOW PRESSURE PASSAGE

COOLER INLET A COOLER OUTLET 9

SWITCH 10 SWITCH SPRING 11 12 SWITCH PISTON

14 RESTRICTED OIL PRESSURE T195408 1—Main Inlet 2—Cooler Inlet 3—Filter 4—Bypass Valve

SECTION A-A

15 HYDRAULIC FILTER - RESTRICTED OPERATION 5—High Pressure Passage 6—Bypass Valve Spring 7—Outlet 8—Low Pressure Passage

Restricted Return Filter Operation—as the filter starts to clog or when the oil is cold, pressure at the inlet side of the filter element increases. When the filter becomes restricted to the point where pressure at the

9—Cooler Outlet 10—Switch 11—Switch Spring 12—Switch Piston

13—Return Oil Pressure 14—Restricted Oil Pressure 15—Hydraulic Filter— Restricted Operation

filter element inlet increases enough to overcome outlet pressure plus a set spring force (6), the bypass valve opens, allowing unfiltered oil to flow to the oil cooler or to the reservoir.

Continued on next page

TM10229 (17MAR09)

5 HIGH PRESSURE PASSAGE 8 LOW PRESSURE PASSAGE

T195408

13 RETURN OIL PRESSURE

–19–08OCT03

9025 05 51

9025-05-51

SJ25320,0000308 –19–02FEB07–3/4

544J Loader (S.N. 611800— ) 032409

PN=925

Theory of Operation The filter restriction indicator switch (10) works on the same principle as the filter bypass valve. High-pressure oil is sensed through the high-pressure passage (1). Restricted oil (14) caused by a clogged filter or cold oil will create higher oil pressure on the inlet side of the filter element. When this inlet pressure overcomes the outlet pressure, sensed by the low-pressure passage (8) plus a set spring (11) force in the switch, the piston (12) moves up (closes), providing a ground for the filter restriction indicator. The switch will cause the filter restriction indicator light to illuminate. The indicator switch is set to close 10 psi

before the bypass valve (4) opens, allowing the operator to perform maintenance on the hydraulic system before the unclean oil passes through the hydraulic oil system. Under normal operation, the restriction indicator light will illuminate when operating the hydraulic functions with cold oil. If the restriction indicator light continues to glow after the oil reaches operating temperature, the return filter is being bypassed. Extended operation in the bypass mode will cause damage to the hydraulic system.

SJ25320,0000308 –19–02FEB07–4/4

9025 05 52

TM10229 (17MAR09)

9025-05-52

544J Loader (S.N. 611800— ) 032409

PN=926

Theory of Operation

T192095B

–UN–18SEP03

Ride Control Operation

1—Not Used 2—Drive, Tail and Marker Switch 3—Automatic Transmission Switch 4—Ride Control Switch 5—Pilot Enable/Boom Down Switch

6—Cab Work Light Switch 7—Beacon Switch 8—Not Used 9—Spin Control Switch 10—Clutch Cut-Off Switch 11—Air Conditioning Switch

12—Pin Disconnect Switch 13—Reversing Cooling Fan Switch 14—Front Washer Switch 15—Front Wiper Switch 16—Not Used

17—Boom Height Kickout Switch 18—Return-to-Carry Switch 19—Rear Washer Switch 20—Rear Wiper Switch

9025 05 53

NOTE: Ride control function (manual, auto) is indicated on Sealed Switch Module (SSM) switch (4).

Continued on next page

TM10229 (17MAR09)

9025-05-53

SJ25320,000030A –19–02FEB07–1/4

544J Loader (S.N. 611800— ) 032409

PN=927

Theory of Operation

1 ROD

2 HEAD

3 5

6 9 8 7 6

ACC 11

ACC TEST 10

13 TRAPPED OIL 14 RETURN OIL 15 HIGH PRESSURE OIL

T145248 1—Rod Port 2—Head Port 3—Ride Control (On/Off) Solenoid (Y18) 4—Low Flow Valve 9025 05 54

5—High Flow Valve 6—Check Valve (2 used) 7—Shuttle Valve 8—Ride Control Boom Solenoid (Y17)

9—Ride Control (On/Off) Solenoid (Y34) 10—Accumulator Test Port 11—Accumulator Port

Engine On, Ride Control In Manual Function—with engine on and ride control in manual function, solenoids (3 and 9) are energized. Pressure spikes from the boom cylinder head end can flow to the accumulator through low flow valve (4) or high flow valve (5). This provides for smooth engagement when ride control is turned on. When accumulator pressure is greater than the boom cylinder head end pressure, check valves (6) are held on their seat by accumulator pressure allowing oil to flow through shuttle valve (7). When boom cylinder

12—Tank Port 13—Trapped Oil 14—Return Oil 15—High Pressure Oil

head end pressure overcomes accumulator pressure, shuttle valve (7) shifts allowing oil to flow to pilot operated low flow valve (4) and high flow valve (5). Valves (4) and (5) open and allow flow to and from accumulator (11). In manual function, the boom cylinder rod end (1) is open to return allowing oil flow in and out of the rod end of the cylinder. The boom cannot be powered down while ride control is on. Ride control can be left engaged during bucket loading, but may be turned off if a more rigid operation is desired.

Continued on next page

TM10229 (17MAR09)

T145248

TANK 12

–UN–25SEP01

9025-05-54

SJ25320,000030A –19–02FEB07–2/4

544J Loader (S.N. 611800— ) 032409

PN=928

Theory of Operation If the bucket dump function is activated while in manual function, ride control will momentarily be shut off. A pressure switch in the bucket dump pilot circuit closes powering boom solenoid (8). When solenoid (8) is energized, oil in the boom cylinder head end can not flow to the accumulator. With bucket in fully dumped position, the bucket cylinder transmits forces through the Z-Bar linkage which can cause the boom cylinders

to partially retract. This is common to wheel loaders with the Z-Bar linkage. With ride control either on or off while dumping the bucket, partial lowering of the boom cylinders is reduced. See Flex Load Controller (FLC) Circuit Theory Of Operation for electrical circuit information. (Group 9015-15.)

Continued on next page

SJ25320,000030A –19–02FEB07–3/4

9025 05 55

TM10229 (17MAR09)

9025-05-55

544J Loader (S.N. 611800— ) 032409

PN=929

Theory of Operation

1 ROD

2 HEAD

3 5

6 9

7 6

ACC 11

ACC TEST 10

13 TRAPPED OIL 14 RETURN OIL 15 HIGH PRESSURE OIL

T145006 1—Rod Port 2—Head Port 3—Ride Control (On/Off) Solenoid (Y18) 4—Low Flow Valve 9025 05 56

5—High Flow Valve 6—Check Valve (2 used) 7—Shuttle Valve 8—Ride Control Boom Solenoid (Y17)

9—Ride Control (On/Off) Solenoid (Y34) 10—Accumulator Test Port 11—Accumulator Port

Engine On, Ride Control Off—with engine on and ride control off, the solenoids (3 and 9) are de-energized and accumulator will charge to highest boom raise pressure. Oil will flow through the low flow valve (4) and high flow valve (5) whenever boom cylinder head end pressure is more than accumulator pressure. Check valves (6) seat blocking oil from

T145006

TANK 12

–UN–14SEP01

12—Tank Port 13—Trapped Oil 14—Return Oil 15—High Pressure Oil

shuttle valve (7) to high flow valve (5). Shuttle valve (7) reads highest pressure differential from accumulator and boom cylinders. See Flex Load Controller (FLC) Circuit Theory Of Operation for electrical circuit information. (Group 9015-15.)

SJ25320,000030A –19–02FEB07–4/4

TM10229 (17MAR09)

9025-05-56

544J Loader (S.N. 611800— ) 032409

PN=930

Group 15

Diagnostic Information

9025 15 1

TM10229 (17MAR09)

9025-15-1

544J Loader (S.N. 611800— ) 032409

PN=931

Diagnostic Information

Hydraulic System Schematic TX1038934 –19–18MAR08

COMPENSATOR 34 VALVE 10 SECONDARY STEERING VALVE

7 HYDRAULIC FAN DRIVE

6 FAN REVERSING VALVE

11 LOAD SENSE PRESSURE TEST PORT

8 HYDRAULIC RETURN FILTER

22 STEERING VALVE

32 INLET SECTION

25 BOOM SECTION 36 M

9 MAIN HYDRAULIC PUMP

26 BUCKET SECTION 35 FAN PUMP

12 HYDRAULIC OIL COOLER

30 RIDE CONTROL VALVE

23 LOADER CONTROL VALVE

AXLE 13 CIRCULATING PUMPS

14 BRAKE ACCUMULATOR

17 AXLE OIL COOLERS

18 PUMP OUTLET PRESSURE TEST PORT

20 PRESSURE REDUCING VALVE

29 RIDE CONTROL ACCUMULATOR

AUX- 27 ILIARY SECTION

31 BOOM DOWN ACCUMULATOR PILOT 19 PRESSURE TEST PORT

33 OUTLET SECTION 15 BRAKE ACCUMULATOR

28 AUXILIARY FUNCTION PILOT CONTROL 39

16 BRAKE VALVE

24 PILOT CONTROL

1 LOW PRESSURE OIL 2 LOAD SENSE OIL 3 PILOT OIL

PIN 21 DISCONNECT VALVE

4 TRAPPED OIL 5 RETURN OIL

TX1038934 Hydraulic Schematic—Neutral OUO1020,00015E9 –19–17MAR08–1/2

TM10229 (17MAR09)

9025-15-2

544J Loader (S.N. 611800— ) 032409

PN=932

Diagnostic Information 1—Low Pressure Oil 2—Load Sense Oil 3—Pilot Oil 4—Trapped Oil 5—Return Oil 6—Fan Reversing Valve 7—Hydraulic Fan Drive 8—Hydraulic Return Filter 9—Main Hydraulic Pump 10—Secondary Steering Valve (optional) 11—Load Sense Pressure Test Port

12—Hydraulic Oil Cooler 13—Axle Circulating Pumps 14—Brake Accumulator 15—Brake Accumulator 16—Brake Valve 17—Axle Oil Coolers (optional) 18—Pump Outlet Pressure Test Port 19—Pilot Pressure Test Port 20—Pressure Reducing Valve 21—Pin Disconnect Valve 22—Steering Valve

23—Loader Control Valve 24—Pilot Control 25—Boom Section 26—Bucket Section 27—Auxiliary Section 28—Auxiliary Function Pilot Control 29—Ride Control Accumulator (optional) 30—Ride Control Valve (optional) 31—Boom Down Accumulator

32—Inlet Section 33—Outlet Section 34—Compensator Valve 35—Fan Pump 36—Secondary Steering Pump (optional) 37—Ride Control Pressure Switch (optional) 38—Brake Light Pressure Switch 39—Brake Pressure Switch

OUO1020,00015E9 –19–17MAR08–2/2

9025 15 3

TM10229 (17MAR09)

9025-15-3

544J Loader (S.N. 611800— ) 032409

PN=933

Diagnostic Information

Hydraulic System Component Location TX1024014 –UN–07JUN07

9 16 22

23 118

117

119 34 10

121

120

TX1024014 Steering and Brake System Component Location WS68074,00011A4 –19–07JUN07–1/6

TM10229 (17MAR09)

9025-15-4

544J Loader (S.N. 611800— ) 032409

PN=934

Diagnostic Information 9—Main Hydraulic Pump 10—Secondary Steering Valve 14—Hydraulic Brake Accumulator 15—Hydraulic Brake Accumulator

16—Brake Valve 22—Steering Valve 23—Loader Control Valve 34—Compensator Valve

117—Steering Valve-to-Front Axle Brake Supply Line 118—Steering Valve-to-Rear Axle Brake Supply Line

Continued on next page

119—Secondary Steering Motor and Pump 120—Steer Cylinder 121—Steer Cylinder

WS68074,00011A4 –19–07JUN07–2/6

9025 15 5

TM10229 (17MAR09)

9025-15-5

544J Loader (S.N. 611800— ) 032409

PN=935

Diagnostic Information TX1024125 –UN–07JUN07

28 113

30 116

103 104 9 21 106 112

102 101 100 115

105

113

114 30

20 31

111 110

105

106 112 29 109

107

108 TX1024125 Loader Control Valve Component Location

Continued on next page

TM10229 (17MAR09)

9025-15-6

WS68074,00011A4 –19–07JUN07–3/6

544J Loader (S.N. 611800— ) 032409

PN=936

Diagnostic Information 8—Hydraulic Oil Filter 9—Hydraulic Pump 20—Pressure Reducing Valve 21—Pin Disconnect Valve 23—Loader Control Valve 24—Main Pilot Control Joystick 28—Auxiliary Pilot Control Lever 29—Ride Control Accumulator 30—Ride Control Valve 31—Boom Down Accumulator

100—Bucket Rollback Hydraulic Hose 101—Bucket Dump Hydraulic Hose 102—Bucket Cylinder 103—Return Hose from Pilot Control Valve-to-Hydraulic Oil Filter 104—Regulated Pressure Supply to Pilot Control Valve

105—Boom Raise Hydraulic Hose 106—Boom Lower Hydraulic Hose 107—Boom Cylinder 108—Pin Disconnect Hydraulic Line 109—Pin Disconnect Hydraulic Line 110—Auxiliary Function Hydraulic Hose 111—Auxiliary Function Hydraulic Hose

Continued on next page

112—Boom Lower Hydraulic Hose 113—Boom Raise Hydraulic Hose 114—Boom Cylinder 115—Ride Control Accumulator Hydraulic Hose 116—Loader Control Valve-to-Hydraulic Filter Return Line

WS68074,00011A4 –19–07JUN07–4/6

9025 15 7

TM10229 (17MAR09)

9025-15-7

544J Loader (S.N. 611800— ) 032409

PN=937

Diagnostic Information TX1024094 –UN–06JUN07

121

7 122

123

35 6

124

8 TX1024094 Fan Drive Component Location

Continued on next page

TM10229 (17MAR09)

9025-15-8

WS68074,00011A4 –19–07JUN07–5/6

544J Loader (S.N. 611800— ) 032409

PN=938

Diagnostic Information 6—Fan Reversing Valve 7—Fan Motor 8—Hydraulic Oil Filter

35—Fan Pump 121—Hydraulic Oil Reservoir 122—Fan Motor Return-to-Filter Hose

123—Reverse Fan Solenoid

124—Fan Proportional Solenoid

WS68074,00011A4 –19–07JUN07–6/6

Hydraulic System Diagnose Malfunctions

OUO1020,0001647 –19–06JUN07–1/1

No Hydraulic Functions Diagnostic Procedure

– – –1/1

1 Hydraulic Enabled Switch Position Check

Check position of hydraulic enable switch.

YES: Move switch to ON position.

Is switch in OFF position? NO: Go to Hydraulic Enable Switch Check. – – –1/1

2 Hydraulic Enable Switch Check

Perform hydraulic control enable circuit check. See Operational Checkout. (Group 9005-10.) Check hydraulic control enable switch and circuit. See System Functional Schematic and Section Legend. (Group 9015-10.) Are switch and circuit working correctly?

YES: Go to Hydraulic System Relief Valve Check. NO: Repair or replace hydraulic enable switch and circuit.

– – –1/1

3 Hydraulic System Relief Valve Check

Check system relief valve. See Loader Control Valve Disassemble and Assemble. (Group 3160.)

YES: Replace system relief valve.

Is system relief valve worn or damaged?

NO: Go to Pilot Pressure Check. – – –1/1

TM10229 (17MAR09)

9025-15-9

544J Loader (S.N. 611800— ) 032409

PN=939

9025 15 9

Diagnostic Information 4 Pilot Pressure Check

Check pressure reducing valve. Perform Pressure Reducing Valve Pressure Test. (Group 9025-25.) Is pilot pressure adjusted to specification?

YES: Check complete. NO: Adjust or replace pressure reducing valve. See Pressure Reducing Valve Manifold Disassemble and Assemble. (Group 3160.)

– – –1/1

Hydraulic Functions Slow Diagnostic Procedure

– – –1/1

1 Hydraulic Oil Temperature Check

Check hydraulic oil temperature.

YES: Go to Engine Speed Check.

Is hydraulic oil at normal operating temperature? NO: Warm up hydraulic oil. Perform Hydraulic Oil Warmup Procedure. (Group 9025-25.)

9025 15 10

– – –1/1

2 Engine Speed Check

Check engine speed.

YES: Go to Pump Suction Line Check.

Is engine speed to specification? NO: Repair engine problem. See PowerTech E 4.5L (4045) John Deere Engine. (Group 9010-15.)

– – –1/1

TM10229 (17MAR09)

9025-15-10

544J Loader (S.N. 611800— ) 032409

PN=940

Diagnostic Information 3 Pump Suction Line Check

Check for foamy hydraulic oil.

YES: Repair pump suction line air leak. See Hydraulic System Component Location. (Group 9025-15.)

Is hydraulic oil foamy?

NO: Go to Hydraulic Oil Level Check.

– – –1/1

4 Hydraulic Oil Level Check

Check hydraulic oil level.

YES: Go to Oil Viscosity Check.

Is hydraulic oil level to specification? NO: Add recommended oil. See Hydraulic Reservoir Oil. (Operator’s Manual.)

– – –1/1

5 Oil Viscosity Check

Check hydraulic reservoir oil. See Hydraulic Reservoir Oil. (Operator’s Manual.)

YES: Go to Hydraulic Line Check.

Is correct oil used? NO: Replace reservoir oil with recommended oil. 9025 15 – – –1/1 11 6 Hydraulic Line Check

Check hydraulic lines. See Hydraulic System Component Location. (Group 9025-15.)

YES: Repair or replace damaged lines.

Are any hydraulic lines blocked or damaged? NO: Go to Relief Valve Pressure Check. – – –1/1

7 Relief Valve Pressure Check

Check relief valve pressure. Perform Loader System Relief and Circuit Relief Valve Pressure Test. (Group 9025-25.)

YES: Go to Pilot Control Pressure Check.

Are relief valves adjusted to specification?

NO: Adjust or replace relief valves. See Loader Control Valve Disassemble and Assemble. (Group 3160.)

– – –1/1

TM10229 (17MAR09)

9025-15-11

544J Loader (S.N. 611800— ) 032409

PN=941

Diagnostic Information 8 Pilot Control Pressure Check

Check pressure reducing valve. Perform Pressure Reducing Valve Pressure Test. (Group 9025-25.)

YES: Go to Pilot Control Valve Check.

Is pressure reducing valve adjusted to specification?

NO: Adjust or replace pressure reducing valve. See Pressure Reducing Valve Manifold Disassemble and Assemble. (Group 3160.)

– – –1/1

9 Pilot Control Valve Check

Check pilot control valves. Perform Pilot Control Valve Pressure Test—Single Lever and perform Pilot Control Valve Pressure Test—Two Lever.

YES: Go to Loader Control Valve Check.

Are pilot control valves adjusted and operating to specification?

NO: Repair or replace pilot control valve. See Pilot Control Valve Disassemble and Assemble. (Group 3160.)

– – –1/1

10 Loader Control Valve Check

Check loader control valve. See Loader Control Valve Disassemble and Assemble. (Group 3160.)

YES: Repair or replace loader control valve.

Is loader control valve worn or damaged?

NO: Go to Pump Regulators Check.

9025 15 12

– – –1/1

11 Pump Regulators Check

Check pump regulators. Perform Pump Load Sense Differential and Standby Pressure Test. (Group 9025-25.)

YES: Go to Secondary Steering Secondary Check Valve Check.

Are pump regulators adjusted to specification? NO: Adjust or repair pump regulators. – – –1/1

12 Secondary Steering Secondary Check Valve Check

Check secondary steering secondary check valve. Perform Secondary Steering Manifold Secondary Check Valve Leakage Test. (Group 9025-25.)

YES: Go to Steering Valve Check.

Is secondary check valve leakage within specification?

NO: Replace secondary steering check valve. – – –1/1

TM10229 (17MAR09)

9025-15-12

544J Loader (S.N. 611800— ) 032409

PN=942

Diagnostic Information 13 Steering Valve Check

Check steering valve leakage. Perform Steering Valve Leakage Test. (Group 9025-25.)

YES: Go to Hydraulic Cylinders Check.

Is steering valve leakage within specification? NO: Repair or replace steering valve. See Steering Valve Remove and Install. (Group 0960.)

– – –1/1

14 Hydraulic Cylinders Check

Check cylinder leakage. Perform Loader Cylinder Drift Test. (Group 9025-25.)

YES: Checks complete.

Is cylinder leakage within specification?

NO: Repair or replace leaking cylinder. See Boom and Bucket Cylinder Repair. (Group 3160.)

– – –1/1

Hydraulic Pump Noisy Diagnostic Procedure

– – –1/1

1 Foamy Hydraulic Oil Check

Check for foamy hydraulic oil.

YES: Repair pump suction line air leak.

Is hydraulic oil foamy? NO: Go to Pump Suction Line Check. – – –1/1

2 Pump Suction Line Check

Check pump suction line. See Hydraulic System Component Location. (Group 9025-15.) Is pump suction line plugged or pinched?

YES: Repair or replace suction line. See Hydraulic Pump Remove and Install. (Group 3160.) NO: Go to Hydraulic Oil Level Check.

– – –1/1

TM10229 (17MAR09)

9025-15-13

544J Loader (S.N. 611800— ) 032409

PN=943

9025 15 13

Diagnostic Information 3 Hydraulic Oil Level Check

Check hydraulic oil level.

YES: Go to Oil Viscosity Check.

Is hydraulic oil level to specification? NO: Add recommended oil. See Hydraulic Reservoir Oil. (Operator’s Manual.)

– – –1/1

Oil Viscosity Check

Check hydraulic reservoir oil.

YES: Go to Hydraulic Line Check.

Is correct oil used? NO: Replace reservoir oil with recommended oil. See Hydraulic Reservoir Oil. (Operator’s Manual.)

– – –1/1

5 Hydraulic Line Check

Check hydraulic lines. See Hydraulic System Component Location. (Group 9025-15.)

YES: Repair or replace damaged lines.

Are any hydraulic lines blocked or damaged? NO: Go to Hydraulic Line Clamps Check.

9025 15 14

– – –1/1

6 Hydraulic Line Clamps Check

Check hydraulic line clamps.

YES: Tighten or replace clamps as necessary.

Are any line clamps loose or missing? NO: Go to Hydraulic Line Installation Check. – – –1/1

7 Hydraulic Line Installation Check

Check hydraulic lines.

YES: Go to Hydraulic Pump Check.

Are hydraulic lines in contact with frame? NO: Install hydraulic lines properly. – – –1/1

TM10229 (17MAR09)

9025-15-14

544J Loader (S.N. 611800— ) 032409

PN=944

Diagnostic Information 8 Hydraulic Pump Check

Check pump flow. Perform Hydraulic Pump Flow Test. (Group 9025-25.)

YES: Checks complete.

Is pump flow to specification?

NO: Repair or replace hydraulic pump. See Hydraulic Pump Disassemble and Assemble. (Group 3160.)

– – –1/1

No Steering Functions Diagnostic Procedure

– – –1/1

1 Frame Locking Bar Check

Check frame locking bar.

YES: Install frame locking bar in storage position.

Is frame locking bar in locked position? NO: Go to No Load Sense Signal Check. – – –1/1

2 No Load Sense Signal Check (Secondary Steering Only)

Check diagnostic trouble codes. See Diagnostic Trouble Codes Quick Reference List. (Group 9015-20.)

YES: Correct problem causing diagnostic trouble code.

Are diagnostic trouble codes displayed? NO: Go to Hydraulic Oil Level Check. – – –1/1

3 Hydraulic Oil Level Check

Check hydraulic oil level.

YES: Go to Steering Line Check.

Is hydraulic oil level to specification? NO: Add recommended oil. See Hydraulic Reservoir Oil. (Operator’s Manual.)

– – –1/1

4 Steering Line Check

Check steering lines. See Hydraulic System Component Location. (Group 9025-15.)

YES: Repair or replace damaged lines.

Are any hydraulic lines pinched or damaged? NO: Go to Steering Valve Check. – – –1/1

TM10229 (17MAR09)

9025-15-15

544J Loader (S.N. 611800— ) 032409

PN=945

9025 15 15

Diagnostic Information 5 Steering Valve Check

Check steering valve leakage. Perform Steering Valve Leakage Test.

YES: Go to Hydraulic Pump Check.

Is steering valve leakage within specification? NO: Repair or replace steering valve. See Steering Valve Remove and Install. (Group 0960.)

– – –1/1

6 Hydraulic Pump Check

Check return filter for metal particles. Perform Hydraulic Oil Filter Inspection Procedure. (Group 9025-25.)

YES: Perform Hydraulic Pump Flow Test. (Group 9020-25.)

Are any metal particles in filter? NO: Go to Pump Drive Check. – – –1/1

7 Pump Drive Check

Check pump drive. See Hydraulic Pump Remove and Install. (Group 3160.)

YES: Repair or replace pump drive.

Is pump drive worn or damaged? NO: Checks complete.

– – –1/1

Boom Float Function Not Working Diagnostic Procedure

9025 15 16

– – –1/1

1 Return-to-Carry Switch Check

Check position of return-to-carry switch.

YES: Move switch to OFF position.

Is switch in ON position? NO: Go to Pilot Control Pressure Check. – – –1/1

2 Pilot Control Pressure Check

Check pressure reducing valve. Perform Pressure Reducing Valve Pressure Test. (Group 9025-25.)

YES: Go to Pilot Controller Detent Check.

Is pressure reducing valve adjusted to specification?

NO: Adjust or replace pressure reducing valve. See Pressure Reducing Valve Manifold Disassemble and Assemble. (Group 3160.)

– – –1/1

TM10229 (17MAR09)

9025-15-16

544J Loader (S.N. 611800— ) 032409

PN=946

Diagnostic Information 3 Pilot Controller Detent Check

Check pilot controller. See Flex Load Controller (FLC) Circuit Theory of Operation. (Group 9015-15.)

YES: Go to Pilot Control Valve Check.

Is flex load controller adjusted to specification?

NO: Repair or replace FLC. – – –1/1

4 Pilot Control Valve Check

Check pilot control valve. Perform Pilot Control Valve Pressure Test—Single Lever or perform Pilot Control Valve Pressure Test—Two Lever. (Group 9025-25.)

YES: Go to Loader Control Valve Check.

Is pilot control valve to specification?

NO: Repair or replace pilot control valve. – – –1/1

5 Loader Control Valve Check

Check loader control valve. See Loader Control Valve Disassemble and Assemble. (Group 3160.)

YES: Repair or replace loader control valve.

Is loader control valve worn or damaged?

NO: Checks complete.

– – –1/1

One Hydraulic Function Not Working Diagnostic Procedure

– – –1/1

1 Pilot Control Valve Check

Check pilot control valve. Perform Pilot Control Valve Pressure Test—Single Lever or perform Pilot Control Valve Pressure Test—Two Lever. (Group 9025-25.)

YES: Go to Circuit Relief Valve Check.

Is pilot control valve to specification?

NO: Repair or replace pilot control valve. – – –1/1

2 Circuit Relief Valve Check

Check circuit relief valve. See Circuit Relief Valve Disassemble and Assemble. (Group 3160.)

YES: Repair or replace circuit relief valve.

Is circuit relief valve stuck open?

NO: Go to Anticavitation Valve Check. – – –1/1

3 Anticavitation Valve Check

Check anticavitation valve. See Boom Anticavitation Valve Disassemble and Assemble. (Group 3160.)

YES: Repair or replace anticavitation valve.

Is anticavitation valve stuck open?

NO: Go to Hydraulic Cylinder Check. – – –1/1

TM10229 (17MAR09)

9025-15-17

544J Loader (S.N. 611800— ) 032409

PN=947

9025 15 17

Diagnostic Information 4 Hydraulic Cylinder Check

Check cylinder leakage. Perform Loader Cylinder Drift Test. (Group 9025-25.)

YES: Go to Hydraulic Line Check.

Is cylinder leakage within specification? NO: Repair or replace leaking cylinder. See Boom and Bucket Cylinder Repair. (Group 3160.)

– – –1/1

5 Hydraulic Line Check

Check hydraulic lines. See Hydraulic System Component Location. (Group 9025-15.)

YES: Repair or replace damaged lines.

Are any hydraulic lines blocked or damaged? NO: Go to Loader Control Valve Check. – – –1/1

6 Loader Control Valve Check

Check loader control valve. See Loader Control Valve Disassemble and Assemble. (Group 3160.)

YES: Repair or replace loader control valve.

Is loader control valve worn or damaged?

NO: Checks complete.

– – –1/1

Hydraulic Function Drifts Down Diagnostic Procedure

9025 15 18

– – –1/1

1 Hydraulic Cylinder Check

Check cylinder leakage. Perform Loader Cylinder Drift Test. (Group 9025-25.)

YES: Go to Circuit Relief Valve Check.

Is cylinder leakage within specification? NO: Repair or replace leaking cylinder. See Boom and Bucket Cylinder Repair. (Group 3160.)

– – –1/1

2 Circuit Relief Valve Check

Check circuit relief valve. See Circuit Relief Valve Disassemble and Assemble. (Group 3160.)

YES: Repair or replace circuit relief valve.

Is circuit relief valve stuck open?

NO: Go to Anticavitation Valve Check. – – –1/1

TM10229 (17MAR09)

9025-15-18

544J Loader (S.N. 611800— ) 032409

PN=948

Diagnostic Information 3 Anticavitation Valve Check

Check anticavitation valve. See Boom Anticavitation Valve Disassemble and Assemble. (Group 3160.)

YES: Repair or replace anticavitation valve.

Is anticavitation valve stuck open?

NO: Go to Ride Control Circuit Check. – – –1/1

4 Ride Control Circuit Check

Check ride control circuit. Perform ride control check. See Operational Checkout. (Group 9005-10.)

YES: Repair ride control circuit.

Is ride control circuit leaking?

NO: Go to Boom Down Accumulator Solenoid Check. – – –1/1

5 Boom Down Accumulator Solenoid Check

Check boom down accumulator solenoid. See Electrical Component Specifications. (Group 9015-20.)

YES: Go to Loader Control Valve Check.

Is boom down accumulator solenoid to specification?

NO: Repair or replace solenoid. – – –1/1

6 Loader Control Valve Check

Check loader control valve for wear or damage. See Loader Control Valve Disassemble and Assemble. (Group 3160.)

YES: Replace loader control valve.

Is loader control valve worn or damaged?

NO: Checks complete.

– – –1/1

Boom Down Does Not Work (Engine Off) Diagnostic Procedure

– – –1/1

1 Pilot Enable/Boom Down Switch Check

Check pilot enable/boom down switch. See Switch Pad. (Operator’s Manual.)

YES: Push and hold switch in ON position.

Is switch in OFF position? NO: Go to Boom Down Accumulator Solenoid Check. – – –1/1

2 Boom Down Accumulator Solenoid Check

Check solenoid resistance. See Electrical Component Specifications. (Group 9015-20.)

YES: Go to Pilot Enable Solenoid Check.

Is solenoid within specifications? NO: Repair or replace solenoid. – – –1/1

3 Pilot Enable Solenoid Check

Check solenoid resistance. See Electrical Component Specifications. (Group 9015-20.) Is solenoid within specifications?

YES: Go to Boom Down Accumulator Precharge Check. NO: Repair or replace solenoid. – – –1/1

TM10229 (17MAR09)

9025-15-19

544J Loader (S.N. 611800— ) 032409

PN=949

9025 15 19

Diagnostic Information 4 Boom Down Accumulator Precharge Check

Check boom down accumulator precharge. Perform Boom Down Accumulator Precharge Test.

YES: Checks complete. NO: Replace accumulator. (not serviceable)

Is accumulator precharge to specification?

– – –1/1

Oil Overheats Diagnostic Procedure

– – –1/1

1 Hydraulic Oil Level Check

Check oil level. See Check Hydraulic Oil Level. (Operator’s Manual.)

YES: Go to Hydraulic Oil Check.

Is oil level to specification? NO: Fill hydraulic reservoir to proper level. – – –1/1

2 Hydraulic Oil Check

Check hydraulic oil. See Hydraulic Reservoir Oil. (Operator’s Manual.)

YES: Go to Cooler Bypass Check.

Is hydraulic oil type and viscosity to specification? NO: Drain reservoir and replace with correct oil. – – –1/1

3 Cooler Bypass Check

Check cooler bypass.

YES: Replace cooler bypass.

Is bypass worn or damaged? NO: Go to Cooler Fins Check.

9025 15 20

– – –1/1

4 Cooler Fins Check

Check cooler fins.

YES: Go to System Relief Valve Check.

Are cooler fins clean and straight? NO: Clean and straighten cooler fins. – – –1/1

5 System Relief Valve Check

Check system relief valve. See Loader Control Valve Disassemble and Assemble. (Group 3160.)

YES: Replace system relief valve.

Is system relief valve worn or damaged?

NO: Go to Circuit Relief Valve Check. – – –1/1

6 Circuit Relief Valve Check

Check circuit relief valve. See Loader Control Valve Disassemble and Assemble. (Group 3160.)

YES: Replace circuit relief valve.

Is circuit relief valve worn or damaged?

NO: Go to Hydraulic Line Check. – – –1/1

TM10229 (17MAR09)

9025-15-20

544J Loader (S.N. 611800— ) 032409

PN=950

Diagnostic Information 7 Hydraulic Line Check

Check hydraulic lines. See Hydraulic System Component Location. (Group 9025-15.)

YES: Repair or replace damaged lines.

Are any hydraulic lines blocked or damaged? NO: Go to Hydraulic Pump Check. – – –1/1

8 Hydraulic Pump Check

Check return filter for metal particles. Perform Hydraulic Oil Filter Inspection Procedure. (Group 9025-25.)

YES: Perform Hydraulic Pump Flow Test. (Group 9020-25.)

Are any metal particles in filter? NO: Go to Pump Drive Check. – – –1/1

9 Pump Drive Check

Check pump drive. See Hydraulic Pump Remove and Install. (Group 3160.)

YES: Repair or replace pump drive.

Is pump drive worn or damaged? NO: Checks complete.

– – –1/1

Hydraulic Oil Foams Diagnostic Procedure

– – –1/1

1 Pump Suction Line Check

Check for foamy hydraulic oil.

YES: Repair pump suction line air leak. See Hydraulic System Component Location. (Group 9025-15.)

Is hydraulic oil foamy?

NO: Go to Hydraulic Oil Level Check.

– – –1/1

2 Hydraulic Oil Level Check

Check hydraulic oil level.

YES: Go to Oil Viscosity Check.

Is hydraulic oil level to specification? NO: Add recommended oil. See Hydraulic Reservoir Oil. (Operator’s Manual.)

– – –1/1

TM10229 (17MAR09)

9025-15-21

544J Loader (S.N. 611800— ) 032409

PN=951

9025 15 21

Diagnostic Information 3 Oil Viscosity Check

Check hydraulic reservoir oil. See Hydraulic Reservoir Oil. (Operator’s Manual.)

YES: Checks complete.

Is correct oil used?

NO: Replace reservoir oil with recommended oil.

– – –1/1

Pin Disconnect Cylinders Will Not Retract Diagnostic Procedure

– – –1/1

1 Electrical Circuit Check

Check pin disconnect electrical circuit. See Flex Load Controller (FLC) Circuit Theory of Operation. (Group 9015-15.) Is electrical circuit malfunctioning?

YES: Repair or replace component. See System Functional Schematic and Section Legend. (Group 9015-10.) NO: Go to Pin Disconnect Pressure Check.

– – –1/1

2 Pin Disconnect Pressure Check

Check pin disconnect pressure. Perform Pin Disconnect Pressure Test. (Group 9025-25.)

YES: Go to Pin Disconnect Cylinder Check.

Is pin disconnect pressure to specification? NO: Adjust pin disconnect pressure reducing valve to specification.

9025 15 22

– – –1/1

3 Pin Disconnect Cylinder Check

Check pin disconnect cylinder for wear or damage.

YES: Repair or replace pin disconnect cylinder.

Is cylinder worn or damaged? NO: Checks complete.

– – –1/1

Constant Steering Required to Maintain Straight Travel Diagnostic Procedure

– – –1/1

TM10229 (17MAR09)

9025-15-22

544J Loader (S.N. 611800— ) 032409

PN=952

Diagnostic Information 1 Hydraulic Oil Check

Check for foamy hydraulic oil.

YES: Repair pump suction line air leaks. See Hydraulic System Component Location. (Group 9025-15.)

Is hydraulic oil foamy?

NO: Go to Steering Valve Check.

– – –1/1

2 Steering Valve Check

Check steering valve for leakage. Perform Steering Valve Leakage Test. (Group 9025-25.)

YES: Go to Steering Cylinder Check.

Is steering valve leakage within specification?

NO: Replace steering valve. (not serviceable) – – –1/1

3 Steering Cylinder Check

Check steering cylinder for leakage. Perform Boom, Bucket, and Steering Cylinder Leakage Test. (Group 9025-25.)

YES: Go to Steering Cylinder Pin and Bore Check.

Is steering cylinder leakage within specification? NO: Repair or replace steering cylinder. See Steering Cylinders Remove and Install. (Group 0960.)

– – –1/1

4 Steering Cylinder Pin and Bore Check

Check steering cylinder pin and bore.

YES: Repair or replace steering cylinder pin or bore.

Is cylinder pin or bore worn or damaged?

NO: Check complete. – – –1/1

Slow Steering Wheel Movement Will Not Cause Frame Movement Diagnostic Procedure

– – –1/1

1 Steering Valve Check

Check steering valve for leakage. Perform Steering Valve Leakage Test. (Group 9025-25.)

YES: Go to Steering Cylinder Check.

Is steering valve leakage within specification?

NO: Replace steering valve. (not serviceable) – – –1/1

TM10229 (17MAR09)

9025-15-23

544J Loader (S.N. 611800— ) 032409

PN=953

9025 15 23

Diagnostic Information 2 Steering Cylinder Check

Check steering cylinder for leakage. Perform Boom, Bucket, and Steering Cylinder Leakage Test. (Group 9025-25.)

YES: Checks complete. NO: Repair or replace steering cylinder. See Steering Cylinders Remove and Install. (Group 0960.)

Is steering cylinder leakage within specification?

– – –1/1

Steering Wheel Turns without Resistance and Causes No Frame Movement Diagnostic Procedure

– – –1/1

1 Steering Column and Splined Coupling Check

Check steering column and coupling. See Steering Column Remove and Install. (Group 0960.)

YES: Replace steering column or coupling as needed.

Is steering column or coupling damaged or broken? NO: Go to Steering Valve Check. – – –1/1

2 Steering Valve Check

Check steering valve for leakage. Perform Steering Valve Leakage Test. (Group 9025-25.)

YES: Go to Steering Cylinder Check.

Is steering valve leakage within specification?

NO: Replace steering valve. (not serviceable)

9025 15 24

– – –1/1

3 Steering Cylinder Check

Check steering cylinder for leakage. Perform Boom, Bucket, and Steering Cylinder Leakage Test. (Group 9025-25.)

YES: Go to Secondary Steering Manifold Primary Check Valve Check.

Is steering cylinder leakage within specification? NO: Repair or replace steering cylinder. See Steering Cylinders Remove and Install. (Group 0960.)

– – –1/1

4 Secondary Steering Manifold Primary Check Valve Check

Check manifold primary check valve for leakage. Perform Secondary Steering Manifold Primary Check Valve Leakage Test. (Group 9025-25.)

YES: Checks complete. NO: Replace steering manifold.

Is leakage within specification?

– – –1/1

TM10229 (17MAR09)

9025-15-24

544J Loader (S.N. 611800— ) 032409

PN=954

Diagnostic Information Steering Erratic Diagnostic Procedure

– – –1/1

1 Hydraulic Oil Check

Check for foamy hydraulic oil.

YES: Repair pump suction line air leaks. See Hydraulic System Component Location. (Group 9025-15.)

Is hydraulic oil foamy?

NO: Go to Hydraulic Oil Level Check.

– – –1/1

2 Hydraulic Oil Level Check

Check hydraulic oil level.

YES: Go to Steering Cylinder Piston Check.

Is hydraulic oil level to specification? NO: Add recommended oil. See Hydraulic Reservoir Oil. (Operator’s Manual.)

– – –1/1

3 Steering Cylinder Piston Check

Check steering cylinder. See Steering Cylinder Remove and Install. (Group 0960.)

YES: Repair or replace steering cylinder.

Is steering cylinder worn or damaged? NO: Go to Steering Valve Check. – – –1/1

4 Steering Valve Check

Check steering valve. See Steering Valve Remove and Install. (Group 0960.)

YES: Replace steering valve. (not serviceable)

Is steering valve worn or damaged? NO: Check complete.

– – –1/1

Steering Wheel Free Play Diagnostic Procedure

– – –1/1

TM10229 (17MAR09)

9025-15-25

544J Loader (S.N. 611800— ) 032409

PN=955

9025 15 25

Diagnostic Information 1 Steering Wheel Nut Check

Check steering wheel nut. See Steering Column Remove and Install. (Group 0960.) Is steering wheel nut tightened to specification?

YES: Go to Steering Column and Steering Valve Splines Check. NO: Tighten nut to specification. – – –1/1

2 Steering Column and Steering Valve Splines Check

Check steering column and steering valve splines. See Steering Valve Remove and Install. (Group 0960.)

YES: Replace steering valve or steering column as needed.

Are splines worn or damaged? NO: Check complete. – – –1/1

Steering Valve Binds or Locks Up Diagnostic Procedure

– – –1/1

1 Steering Column Check

Check steering column and steering valve spline. See Steering Column Remove and Install. (Group 0960.)

YES: Replace steering valve or steering column as needed.

Are splines worn or damaged? NO: Go to Steering Valve Return Pressure Check. – – –1/1

2 Steering Valve Return Pressure Check

Check for pinched or damaged steering valve return line. See Hydraulic System Component Location. (Group 9025-25.)

YES: Replace steering valve return line.

Is steering return line pinched or damaged?

NO: Go to Hydraulic Filter Contamination Check.

9025 15 26

– – –1/1

3 Hydraulic Filter Contamination Check

Check hydraulic filter for contamination. See Hydraulic Oil Filter Inspection Procedure. (Group 9025-25.) Is steering valve contaminated?

YES: Perform Hydraulic Oil Cleanup Procedure Using Portable Filter Caddy. (Group 3160.) NO: Go to Steering Valve Check.

– – –1/1

4 Steering Valve Check

Check steering valve. See Steering Valve Remove and Install. (Group 0960.)

YES: Replace steering valve.

Is steering valve worn or damaged? NO: Checks complete.

– – –1/1

TM10229 (17MAR09)

9025-15-26

544J Loader (S.N. 611800— ) 032409

PN=956

Diagnostic Information Steering Wheel Turns by Itself Diagnostic Procedure

– – –1/1

1 Steering Line Check

Check steering line locations. See Hydraulic System Component Location. (Group 9025-15.)

YES: Connect steering lines to correct ports.

Are steering lines connected to wrong ports?

NO: Go to Steering Valve Check. – – –1/1

2 Steering Valve Check

Check steering valve for leakage. Perform Steering Valve Leakage Test. (Group 9025-25.)

YES: Check complete. NO: Replace steering valve. (not serviceable)

Is steering valve leakage within specification?

– – –1/1

Machine Turns in Opposite Direction as Steering Wheel Diagnostic Procedure

– – –1/1

1 Steering Line Check

Check steering line locations. See Hydraulic System Component Location. (Group 9025-15.)

YES: Connect steering lines to correct ports.

Are steering lines connected to wrong ports?

NO: Check complete.

– – –1/1

Steering Wheel Kickback Diagnostic Procedure

– – –1/1

1 Secondary Steering Manifold Check Valve Check

NOTE: Steering wheel kickback is normal on machines without secondary steering when both steering and a loader function are held in relief at the same time, and then the loader lever is released.

YES: Check complete. NO: Replace secondary check valve.

Check secondary steering manifold check valve. Perform Secondary Steering Manifold Secondary Check Valve Leakage Test. (Group 9025-25.) Is leakage within specification?

– – –1/1

TM10229 (17MAR09)

9025-15-27

544J Loader (S.N. 611800— ) 032409

PN=957

9025 15 27

Diagnostic Information Steering Jerky Diagnostic Procedure

– – –1/1

1 Pump Load Sense Differential Pressure Check

Check load sense differential pressure. Perform Pump Load Sense Differential and Standby Pressure Test. (Group 9025-25.)

YES: Go to Steering Valve Contamination Check.

Are pump load sense and differential pressures adjusted to specification? NO: Adjust pump pressures to specification. – – –1/1

2 Steering Valve Contamination Check

Check hydraulic oil filter for contamination. See Hydraulic Oil Filter Inspection Procedure. (Group 9025-25.)

YES: Perform Hydraulic Oil Cleanup Procedure Using Portable Filter Caddy. (Group 3160.)

Is steering valve contaminated?

NO: Check complete. – – –1/1

Secondary Steering Motor Will Not Operate Diagnostic Procedure

– – –1/1

1 Electrical Check

Check secondary steering circuit. See Flex Load Controller (FLC) Circuit Theory of Operation. (Group 9015-15.)

YES: Repair or replace FLC circuit components.

Is FLC circuit malfunctioning?

NO: Go to Secondary Steering Pump Check.

9025 15 28

– – –1/1

2 Secondary Steering Pump Check

Check secondary steering pump.

YES: Check complete.

Does secondary steering pump spin freely?

NO: Replace secondary steering pump.

– – –1/1

Secondary Steering Pump Runs but Will Not Steer Machine Diagnostic Procedure

– – –1/1

1 Secondary Steering Manifold Primary Check Valve Check

Check secondary steering primary check valve. See Secondary Steering Manifold Primary Check Valve Leakage Test. (Group 9025-25.) Is primary check valve leakage within specification?

YES: Check complete. NO: Replace secondary steering manifold and primary check valve. – – –1/1

TM10229 (17MAR09)

9025-15-28

544J Loader (S.N. 611800— ) 032409

PN=958

Group 20

Adjustments Hydraulic Oil Clean-Up Procedure Using Portable Filter Caddy A hydraulic oil cleanup procedure must be done prior to starting machine after a component has been repaired or replaced. The use of attachments increases the need to monitor and filter oil. See

General Oil Cleanup Procedure See General Oil Cleanup Procedure or see Hydraulic Component Failure Cleanup Procedure see Hydraulic Component Failure Cleanup Procedure. (CTM 310.)

SJ25320,0000221 –19–15NOV06–1/1

Return-to-Dig Adjustment To adjust return-to-dig setting, see Return-To-Dig Adjustment—Z-Bar Linkage or see Return-To-Dig Adjustment—Powerllel Linkage. (Group 9015-20.)

AA95137,0000780 –19–02FEB07–1/1

Return-to-Carry and Boom Height Kickout Adjustment To adjust return-to-carry or boom height kickout setting, see Boom Height Kickout/Return-to-Carry Adjustment. (Group 9015-20.)

9025 20 1

AA95137,0000781 –19–02FEB07–1/1

Pump Load Sense Differential and Standby Pressure Adjustment To adjust pump load sense differential or standby pressure, see Pump Load Sense Differential and Standby Pressure Test. (Group 9025-25.)

DW09104,000009F –19–28FEB06–1/1

TM10229 (17MAR09)

9025-20-1

544J Loader (S.N. 611800— ) 032409

PN=959

Adjustments

Pilot Controller Adjustment—Two Lever Pilot 1. Turn engine off. 2. Slide boot up and over pilot control lever.

LS10960,0000026 –19–02OCT03–1/2

3. Turn adjustment screw (2) up to lock nut (1). 4. Turn out adjustment screw equal number of turns until contact is made with push pin (3). –UN–04SEP02

NOTE: Hydraulic functions will be limited if both pilot control levers are not vertical after adjustment.

T159121B

5. Check adjustment. Lever must be vertical with no loose movement. 6. When adjustment is complete, slide boot down over pilot control levers. 1—Lock Nut (4 used) 2—Adjustment Screw (4 used) 3—Push Pin (4 used)

9025 20 2

LS10960,0000026 –19–02OCT03–2/2

TM10229 (17MAR09)

9025-20-2

544J Loader (S.N. 611800— ) 032409

PN=960

Adjustments

Ride Control Accumulator Hydraulic Discharge Procedure SPECIFICATIONS Ride Control Hydraulic Pressure

0 kPa 0 bar 0 psi

SERVICE EQUIPMENT AND TOOLS JT02156A Digital Pressure and Temperature Analyzer

This test will ensure that no hydraulic pressure remains in ride control accumulator prior to charging ride control accumulator or removing hydraulic loader components. 1. Install frame articulation lock bar. CAUTION: Prevent possible crushing injury from falling boom. Always support boom with boom lock before working on or around this machine with the boom raised. Empty bucket and place in dump position before installing boom lock. IMPORTANT: If the machine is equipped with the optional pin disconnect feature, disconnect the attachment before installing boom lock. 2. Dump bucket and raise boom to install boom lock. See Boom Lock. (Operator’s Manual.)

9025 20 3

3. Turn key to the OFF position. IMPORTANT: Ride control accumulator hydraulic pressure can not be discharged if ride control switch is in automatic position, with two lights on switch illuminated. When the ride control switch is in manual position, left light on ride control switch will be illuminated. 4. Turn key switch to ON position, do not start engine.

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PN=961

Adjustments 5. Press return-to-carry switch (1) to OFF position, if equipped.

–UN–18SEP03

CAUTION: Prevent possible injury from moving components. Make sure area around boom and bucket is clear. Boom may move upward when ride control is turned on.

T192464A

6. Cycle ride control switch (2) to off then to on (manual mode), left light illuminated. 7. Press and hold pilot enable/boom down switch (3) and lower boom to engage boom lock.

Switches 1—Return-to-Carry Switch 2—Ride Control Switch 3—Pilot Enable/Boom Down Switch

8. Press and hold pilot enable/boom down switch and engage boom float for 5 seconds. 9. Press and hold pilot enable/boom down switch, then move all other hydraulic control levers to relieve hydraulic pressure.

Continued on next page

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TM10229 (17MAR09)

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544J Loader (S.N. 611800— ) 032409

PN=962

Adjustments NOTE: If service work is not planned, the test gauge can be installed though the rear of loader frame without removing loader frame valve cover.

11. Install JT02156A Digital Pressure Analyzer with 5000 psi pressure transducers to ride control quick coupler (2). Perform Digital Pressure and Temperature Analyzer Installation procedure. (Group 9025-25.)

T164577B

CAUTION: Prevent possible injury from high pressure fluid. Discharge accumulator before servicing any ride control components. Hydraulic oil in accumulator can be stored at pressures equal to or above system relief pressures.

–UN–27JAN03

10. Remove loader frame valve cover.

Ride Control Valve 1—Ride Control Valve 2—Quick Coupler

If quick coupler can not be installed: 1. Repeat discharge procedure. 2. If quick coupler still can not be installed, ride control is malfunctioning and must be repaired. Check for DTCs, see Diagnostic Trouble Codes (DTC) Quick Reference List—Flex Load Controller (FLC). (Group 9015-15.) 12. Verify that ride control pressure is at specifications. Specification Ride Control Hydraulic—Pressure .................................................... 0 kPa 0 bar 0 psi

9025 20 5

13. Turn key off.

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544J Loader (S.N. 611800— ) 032409

PN=963

Adjustments

Ride Control Accumulator Charge Procedure SPECIFICATIONS Charge Ride Control Accumulator Charge Pressure

IMPORTANT: If the machine is equipped with the optional pin disconnect feature, disconnect the attachment before installing boom lock.

1938—2206 kPa 19—21 bar 280—320 psi

SERVICE EQUIPMENT AND TOOLS

3. Dump bucket and raise boom to install boom lock. See Boom Lock. (Operator’s Manual.)

JT01735 Gas Cock

1. If machine is operational use the following procedure to charge the accumulator.

4. Turn key OFF.

If accumulator has already been removed from the machine, start procedure at step 13. 2. Install frame articulation lock bar. CAUTION: Prevent possible crushing injury from falling boom. Always support boom with boom lock before working on or around this machine with the boom raised.

5. Press return-to-carry switch (1) to off position, if equipped. NOTE: Ride control accumulator hydraulic pressure can not be discharged if ride control switch is in automatic position, with two lights on switch illuminated. When the ride control switch is in manual position, left light on ride control switch will be illuminated. 6. Turn key switch to on position, do not start engine.

Empty bucket and place in dump position before installing boom lock.

9025 20 6

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Adjustments

–UN–18SEP03

CAUTION: Prevent possible injury from moving components. Make sure area around boom and bucket is clear. Boom may move upward when ride control is turned on. 7. Cycle ride control switch (2) to off then to on (manual mode), left light illuminated.

T192464A

8. Press and hold pilot enable/boom down switch (3) and lower boom to engage boom lock. IMPORTANT: All hydraulic pressure must be relieved from accumulator so piston can travel to bottom of accumulator before attempting to charge accumulator. Piston will make a clunking sound when it hits bottom of accumulator during discharging of ride control circuit.

Switches 1—Return-to-Carry Switch 2—Ride Control Switch 3—Pilot Enable/Boom Down Switch

9. Press and hold pilot enable/boom down switch and engage boom float for 5 seconds. 10. Press and hold pilot enable/boom down switch, then move all other hydraulic control levers to relieve hydraulic pressure. 11. Turn key OFF. 12. Remove loader frame valve cover.

9025 20 7

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PN=965

Adjustments

14. Turn handle on gas cock (1) fully counterclockwise. Attach regulator hose with gas cock to accumulator charging valve (2) and tighten fitting.

TX1008871

IMPORTANT: Charge accumulator using only dry nitrogen. Dry nitrogen does not mix with oil and is non-combustible. It will not cause oxidation or condensation inside accumulator and is not harmful to piston seal. Do not use air or any combustible gas as these can cause oxidation and condensation. Oxidation and condensation are harmful to piston seal and accumulator.

–UN–12JUN06

13. Remove cap from charging valve on top of accumulator.

Ride Control Accumulator 1—Gas Cock 2—Charging Valve

CAUTION: Prevent possible injury from pressurized gas, loose fitting under pressure can cause injury. Do not remove charging valve if accumulator is charged. 15. Turn gas cock handle in, clockwise, to open accumulator charging valve. 16. Back off regulator valve and open the valve handle on the nitrogen tank. 17. Slowly turn in regulator valve to pressurize accumulator to specifications. 9025 20 8

Specification Charge Ride Control Accumulator—Charge Pressure ...................................... 1938—2206 kPa 19—21 bar 280—320 psi

18. Turn handle on gas cock fully counterclockwise. 19. Close the valve handle on the nitrogen tank. 20. Slowly loosen the gas cock from charging valve to release pressure from hose. 21. Remove gas cock from accumulator. Install cap.

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TM10229 (17MAR09)

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544J Loader (S.N. 611800— ) 032409

PN=966

Adjustments

Auxiliary Valve Section—Stroke Adjustment

T121154

–UN–13APR99

NOTE: The auxiliary sections (3rd and 4th) of the loader control valve are equipped with spool stroke adjusters in each end cap. The adjusters allow the maximum auxiliary section flow to be set anywhere from a few gallons per minute (gpm) to full pump flow. This is done by limiting spool travel in the valve section and in turn limiting flow. They are set at full flow at the factory. 1. Install frame articulation lock bar. 2. Install boom lock. 3. Release hydraulic oil pressure from system. See Ride Control Accumulator Hydraulic Discharge Procedure . (Group 9025-20.)

A—End Cap B—Cartridge C—Hex Nut D—Set Screw E—Cap Screw F—Auxiliary Valve Section

4. Install flow meter in implement circuit to be tested to check flow. 5. Loosen hex nut (C) and adjust set screw (D) in the end cap of the auxiliary valve section of main control valve. Adjust flow to specification for implement desired.

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544J Loader (S.N. 611800— ) 032409

PN=967

9025 20 9

Adjustments

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TM10229 (17MAR09)

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544J Loader (S.N. 611800— ) 032409

PN=968

Group 25

Test Hydraulic Oil Warmup Procedure NOTE: The Service ADVISOR application or CAN monitor unit (CMU) may be used to indicate hydraulic oil temperature. The temperature sensor is located in the return oil manifold tube on the reservoir.

3. Hold bucket rollback function over relief and raise and lower the boom. 4. Periodically cycle all hydraulic functions to distribute warm oil. 5. Allow hydraulic oil to heat to specification.

1. To display hydraulic oil temperature using the CMU, access the Diagnostics / Hydraulic menu in the CMU main menu. See CAN Monitor Unit (CMU) Menu Structure—Service Mode. (Group 9015-20.) 2. Operate engine at fast idle with park brake in the OFF position.

Specification Hydraulic Oil—Temperature ................................................. 60—71°C 140—160°F

6. Push MENU once to return to home screen.

Service ADVISOR is a trademark of Deere & Company

SJ25320,00002A8 –19–24JAN07–1/1

9025 25 1

TM10229 (17MAR09)

9025-25-1

544J Loader (S.N. 611800— ) 032409

PN=969

Test

Hydraulic System Pressure and Accumulators Discharge

–UN–08DEC08

CAUTION: To avoid injury from escaping fluid under pressure, stop engine, and relieve the pressure in the system before disconnection hydraulic or other lines. Tighten all connections before applying pressure.

X9811

The purpose of this procedure is to remove any working or static pressure from the hydraulic system before performing any maintenance.

Avoid High-Pressure Fluids

1. Install frame articulation lock bar. CAUTION: Prevent possible crushing injury from falling boom. Always support boom before working on or around this machine with the boom raised. Empty bucket and place in dump position before installing boom support. If the machine is equipped with the optional pin disconnect feature, disconnect the attachment before installing boom support. 2. Dump bucket and raise boom to install boom lock. See Boom Lock. (Operator’s Manual.) 3. Turn key switch to the OFF position. 9025 25 2

NOTE: Ride control accumulator hydraulic pressure can not be discharged if ride control switch is in automatic position, with two lights on switch illuminated. When the ride control switch is in manual position, left light on ride control switch will be illuminated. 4. Turn key switch to the ON position, DO NOT start engine

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PN=970

Test 5. Press return-to-carry switch (1) to off, if equipped.

–UN–18SEP03

CAUTION: Prevent possible injury from moving components. Make sure area around boom and bucket is clear. Boom may move upward when ride control is turned on.

T192464A

6. Cycle ride control switch (2) to off then to on (manual mode), left light illuminated. 7. Press and hold pilot enable/boom down switch (3) and lower boom to supports.

Switches

8. Press and hold pilot enable/boom down switch, engage boom float for 5 seconds.

1—Return-to-Carry Switch 2—Ride Control Switch 3—Pilot Enable/Boom Down Switch

9. Press and hold pilot enable/boom down switch, then move all other hydraulic control levers to relieve hydraulic pressure. NOTE: Pilot enable/boom down accumulator pressure will cause the hydraulic control lever to kickback when lever is partially engaged and switch is pressed. 10. Pull hydraulic control lever out of neutral and hold, press and release pilot enable/boom down switch (3). Repeat procedure until no movement can be felt in the hydraulic control lever. 11. Access the CMU to display the service brake accumulator pressures. See CAN Monitor Unit (CMU) Menu Structure—Service Mode. (Group 9015-20.)

9025 25 3

NOTE: Each service brake accumulator has its own pressure sensor to indicate low pressure in either the front or rear brake system. It may take 25-40 application of brake pedal to discharge brake system. Displayed pressure may not drop to zero, but should drop to below 207 kPa (2.1 bar) (30 psi) when accumulator are discharged. 12. Watch monitor display, push and release brake pedal until low brake pressure warning light comes on. Continue to push and release brake pedal until both accumulators are discharged.

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PN=971

Test 13. Turn the steering wheel left and right to relieve steering cylinder pressure. 14. Turn key switch to the OFF position. MH66O88,00005EA –19–30APR07–3/3

Digital Pressure and Temperature Analyzer Installation SERVICE EQUIPMENT AND TOOLS

–UN–25AUG95

JT02156A Digital Pressure and Temperature Analyzer

Transducers (B) are temperature sensitive. Allow transducer to warm to system temperature. After transducer is warmed and no pressure applied, push sensor zero button for 1 second to set the true zero point. When using different pressures, turn selector to OFF for 2 seconds and then to the proper pressure range. Readings are inaccurate if the range for transducer is not used.

9025 25 4

T8543AI

Use JT02156A Digital Pressure and Temperature Analyzer in place of analog gauges and a separate temperature reader.

JT02156A Digital Pressure and Temperature Analyzer A—Digital Pressure and Temperature Analyzer B—3400 kPa (35 bar) (500 psi) Transducer 34 000 kPa (350 bar) (5000 psi) Transducer 70 000 kPa (700 bar) (10 000 psi) Transducer

MH66O88,0000473 –19–04JAN07–1/1

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544J Loader (S.N. 611800— ) 032409

PN=972

Test

Pump Load Sense Differential and Standby Pressure Test SPECIFICATIONS Hydraulic Oil Temperature

40—50°C 104—122°F

Engine Speed

Slow Idle

Load Sense Differential Pressure

1799—2006 kPa 17.9—20 bar 261—291psi

Hydraulic Standby Pressure

4798—5205 kPa 47.9—52 bar 696—755 psi

SERVICE EQUIPMENT AND TOOLS JT02156A Digital Pressure and Temperature Analyzer Transducer 0—34 450 kPa (0—345 bar) (0—5000 psi)

The purpose of this test is to check and, if necessary, adjust the pump load sense differential and standby pressure. 1. Perform Hydraulic Oil Warmup Procedure. (Group 9025-25.) Specification Hydraulic Oil—Temperature ........................................................ 40—50°C 104—122°F

2. Install frame articulation locking bar. 3. Stop engine and relieve hydraulic pressure. 9025 25 5

Turn key to the ON position and operate loader, bucket, or auxiliary function to relieve hydraulic pressure. If equipped, discharge ride control, see Ride Control Accumulator Hydraulic Discharge Procedure. (Group 9025-25.)

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PN=973

Test 4. Install JT02156A Digital Pressure and Temperature Analyzer, connect pressure transducers to pump outlet pressure quick coupler (4) and load sense pressure quick coupler (8). Perform Digital Pressure and Temperature Analyzer Installation procedure. (Group 9025-25.)

T194331A

–UN–21AUG03

1—Regulated Pressure Quick Coupler 2—Pressure Reducing Adjustment Lock Nut 3—Pressure Reducing Adjustment Screw 4—Pump Outlet Pressure Quick Coupler 5—Pressure Reducing Manifold

Pressure Reducing Manifold

9025 25 6

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PN=974

Test IMPORTANT: Avoid fluid contamination. Do not remove standby pressure adjustment screw (10) from control valve.

–UN–17NOV06

Standby pressure adjustment must be reset to specification after load sense adjustment test for machine hydraulics to operate correctly.

TX1015088A

5. Remove caps from both pressure adjustment screws. Turn standby pressure adjustment screw (10) out five full turns. 6. To check load sense differential pressure, set the digital pressure analyzer to 5000 psi delta setting. 6—Hydraulic Pump 7—Hydraulic Pump Control Valve 8—Load Sense Pressure Quick Coupler 9—Load Sense Differential Pressure Adjustment Screw 10—Standby Pressure Adjustment Screw

7. Start engine and run at slow idle. Specification Engine—Speed ............................................................................ Slow Idle

8. Record load sense differential pressure reading. 9. Compare reading to specification. Specification Load Sense Differential— Pressure .......................................................................... 1799—2006 kPa 17.9—20 bar 261—291 psi

If load sense pressure is at specification go to next step. 9025 25 7

If load sense pressure requires adjustment, use the following procedure: • Remove cap from load sense valve. • Loosen lock nut. • Turn load sense differential pressure adjustment screw (9) in to increase pressure or out to decrease pressure. • Tighten lock nut and install cap.

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PN=975

Test IMPORTANT: Standby pressure adjustment must be reset to specification after load sense adjustment test for machine hydraulics to operate correctly. 10. Adjust standby pressure back to specifications. Use the following procedure: • Set digital pressure analyzer to 5000 psi setting. • Set digital pressure analyzer to read pump outlet pressure quick coupler (4) transducer. • Slowly turn standby pressure adjustment screw (10) in until pressure is within specification. Specification Hydraulic Standby—Pressure ......................................... 4798—5205 kPa 47.9—52 bar 696—755 psi

11. Remove test equipment.

SJ25320,0000268 –19–04JAN07–4/4

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TM10229 (17MAR09)

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544J Loader (S.N. 611800— ) 032409

PN=976

Test

Maximum System Pressure Test SPECIFICATIONS Hydraulic Oil Temperature

40—50°C 104—122°F

Engine Speed

Slow Idle

Load Sense Relief Pressure

24 821—25 511 kPa 248—255 bar 3600—3700 psi

SERVICE EQUIPMENT AND TOOLS JT02156A Digital Pressure and Temperature Analyzer Transducer 0—34 450 kPa (0—345 bar) (0—5000 psi)

IMPORTANT: Before doing this test perform Pump Load Sense Differential and Standby Pressure Test. (Group 9025-25.) The purpose of this test is to check the pressure setting of the load sense relief valve. Maximum system pressure should not exceed this load sense relief specification. 1. Install frame articulation locking bar. 2. Perform Hydraulic Oil Warmup Procedure. (Group 9025-25.) Specification Hydraulic Oil—Temperature ........................................................ 40—50°C 104—122°F

9025 25 9

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PN=977

Test 3. Install JT02156A Digital Pressure and Temperature Analyzer and connect 5000 psi pressure transducer to pump outlet pressure quick coupler (4). Perform Digital Pressure And Temperature Analyzer Installation procedure. (Group 9025-25.) 4. Start engine and run at slow idle. Specification Engine—Speed ............................................................................ Slow Idle

5. Record load sense relief pressure reading while holding bucket rollback function over relief. Compare pressure reading to specification. Specification Load Sense Relief—Pressure ................................... 24 821—25 511 kPa 248—255 bar 3600—3700 psi

T194331A

–UN–21AUG03

1—Regulated Pressure Quick Coupler 2—Pressure Reducing Adjustment Lock Nut 3—Pressure Reducing Adjustment Screw 4—Pump Outlet Pressure Quick Coupler 5—Pressure Reducing Manifold

Main Hydraulic Manifold

9025 25 10

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PN=978

Test 6. If pressure is not within specification, install boom lock. See Boom Lock. (Operator’s Manual.) Adjust load sense relief valve located on the inlet section of hydraulic control valve as required. Turn relief valve in to increase pressure or out to decrease pressure.

4 1

7. Hold bucket rollback function over relief several times when adjustment is complete to seat relief poppet and spring.

–UN–10AUG04

Repeat test procedure and compare to specifications:

• Repeat adjustment procedure. • Before replacing load sense relief, determine if problem is in load sense relief valve or loader system relief valve. Perform Loader System Relief and Circuit Relief Valve Pressure Test. (Group 9025-25.)

T202105

If pressure is not within specifications

Hydraulic Control Valve

1—Load Sense Relief Valve 2—Lock Nut 3—Adjustment Screw 4—Loader System Relief Valve

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544J Loader (S.N. 611800— ) 032409

PN=979

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Test

Hydraulic Pump Flow Test SPECIFICATIONS Hydraulic Oil Temperature

60—71°C 140—160°F

Hydraulic Pump Test Pressure

6894 kPa 69 bar 1000 psi

New Pump Minimum Flow

174 L/min 46 gpm

Used Pump Minimum Flow

155 L/min 41 gpm

SERVICE EQUIPMENT AND TOOLS JT07148 Flowmeter 38H1483 Reducer (-16 F x -12 M ORFS) 38H1473 Reducer (-12 F x -6 M ORFS) Tee (-16 M x -16 M x -16 F ORFS) Cap (-20 M ORFS) Plug (-16 F ORFS) Plug (-6 F ORFS)

The purpose of this test is to determine hydraulic pump flow rate and pump performance. 1. Install frame articulation locking bar. 2. Before performing this test, see Pump Load Sense Differential and Standby Pressure Test. (Group 9025-25.) 9025 25 12

3. Drain or apply vacuum to hydraulic reservoir.

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PN=980

Test 4. Disconnect and close load sense hose from pump control valve (7) with a plug. Install test hose (3) from pump control valve to tee fitting (2) as shown. 5. Disconnect pump outlet hose (1) from loader control valve and install to flowmeter (4) inlet. –UN–17NOV06

Close loader control valve port with a cap.

TX1015088A

6. Disconnect return line (5) from loader control valve and install to flowmeter (4) outlet. Close loader control valve port with a cap. IMPORTANT: The Flowmeter is connected directly to pump for this test. The hydraulic system will not be protected against high pressure spikes as the relief valve is not located in the test circuit. Flowmeter control valve must be left open at all times except during warmup and test procedures.

Hydraulic Pump and Control Valve

7. Heat hydraulic oil to specifications by restricting flow through the flowmeter. Operate engine at constant mid-range speed. Do not increase speed when flowmeter is restricting flow.

–UN–06OCT03

Specification Hydraulic Oil—Temperature ........................................................ 60—71°C 140—160°F

T194752A

8. Operate the engine at fast idle. Slowly close flowmeter control valve until specified pressure is indicated. Recheck engine speed and take flow reading. Specification Hydraulic Pump—Test Pressure ................................................. 6894 kPa 69 bar 1000 psi

Pump Flow Test 1—Pump Outlet-to-Flowmeter Test Hose 2—Tee Fitting 3—Load Sense Test Hose 4—Flow Meter 5—Return Hose from Control Valve to Filter 6—Hydraulic Pump 7—Hydraulic Pump Control Valve 8—Load Sense Pressure Quick Coupler 9—Standby Pressure Adjustment Screw 10—Load Sense Differential Pressure Adjustment Screw

9. If flow is below specification, check hydraulic reservoir suction hose for restriction and repeat test. If hose is not restricted, check steering system leakage before replacing pump. Specification New Pump—Minimum Flow ....................................................... 174 L/min 46 gpm

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PN=981

9025 25 13

Test Specification Used Pump—Minimum Flow ...................................................... 155 L/min 41 gpm

10. Replace pump if flow is still below specification. 11. If pump is replaced, before returning machine to service, perform Pump Load Sense Differential and Standby Pressure Test. (Group 9025-25.)

SJ25320,0000269 –19–04JAN07–3/3

Hydraulic Pump Case Drain Test SPECIFICATIONS Hydraulic Oil Temperature

60—71°C 140—160°F

Engine Speed

2300—2350 rpm

Hydraulic Pump Case Drain Maximum Leakage

45.4 L/min 12 gpm

The purpose of this test is to determine the efficiency of the pump rotating group by measuring the amount of case drain with the pump at maximum pressure. This test will help isolate a pump performance problem to either the rotating group or the pump control. Perform this test before removing or replacing the pump. 1. Install frame articulation locking bar. 9025 25 14

2. Perform Hydraulic Oil Warmup Procedure. (Group 9025-25.) Specification Hydraulic Oil—Temperature ........................................................ 60—71°C 140—160°F

3. Apply vacuum to the hydraulic reservoir.

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PN=982

Test 4. Disconnect pump case drain hose (11) from top of pump (6). IMPORTANT: A non-adjustable flowmeter (2) is the best tool for this test. If using an adjustable flow meter, the flowmeter control valve must be open at all times. Serious hydraulic pump damage may result if pump back pressure is increased.

–UN–06OCT03

5. Connect test hose (1) from pump case drain hose (11) port to non-adjustable flowmeter (2). 6. Connect test hose from outlet port of flowmeter (2) to hydraulic reservoir fill hole (4).

T194857A

7. Remove vacuum from reservoir. 8. Operate engine at specified speed. Pump Case Drain Test Specification Engine—Speed ............................................................... 2300—2350 rpm

9. Hold bucket rollback function over relief and record flow. Case drain flow must be within specification.

Specification Hydraulic Pump Case Drain— Maximum Leakage .................................................................... 45.4 L/min 12 gpm

9025 25 15

–UN–06DEC06

9 8

TX1015712

1—Pump Return-to-Flowmeter Test Hose 2—Flowmeter 3—Flowmeter-to-Reservoir Test Hose 4—Hydraulic Reservoir Fill Hole 6—Hydraulic Pump 7—Hydraulic Pump Control Valve 8—Load Sense Pressure Quick Coupler 9—Standby Pressure Adjustment Screw 10—Load Sense Differential Pressure Adjustment Screw 11—Hydraulic Pump Case Drain Hose

Hydraulic Pump and Control Valve

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PN=983

Test

Loader System Relief and Circuit Relief Valve Pressure Test SPECIFICATIONS Hydraulic Oil Temperature

60—71°C 140—160°F

Engine Speed

Slow idle

Loader System Relief Pressure

24 820—25 510 kPa 248—255 bar 3600—3700 psi

Circuit Reliefs Bucket Rollback Pressure

28 613—29 993 kPa 286—300 bar 4150—4350 psi

Bucket Dump Pressure (ZB, ZBHL, and PL)

17 237—18 616 kPa 172—186 bar 2500—2700 psi

Bucket Dump Pressure (TC)

12 410—13 789 kPa 124—138 bar 1800—2000 psi

Bucket Curl and Auxiliary Pressure (ZB, ZBHL, and PL)

28 613—29 993 kPa 286—300 bar 4150—4350 psi

ESSENTIAL TOOLS 38H1473 Reducer (-12 F x -6 M ORFS) JT07192 Relief Valve Tester 38H1418 Cap (-12 F ORFS) SERVICE EQUIPMENT AND TOOLS JT02156A Digital Pressure and Temperature Analyzer Transducer 0—34 450 kPa (0—345 bar) (0—5000 psi) 9025 25 16

The purpose of this test is to determine the pressure settings of the loader system valve and circuit relief valves. Loader System Relief Valve Test NOTE: The loader system relief valve acts as a clipper relief valve to protect loader circuit against hydraulic pressure spikes. 1. Install boom lock. See Boom Lock. (Operator’s Manual.) 2. Install hose from flowmeter to control valve.

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SJ25320,000025B –19–25MAR08–1/6

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PN=984

Test 3. Perform Hydraulic Oil Warmup Procedure. (Group 9025-25.) Specification Hydraulic Oil—Temperature ........................................................ 60—71°C 140—160°F Engine—Speed ............................................................................ Slow idle

SJ25320,000025B –19–25MAR08–2/6

4. Install JT02156A Digital Pressure and Temperature Analyzer with 5000 psi, (345 bar), (450 kPa) pressure transducer on pump outlet pressure quick coupler (4). Perform Digital Pressure and Temperature Analyzer Installation procedure. (Group 9025-25.) 5. Start engine and run at slow idle. 6. Record maximum system pressure reading while holding bucket rollback over relief.

T194331A

–UN–21AUG03

1—Regulated Pressure Quick Coupler 2—Pressure Reducing Adjustment Lock Nut 3—Pressure Reducing Adjustment Screw 4—Pump Outlet Pressure Quick Coupler 5—Pressure Reducing Manifold

Pressure Reducing Valve

Continued on next page

TM10229 (17MAR09)

9025-25-17

SJ25320,000025B –19–25MAR08–3/6

544J Loader (S.N. 611800— ) 032409

PN=985

9025 25 17

Test IMPORTANT: Load sense relief must be adjusted up above system relief setting to do this test. Load sense relief must be reset to original specifications after this test to prevent damage to machine.

4 1

7. Stop engine. Mark load sense relief screw position for later reference.

–UN–10AUG04

Loosen lock nut (2) and turn in adjustment screw (3) two turns to raise load sense relief above system (clipper) relief valve specification.

T202105

Tighten lock nut and check loader system relief pressure. 8. Start engine and run at slow idle. 9. Record pressure while holding bucket rollback over relief. Compare reading to specification.

Relief Valve Test 1—Load Sense Relief Valve 2—Lock Nut 3—Adjustment Screw 4—System Relief Valve

Specification Loader System Relief—Pressure .............................. 24 820—25 510 kPa 248—255 bar 3600—3700 psi

10. If pressure reading is low, turn adjustment screw (3) in one more turn and repeat test.

9025 25 18

11. If pressure reading is high, replace system relief valve (4). IMPORTANT: To prevent hydraulic or structural damage to machine, load sense relief must be reset to correct pressure. 12. Turn load sense relief adjustment screw (3) back to original position. Perform Maximum System Pressure Test to check load sense relief valve pressure setting. (Group 9025-25.) Circuit Relief Valve Test 1. Install boom lock. See Boom Lock. (Operator’s Manual.)

Continued on next page

TM10229 (17MAR09)

9025-25-18

SJ25320,000025B –19–25MAR08–4/6

544J Loader (S.N. 611800— ) 032409

PN=986

Test 2. Stop engine and relieve hydraulic pressure. Turn key to the ON position, and operate loader, bucket, or auxiliary function to relieve hydraulic pressure. If equipped, discharge ride control. See Ride Control Accumulator Hydraulic Discharge Procedure. (Group 9025-20.)

SJ25320,000025B –19–25MAR08–5/6

3. Connect JT07192 relief valve tester hose to the control valve inlet. Disconnect hose for circuit to be tested at cylinder (bucket dump shown). Install 38H1418 cap (D) on the cylinder fitting. –UN–17FEB97

4. Install union (B) and 38H1473 reducer (A) on loader hose and connect to tester hose. Install digital pressure transducer to hose tee.

6. If pressure is not within specification, adjust appropriate circuit relief valve accordingly. Cycle tester several times after any adjustments to seat relief valve spring and poppet; then recheck pressure to specification.

T107353B

5. Run tester until pressure reaches maximum pressure.

Circuit Relief Valve Test

Specification Bucket Rollback—Pressure ....................................... 28 613—29 993 kPa 286—300 bar 4150—4350 psi Bucket Dump (ZB, ZBHL, and PL)—Pressure ........................................................... 17 237—18 616 kPa 172—186 bar 2500—2700 psi Bucket Dump (TC)—Pressure................................... 12 410—13 789 kPa 124—138 bar 1800—2000 psi Bucket Curl and Auxiliary (ZB, ZBHL, and PL)—Pressure......................................... 28 613—29 993 kPa 286—300 bar 4150—4350 psi

9025 25 19

T107354B

–UN–17FEB97

A—Reducer B—Union D—Cap

Relief Valve Pressure Tester SJ25320,000025B –19–25MAR08–6/6

TM10229 (17MAR09)

9025-25-19

544J Loader (S.N. 611800— ) 032409

PN=987

Test

Loader Cylinder Drift Test SPECIFICATIONS Hydraulic Oil Temperature

60—71°C 140—160°F

Overall Drift Distance

51 mm/min 2.00 in./min

Boom Cylinder Drift Down Distance

5 mm/min 0.20 in./min

Bucket Cylinder Drift Distance

6 mm/min 0.24 in./min

Boom Cylinder Drift Up Maximum Distance (Engine On)

6 mm in 2 min 0.24 in. in 2 min

SERVICE EQUIPMENT AND TOOLS Temperature Reader Stopwatch Dial Indicator

The purpose of this test is to determine cylinder drift. Accelerated drift can indicate excess wear on internal cylinder components.

Continued on next page

SJ25320,00002B4 –19–05JAN07–1/2

9025 25 20

TM10229 (17MAR09)

9025-25-20

544J Loader (S.N. 611800— ) 032409

PN=988

Test 1. Fasten temperature probe to port of cylinder being tested. Cover probe with a shop towel. 2. Perform Hydraulic Oil Warmup Procedure. (Group 9025-25.) Specification Hydraulic Oil—Temperature ........................................................ 60—71°C 140—160°F

3. Stop engine.

–UN–21OCT88

4. To check boom and bucket overall drift rate, measure drift down at tooth tip (A) for 1 minute using monitor for time.

If drift rate is excessive, measure individual cylinder drift with a dial indicator to determine which circuit is leaking.

T6203AT

Specification Overall Drift—Distance ............................................................. 51 mm/min 2.00 in./min

Loader Cylinder Drift Test (1 of 2)

–UN–26OCT88

Specification Boom Cylinder Drift Down— Distance ...................................................................................... 5 mm/min 0.20 in./min Bucket Cylinder Drift—Distance ................................................. 6 mm/min 0.24 in./min

NOTE: Boom down solenoid valve leakage can cause boom to drift up with engine running. Stop engine. Install and zero dial indicator. Start engine.

T6222AN

5. If drift is excessive for any cylinder, see Boom, Bucket and Steering Cylinder Leakage Test. (Group 9025-10.) determine if leakage is in cylinder or control valve.

Loader Cylinder Drift Test (2 of 2) A—Tooth Tip

If cylinder drifts up more than specification, remove solenoid valve and check seals. Specification Boom Cylinder Drift Up— Maximum Distance (Engine On) ......................................... 6 mm in 2 min 0.24 in. in 2 min

SJ25320,00002B4 –19–05JAN07–2/2

TM10229 (17MAR09)

9025-25-21

544J Loader (S.N. 611800— ) 032409

PN=989

9025 25 21

Test

Boom, Bucket and Steering Cylinder Leakage Test The purpose of this test is to determine leakage rates through the boom, bucket, and steering cylinders. Accelerated leakage can indicate excessive wear on internal cylinder components.

Continued on next page

SJ25320,00002B5 –19–22JAN07–1/3

9025 25 22

TM10229 (17MAR09)

9025-25-22

544J Loader (S.N. 611800— ) 032409

PN=990

Test

Hydraulic Oil Temperature

60—71°C 140—160°F

Leakage Test Time

1 minute

Cylinder Leakage Maximum

15 mL/min 1/2 oz/min

–UN–26OCT88

SPECIFICATIONS

ESSENTIAL TOOLS 38H1151 Plug (-20 ORFS) Head End Boom

T6222AL

20 PNLO-S Plug (-20 ORFS) (Parker No.) Head End Boom 38H1150 Plug (-16 ORFS) Rod End Boom 16 PNLO-S Plug (-16 ORFS) (Parker No.) Rod End Boom

Boom, Bucket and Steering Cylinder Leakage

38H1151 Plug (-20 ORFS) (2 used) Bucket 20 PNLO-S Plug (-20 ORFS) (Parker No.) (2 used) Bucket

1. Fasten the temperature sensor to head end port of cylinder to be tested. Cover sensor with a shop towel. 2. Perform Hydraulic Oil Warmup Procedure. (Group 9025-25.) Specification Hydraulic Oil—Temperature ........................................................ 60—71°C 140—160°F

CAUTION: Avoid possible injury from crushing. Never work under raised equipment unless supported with hoist or support stands. 3. Fully extend the cylinder to be tested. If testing the boom cylinders, restrain boom in the fully raised position using a hoist or a stand.

9025 25 23

NOTE: Check cylinders for leakage in the fully extended position only. In the retracted position, the piston contacts the end of the cylinder and seals off piston seal leakage. 4. Remove and close cylinder rod end hose or line with a plug.. 5. Operate engine at slow idle

Continued on next page

TM10229 (17MAR09)

9025-25-23

SJ25320,00002B5 –19–22JAN07–2/3

544J Loader (S.N. 611800— ) 032409

PN=991

Test 6. Move control lever to extend cylinder for specified time while measuring leakage from open port. Use monitor or Service ADVISORService ADVISOR timer. Specification Leakage Test—Time .................................................................... 1 minute

If leakage is within specification, excessive cylinder drift is caused by leakage in the loader control valve or circuit relief valve. Specification Cylinder—Leakage (Maximum) ................................................. 15 mL/min 1/2 oz/min

Service ADVISOR is a trademark of Deere & Company

SJ25320,00002B5 –19–22JAN07–3/3

Steering Valve Leakage Test The purpose of this test is to determine leakage rate through the steering valve. Accelerated leakage can indicate excessive wear on internal steering valve components.

9025 25 24

Continued on next page

TM10229 (17MAR09)

9025-25-24

SJ25320,000025C –19–09JAN07–1/3

544J Loader (S.N. 611800— ) 032409

PN=992

Test

9025 25 25

TM10229 (17MAR09)

9025-25-25

544J Loader (S.N. 611800— ) 032409

PN=993

Test TX1017400 –UN–09JAN07

1 21 2

5 6

13 7 15 16 12

8 11

TX1017400 Steering and Brake Hydraulic Component Location

Continued on next page

TM10229 (17MAR09)

9025-25-26

SJ25320,000025C –19–09JAN07–2/3

544J Loader (S.N. 611800— ) 032409

PN=994

Test 1—Brake Valve-to-Reservoir Hydraulic Hose 2—Brake Valve 3—Steering Valve 4—Steering Valve-to-Reservoir Hydraulic Hose 5—Pump Outlet-to-Steering Valve Hydraulic Hose 6—Right Steering Cylinder 7—Steering Valve-to-Main Control Valve Load Sense Hose

8—Pin Disconnect Valve 9—Brake Valve-to-Axle Hydraulic Hose 10—Main Control Valve-to-Pin Disconnect Valve Hydraulic Hose 11—Park Brake Valve-to-Park Brake Hose 12—Park Brake Valve

SPECIFICATIONS Hydraulic Oil Temperature

60—71°C 140—160°F

Steering Shaft Torque

11 N•m 8 lb-ft

Steering Valve Maximum Leakage

11.4 L/min 3 gpm

13—Transmission-to-Park Brake Hose 14—Steering Valve-to-Steering Cylinder Hydraulic Hose 15—Pressure Reducing Valve 16—Left Steering Cylinder 17—Steering Cylinder Connection Hose

18—Steering Cylinder Connection Hose 19—Steering Cylinder Bushing Grease Hose 20—Steering Cylinder Bushing Grease Hose 21—Hydraulic Brake Accumulator

5. Quickly turn steering wheel against locking bar to seat internal check balls in steering valve. 6. Apply specified torque to steering shaft to turn valve. Specification Steering Shaft—Torque ........................................................... 11 N•m 8 lb-ft

1. Install frame articulation locking bar. 2. Perform Hydraulic Oil Warmup Procedure. (Group 9025-25.) Specification Hydraulic Oil—Temperature ................................................. 60—71°C 140—160°F

3. Disconnect return hose (4) from return filter and route to appropriate container. Close opening on filter with a cap.

7. Measure oil flow from return hose. Specification Steering Valve—Maximum Leakage .............................................................................. 11.4 L/min 3 gpm

Steering valve is not serviceable. If leakage is greater than specification, replace steering valve.See Steering Valve Remove and Install. (Group 0960.)

4. Operate engine at slow idle.

9025 25 27

SJ25320,000025C –19–09JAN07–3/3

TM10229 (17MAR09)

9025-25-27

544J Loader (S.N. 611800— ) 032409

PN=995

Test

Steering Valve Drift Test SPECIFICATIONS Hydraulic Oil Temperature

60—71°C 140—160°F

Pre-Test Distance

254 mm 10 in.

Steering Cylinder Test Pressure

6895 kPa 69 bar 1000 psi

Steering Cylinder Test Time

30 seconds

Steering Cylinder Maximum Drift

64 mm for one min 2.5 in for one min

ESSENTIAL TOOLS 38H1031 Tee (—8 M x —8 F x —8 M ORFS) JT03457 Adaptor (7/16—20 M x —8 F ORFS) SERVICE EQUIPMENT AND TOOLS Gauge 20 000 kPa (200 bar) (3000 psi)

SJ25320,00002B6 –19–05JAN07–1/3

1. Install frame articulation locking bar. Install tee in head end of steering cylinder and attach gauge. Remove the locking bar.

–UN–17FEB97

2. Perform Hydraulic Oil Warmup Procedure. (Group 9025-25.) Steer machine back and forth to make sure steering cylinders contain heated oil. Specification Hydraulic Oil—Temperature ........................................................ 60—71°C 140—160°F

T107167B

9025 25 28

3. Align machine so bucket corner is against an immovable object such as a loading dock. Engage park brake.

Steering Valve Drift (1 of 2) A—Tee B—Adapter

Continued on next page

TM10229 (17MAR09)

9025-25-28

SJ25320,00002B6 –19–05JAN07–2/3

544J Loader (S.N. 611800— ) 032409

PN=996

Test 4. Adjust steering angle to get specification dimension (A) on cylinder with gauge on it.

–UN–21OCT88

Specification Pre-Test—Distance ....................................................................... 254 mm 10 in.

NOTE: Do test with hands off steering wheel. If wheel rotates, move wheel back and forth slightly to center wheel.

T6569AE

5. Display monitor stopwatch. See Monitor Display Unit— Main Menu—Machine Settings—Stopwatch. (Operator’s Manual.)

Steering Valve Drift (2 of 2)

6. Disengage park brake. Put machine in 2nd gear forward and apply power to maintain specified pressure reading for specified time. Specification Steering Cylinder Test—Pressure ............................................... 6895 kPa 69 bar 1000 psi Steering Cylinder Test—Time .................................................. 30 seconds

7. Measure distance (A) at end of test. Subtract from original setting and compare to specifications. Specification Steering Cylinder—Maximum Drift .............................. 64 mm for one min 2.5 in. for one min

• If drift is less than specification, steering drift is normal. • If drift is more than specification, before repairing or replacing steering valve,see Boom, Bucket and Steering Cylinder Leakage Test. (Group 9025-25.)

9025 25 29

8. Install locking bar and remove test equipment.

SJ25320,00002B6 –19–05JAN07–3/3

TM10229 (17MAR09)

9025-25-29

544J Loader (S.N. 611800— ) 032409

PN=997

Test

Secondary Steering Pump Relief Valve Pressure Test The purpose of this test is to determine secondary steering pump relief valve pressure setting.

Continued on next page

SJ25320,00002A0 –19–05JAN07–1/3

9025 25 30

TM10229 (17MAR09)

9025-25-30

544J Loader (S.N. 611800— ) 032409

PN=998

Test SPECIFICATIONS Hydraulic Oil Temperature

60—71°C 140—160°F

Engine Speed

0 rpm

Relief Valve Pressure

5172—5860 kPa 51.7—58.6 bar 750—850 psi ESSENTIAL TOOLS

38H1031 Tee (—8M x —8F x —8M ORFS) JT03457 Adapter (7/16—20M x —8F ORFS) SERVICE EQUIPMENT AND TOOLS Temperature Reader Gauge 0—7000 kPa (0—70 bar) (0—1000 psi)

1. Install frame articulation locking bar.

–UN–15SEP97

2. Perform Hydraulic Oil Warmup Procedure. (Group 9025-25.)

3. Remove outlet hose (C) from secondary steering pump at elbow.

T109554C

Specification Hydraulic Oil—Temperature ........................................................ 60—71°C 140—160°F

Secondary Steering Pump Relief Valve Pressure Test C—Hose From Secondary Steering Pump Elbow D—Adjusting Screw

4. Install adapter and tee into hose and elbow. Install gauge into tee. IMPORTANT: DO NOT operate secondary steering pump and motor for more than 15 seconds with the steering in neutral or damage to the pump and motor can occur.

9025 25 31

5. Start the engine and remove fuel shutoff fuse. Engine will stop. Secondary steering pump will start. Read pressure gauge. Specification Engine—Speed ................................................................................. 0 rpm Specification Relief Valve—Pressure ................................................... 5172—5860 kPa 51.7—58.6 bar 750—850 psi

Continued on next page

TM10229 (17MAR09)

9025-25-31

SJ25320,00002A0 –19–05JAN07–2/3

544J Loader (S.N. 611800— ) 032409

PN=999

Test If pressure is not to specification, remove cover and turn adjusting screw to adjust pressure. If pressure is low and cannot be adjusted to specifications: • Perform Secondary Steering Manifold Primary Check Valve Leakage Test. (Group 9025-25.) • Perform Steering Valve Leakage Test. (Group 9025-25.) • Replace secondary steering pump. (See Group 0930).

SJ25320,00002A0 –19–05JAN07–3/3

Secondary Steering Manifold Primary Check Valve Leakage Test SPECIFICATIONS Hydraulic Oil Temperature

60—71°C 140—160°F

Engine Speed

0 rpm

Secondary Steering Pump Leakage/min

5 ml 0.17 oz

ESSENTIAL TOOLS 38H1418 Cap (-12 F ORFS) 12 FNL-S Cap (-12 F ORFS) (Parker No.) SERVICE EQUIPMENT AND TOOLS Monitor Display Unit 9025 25 32

Continued on next page

TM10229 (17MAR09)

9025-25-32

SJ25320,00002A1 –19–05JAN07–1/2

544J Loader (S.N. 611800— ) 032409

PN=1000

Test Primary check valve leakage will allow oil to flow from the secondary steering circuit into the main hydraulic system during secondary steering operation. This leakage can cause slow secondary steering. 1. Perform Hydraulic Oil Warmup Procedure. (Group 9025-25.) 2. Install frame articulation locking bar. 3. Disconnect line (B) from main hydraulic pump. Install cap (A) to pump outlet fitting. IMPORTANT: Do not operate secondary steering pump and motor for more than 15 seconds with the steering in neutral or damage to the pump and motor can occur.

–UN–16SEP97

4. Start engine and remove fuel shutoff fuse. Engine will stop. Secondary steering pump will start.

T111323

Specification Engine—Speed ................................................................................. 0 rpm

5. Observe leakage from hose (B). If leakage is more than specification, replace manifold block. (See Repair Manual.)

Secondary Steering Manifold Primary Check Valve Leakage Test

Specification Secondary Steering Pump— Leakage/min ........................................................................................ 5 ml 0.17 oz

A—38H1418 Cap (-12 F ORFS) (Parker No. 12 FNL-S) B—Hose from Secondary Steering Pump to Steering Valve 9025 25 33

SJ25320,00002A1 –19–05JAN07–2/2

TM10229 (17MAR09)

9025-25-33

544J Loader (S.N. 611800— ) 032409

PN=1001

Test

Secondary Steering Manifold Secondary Check Valve Leakage Test SPECIFICATIONS Hydraulic Oil Temperature

60—71°C 140—160°F

Slow Idle Engine Speed

875—925 rpm

Secondary Check Valve Maximum Leakage/min

5 mL/min 80 drops/min ESSENTIAL TOOLS

38H1147 Plug (—8 M ORFS) 8 PNLO-S Plug (—8 M ORFS) (Parker No.) SERVICE EQUIPMENT AND TOOLS Temperature Reader

–UN–21OCT88

Secondary check valve leakage will allow oil to flow from the main hydraulic system to the reservoir through the secondary steering pump. This leakage can cause slow cycle times.

2. Perform Hydraulic Oil Warmup Procedure. (Group 9025-5.)

T6569AJ

1. Install frame articulation locking bar.

Secondary Steering Manifold Secondary Check Valve Leakage

3. Remove hose from check valve (A) on secondary steering manifold.

A—Secondary Steering Valve Check Valve B—Plug

4. Install plug (B) in hose. 9025 25 34

5. Operate engine at slow idle. 6. Observe leakage from check valve (A). If leakage is more than specification, clean or replace check valve. (See Group 0930.) Specification Secondary Check Valve— Maximum Leakage/min ............................................................... 5 mL/min 80 drops/min

SJ25320,00002A2 –19–05JAN07–1/1

TM10229 (17MAR09)

9025-25-34

544J Loader (S.N. 611800— ) 032409

PN=1002

Test

Pilot Control Valve Pressure Test—Single Lever SPECIFICATIONS Hydraulic Oil Temperature

60—71°C 140—160°F

Engine Speed

Slow Idle

Begin Metering Top of Control Lever Deflection

10—16 mm 3/8—5/8 in.

Jump-To Pressure

550—790 kPa 5.5—7.9 bar 80—115 psi

Feel Position Boom Power Down Pressure

1860—2082 kPa 18.6—20.8 bar 270—300 psi

Boom Raise Pressure

1860—2082 kPa 18.6—20.8 bar 270—300 psi

Bucket Rollback Pressure

1960—2180 kPa 19.6—21.8 bar 285—315 psi

Bucket Dump and Auxiliary Valve Pressure

1960—2180 kPa 19.6—21.8 bar 285—315 psi

Detent Position Boom Float Pressure

4309—4653 kPa 43—47 bar 625—675 psi

Full Travel Position (Pilot Pressure) All Functions Pressure

4309—4653 kPa 43—47 bar 625—675 psi

9025 25 35

ESSENTIAL TOOLS JDG1385 Seal Tight Connector (STC) Tool AT306852 STC Tee 62H1042 Male STC to -6 ORFS male Adapter -6 ORFS 45° Adapter -6 ORFS Quick Coupler SERVICE EQUIPMENT AND TOOLS Gauge 0—6895 kPa (0—69 bar) (0—1000 psi)

This test will determine if adequate pilot pressure is available to move the loader control valve spools.

Continued on next page

TM10229 (17MAR09)

9025-25-35

SJ25320,0000281 –19–05JAN07–1/6

544J Loader (S.N. 611800— ) 032409

PN=1003

Test 1. Lower bucket to ground and stop engine. 2. Turn key to the ON position. 3. Press and hold pilot enable/boom down switch, then move all other hydraulic control levers to relieve hydraulic pressure. NOTE: Pilot enable/boom down accumulator pressure will cause the hydraulic control lever to kickback when lever is partially engaged and switch is pressed. 4. Pull hydraulic control lever out of neutral and hold, press and release pilot enable/boom down switch. Repeat procedure until no movement can be felt in the hydraulic control lever. 5. Turn key off.

SJ25320,0000281 –19–05JAN07–2/6

–UN–24NOV03

JDG1385 STC Tool supplied with vehicle and located in operator’s manual packet. 6. Open right side console outer door to access pilot controller hoses. 7—Pilot Control Valve 8—Pilot Control Valve Lines 9—Auxiliary Pilot Control Valve Lines

T196380A

9025 25 36

NOTE: For machines equipped with single lever control and auxiliary hydraulics, remove pilot control console to gain access to STC connectors at auxiliary hydraulic valve.

Pilot Control Lines (Single Lever with Auxiliary Function Shown)

Continued on next page

TM10229 (17MAR09)

9025-25-36

SJ25320,0000281 –19–05JAN07–3/6

544J Loader (S.N. 611800— ) 032409

PN=1004

Test Remove hydraulic hose to be tested from pilot control valve using JDG1385 STC Tool. Install STC tee and test fittings.

T A

7. Connect gauge to the test fitting of the control valve function to be tested. B

Specification Hydraulic Oil—Temperature ........................................................ 60—71°C 140—160°F

TX1012032

P C

9. Install tape measure to measure top of control valve lever travel.

–UN–20SEP06

8. Perform Hydraulic Oil Warmup Procedure. (Group 9025-25.)

TX1012032 Bottom View of Pilot Controller Ports

NOTE: As the control lever is moved from neutral, the pilot pressure will suddenly jump to approximately 620 kPa (6.2 bar) (90 psi) at 10—16 mm (3/8— 5/8 in.) travel. The pressure should then increase smoothly to the specification at the feel position at 45-50 mm (1.75—2.0 in.) top of lever travel, and then jump up to 4309—4653 kPa (43—47 bar) (625—675 psi) as the lever is moved into detent or full travel.

A—Boom Lower B—Bucket Dump C—Boom Raise D—Bucket Rollback P—Pressure Oil T—Return Oil (Tank)

The feel position is when lever is moved to just feel the detent ramp the detent position is when lever is at maximum travel or when it is held in place by a detent or solenoid. 10. Operate engine at specification. Activate function to be checked and record pressure reading. Move test tee and gauge to next function to be tested.

9025 25 37

Continued on next page

TM10229 (17MAR09)

9025-25-37

SJ25320,0000281 –19–05JAN07–4/6

544J Loader (S.N. 611800— ) 032409

PN=1005

Test Specification Feel Position Boom Raise— Pressure .......................................................................... 1860—2082 kPa 18.6—20.8 bar 270—300 psi Feel Position Bucket Rollback— Pressure .......................................................................... 1960—2180 kPa 19.6—21.8 bar 285—315 psi Feel Position Bucket Dump and Auxiliary Valve—Pressure ............................................... 1960—2180 kPa 19.6—21.8 bar 285—315 psi Detent Position Boom Float— Pressure Change............................................................. 4309—4653 kPa 43—47 bar 625—675 psi Full Travel Position (Pilot Pressure) All Functions— Pressure .......................................................................... 4309—4653 kPa 43—47 bar 625—675 psi

If full travel position (pilot pressure) is not to specification:

9025 25 38

• Check pressure reducing valve pressure. See Pressure Reducing Valve Pressure Test. (Group 9025-25.) • If pressure reducing valve cannot be adjusted to specification, pump standby pressure is low. Perform Pump Load Sense Differential and Standby Pressure Test. (Group 9025-25.) • If pressure reducing valve pressure is at specification, check pilot control valve for loose or worn parts. Internal valve component parts are not serviced, install new pilot control valve. If begin metering or feel position pressure is OK in some functions and not in all: • Remove and cap pilot hose to control valve and repeat test. • If pressure is now OK, repair control valve pilot components. See Loader Control Valve Disassemble and Assemble. (Group 3160.)

Continued on next page

TM10229 (17MAR09)

9025-25-38

SJ25320,0000281 –19–05JAN07–5/6

544J Loader (S.N. 611800— ) 032409

PN=1006

Test • If pressure is still low, internal valve component parts are non-serviceable; install new pilot control valve. See Pilot Control Valve Remove and Install. (Group 3160.) SJ25320,0000281 –19–05JAN07–6/6

9025 25 39

TM10229 (17MAR09)

9025-25-39

544J Loader (S.N. 611800— ) 032409

PN=1007

Test

Pilot Control Valve Pressure Test—Two Lever SPECIFICATIONS Hydraulic Oil Temperature

60—71°C 140—160°F

Engine Speed

Slow Idle

Begin Metering Top of Control Lever Deflection

8—12 mm 0.3—0.5 in.

Jump-To Pressure

580—760 kPa 5.8—7.6 bar 85—110 psi

Feel Position Top of Control Lever Deflection

35—40 mm 1.4—1.6 in.

Boom Power Down Pressure

1860—2082 kPa 18.6—20.8 bar 270—302 psi

Boom Raise Pressure

1860—2082 kPa 18.6—20.8 bar 270—302 psi

Bucket Rollback Pressure

1960—2180 kPa 19.6—21.8 bar 284—316 psi

Bucket Dump Pressure

1960—2180 kPa 19.6—21.8 bar 284—316 psi

Detent Position Boom Float Pressure

9025 25 40

4309—4654 kPa 43—46.5 bar 625—675 psi

Full Travel Position (Pilot Pressure) Top of Control Lever Deflection

45—50 mm 1.8—2.0 in.

All Functions Pressure

4309—4654 kPa 43—46.5 bar 625—675 psi

SERVICE EQUIPMENT AND TOOLS JT02156A Digital Pressure and Temperature Analyzer Transducer 0—34 450 kPa (0—345 bar) (0—5000 psi) —6 ORFS TeeFitting with Diagnostic Coupler

This test will determine if adequate pilot pressure is available to move the loader control valve spools and if pilot circuit is in good operating condition.

Continued on next page

TM10229 (17MAR09)

9025-25-40

SJ25320,0000282 –19–22JAN07–1/5

544J Loader (S.N. 611800— ) 032409

PN=1008

Test 1. Warm hydraulic oil to test specification. See Hydraulic Oil Warmup Procedure. (Group 9025-25.) To display the hydraulic oil temperature, use Service ADVISOR or refer to CAN Monitor Unit (CMU) Circuit Theory of Operation. (Group 9015-15.) Specification Hydraulic Oil—Temperature ........................................................ 60—71°C 140—160°F

2. Lower boom to ground. 3. Install frame articulated locking bar. 4. Stop engine and relieve hydraulic pressure by using boom down lower switch and putting in boom float position.

Service ADVISOR is a trademark of Deere & Company

Continued on next page

SJ25320,0000282 –19–22JAN07–2/5

9025 25 41

TM10229 (17MAR09)

9025-25-41

544J Loader (S.N. 611800— ) 032409

PN=1009

Test

2 1

4 3

5 6

TX1017192

–UN–03JAN07

9025 25 42

TX1017192 Pilot Controller Hose Routing 1—Auxiliary Port A 2—Auxiliary Port B

3—Boom Lower Hose 4—Boom Raise Hose

5—Bucket Rollback Hose

NOTE: Test boom lower circuit first, if problem is present in all functions. This circuit has detent and makes test easier to understand before testing other circuits. If only one circuit has problem, test that circuit first.

5. Disconnect line to be tested at pilot control lever (located inside front compartment on right side of cab). Install tee with pressure transducer or gauge to connect hoses.

Continued on next page

TM10229 (17MAR09)

6—Bucket Dump Hose

9025-25-42

SJ25320,0000282 –19–22JAN07–3/5

544J Loader (S.N. 611800— ) 032409

PN=1010

Test 6. Mark top center of each control lever and install tape measure as shown. NOTE: As the control lever is moved from neutral, the pilot pressure will suddenly jump to approximately 620 kPa (6.2 bar) (90 psi) at 8—12 mm (0.3—0.5 in.) travel. The pressure should then increase smoothly to the specification at the feel position, and then jump up to 4309—4654 kPa (43—46.5 bar) (625—675 psi) as the lever is moved into detent or full travel.

TX1010873A

–UN–08AUG06

The feel position is when lever is moved to just feel the detent ramp; the detent position is when lever is at maximum travel or when it is held in place by solenoid. 7. Operate engine at specification. Move control lever function to be checked, record top of lever deflection and pressure reading. Move test gauge to next function to be tested

Measuring Lever Deflection 1—Auxiliary Control Lever 2—Boom Control Lever 3—Bucket Control Lever 4—Tape Measure

Specification Engine—Speed ............................................................................ Slow Idle Begin Metering Top of Control Lever—Deflection ...................................................................... 8—12 mm 0.3—0.5 in. Begin Metering Jump-To— Pressure ............................................................................. 580—760 kPa 5.8—7.6 bar 85—110 psi Feel Position Top of Control Lever—Deflection ..................................................................... 35—40 mm 1.4—1.6 in. Feel Position Boom Power Down—Pressure.............................................................. 1860—2082 kPa 18.6—20.8 bar 270—302 psi Feel Position Boom Raise— Pressure .......................................................................... 1860—2082 kPa 18.6—20.8 bar 270—302 psi Feel Position Bucket Rollback— Pressure .......................................................................... 1960—2180 kPa 19.6—21.8 bar 284—316 psi Feel Position Bucket Dump— Pressure .......................................................................... 1960—2180 kPa 19.6—21.8 bar 284—316 psi

9025 25 43

Continued on next page

TM10229 (17MAR09)

9025-25-43

SJ25320,0000282 –19–22JAN07–4/5

544J Loader (S.N. 611800— ) 032409

PN=1011

Test Specification Detent Position Boom Float— Pressure .......................................................................... 4309—4654 kPa 43—46.5 bar 625—675 psi Full Travel Position (Pilot Pressure) Top of Control Lever— Deflection .................................................................................. 45—50 mm 1.8—2.0 in. Full Travel Position (Pilot Pressure) All Functions— Pressure .......................................................................... 4309—4654 kPa 43—46.5 bar 625—675 psi

If pressure is not to specification: • Check pressure reducing valve pressure. See Pressure Reducing Valve Pressure Test. (Group 9025-25.) • If pressure reducing valve pressure is at specification, check for loose or worn parts on pilot control valve. Replace components as required. See Pilot Control Valve Disassemble and Assemble. (Group 3160.) • If pilot control linkage is OK, remove tee and deadhead function. Repeat test procedure. If pressure is now at specifications, repair control valve. See Loader Control Valve Disassemble and Assemble. (Group 3160.) • If deadheaded pressure is not at specification, replace pilot control valve.

9025 25 44

SJ25320,0000282 –19–22JAN07–5/5

TM10229 (17MAR09)

9025-25-44

544J Loader (S.N. 611800— ) 032409

PN=1012

Test

Pressure Reducing Valve Pressure Test The purpose of this test is to determine the pressure setting of the pressure reducing valve (PRV). The PRV regulates pressure to the pilot control systems. SPECIFICATIONS Hydraulic Oil Temperature

60—71°C 140—160°F

Slow Idle Engine Speed

875—925 rpm

Pilot Control Pressure

4309—4654 kPa 43—46.5 bar 625—675 psi

SERVICE EQUIPMENT AND TOOLS JT02156A Digital Pressure and Temperature Analyzer

This procedure is used to test and adjust regulated pressure in the pilot control system. 1. Perform Hydraulic Oil Warmup Procedure. (Group 9025-25.) 2. Install frame articulation locking bar.

Continued on next page

TM10229 (17MAR09)

9025-25-45

SJ25320,0000283 –19–18SEP07–1/2

544J Loader (S.N. 611800— ) 032409

PN=1013

9025 25 45

Test 3. Install JT02156A Digital Pressure and Temperature Analyzer with 5000 psi pressure transducers to quick coupler (1). Perform Digital Pressure and Temperature Analyzer Installation procedure. (Group 9025-25.) 4. Start engine and record pressure. Pressure should be within specification. Specification Pilot Control—Pressure ................................................... 4309—4654 kPa 43—46.5 bar 625—675 psi

5. If pressure is not within specification, loosen pressure reducing adjustment Lock Nut (2) and turn pressure reducing adjustment screw (3) in to increase or out to decrease pressure.

T194331A

–UN–21AUG03

1—Regulated Pressure Quick Coupler 2—Pressure Reducing Adjustment Lock Nut 3—Pressure Reducing Adjustment Screw 4—Pump Outlet Pressure Quick Coupler 5—Pressure Reducing Manifold

Pressure Reducing Manifold

9025 25 46

SJ25320,0000283 –19–18SEP07–2/2

Cycle Time Test For machine cycle times, see Operational Checkout. (Group 9005-10.) OUO1010,00009C7 –19–29JAN07–1/1

TM10229 (17MAR09)

9025-25-46

544J Loader (S.N. 611800— ) 032409

PN=1014

Test

Brake Accumulator Precharge Test SPECIFICATIONS Hydraulic Oil Minimum Temperature

60—71°C 140—160°F

Low Brake Pressure Warning Pressure

2068 kPa 20.7 bar 300 psi

Hydraulic Standby Pressure

4799—5206 kPa 48—52 696—755

Service Brake Accumulator Precharge—Minimum Pressure

1069 kPa 10.7 bar 155 psi

NOTE: Both brake pedals operate the same brake valve with a mechanical linkage between them. The purpose of this test is to check the brake accumulator’s precharge. 1. Warm hydraulic oil to test specification. See Hydraulic Oil Warmup Procedure. (Group 9025-25.) To display the hydraulic oil temperature, use Service ADVISOR or see CAN Monitor Unit (CMU) Menu Structure— Service Mode. (Group 9015-20.) Specification Hydraulic Oil Temperature— Minimum ...................................................................................... 60—71°C 140—160°F

2. Stop engine. 9025 25 47

3. Access the CMU to display the service brake accumulator pressures. See CAN Monitor Unit (CMU) Menu Structure—Service Mode. (Group 9015-20.)

Service ADVISOR is a trademark of Deere & Company

TM10229 (17MAR09)

Continued on next page

9025-25-47

SJ25320,000025D –19–18SEP07–1/3

544J Loader (S.N. 611800— ) 032409

PN=1015

Test NOTE: Each service brake accumulator has its own pressure sensor to indicate low pressure in either the front or rear brake system. The sensitivity of the pressure sensors will allow an accurate pressure reading to be displayed in the CAN Monitor Unit (CMU). Brake pressure indicator light will come on when brake accumulator pressure drops below specification. 4. Watch the monitor display, and push and release the brake pedal until the low brake pressure warning light comes on. Compare pressure on display to specifications. If brake pressure light does not come on near specification, check for DTCs. See Diagnostic Trouble Codes Quick Reference List. (9015-20.) Specification Low Brake Pressure Warning— Pressure ...................................................................................... 3447 kPa 34.5 bar 500 psi

NOTE: Brake pressure will drop in even increments until it reaches accumulator precharge pressure. When accumulator pressure is reached, the pressure will drop more than 345 kPa (3.4 bar) (50 psi). It may take 25—40 applications of brake pedal to discharge brake system. Displayed pressure may not drop to zero, but should drop to below 207 kPa (2.1 bar) (30 psi) when accumulators are discharged. 9025 25 48

5. While watching the brake accumulator pressure, push and release the brake pedal. Note pressure after each application. Repeat procedure until hydraulic pressure in brake accumulators is discharged. The last number value seen before pressure drops more than 345 kPa (3.4 bar) (50 psi) will be the accumulator precharge. Compare pressure reading to specification.

Continued on next page

TM10229 (17MAR09)

9025-25-48

SJ25320,000025D –19–18SEP07–2/3

544J Loader (S.N. 611800— ) 032409

PN=1016

Test Specification Service Brake Accumulator Precharge—Pressure ...................................................... 2482—2689 kPa 24.8—26.8 bar 360—390 psi

6. Replace accumulators if precharge pressure is below specification. Accumulators are not serviceable.

SJ25320,000025D –19–18SEP07–3/3

Boom Down Accumulator Precharge Test SPECIFICATIONS Pilot Control Pressure

4309—4654 kPa 43—47 bar 625—675 psi

Boom Down Accumulator Precharge Minimum Pressure

1517 kPa 15 bar 220 psi

SERVICE EQUIPMENT AND TOOLS JT02156A Digital Pressure and Temperature Analyzer

The purpose of this test is to determine boom down accumulator precharge pressure. 1. Install frame articulation locking bar. 9025 25 49

2. Turn key to the ON position.

Continued on next page

TM10229 (17MAR09)

9025-25-49

SJ25320,00002A3 –19–18SEP07–1/3

544J Loader (S.N. 611800— ) 032409

PN=1017

Test NOTE: Pilot enable/boom down accumulator pressure will cause the hydraulic control lever to kickback when lever is partially engaged and switch is pressed.

–UN–18SEP03

3. Pull hydraulic control lever out of neutral and hold, press and release pilot enable/boom down switch (3). Repeat procedure until no movement can be felt in the hydraulic control lever.

T192464A

4. Remove left engine frame transmission shield. 1—Return-to-Carry Switch 2—Ride Control Switch 3—Pilot Enable/Boom Down Switch

Switches

Continued on next page

SJ25320,00002A3 –19–18SEP07–2/3

9025 25 50

TM10229 (17MAR09)

9025-25-50

544J Loader (S.N. 611800— ) 032409

PN=1018

Test 5. Install JT02156A Digital Pressure Analyzer with 5000 psi pressure transducers to regulated pressure quick coupler (1). Perform Digital Pressure and Temperature Analyzer Installation procedure. (Group 9025-25.) 6. Start engine and record pressure. Compare to specification. If pressure is not within specification, adjust before continuing with test. see Pressure Reducing Valve Pressure Test. (Group 9025-25.) Specification Pilot Control—Pressure .................................................. 4309—4654 kPa 43—47 bar 625—675 psi

7. Stop engine.

–UN–21AUG03

8. Turn key to the ON position.

9. Hold the pilot enable/boom switch down. Observe pressure while slowly cycling the pilot control lever to boom up and boom down positions. 10. Record accumulator precharge when brake pressure drops by more than 345 kPa (3.4 bar) (50 psi). Accumulator precharge pressure must be within specification.

T194331A

NOTE: Boom down accumulator pressure will drop slowly when cycling lever. The last pressure seen before pressure drop more than 345 kPa (3.4 bar) (50 psi) is accumulator precharge.

Pressure Reducing Manifold Rear View 1—Regulated Pressure Quick Coupler 2—Pressure Reducing Adjustment Lock Nut 3—Pressure Reducing Adjustment Screw 4—Pump Outlet Pressure Quick Coupler 5—Pressure Reducing Manifold 9025 25 51

Specification Boom Down Accumulator Precharge Minimum—Pressure .................................................. 1517 kPa 15 bar 220 psi

11. Replace accumulator if precharge pressure is below specification. Accumulator’s are not serviceable.

SJ25320,00002A3 –19–18SEP07–3/3

TM10229 (17MAR09)

9025-25-51

544J Loader (S.N. 611800— ) 032409

PN=1019

Test

Brake Valve Pressure Test SPECIFICATIONS

SERVICE EQUIPMENT AND TOOLS

Hydraulic Oil Temperature

60—71°C 140—160°F

JT05510 Vacuum Pump

Engine Speed

Low idle (875—925 rpm)

JT02156A Digital Pressure and Temperature Analyzer

Front Brakes Applied Pressure

2964—3447 kPa 29.6—34.4 bar 430—500 psi

Transducer 0—34 450 kPa (0—345 bar) (0—5000 psi)

Front Brakes Released Pressure

0—138 kPa 0—1.4 bar 0—20 psi

Rear Brakes Applied Pressure

2964—3447 kPa 29.6—34.4 bar 430—500 psi

Rear Brakes Released Pressure

0—138 kPa 0—1.4 bar 0—20 psi

—8 ORFS Swivel Run Tee with Diagnostic Coupler

Gauge 0—34 450 kPa (0—345 bar) (0—5000 psi)

Continued on next page

SJ25320,000025E –19–22JAN07–1/4

9025 25 52

TM10229 (17MAR09)

9025-25-52

544J Loader (S.N. 611800— ) 032409

PN=1020

Test

–UN–08SEP05

T214142

Brake Valve Port Identification 1—Front Brake Work Port 2—Rear Brake Work Port 3—Front Brake Supply Pressure from Accumulator

4—Rear Brake Supply Pressure from Accumulator

1. Warm hydraulic oil to test specification. See Hydraulic Oil Warmup Procedure. (Group 9025-25.) To display the hydraulic oil temperature, use Service ADVISOR or see CAN Monitor Unit (CMU) Circuit Theory of Operation. (Group 9015-15.) Specification Hydraulic Oil—Temperature ................................................. 60—71°C 140—160°F

2. Install frame articulation locking bar.

Service ADVISOR is a trademark of Deere & Company

TM10229 (17MAR09)

5—Front Brake Return 6—Rear Brake Return

42—Service Brake Valve

NOTE: Both brake pedals operate the same brake valve with a mechanical linkage between them. NOTE: The service brake valve consists of two separate sections. The front section provides oil to the rear brakes, while the rear section provides oil to the front brakes. Each section needs to be tested separately. 3. To minimize oil loss, pull a vacuum in reservoir using a vacuum pump.

Continued on next page

9025-25-53

SJ25320,000025E –19–22JAN07–2/4

544J Loader (S.N. 611800— ) 032409

PN=1021

9025 25 53

Test 4. Install a swivel run tee fitting with diagnostic coupler between the rear service brake line and the rear axle port (2).

–UN–09SEP05

5. Install a swivel run tee fitting with diagnostic coupler between the front service brake line and the front axle work port (1).

T214150A

6. Connect a pressure transducer or gauge to the front diagnostic coupler in the front service brake work port (1). Service Brake Work Ports

7. Start engine. Operate engine at slow idle.

1—Front Brake Work Port with Diagnostic Coupler 2—Rear Brake Work Port with Diagnostic Coupler

8. Slowly apply brake pedal and observe pressure gauge. Pressure should slowly increase as pedal is depressed. As the pedal nears the end of its travel, the brake pressure will reach the specification pressure. Specification Engine Speed—Low Idle .................................................... 875—925 rpm Front Brakes Applied—Pressure ..................................... 2964—3447 kPa 29.6—34.4 bar 430—500 psi Front Brakes Released— Pressure .................................................................................. 0—138 kPa 0—1.4 bar 0—20 psi

9025 25 54

IMPORTANT: After brake pedal valve test is completed and brake pedal is released, pressure must go to a zero reading. If not, excess heat and damage to brakes may occur. NOTE: If brake pressure cannot be modulated or does not meet specifications, perform Pump Load Sense Differential and Standby Pressure Test. (Group 9025-25.) If low standby pressure is to specification, replace brake valve. 9. Move the pressure transducer or gauge to the diagnostic coupler on the rear service brake work port (2). 10. Slowly apply brake pedal and observe pressure gauge.

Continued on next page

TM10229 (17MAR09)

9025-25-54

SJ25320,000025E –19–22JAN07–3/4

544J Loader (S.N. 611800— ) 032409

PN=1022

Test Pressure should slowly increase as pedal is depressed. As the pedal nears the end of its travel, the brake pressure will suddenly go to specification pressure. Record this gauge pressure. 11. Compare reading to specifications. If specification pressure cannot be reached, inspect linkage for full travel. Specification Rear Brakes Applied—Pressure ..................................... 2964—3447 kPa 29.6—34.4 bar 430—500 psi Rear Brakes Released—Pressure .......................................... 0—138 kPa 0—1.4 bar 0—20 psi

IMPORTANT: After brake pedal valve test is completed and brake pedal is released, pressure must go to a zero reading. If not, excess heat and damage to brakes may occur. NOTE: If brake pressure cannot be modulated or does not meet specifications, perform Pump Load Sense Differential and Standby Pressure Test. (Group 9025-25.) If low standby pressure is to specification, replace brake valve. 12. When the test is completed, stop the engine. Remove the fittings and connect the service brake hoses to the service brake valve. 9025 25 55

SJ25320,000025E –19–22JAN07–4/4

Brake Valve Leakage Test SPECIFICATIONS Hydraulic Oil Temperature

60—71°C 140—160°F

Brake Valve Leakage— Maximum (brake released)

40 ml/min 1.3 oz/min

Brake Valve Leakage— Maximum (brake applied)

65 ml/min 2.2 oz/min

SERVICE EQUIPMENT AND TOOLS Cap (—8 F ORFS) Measuring Container

Continued on next page

TM10229 (17MAR09)

9025-25-55

SJ25320,000025F –19–22JAN07–1/4

544J Loader (S.N. 611800— ) 032409

PN=1023

Test

–UN–08SEP05

T214142

Brake Valve Port Identification 1—Front Brake Work Port 2—Rear Brake Work Port 3—Front Brake Supply Pressure from Accumulator

9025 25 56

4—Rear Brake Supply Pressure from Accumulator

1. Warm hydraulic oil to test specification. Perform Hydraulic Oil Warmup Procedure. (Group 9025-25.) To display the hydraulic oil temperature, use Service ADVISOR or see CAN Monitor Unit (CMU) Circuit Theory of Operation. (Group 9015-15.) Specification Hydraulic Oil—Temperature ................................................. 60—71°C 140—160°F

Service ADVISOR is a trademark of Deere & Company

TM10229 (17MAR09)

5—Front Brake Return 6—Rear Brake Return

42—Service Brake Valve

2. Install frame articulation locking bar. 3. Stop engine. Do not depress brake pedal to discharge accumulator. 4. Disconnect the rear service brake valve return line (6) from the service brake valve. Uses a —8 ORFS F cap to close the line.

Continued on next page

9025-25-56

SJ25320,000025F –19–22JAN07–2/4

544J Loader (S.N. 611800— ) 032409

PN=1024

Test

T213379A

–UN–10AUG05

5. Install a drain hose to the rear service brake return port (6). Place the open end of the drain hose into a container. Measure leakage from the rear brake valve return port.

Hose from Service Brake Return Port

SJ25320,000025F –19–22JAN07–3/4

If leakage is greater than specification, replace brake valve. See Brake Valve Remove and Install. (Group 1060.) Specification Brake Valve Leakage—Maximum (brake released)—Leakage ......................................................... 40 ml/min 1.3 oz/min Brake Valve Leakage—Maximum (brake applied)—Leakage ........................................................... 65 ml/min 2.2 oz/min 9025 25 57 –UN–10AUG05

6. Connect the rear service brake return line to the service brake valve.

8. Install a drain hose to the front service brake return port (5). Place the drain hose into a container. Measure leakage from the front brake valve return port.

T213378A

7. To check the front brake valve for leakage, disconnect the front brake valve return line (5) from the service brake valve. Uses a —8 ORFS F cap to close the line.

Service Brake Valve Leak Test

If leakage is greater than specification, replace brake valve. See Brake Valve Remove and Install. (Group 1060.) 9. Connect front service brake return line to the service brake valve.

SJ25320,000025F –19–22JAN07–4/4

TM10229 (17MAR09)

9025-25-57

544J Loader (S.N. 611800— ) 032409

PN=1025

Test

Brake Accumulator Inlet Check Valve Leakage Test The purpose of this test is to check for any accumulator discharge created by a problem with the inlet check valve. 1. Warm hydraulic oil to test specification. Perform Hydraulic Oil Warmup Procedure. (Group 9025-25.) To display the hydraulic oil temperature, use Service ADVISOR or see CAN Monitor Unit (CMU) Circuit Theory of Operation. (Group 9015-15.) Specification Hydraulic Oil—Temperature ........................................................ 60—71°C 140—160°F

2. Install frame articulation locking bar. 3. Stop engine. 4. Access the service brake accumulator pressure from the CAN Monitor Unit (CMU). See CAN Monitor Unit (CMU) Circuit Theory of Operation. (Group 9015-15.) 5. Monitor accumulator pressure. If there is a noticeable bleed-off of pressure in accumulators, perform Brake Valve Leakage Test. (Group 9025-25.) 6. If the service brake leak test is good, discharge and remove the brake accumulator to inspect check valve.

9025 25 58

Service ADVISOR is a trademark of Deere & Company

SJ25320,0000260 –19–22JAN07–1/1

Pin Disconnect Pressure Test The purpose of this test is to determine regulated pressure setting from the pin disconnect valve.

ESSENTIAL TOOLS JT03456 Adapter (7/16-20 M JIC X -6 F ORFS) 38H1030 Tee (-6 M x -6 F x -6 M ORFS)

SPECIFICATIONS Pin Disconnect Pressure

5860—7239 kPa 58.6—72.3 bar 850—1050 psi

SERVICE EQUIPMENT AND TOOLS Gauge 34 474 kPa (345 bar) (5000 psi)

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TM10229 (17MAR09)

9025-25-58

SJ25320,000025A –19–22MAY08–1/3

544J Loader (S.N. 611800— ) 032409

PN=1026

Test 1. Perform Hydraulic Oil Warmup Procedure. (Group 9025-25.)

T121138

–UN–15APR99

NOTE: The pin disconnect circuit operates with reduced pressure oil from the pin disconnect valve block. The valve is located on the left, inside the loader frame. It controls pressure by using an adjustable pressure reducing relief valve. The valve block is sourced with full system pressure from the main pump. 2. Connect test gauge to pin disconnect line at loader boom.

Pin Disconnect Pressure Test A—Existing Hydraulic Hose B—JT03456 Adapter (7/16-20 M x -6F ORFS) C—38H1030 Tee (-6 M x -6 F x -6 M ORFS)

3. Perform Hydraulic Oil Warmup Procedure. (Group 9025-25.) NOTE: When this test is performed, it is important to have system pressure higher than standby. Pin disconnect pressure reducing relief valve setting is higher than standby pressure. Activate boom or bucket function to increase system pressure. 4. Operate engine at slow idle.

SJ25320,000025A –19–22MAY08–2/3

5. Pressure must reach test specifications.

If pressure is not within specification, adjust pressure reducing valve (4) by removing cap and turning adjusting screw.

1—Pin Disconnect Valve 2—Loader Control Valve 3—Solenoid Valve 4—Pressure Reducing Valve

–UN–27MAY08

TX1042766

Specification Pin Disconnect—Pressure............................................... 5860—7239 kPa 58.6—72.3 bar 850—1050 psi

Pin Disconnect Valve

SJ25320,000025A –19–22MAY08–3/3

TM10229 (17MAR09)

9025-25-59

544J Loader (S.N. 611800— ) 032409

PN=1027

9025 25 59

Test

Hydraulic Fan Pump Pressure Test accessing Machine Config under Main Menu in the CAN Monitor Unit (CMU). See CAN Monitor Unit (CMU) Circuit Theory of Operation. (Group 9015-15.)

The purpose of this test is to determine fan pump outlet pressure. Pressure not within specification can indicate excessive wear on internal components. SPECIFICATIONS Fan Pump Pressure

This test checks hydraulic fan pump output pressure. In place of this test, if JT05719 Digital Hand Held Tachometer is available, perform Hydraulic Fan Motor Speed Test. (Group 9025-25.) in place of this test.

15341—17409 kPa 153—174 bar 2225—2525 psi

SERVICE EQUIPMENT AND TOOLS JT02156A Digital Pressure and Temperature Analyzer

1. Install frame articulation locking bar.

NOTE: Deactivate proportional fan drive before performing test. Set fan speed to 100% by

SJ25320,0000266 –19–05JAN07–1/2

2. Make test connections as shown using existing pump outlet hose (3). Pump is located on left side rear of engine. 3. Perform Hydraulic Oil Warmup Procedure. (Group 9025-25.)

–UN–02OCT03

5. Operate engine at fast idle and record pressure. Pressure must be within specification. Specification Fan Pump—Pressure .................................................. 15341—17409 kPa 153—174 bar 2225—2525 psi

6. If fan pump pressure is not within specification: • Perform Hydraulic Fan Pump Flow Test. (Group 9025-25.) • Inspect proportional fan solenoid for contamination or seal leakage. Replace if necessary.

T195352A

9025 25 60

4. Install JT02156A Digital Pressure and Temperature Analyzer with 5000 psi (345bar) (34 374kPa) pressure transducers to quick coupler (2). Perform Digital Pressure and Temperature Analyzer Installation. (Group 9025-25.)

1—Fan Pump 2—Quick Coupler 3—Pump Outlet Hose

7. After performing this test, cycle key switch to restart engine. This will activate proportional fan drive.

SJ25320,0000266 –19–05JAN07–2/2

TM10229 (17MAR09)

9025-25-60

544J Loader (S.N. 611800— ) 032409

PN=1028

Test

Hydraulic Fan Motor Speed Test The purpose of this test is to determine fan motor speed. Motor speed not within specification can indicate improper fan pump flow or excessive wear on internal components.

Specification Fan Motor—Minimum Speed at 100% setting ......................................................................... 1750 rpm

SPECIFICATIONS Fan Motor Maximum Speed at 10% Setting

900 rpm

Fan Motor Minimum Speed at 100% Setting

1750 rpm

4. Operate engine at fast idle and record rpm using (JT05719) Digital Hand Held Tachometer . Motor must be within specification.

5. Set fan speed at 10% by accessing Machine Config under Main Menu in the CAN Monitor Unit (CMU). See CAN Monitor Unit (CMU) Circuit Theory of Operation

SERVICE EQUIPMENT AND TOOLS JT05709 Reflective Tape JT05719 Digital Hand Held Tachometer

6. Operate engine at fast idle and record speed. Motor RPM must be within specification

NOTE: This test requires two people to complete. One operates machine while other obtains reading from digital held tachometer.

Specification Fan Motor—Maximum Speed at 10% Setting ............................................................................ 900 rpm

1. Place piece of (JT05709) Reflective Tape on fan hub.

7. If fan motor speed is not within specification:

2. Set fan speed to 100% by accessing Machine Config under Main Menu in the CAN Monitor Unit (CMU). See CAN Monitor Unit (CMU) Circuit Theory of Operation. (Group 9015-15.)

• Perform Hydraulic Fan Pump Flow Test. (Group 9025-25.) • Inspect proportional fan solenoid for contamination or seal leakage. Replace if necessary.

3. Perform Hydraulic Oil Warmup Procedure. (Group 9025-25.) 9025 25 61

SJ25320,0000265 –19–05JAN07–1/1

TM10229 (17MAR09)

9025-25-61

544J Loader (S.N. 611800— ) 032409

PN=1029

Test

Hydraulic Fan Pump Flow Test The purpose of this test is to determine fan pump flow. Flow not within specification can indicate excessive wear on internal components. SPECIFICATIONS New Fan Pump Minimum Flow

52.9 L/min 14.0 gpm

Used Fan Pump Minimum Flow

48.4 L/min 12.8 gpm

Perform Hydraulic Fan Pump Pressure Test or perform Hydraulic Fan Motor Speed Test (Group 9025-25.)before performing this test. NOTE: Deactivate proportional fan drive before performing test. Set fan speed to 100% by accessing Machine Config under Main Menu in the CAN Monitor Unit (CMU). See CAN Monitor Unit (CMU) Circuit Theory of Operation. (Group 9015-15.) 1. Install frame articulation locking bar.

9025 25 62

Continued on next page

TM10229 (17MAR09)

9025-25-62

SJ25320,0000264 –19–05JAN07–1/3

544J Loader (S.N. 611800— ) 032409

PN=1030

Test

T195095

–UN–06OCT03

9025 25 63

1—Fan Pump Inlet from Reservoir 2—Fan Pump 3—Fan Motor

4—Fan Proportional Solenoid 5—Reverse Fan Solenoid 6—Fan Reversing Valve

2. Disconnect hose (7) from fan drive pump and install to flowmeter. Assemble test hose from flowmeter to fan pump outlet.

7—Fan Pump Outlet-to-Fan Reversing Valve Hose 8—Fan Reversing Valve Return-to-Filter Hose

3. Perform Hydraulic Oil Warmup Procedure. (Group 9025-25.)

Continued on next page

TM10229 (17MAR09)

9—Fan Motor Return-to-Filter Hose

9025-25-63

SJ25320,0000264 –19–05JAN07–2/3

544J Loader (S.N. 611800— ) 032409

PN=1031

Test 4. Run test at 100% command fan speed in monitor. 5. Set flowmeter to a no-load condition. 6. Operate engine at fast idle and record pump flow. Pump flow must be within specification. Specification New Fan—Minimum Pump Flow .................................................................................... 52.9 L/min 14.0 gpm

7. If fan pump flow is not within specification: • Perform Hydraulic Fan Motor Case Drain Test. (Group 9025-25.) • Remove and inspect fan pump and replace if necessary. 8. After performing this test, cycle key switch to restart engine. This will activate proportional fan drive.

Specification Used Fan—Minimum Pump Flow .................................................................................... 48.4 L/min 12.8 gpm

SJ25320,0000264 –19–05JAN07–3/3

Hydraulic Fan Motor Case Drain Test SPECIFICATIONS Case Drain Maximum Leakage/min

0.25 gal/min 945 mL/min 32 oz/min ESSENTIAL TOOLS

38H1415 Cap (-6 F ORFS)

9025 25 64

The purpose of this test is to determine if case drain leakage is within specification. Accelerated case drain can indicate excessive wear on internal components. 1. Install frame locking bar. 2. Drain or apply vacuum to hydraulic reservoir. 3. Perform Hydraulic Oil Warmup Procedure. (Group 9025-25.)

Continued on next page

TM10229 (17MAR09)

9025-25-64

SJ25320,00002A4 –19–18SEP07–1/3

544J Loader (S.N. 611800— ) 032409

PN=1032

Test

T195095

–UN–06OCT03

9025 25 65

1—Fan Pump Inlet From Reservoir 2—Fan Pump 3—Fan Motor

4—Fan Proportional Solenoid 5—Reverse Fan Solenoid 6—Fan Reversing Valve

7—Fan Pump Outlet-to-Fan Reversing Valve Hose 8—Fan Reversing Valve Return-to-Filter Hose

9—Fan Motor Return-to-Filter Hose

4. Disconnect return hose (9) from hydraulic filter head and close opening with cap.

Continued on next page

TM10229 (17MAR09)

9025-25-65

SJ25320,00002A4 –19–18SEP07–2/3

544J Loader (S.N. 611800— ) 032409

PN=1033

Test IMPORTANT: A non-adjustable flowmeter is the best tool for this test. If using an adjustable flowmeter, flowmeter control valve must be open at all times. Serious hydraulic pump damage may result if pump back pressure is increased. 5. Connect non-adjustable flow meter in line between test hose and return hose (9). Route test hose to reservoir.

Specification Case Drain—Maximum Leakage/min .................................................................... 0.25 gal/min 945 mL/min 32 oz/min

8. If case drain flow is not within specification, disassemble and inspect seals for damage. Replace seals if they appear worn or damaged and re-run test. Replace motor if seals show no visual signs of damage.

6. Remove vacuum and/or fill hydraulic reservoir. 7. Operate engine at fast idle and record case drain flow. Case drain flow must be within specification.

SJ25320,00002A4 –19–18SEP07–3/3

Hydraulic Oil Filter Inspection Procedure ESSENTIAL TOOLS JT05536 Oil Filter Cutting Tool

9025 25 66

CED,TX13067,39 –19–16SEP92–1/2

1. Remove filter. 2. Pour oil out of filter to inspect for water contamination.

5. Excessive amounts of brass and steel particles can indicate a failed hydraulic pump or a pump failure in progress. A rubber type material can indicate cylinder packing failure.

T6238AK

4. Remove filter element and inspect for metal particles and debris in bottom of filter can.

–UN–13MAR89

3. Use an oil filter cutting tool to cut top off filter.

CED,TX13067,39 –19–16SEP92–2/2

TM10229 (17MAR09)

9025-25-66

544J Loader (S.N. 611800— ) 032409

PN=1034

Section 9031

Heating And Air Conditioning Contents Page

Group 05—Theory Of Operation Air Conditioning System Cycle Of Operation. . . . . . . . . . . . . . . . . . . . . . . . . .9031-05-1 Group 15—Diagnostic Information Air Conditioning System Diagnose Malfunctions . . . . . . . . . . . . . . . . . . . . . . .9031-15-1 Air Conditioning System Does Not Operate Diagnostic Procedure. . . . . . . . . . . . . . . . .9031-15-1 Air Conditioner Does Not Cool Interior of Cab Diagnostic Procedure. . . . . . . . . . . . . . . . .9031-15-3 Air Conditioner Runs Constantly, Too Cold Diagnostic Procedure. . . . . . . . . . . . . . . . .9031-15-5 Interior Windows Continue to Fog Diagnostic Procedure . . . . . . . . . . . . . . . . . . . . . . . . .9031-15-6 Heater System Diagnose Malfunctions . . . . .9031-15-6 Heater System Does Not Operate Diagnostic Procedure . . . . . . . . . . . . . . . . . . . . . . . . .9031-15-6 Heater Does Not Warm Interior of Cab Diagnostic Procedure. . . . . . . . . . . . . . . . .9031-15-8 Interior Windows Continue to Fog Diagnostic Procedure . . . . . . . . . . . . . . . . . . . . . . . . .9031-15-9 Group 25—Tests Air Conditioning System Fittings Reference Chart . . . . . . . . . . . . . . . . . . . .9031-25-1 Refrigerant Cautions and Proper Handling . . . . . . . . . . . . . . . . . . . . . . . . . .9031-25-3 R134a Oil Charge Capacity. . . . . . . . . . . . . .9031-25-4 R134a Refrigerant Charge Capacity . . . . . . .9031-25-4 Refrigerant Hoses And Tubing Inspection . . .9031-25-5 R134a Air Conditioning System Test . . . . . . .9031-25-6 Operating Pressure Diagnostic Chart . . . . . .9031-25-8 Air Conditioning High/Low Pressure Switch Test . . . . . . . . . . . . . . . . . . . . . . .9031-25-11 Freeze Control Switch Test . . . . . . . . . . . . .9031-25-13 Refrigerant Leak Testing . . . . . . . . . . . . . . .9031-25-14

TM10229 (17MAR09)

9031-1

9031

544J Loader (S.N. 611800— ) 032409

PN=1

Contents

9031

TM10229 (17MAR09)

9031-2

544J Loader (S.N. 611800— ) 032409

PN=2

Group 05

Theory Of Operation Air Conditioning System Cycle Of Operation

7 8

6 –UN–20JUN01

9 10

T142307

11 T142307 1—Evaporator Core 2—Compressor 3—Condenser Core

4—Circulation Blower Motor 5—Expansion Valve 6—Receiver-Dryer

The compressor is belt driven and engaged by an electro-magnetic clutch. The air conditioning circuit automatically controls compressor engagement or disengagement when system is in operation. See System Functional Schematic and Section Legend. (Group 9015-10.) Compressor draws low pressure gas from evaporator and compresses it into high pressure gas. This causes

7—High Pressure Liquid 8—High Pressure Gas 9—Low Pressure Liquid

9031 05 1

temperature of refrigerant to rise higher than that of outside air. High pressure gas leaves compressor and flows through condenser where heat is removed and transferred to outside air being drawn through condenser core by fan. Cooling refrigerant causes it to condense and refrigerant leaves condenser as high pressure liquid.

Continued on next page

TM10229 (17MAR09)

10—Low Pressure Gas 11—Air Flow

9031-05-1

AA95137,00005C0 –19–04JAN07–1/2

544J Loader (S.N. 611800— ) 032409

PN=1037

Theory Of Operation High pressure liquid flows into receiver-dryer where moisture and contaminants (acid, solids, etc.) are removed. Receiver-dryer may contain 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. Receiver-dryer also stores refrigerant allowing a longer period of time before additional refrigerant is needed. Refrigerant hoses allow a small amount of refrigerant to migrate through their walls.

A freeze control switch senses temperature of evaporator coil through a capillary tube. This prevents the evaporator from becoming cold enough to freeze moisture that condenses on evaporator coil. Condensed moisture is drained away through drain tubes connected to drain pan under evaporator.

Refrigerant flows from receiver-dryer through expansion valve to evaporator. Expansion valve senses refrigerant temperature and pressure to modulate refrigerant flow. Expansion valve changes refrigerant to low pressure liquid entering evaporator. Actual cooling and drying of cab air takes place at evaporator. Heat absorbed by evaporator and transferred to refrigerant causes refrigerant to vaporize into low pressure gas. Low pressure gas is drawn from evaporator by compressor and cycle is repeated.

Accumulator is located between evaporator and compressor in low pressure gas hose to retain a quantity of oil to protect compressor from a dry start after long periods of not being used.

System pressure is monitored by high and low pressure switch, located on high pressure side of expansion valve. If pressure becomes too high or too low the switch opens and stops compressor, interrupting the cycle.

For location of machine heater and A/C components, see Heater and Air Conditioner Harness (W20) Component Location. (Group 9015-10.) .

AA95137,00005C0 –19–04JAN07–2/2

9031 05 2

TM10229 (17MAR09)

9031-05-2

544J Loader (S.N. 611800— ) 032409

PN=1038

Group 15

Diagnostic Information Air Conditioning System Diagnose Malfunctions

AA95137,0000996 –19–05JUN07–1/1

Air Conditioning System Does Not Operate Diagnostic Procedure

– – –1/1

1 Fuse Check

Remove fuses (F05 and F33). See Fuse and Relay Specifications. (Group 9015-10.)

YES: Go to Blower Speed Switch Check.

Check continuity of fuses (F05 and F33). NO: Replace fuse(s) without continuity indicated.

Is continuity indicated?

– – –1/1

2 Blower Speed Switch Check

Check blower speed switch (S21). See Load Center Harness (W3) Component Location. (Group 9015-10.)

YES: Go to Blower Speed Resistor Check.

Check continuity of blower speed switch (S21) in all switch positions. See Load Center Harness (W3) Wiring Diagram. (Group 9015-10.)

NO: Blower speed switch (S21) malfunction. Replace switch.

Switch Position

Continuity Between Pins

Off

No Continuity

Low

1 and Battery Power

Medium

1, 2 and Battery Power

High

1, 3 and Battery Power

Maximum

1, 4 and Battery Power

Is switch operating properly?

9031 15 1 – – –1/1

TM10229 (17MAR09)

9031-15-1

544J Loader (S.N. 611800— ) 032409

PN=1039

Diagnostic Information 3 Blower Speed Resistor Check

Disconnect blower speed resistor (R3). See Heater and Air Conditioner Harness (W20) Component Location. (Group 9015-10.)

YES: Go to Blower Motor Check.

Measure low-speed resistance between terminals 2 and 4 on blower speed resistor (R3).

NO: Blower speed resistor (R3) malfunction. Replace resistor.

Measure medium-speed resistance between terminals 2 and 3 on blower speed resistor (R3). Measure high-speed resistance between terminals 2 and 1 on blower speed resistor (R3). Compare resistance values to specification. Specification Blower Speed Resistor (R3)— Low-Speed Resistance .......................................................................... 3.07—3.75 ohms Medium-Speed Resistance .................................................................... 1.40—1.72 ohms High-Speed Resistance .......................................................................... 0.58—0.70 ohms Are all resistance values within specification?

– – –1/1

4 Blower Motor Check

Disconnect blower motor (M6). See Heater and Air Conditioner Harness (W20) Component Location. (Group 9015-10.)

YES: Go to Pressurizer Motor Check.

Supply 24 volts and ground to blower motor (M6).

NO: Motor malfunction. Replace blower motor (M6).

Does motor run?

– – –1/1

5 Pressurizer Motor Check

Disconnect pressurizer blower motor (M7). See Heater and Air Conditioner Harness (W20) Component Location. (Group 9015-10.)

YES: Go to A/C (On/Off) Switch Check.

Supply 24 volts and ground to pressurizer blower motor (M7).

NO: Motor malfunction. Replace pressurizer blower motor (M7).

Does motor run?

– – –1/1

6 A/C (On/Off) Switch Check

Turn key switch ON.

YES: Go to Freeze Control Switch Check.

Access the Diagnostics / Switch Module menu on the CAN monitor unit (CMU). See CAN Monitor Unit (CMU) Menu Structure—Service Mode. (Group 9015-20.)

9031 15 2

Push the A/C (on/off) switch on the sealed switch module (SSM).

NO: See SSM trouble code 523528.10—A/C Keypad Stuck. (Group 9001-50.)

Does the corresponding light on the CMU turn white when A/C (on/off) switch is pushed?

– – –1/1

7 Freeze Control Switch Check

Test freeze control switch (B35). See Freeze Control Switch Test. (Group 9031-25.)

YES: Go to A/C Binary Pressure Switch Check.

Does freeze control switch (B35) test good? NO: Freeze control switch (B35) malfunction. Replace switch. – – –1/1

TM10229 (17MAR09)

9031-15-2

544J Loader (S.N. 611800— ) 032409

PN=1040

Diagnostic Information 8 A/C Binary Pressure Switch Check

Test A/C binary pressure switch (B50). See Air Conditioning High/Low Pressure Switch Test. (Group 9031-25.)

YES: Go to A/C Clutch Diode Check.

Does A/C binary pressure switch (B50) test good?

NO: A/C binary pressure switch (B50) malfunction. Replace switch. – – –1/1

9 A/C Clutch Diode Check

Remove A/C clutch 1-amp diode (V11). See Engine Harness (W6) Component Location. (Group 9015-10.)

YES: Go to A/C Compressor Clutch Check.

Check continuity of A/C clutch diode (V11) between terminals, then reverse test leads and repeat continuity check. Is continuity indicated in one direction but not the other?

NO: A/C clutch diode (V11) malfunction. Replace diode.

– – –1/1

10 A/C Compressor Clutch Check

Disconnect A/C compressor clutch (Y16). See Engine Harness (W6) Component Location. (Group 9015-10.)

YES: Go to Wiring Harness Check.

Measure resistance between pins A and B on A/C compressor clutch (Y16) connector.

NO: A/C compressor clutch (Y16) malfunction. Replace compressor clutch.

Compare resistance to specification. Specification A/C Compressor Clutch (Y16)— Resistance .............................................................................................. 12.6—15.4 ohms Is resistance within specification?

– – –1/1

11 Wiring Harness Check

Check A/C system wiring for open and short circuits. For schematic, see Flex Load Controller (FLC) Circuit Theory of Operation. (Group 9015-15.) For wiring diagrams, see Load Center Harness (W3) Wiring Diagram, see Engine Harness (W6) Wiring Diagram, and see Heater and Air Conditioner Harness (W20) Wiring Diagram. (Group 9015-10.)

YES: Checks complete. NO: Repair or replace air 9031 conditioner wiring. 15 3

Is air conditioner wiring OK?

– – –1/1

Air Conditioner Does Not Cool Interior of Cab Diagnostic Procedure

– – –1/1

TM10229 (17MAR09)

9031-15-3

544J Loader (S.N. 611800— ) 032409

PN=1041

Diagnostic Information 1 Fresh Air Filter Component Check

Check fresh air filter for debris or air flow restrictions.

YES: Replace fresh air filter.

Is fresh air filter clogged? NO: Go to Condenser Restriction Check. – – –1/1

2 Condenser Restriction Check

Check condenser fins for air flow restrictions.

YES: Clean condenser fins.

Are condenser fins clogged with debris? NO: Go to Recirculating Air Filter Restriction Check. – – –1/1

3 Recirculating Air Filter Restriction Check

Check recirculating air filter for flow restrictions.

YES: Clean or replace recirculating air filter.

Is recirculating air filter dirty or clogged with debris? NO: Go to Refrigerant Hose Restriction Check. – – –1/1

4 Refrigerant Hose Restriction Check

Check refrigerant hoses. See Refrigerant Hoses And Tubing Inspection. (Group 9031-25.)

YES: Reroute or re-index hoses. Replace kinked or collapsed hoses.

Are any hoses kinked, pinched or collapsed? NO: Go to Condenser Core and Evaporator Core Air Flow Restriction Check.

– – –1/1

9031 15 4

5 Condenser Core and Evaporator Core Air Flow Restriction Check

Check condenser core and evaporator core fins for debris. Are the condenser core or evaporator core fins clogged with debris?

YES: Clean condenser core and evaporator core fins. NO: Go to Blower Motor and Blower Speed Resistor Check.

– – –1/1

TM10229 (17MAR09)

9031-15-4

544J Loader (S.N. 611800— ) 032409

PN=1042

Diagnostic Information 6 Blower Motor and Blower Speed Resistor Check

Check blower motor (M6) by applying 24 volts to the motor. Check to see if motor is running when voltage is applied. See Heater and Air Conditioner Harness (W20) Component Location. (Group 9015-10.) Check blower speed resistor (R3). See Heater and Air Conditioner Harness (W20) Wiring Diagram. (Group 9015-10.) For specifications, see Electrical Component Specifications. (Group 9015-20.)

YES: Go to Compressor Belt Check. NO: Replace heater blower motor and/or resistor.

Are heater blower motor and cab heater blower resistor both functioning properly?

– – –1/1

7 Compressor Belt Check

Check A/C compressor belt. See Inspect A/C Compressor and Alternator Belt. (Operator’s Manual.)

YES: Go to Cab Seals Check.

Is belt tension OK?

NO: Adjust or replace belt. – – –1/1

8 Cab Seals Check

Check windows and doors to make sure seals are good.

YES: Go to System Refrigerant (R134a) Leak Check.

Are seals on all windows and doors functioning properly?

NO: Repair or replace malfunctioning seals. – – –1/1

9 System Refrigerant (R134a) Leak Check

Check for leaks in refrigerant system. See Refrigerant Leak Testing. (Group 9031-25.) Are any leaks present in refrigerant system?

YES: Repair or replace hoses and recharge system. See R134a System Charge. (Group 1830.) NO: Charge system. See R134a System Charge. (Group 1830.) Go to Evaporator Core Fins Check. 9031 15 5 – – –1/1

10 Evaporator Core Fins Check

Check evaporator core fins for frosting or freezing. Is there any ice or frost on evaporator fins?

YES: Thermostat switch not positioned correctly in evaporator core. Reposition switch. NO: Checks complete. – – –1/1

Air Conditioner Runs Constantly, Too Cold Diagnostic Procedure

– – –1/1

TM10229 (17MAR09)

9031-15-5

544J Loader (S.N. 611800— ) 032409

PN=1043

Diagnostic Information 1 Evaporator Core Component Check

Check evaporator core fins for frosting or freezing.

YES: Thermostat switch not positioned correctly in evaporator core. Reposition switch in evaporator core.

Is there any ice or frost on evaporator fins?

NO: Compressor clutch running constantly. Go to Freeze Control Switch Check.

– – –1/1

2 Freeze Control Switch Check

Remove freeze control switch (B35). See Heater and Air Conditioner Harness (W20) Component Location. (Group 9015-10.) Check freeze control switch (B35). See Freeze Control Switch Test. (Group 9031-25.)

YES: Checks complete. NO: Switch malfunction. Replace air conditioning freeze switch (B22).

Does freeze control switch (B35) test good? – – –1/1

Interior Windows Continue to Fog Diagnostic Procedure

– – –1/1

1 Fresh Air Filter Component Check

Check fresh air filter for debris or air flow restrictions.

YES: Replace fresh air filter.

Is fresh air filter clogged? NO: Checks complete.

– – –1/1

Heater System Diagnose Malfunctions 9031 15 6 AA95137,0000997 –19–05JUN07–1/1

Heater System Does Not Operate Diagnostic Procedure

– – –1/1

1 Fuse Check

Remove fuses (F05 and F33). See Fuse and Relay Specifications. (Group 9015-10.)

YES: Go to Blower Speed Switch Check.

Check continuity of fuses (F05 and F33). NO: Replace fuse(s) without continuity indicated.

Is continuity indicated?

– – –1/1

TM10229 (17MAR09)

9031-15-6

544J Loader (S.N. 611800— ) 032409

PN=1044

Diagnostic Information 2 Blower Speed Switch Check

Check blower speed switch (S21). See Load Center Harness (W3) Component Location. (Group 9015-10.)

YES: Go to Blower Speed Resistor Check.

Check continuity of blower speed switch (S21) in all switch positions. See Load Center Harness (W3) Wiring Diagram. (Group 9015-10.)

NO: Blower speed switch (S21) malfunction. Replace switch.

Switch Position

Continuity Between Pins

Off

No Continuity

Low

1 and Battery Power

Medium

1, 2 and Battery Power

High

1, 3 and Battery Power

Maximum

1, 4 and Battery Power

Is switch operating properly?

– – –1/1

3 Blower Speed Resistor Check

Disconnect blower speed resistor (R3). See Heater and Air Conditioner Harness (W20) Component Location. (Group 9015-10.)

YES: Go to Wiring Harness Check.

Measure low-speed resistance between terminals 2 and 4 on blower speed resistor (R3).

NO: Blower speed resistor (R3) malfunction. Replace resistor.

Are all resistance values within specification?

– – –1/1

4 Wiring Harness Check

YES: Checks complete. NO: Repair or replace air conditioner wiring.

Is air conditioner wiring OK?

– – –1/1

TM10229 (17MAR09)

9031-15-7

544J Loader (S.N. 611800— ) 032409

PN=1045

Diagnostic Information Heater Does Not Warm Interior of Cab Diagnostic Procedure

– – –1/1

1 Fresh Air Filter Component Check

Check fresh air filter for debris or air flow restrictions.

YES: Replace fresh air filter.

Is fresh air filter clogged? NO: Go to Recirculating Air Filter Restriction Check. – – –1/1

2 Recirculating Air Filter Restriction Check

Check recirculating air filter for flow restrictions.

YES: Clean or replace recirculating air filter.

Is recirculating air filter dirty or clogged with debris? NO: Go to Refrigerant Hose Restriction Check. – – –1/1

3 Refrigerant Hose Restriction Check

Check refrigerant hoses. See Refrigerant Hoses And Tubing Inspection. (Group 9031-25.)

YES: Reroute or re-index hoses. Replace kinked or collapsed hoses.

Are any hoses kinked, pinched or collapsed? NO: Go to Condenser Core and Evaporator Core Air Flow Restriction Check.

– – –1/1

9031 15 8

4 Condenser Core and Evaporator Core Air Flow Restriction Check

Check condenser core and evaporator core fins for debris. Are the condenser core or evaporator core fins clogged with debris?

YES: Clean condenser core and evaporator core fins. NO: Go to Blower Motor Check. – – –1/1

5 Blower Motor Check

Disconnect blower motor (M6). See Heater and Air Conditioner Harness (W20) Component Location. (Group 9015-10.)

YES: Go to Heater Valve Check.

Supply 24 volts and ground to blower motor (M6).

NO: Motor malfunction. Replace blower motor (M6).

Does motor run?

– – –1/1

6 Heater Valve Check

Inspect heater valve cable or adjust as necessary.

YES: Checks complete.

Is cable adjusted properly and connected to heater valve?

NO: Replace heater valve cable.

– – –1/1

TM10229 (17MAR09)

9031-15-8

544J Loader (S.N. 611800— ) 032409

PN=1046

Diagnostic Information Interior Windows Continue to Fog Diagnostic Procedure

– – –1/1

1 Fresh Air Filter Component Check

Check fresh air filter for debris or air flow restrictions.

YES: Replace fresh air filter.

Is fresh air filter clogged? NO: Checks complete.

– – –1/1

9031 15 9

TM10229 (17MAR09)

9031-15-9

544J Loader (S.N. 611800— ) 032409

PN=1047

Diagnostic Information

9031 15 10

TM10229 (17MAR09)

9031-15-10

544J Loader (S.N. 611800— ) 032409

PN=1048

Group 25

Tests Air Conditioning System Fittings Reference Chart SERVICE EQUIPMENT AND TOOLS JT02098 Flush Fitting Kit

The JT02098 Flush Fitting Kit contains fittings for flushing or leak testing sections or individual components to the air conditioning system. Following chart lists service fittings used at each specific location. Continued on next page

CED,OUOE012,235 –19–02AUG99–1/2

9031 25 1

TM10229 (17MAR09)

9031-25-1

544J Loader (S.N. 611800— ) 032409

PN=1049

Tests Location

Size

ServiceGard Number

O-Ring Number

1. Suction Port (F)

7/8—18

JT02099

R113050

2. Discharge Port (F)

3/4—18

JT02100

3. Inlet End (M)

3/4—18

JT02102

R113050

4. Outlet End (F)

3/4—18

JT02100

R113050

5. Inlet Port (M)

3/4—18

JT02102

6. Outlet Port (M)

5/8—18

JT03183

7. Inlet End (F)

5/8—18

JT03188

R10093

8. Outlet End (M)

5/8—18

JT03197

R10093

9. Inlet Port (F)

5/8—18

JT03196 or JT02110

10. Outlet Port (M)

5/8—18

JT03183

11. Inlet End (F)

5/8—18

JT03188

12. Outlet End (M)

5/8—18

JT03183

13. Inlet End (F)

5/8—18

JT03188

R10093

14. Outlet End (M)

3/8

JT02106 and JT02104

R10093

3/8

JT02103

Compressor Manifold:

Compressor Discharge Hose:

Condenser:

Condenser to Receiver-Dryer Hose:

Receiver-Dryer:

Receiver-Dryer to Evaporator Hose: R10093

A/C Inlet Tube

Expansion Valve: 15. Liquid Inlet (F) 16. Liquid Outlet (F)

1/2

JT02104

19. Gas Inlet (F)

5/8

JT02105

20. Gas Outlet (F)

3/4

JT02147

17. Inlet Tube (M)

1/2

JT02106 and JT02103

R113050

18. Outlet Tube (M)

5/8

JT02106 and JT02105

R33259

21. Inlet End (M)

3/4

TEV and JT02105

T143169

22. Outlet End (F)

1-1/16—14

Not Available

T143169

23. Inlet End (M)

1-1/16—14

Not Available

24. Outlet End (M)

7/8—18

JT02101

Evaporator Core:

A/C Outlet Tube:

9031 25 2

Evaporator to Compressor Hose

R33259

CED,OUOE012,235 –19–02AUG99–2/2

TM10229 (17MAR09)

9031-25-2

544J Loader (S.N. 611800— ) 032409

PN=1050

Tests

Refrigerant Cautions and Proper Handling 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.

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.

Use correct refrigerant recovery, recycling and charging stations. Never mix refrigerants, hoses, fittings, components or refrigerant oils.

DO NOT allow refrigerant to contact open flames or very hot surfaces such as electric welding arc, electric heating element and lighted smoking materials.

Use only John Deere approved R134a refrigerant products. Mixing of products not compatible will cause system damage and contaminate recovery, recycling and charging station equipment. Care must be taken to identify and use equipment, refrigerant oil and refrigerant designed only for R134a refrigerant systems. Refrigerant should be tested for type and purity before recovery, recycling or charging of system. JT02167A refrigerant test instrument should be used before any testing or repair to system is preformed.

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,

9031 25 3

Continued on next page

TM10229 (17MAR09)

9031-25-3

LD30992,00000A1 –19–08SEP03–1/2

544J Loader (S.N. 611800— ) 032409

PN=1051

Tests Prism Pro Refrigerant Identification Instrument . . . . . . . . . . . . . . . . . . . . . . . JT02167A To safely identify type and check purity of refrigerant prior to recovery, recycling and recharging of A/C systems.

LD30992,00000A1 –19–08SEP03–2/2

R134a Oil Charge Capacity Item

Measurement

Specification

Oil Charge

Capacity

336 mL 11.36 fl oz

TX14826,000009E –19–21AUG03–1/1

R134a Refrigerant Charge Capacity

9031 25 4

Item

Measurement

Specification

Refrigerant Charge (Automated Charge Station)

Capacity

2.268 kg 5 lb

Item

Measurement

Specification

Refrigerant Charge (Portable Charge Station)

Capacity

2.381 kg 5.25 lb SJ25320,0000333 –19–12DEC06–1/1

TM10229 (17MAR09)

9031-25-4

544J Loader (S.N. 611800— ) 032409

PN=1052

Tests

Refrigerant Hoses And Tubing Inspection When a component is disconnected from the system, special care should be given to inspecting hoses and tubing for moisture, grease, dirt, rust, or other foreign material. If such contamination is present in hoses, tubing, or fittings and cannot be removed by cleaning, then replace parts.

hose and tube connections. Dip O-rings in correct viscosity oil before assembling. IMPORTANT: Hose used for air conditioning systems contains special barriers in its walls to prevent migration of refrigerant gas.

Fittings that have grease or dirt on them should be wiped clean with a cloth dampened with alcohol. Chlorinated solvents (such as trichloroethylene) are contaminants, and must not be used for cleaning. To assist in making leak-proof joints, use a small amount of clean correct viscosity refrigerant oil on all

DO NOT use hydraulic hoses as replacement hoses in the air conditioning system. Use ONLY certified hose meeting SAE J51B requirements.

MODTX9031QQ1882 –19–17JUN94–1/1

9031 25 5

TM10229 (17MAR09)

9031-25-5

544J Loader (S.N. 611800— ) 032409

PN=1053

Tests

R134a Air Conditioning System Test SPECIFICATIONS Cab Position

Open

Engine rpm

2000 rpm

Temperature Control Switch Position

Maximum

Blower Speed

High

Run Unit Time

At least 5 minutes ESSENTIAL TOOLS

JT02045 R134a Refrigerant Recovery/Recycling and Charging Station

NOTE: Disengage proportional fan drive before doing test. Set fan speed to 100% by accessing Machine Config under Main Menu in the CAN Monitor Unit (CMU). See CAN Monitor Unit (CMU) Circuit Theory of Operation. Temperature/Pressure Chart 544J Ambient Temperature

Air Duct Temperature

Low Pressure Gauge

High Pressure Gauge

15.6—21.1°C (60—70°F)

8°C (46°F)

68.9—103.4 kPa

965.3—1013.5 kPa

21.1—26.7°C (70—80°F)

8°C (47°F)

68.9—104.4 kPa

985.0—1241 kPa

26.7—32.2°C (80—90°F)

11°C (51°F)

89.6—137.9 kPa

1172—1482 kPa

32.2—37.8°C (90—100°F)

14°C (58°F)

124.1—144.8 kPa

1379—1724 kPa

37.8—43.4°C (100—110°F)

18°C (64°F)

137.9—172.4 kPa

1586—2172 kPa

NOTE: JTO2046 and JTO2050 Recovery and Charging Stations can be substituted for the JTO2045 station.

9031 25 6

IMPORTANT: Use correct refrigerant recovery, recycling and charging stations. DO NOT use refrigerant, hoses, fittings, components or refrigerant oils intended for R12 refrigerant. 1. Connect refrigerant recovery, recycling and charging station. See Refrigerant Cautions and Proper Handling. (Group 9031-25.) 2. Close both low and high pressure valves on refrigerant recovery, recycling and charging station. 3. Open cab doors and windows. Disconnect Proportional Fan Solenoid (Y37) and Reverse Fan Solenoid (Y38).

Continued on next page

TM10229 (17MAR09)

9031-25-6

SJ25320,00002BB –19–18DEC06–1/3

544J Loader (S.N. 611800— ) 032409

PN=1054

Tests Specification Cab—Position .................................................................................... Open

SJ25320,00002BB –19–18DEC06–2/3

4. Start engine and run at rated engine speed. Specification Engine—Speed ........................................................................... 2000 rpm

5. Turn temperature control switch to the maximum cooling position. Specification Temperature Control Switch— Position ........................................................................................ Maximum

6. Turn blower switch to high speed. Specification Blower—Speed .................................................................................... High

7. Check sight glass in receiver-dryer to condenser line. 8. Run unit for at least 5 minutes. –UN–06DEC93

Specification Run Unit—Time ............................................................. At least 5 minutes

T8118AG

9. Measure air temperature at condenser air inlet and at air ducts in air conditioning unit. 10. Compare air duct temperature reading to the temperatures shown in the specifications. 11. Observe low-side pressure (C) and high-side pressure (B) on gauges. 12. Compare pressure readings to the pressure shown in specifications. See Operating Pressure Diagnostic Chart. (Group 9031-25.)

A—High Pressure Hose Charge Port Cap B—Red Hose (High Pressure) C—Blue Hose (Low Pressure) D—High Pressure Relief Valve E—Refrigerant Recovery/Recycling and Charging System

9031 25 7

SJ25320,00002BB –19–18DEC06–3/3

TM10229 (17MAR09)

9031-25-7

544J Loader (S.N. 611800— ) 032409

PN=1055

Tests

Operating Pressure Diagnostic Chart NOTE: Inspection of the sight glass will not give proper indicators of air conditioning concerns on R134a systems. OPERATING PRESSURE DIAGNOSTIC CHART

9031 25 8

Low Side Pressure

High Side Pressure

Problem

Solution

Low

Low or Normal

Loss of refrigerant.

Leak in system. Do leak test. Add refrigerant. Normal migration through hoses. Add refrigerant.

Low

Low or Normal

Loss of refrigerant.

Leak in system. Do leak test. Repair leak. Add refrigerant in this group.

Low

Low or Normal

Loss of refrigerant.

Normal migration through hoses. Add refrigerant in this group

Low

Low or Normal

Restriction in system: 1. Between compressor and condenser. 2. Inside condenser. 3. Between condenser and receiver-dryer. 4. Inside receiver-dryer.

Inspect for bent, kinked, or dented lines. Feel lines for a temperature change. Remove refrigerant by recovery method. Inspect and clean each component.

Low

Low or Normal

Blower motor running too slow.

Check for motor shaft binding or defective electrical connections.

Low

Low or Normal

Evaporator core dirty or air flow through evaporator restricted.

Clean evaporator and straighten fins.

Low

Low or Normal

Expansion valve malfunction.

Replace expansion valve.

Low

Low or Normal

Restriction in system: 1. Between receiver-dryer and expansion valve. 2. Between expansion valve and evaporator. 3. Between evaporator and compressor.

Inspect for bent, kinked, or dented lines. Feel lines for a temperature change. Remove refrigerant by recovery method. Inspect and clean each component.

Low

Low or Normal

Moisture in system.

Remove refrigerant using recovery method, evacuate and charge the system. See Recover R134a System. See Evacuate R134a System. See Charge R134a System. (Group 1830.)

Low

High

Restriction in system: 1. Between compressor and condenser. 2. Inside condenser. 3. Between condenser and receiver-dryer. 4. Inside receiver-dryer. 5. Between receiver-dryer and expansion valve.

Inspect for bent, kinked, or dented lines. Feel lines for a temperature change. Remove refrigerant by recovery method. Inspect and clean each component.

Normal

Heater valve not closing.

Close heater shut-off valve on engine block or clamp heater hoses shut

Continued on next page

TM10229 (17MAR09)

9031-25-8

TX,9031,SS3610 –19–17SEP07–1/3

544J Loader (S.N. 611800— ) 032409

PN=1056

Tests OPERATING PRESSURE DIAGNOSTIC CHART Low Side Pressure

High Side Pressure

Problem

Solution

Normal

Expansion valve malfunction.

Replace expansion valve.

Normal

Moisture in system (intermittent cooling below 27°C [80°F] ambient).

Remove refrigerant using recovery method, evacuate and charge the system. See Recover R134a System. See Evacuate R134a System. See Charge R134a System. (Group 1830.)

Normal

Loss of refrigerant.

Leak in system. Do leak test. Repair leak. Add refrigerant.

Normal

Loss of refrigerant

Normal migration through hoses. Add refrigerant in this group.

Normal

Air is system.

Remove refrigerant using recovery method, evacuate and charge the system. See Recover R134a System. See Evacuate R134a System. See Charge R134a System. (Group 1830.)

Normal

High

Restricted air flow through condenser or radiator.

Inspect for debris. Straighten fins.

Normal

High

Overcharge of refrigerant.

Start engine and run at fast idle. Operate air conditioner at maximum cooling. Remove refrigerant from low-side of system using recovery operation until bubbles appear in sight glass. Add 0.7 kg (1.5 lb) of refrigerant through low-side valve.

Normal

High

Expansion valve malfunction.

Replace expansion valve.

Normal

High

Restriction in system: 1. Between compressor and condenser. 2. Inside condenser. 3. Between condenser and receiver-dryer. 4. Inside receiver-dryer.

Inspect for bent, kinked, or dented lines. Feel lines for a temperature change. Remove refrigerant by recovery method. Inspect and clean each component.

Normal

High

Restriction in system: 1. Between compressor and condenser. 2. Inside condenser. 3. Between condenser and receiver-dryer. 4. Inside receiver-dryer.

Inspect for bent, kinked, or dented lines. Feel lines for a temperature change. Remove refrigerant by recovery method. Inspect and clean each component.

High

Low

Compressor belt loose.

Tighten belt.

High

Low

Compressor clutch slipping.

Check for battery voltage at compressor clutch with clutch engaged. Clean electrical connections or replace relay.

High

Low

Compressor clutch slipping.

Inspect and repair clutch.

High

Low

Compressor failure.

Test compressor efficiency. (Group 1830.)

High

Normal

Expansion valve malfunction.

Replace expansion valve.

High

Restricted air flow through condenser or radiator.

Inspect for debris. Straighten fins.

High

Expansion valve malfunction.

Replace expansion valve.

Continued on next page

TM10229 (17MAR09)

9031-25-9

9031 25 9

TX,9031,SS3610 –19–17SEP07–2/3

544J Loader (S.N. 611800— ) 032409

PN=1057

Tests OPERATING PRESSURE DIAGNOSTIC CHART Low Side Pressure

High Side Pressure

Problem

Solution

High

Overcharge of refrigerant.

Start engine and run at fast idle. Operate air conditioner at maximum cooling. Remove refrigerant from low-side of system using refrigerant recovery method until bubbles appear in sight glass. Add 0.7 kg (1.5 lb) of refrigerant through low-side valve.

High

Restriction in system:

Inspect for bent, kinked, or dented lines. Feel lines for a temperature change. Remove refrigerant by recovery method. Inspect and clean each component.

High

Air in system.

Remove refrigerant using recovery method, evacuate and charge the system. See Recover R134a System.See Evacuate R134a System. See Charge R134a System. (Group 1830.)

High

Restriction in system: 1. Between compressor and condenser. 2. Inside condenser. 3. Between condenser and receiver-dryer. 4. Inside receiver-dryer.

Inspect for bent, kinked, or dented lines. Feel lines for a temperature change. Remove refrigerant by recovery method. Inspect and clean each component.

TX,9031,SS3610 –19–17SEP07–3/3

9031 25 10

TM10229 (17MAR09)

9031-25-10

544J Loader (S.N. 611800— ) 032409

PN=1058

Tests

Air Conditioning High/Low Pressure Switch Test

Low Pressure

1.379—2.275 bar 20—33 psi

Low Pressure (Normally Open) Closing Pressure

158.6—255.1 kPa 1.586—2.551 bar

Low Pressure (Normally Open)

23—37 psi 2620—2895 kPa

High Pressure

26.20—28.95 bar 380—420 psi

High Pressure (Normally Closed) Closing Pressure

1379—2068 kPa 13.79—20.68 bar 200—300 psi

T8426AD

137.9—227.5 kPa –UN–06MAR95

SPECIFICATIONS Low Pressure Opening Pressure

ESSENTIAL TOOLS JT02148 Straight Connector SERVICE EQUIPMENT AND TOOLS Multimeter

NOTE: Low pressure switch is normally open when removed from machine. When installed the switch becomes closed because of normal system pressure. • Turn key switch on but do not start engine. Turn blower switch on. Turn temperature control switch to the maximum cooling position. • Disconnect and connect low pressure switch at harness connector. Compressor clutch must engage and disengage (click). NOTE: The line that attaches the low pressure switch has a valve to prevent discharging the air conditioning system when switch is removed.

9031 25 11

• Disconnect harness from switch and remove switch from line. Connect low pressure switch to harness. Specification Low Pressure—Opening Pressure ............................... 137.9—227.5 kPa 1.379—2.275 bar 20—33 psi

Continued on next page

TM10229 (17MAR09)

9031-25-11

SJ25320,0000279 –19–02FEB07–1/2

544J Loader (S.N. 611800— ) 032409

PN=1059

Tests Specification Low Pressure (Normally Open)— Closing Pressure ........................................................... 158.6—255.1 kPa 1.586—2.551 bar 23—37 psi

Compressor clutch must not engage (click). • The actual pressure setting of switch can be checked by connecting it to a pressure source such as a regulated air supply or dry nitrogen. • Switch must not have continuity between terminals until pressure increases to switch closing pressure specification. Slowly release pressure. Switch must have continuity until pressure decreases to switch opening pressure specification. • Connect a portable pressure source, such as dry nitrogen, to switch. Specification High Pressure—Opening Pressure .......................................................................... 2620—2895 kPa 26.20—28.95 bar 380—420 psi High Pressure (Normally Closed)—Closing Pressure ............................................. 1379—2068 kPa 13.79—20.68 bar 200—300 psi

9031 25 12

• Switch must have continuity between terminals until pressure increases to switch opening pressure specification. • Slowly release pressure. Switch must not have continuity until pressure decreases to switch closing pressure specification. • The switch can also be checked when installed in air conditioning system, however, pressure is slow to increase to test specification. Connect an air conditioning gauge set to service fittings at compressor. Cover condenser with paper or plastic to stop air flow. Operate air conditioner on maximum cooling. Note high-side pressure when high pressure switch opens and then closes.

SJ25320,0000279 –19–02FEB07–2/2

TM10229 (17MAR09)

9031-25-12

544J Loader (S.N. 611800— ) 032409

PN=1060

Tests

Freeze Control Switch Test -1.4—0.28°C 29.5—32.5°F

Freeze Control Switch (Normally Closed) Closes as Temperature rises Closing Temperature

1.38—3.06°C 34.5—37.5°F

• Remove freeze control switch from evaporator. • Connect ohmmeter to switch terminals. Switch must be closed at room temperature. • Put switch into a freezer (temperature must be below -0.56 ± 0.84°C [31 ± 1.5°F]). Switch must open, and continuity must not be read.

T7199EZ

Freeze Control Switch (Normally Closed) Opens As Temperature Drops Opening Temperature

–UN–13NOV90

SPECIFICATIONS

Specification Freeze Control Switch (Normally Closed) Opens As Temperature Drops—Opening Temperature .............................................. -1.4—0.28°C 29.5—32.5°F

• Remove switch from freezer. Put sensing tube into a glass of warm water. Switch must close, and continuity must be read. Specification Freeze Control Switch (Normally Closed) Closes As Temperature Rises—Closing Temperature ................................................ 1.38—3.06°C 34.5—37.5°F

• If switch does not open and close during testing, install new switch.

9031 25 13 SJ25320,0000278 –19–17NOV06–1/1

TM10229 (17MAR09)

9031-25-13

544J Loader (S.N. 611800— ) 032409

PN=1061

Tests

Refrigerant Leak Testing • If a leak detector is used, move the leak detector probe under the hoses and around the connections at a rate of 25 mm (1 in.) per second.

SPECIFICATIONS Move Leak Detector Speed

25 mm per second 1 in. per second

• Inspect all lines, fittings, and components for oily or dusty spots. When refrigerant leaks from the system, a small amount of oil is carried out with it. • A soap and water solution can be sprayed on the components in the system to form bubbles at the source of the leak.

Specification Move Leak Detector—Speed ................................ 25 mm per second 1 in. per second

• Some refrigerant manufacturers add dye to refrigerant to aid in leak detection.

SJ25320,0000277 –19–17NOV06–1/1

9031 25 14

TM10229 (17MAR09)

9031-25-14

544J Loader (S.N. 611800— ) 032409

PN=1062

Index Page

Page

Accumulator, brake Precharge test . . . . . . . . . . . . . . . . . . .9025-25-47 Adjustment Load sense differential and standby pressure . . . . . . . . . . . . . . . . . . . . . . .9025-20-1 Pilot control lever . . . . . . . . . . . . . . . . . .9025-20-2 Return-to-carry and boom height kickout . . . . . . . . . . . . . . . . . . . . . . . . .9025-20-1 Return-to-dig . . . . . . . . . . 9015-20-55, 9015-20-56, 9025-20-1 Air conditioning Freeze control switch test . . . . . . . . . . .9031-25-13 Hoses and tubing inspection . . . . . . . . . .9031-25-5 Leak testing . . . . . . . . . . . . . . . . . . . . .9031-25-14 Low pressure switch test. . . . . . . . . . . .9031-25-11 Pressure diagnostic chart . . . . . . . . . . . .9031-25-8 Refrigerant cycle . . . . . . . . . . . . . . . . . . .9031-05-1 R134a oil charge capacity. . . . . . . . . . . .9031-25-4 R134a Refrigerant charge capacity . . . . .9031-25-4 System Test . . . . . . . . . . . . . . . . . . . . . .9031-25-6 Air conditioning (A/C) circuit . . . . . . . . . . .9015-15-12 Air conditioning system Fittings reference chart . . . . . . . . . . . . . .9031-25-1 Alarm, backup Change volume. . . . . . . . . . . . . . . . . . .9015-20-61 Alternator Test . . . . . . . . . . . . . . . . . . . . . . . . . . .9015-20-63 Anticavitation Valve Operation . . . . . . . . . . . . . . . . . . . . . . .9025-05-48 Attachments Adding safely . . . . . . . . . . . . . . . . . . . .9000-01-13 Operating safely . . . . . . . . . . . . . . . . . .9000-01-13 Automatic shift and speedometer check Operational check . . . . . . . . . . . . . . . . . .9005-10-8 Auxiliary section Stroke Adjuster Operation . . . . . . . . . . .9025-05-31 Axle Breather test . . . . . . . . . . . . . . . . . . . . .9020-25-41 Circulation. . . . . . . . . . . . . . . . . . . . . . .9020-05-18 Diagnose malfunctions . . . . . . . . . . . . .9020-15-27 Differential lock . . . . . . . . . . . . . . . . . . .9020-05-17 Axle breather Test . . . . . . . . . . . . . . . . . . . . . . . . . . .9020-25-41 Axle circulation Dual pump operation. . . . . . . . . . . . . . .9020-05-18 Axle circulation dual pump Flow test . . . . . . . . . . . . . . . . . . . . . . . .9020-25-39 Axle pumps Circulation. . . . . . . . . . . . . . . . . . . . . . .9020-05-18

Backup alarm Change volume. . . . . . . . . . . . . . . . . . .9015-20-61 Battery check Operational checks . . . . . . . . . . . . . . . . .9005-10-2 Battery explosions Prevent . . . . . . . . . . . . . . . . . . . . . . . . . .9000-01-5 Beacon light circuit . . . . . . . . . . . . . . . . . .9015-15-12 Blade terminals Remove from connector body . . . . . . . .9015-20-79 Bleeding procedure Service brake . . . . . . . . . . . . . . . . . . . . .9020-20-1 Blower and A/C harness (W19) Component location . . . . . . . . . . . . . . 9015-10-104 Wiring diagram . . . . . . . . . . . . . . . . . . 9015-10-106 Boom and bucket cylinder drift check Operational check . . . . . . . . . . . . . . . . .9005-10-17 Boom down accumulator Precharge test . . . . . . . . . . . . . . . . . . .9025-25-49 Boom height kickout Adjustment . . . . . . . . . . . . . . . . . . . . . .9015-20-54 Boom height kickout (BHKO) circuit . . . . .9015-15-12 Boom height kickout check Operational check . . . . . . . . . . . . . . . . .9005-10-15 Boom section Boom down and steering operation. . . .9025-05-26 Boom raise and bucket dump . . . . . . . .9025-05-28 Brake Bleeding procedure . . . . . . . . . . . . . . . . .9020-20-1 Service brake hydraulic system. . . . . . .9025-05-15 Service, diagnose malfunctions . . . . . . .9020-15-34 Test . . . . . . . . . . . . . . . . . . . . . . . . . . .9025-25-58 Brake accumulator Check valve . . . . . . . . . . . . . . . . . . . . .9025-25-58 Operation . . . . . . . . . . . . . . . . . . . . . . .9025-05-16 Precharge test . . . . . . . . . . . . . . . . . . .9025-25-47 Brake valve Operation . . . . . . . . . . . . . . . . . . . . . . .9025-05-18 Brake vavle Pressure test. . . . . . . . . . . . . . . . . . . . .9025-25-52 Bucket section Boom raise and bucket dump . . . . . . . .9025-05-30 Bypass valve Operation . . . . . . . . . . . . . . . . . . . . . . .9020-05-14

TM10229 (17MAR09)

C Cab roof harness (W19) Component location . . . . . . . . . . . . . . 9015-10-100 Wiring diagram . . . . . . . . . . . . . . . . . . 9015-10-102

Index-1

544J Loader (S.N. 611800— ) 032409

PN=1

Indx 1

Index

Indx 2

Page

Cab system Operational checks . . . . . . . . . . . . . . . . .9005-10-3 CAN circuit Test . . . . . . . . . . . . . . . . . . . . . . . . . . .9015-20-41 CAN monitor unit (CMU) Diagnostic trouble codes (DTC) . . . . . . .9001-10-1 CAN Monitor Unit (CMU) Menu Structure-Service Mode. . . . . . . .9015-20-20 Remove and install . . . . . . . . . . . . . . . .9015-20-84 Reprogram . . . . . . . . . . . . . . . . . . . . . .9015-20-84 Theory of operation. . . . . . . . . . . . . . . .9015-15-32 Charging circuit Theory of operation. . . . . . . . . . . . . . . . .9015-15-1 Check and adjust Engine speed . . . . . . . . . . . . . . . . . . . . .9010-25-1 Chemical products Handling . . . . . . . . . . . . . . . . . . . . . . . . .9000-01-6 Cinch connector Install contact . . . . . . . . . . . . . . . . . . . .9015-20-75 Cinch connector (32 and 48 Way) Repair . . . . . . . . . . . . . . . . . . . . . . . . . .9015-20-76 Cinch connectors Replace Connector . . . . . . . . . . . . . . . .9015-20-73 Circuit Modulation . . . . . . . . . . . . . . . . . . . . . .9020-05-10 Circuit relief valve Pressure test. . . . . . . . . . . . . . . . . . . . .9025-25-16 Circuit relief valve operation . . . . . . . . . . .9025-05-41 Clutch cut-off check Operational check . . . . . . . . . . . . . . . . . .9005-10-7 Clutch cutoff sensor Adjustment . . . . . . . . . . . . . . . . . . . . . .9015-20-53 Check . . . . . . . . . . . . . . . . . . . . . . . . . .9015-20-53 Clutch modulation Transmission. . . . . . . . . . . . . . . . . . . . .9020-05-13 Clutch pressure test Transmission. . . . . . . . . . . . . . . . . . . . .9020-25-10 Component location Cab roof harness (W19) . . . . . . . . . . . 9015-10-100 Electrical, GlobalTRACS terminal (GTT) harness (W29) . . . . . . . . . . . . . . . . . . . . . . . 9015-10-108 Electrical, machine information gateway (MIG) harness (W30). . . . . . . . . . . . . . . . . 9015-10-108 Engine cooling system . . . . . . . . . . . . . .9010-15-2 Information . . . . . . . . . . . . . . . . . . . . . . .9015-05-2 Loader hydraulic system . . . . . . . . . . . . .9025-15-4 Power train . . . . . . . . . . . . . . . . . . . . . . .9020-15-6 Components Transmission control valve . . . . . . . . . .9020-05-10 Connection procedure JDLink . . . . . . . . . . . . . . . . . . . . . . . .9015-20-19 Connector Metri-Pack. . . . . . . . . . . . . . . . . . . . . . .9015-20-66

Connector body Blade terminals remove . . . . . . . . . . . .9015-20-79 Control circuit Transmission. . . . . . . . . . . . . . . . . . . . . .9020-15-2 Control valve components Transmission. . . . . . . . . . . . . . . . . . . . .9020-05-10 Controller Area Network (CAN) Theory of operation. . . . . . . . . . . . . . . . .9015-15-4 Coolers Axle, differential . . . . . . . . . . . . . . . . . .9020-05-18 Cycle time test . . . . . . . . . . . . . . . . . . . . .9025-25-46 Cycle time test check Operational check . . . . . . . . . . . . . . . . .9005-10-18 Cylinder, boom and bucket Leakage test . . . . . . . . . . . . . . . . . . . . .9025-25-22 Cylinder, loader Drift test . . . . . . . . . . . . . . . . . . . . . . . .9025-25-20

TM10229 (17MAR09)

D Diagnose malfunctions Differential and axle . . . . . . . . . . . . . . .9020-15-27 Driveline . . . . . . . . . . . . . . . . . . . . . . . .9020-15-38 Hydraulic system. . . . . . . . . . . . . . . . . . .9025-15-9 Park brake . . . . . . . . . . . . . . . . . . . . . .9020-15-39 Service brakes . . . . . . . . . . . . . . . . . . .9020-15-34 Transmission system . . . . . . . . . . . . . . .9020-15-9 Diagnostic trouble code check . . . . . . . . . .9005-10-1 Diagnostic trouble codes FLC quick reference list . . . . . . . . . . . . .9001-40-1 Reading, Service ADVISOR . . . . . . . . .9015-20-16 Diagnostic Trouble Codes Service ADVISOR. . . . . . . . . . . . . . . . .9015-20-13 Diagnostic trouble codes transmission control unit (TCU) . . . . . . . .9001-30-1 Diagnostic trouble codes (DTC) CAN monitor unit (CMU) . . . . . . . . . . . . .9001-10-1 Engine control unit (ECU) . . . . . . . . . . . .9001-20-1 Sealed switch module (SSM) . . . . . . . . .9001-50-1 Diagnostic Trouble Codes (DTCs) Quick reference list . . . . . . . . . . . . . . . . .9015-20-1 Differential Axle coolers . . . . . . . . . . . . . . . . . . . . .9020-05-18 Diagnose malfunctions . . . . . . . . . . . . .9020-15-27 Standard operation . . . . . . . . . . . . . . . .9020-05-16 Differential and axle diagnose malfunction Axle overheats diagnostic procedure. . .9020-15-33 Axle wheel hub face seal leaking diagnostic procedure . . . . . . . . . . . . . . . . . . . . .9020-15-32 Differential and axle noise excessive diagnostic procedure . . . . . . . . . . . . . . . . . . . . .9020-15-31

Index-2

544J Loader (S.N. 611800— ) 032409

PN=2

Index

Page

Differential lock slips and chatters diagnostic procedure . . . . . . . . . . . . . . . . . . . . .9020-15-28 Differential lock will not disengage diagnostic procedure . . . . . . . . . . . . . . . . . . . . .9020-15-29 Differential lock will not engage diagnostic procedure . . . . . . . . . . . . . . . . . . . . .9020-15-28 Differential oil level low diagnostic procedure . . . . . . . . . . . . . . . . . . . . .9020-15-30 Differential oil level rises diagnostic procedure . . . . . . . . . . . . . . . . . . . . .9020-15-30 Differential lock Pressure test. . . . . . . . . . . . . . . . . . . . .9020-25-18 Differential lock check Operational check . . . . . . . . . . . . . . . . .9005-10-11 Differential pressure adjustment . . . . . . . . .9025-25-5 Digital pressure and temperature analyzer installation. . . . . . . . . . . . . . . . . . . . . . . .9025-25-4 Display and clear trouble codes . . . . . . . . .9005-10-1 Drive light circuit. . . . . . . . . . . . . . . . . . . .9015-15-12 Driveline Diagnose malfunction . . . . . . . . . . . . . .9020-15-38 Driveline diagnose malfunctions Driveline excessive vibration or noise diagnostic procedure . . . . . . . . . . . . . . . . . . . . .9020-15-38 Driving metal pins. . . . . . . . . . . . . . . . . . .9000-01-16 DTC quick reference list FLC diagnostic trouble codes . . . . . . . . .9001-40-1

Engine frame harness (W5) Component location . . . . . . . . . . . . . . .9015-10-72 Wiring diagram . . . . . . . . . . . . . . . . . . .9015-10-74 Engine harness (W6 Component location . . . . . . . . . . . . . . .9015-10-78 Wiring diagram . . . . . . . . . . . . . . . . . . .9015-10-82 Exhaust fumes . . . . . . . . . . . . . . . . . . . . . .9000-01-5 Explosion Battery . . . . . . . . . . . . . . . . . . . . . . . . . .9000-01-5 External service brake inpection . . . . . . . . .9020-20-2

E ECU connector Repair . . . . . . . . . . . . . . . . . . . . . . . . . .9015-20-76 Electrical Component specifications . . . . . . . . . . .9015-20-47 Schematic, wiring diagram, and component location information . . . . . . . . . . . . . . .9015-05-2 Electronic clutch calibration Transmission control unit . . . . . . . . . . . .9020-20-5 Element leakage test Transmission. . . . . . . . . . . . . . . . . . . . .9020-25-14 Emergency preparation . . . . . . . . . . . . . . .9000-01-6 Engine Cooling system component location . . . .9010-15-2 Fuel system component location . . . . . . .9010-15-3 Speed check and adjust . . . . . . . . . . . . .9010-25-1 Theory of operation. . . . . . . .9010-05-1, 9010-15-1 Engine control unit (ECU) Diagnostic trouble codes (DTC) . . . . . . .9001-20-1 Engine Control Unit (ECU) Remove and install . . . . . . . . . . . . . . . .9015-20-79 Theory of operation. . . . . . . . . . . . . . . . .9015-15-6 TM10229 (17MAR09)

F Fan drive Hydraulic operation . . . . . . . . . . . . . . . . .9025-05-4 Fan motor Case drain test . . . . . . . . . . . . . . . . . . .9025-25-64 speed test . . . . . . . . . . . . . . . . . . . . . . .9025-25-61 Fan pump Flow test . . . . . . . . . . . . . . . . . . . . . . . .9025-25-62 Fan pump pressure Hydraulic fan pressure test . . . . . . . . . .9025-25-60 Fault code verification check . . . . . . . . . .9015-20-57 Filter Hyraulic. . . . . . . . . . . . . . . . . . . . . . . . .9025-05-49 Fire prevention . . . . . . . . . . . . . . . . . . . . . .9000-01-5 First gear forward Transmission operation . . . . . . . . . . . . . .9020-05-6 FLC connector Repair . . . . . . . . . . . . . . . . . . . . . . . . . .9015-20-76 Flex load controller DTC quick reference list . . . . . . . . . . . . .9001-40-1 Flex Load Controller (FLC) Fault exceptions . . . . . . . . . . . . . . . . . .9015-20-38 Remove and install . . . . . . . . . . . . . . . .9015-20-81 Theory of operation. . . . . . . . . . . . . . . .9015-15-12 Flow test Axle circulation dual pump . . . . . . . . . .9020-25-39 Hydraulic pump . . . . . . . . . . . . . . . . . . .9025-25-12 Front console harness (W4) Component location . . . . . . . . . . . . . . .9015-10-68 Wiring diagram . . . . . . . . . . . . . . . . . . .9015-10-70 Fuel system Component Location . . . . . . . . . . . . . . . .9010-15-3 Functional Schematic Electrical . . . . . . . . . . . . . . . . . . . . . . . .9015-10-10 Functional Schematic and Component Location Legend . . . . . . . . . . . . . . . . . . . . . . . . . .9015-10-4 Fuse Specifications . . . . . . . . . . . . . . . . . . . . .9015-10-2

Index-3

544J Loader (S.N. 611800— ) 032409

PN=3

Indx 3

Index

Page

G GlobalTRACS terminal (GTT) harness (W29) Component location . . . . . . . . . . . . . . 9015-10-108 Wiring diagram . . . . . . . . . . . . . . . . . . 9015-10-110

Indx 4

Handhold use . . . . . . . . . . . . . . . . . . . . . . .9000-01-7 High-pressure oils Avoid . . . . . . . . . . . . . . . . . . . . . . . . . . .9000-01-4 Horn Operational check . . . . . . . . . . . . . . . . . .9005-10-2 Hydraulic and transmission oil warmup procedure . . . . . . . . . . . . . . . . . . . . . . . .9005-10-5 Hydraulic fan Flow test . . . . . . . . . . . . . . . . . . . . . . . .9025-25-62 Hydraulic fan drive Operation . . . . . . . . . . . . . . . . . . . . . . . .9025-05-4 Hydraulic fan motor Case drain test . . . . . . . . . . . . . . . . . . .9025-25-64 Hydraulic oil filter Inspection procedure. . . . . . . . . . . . . . .9025-25-66 Hydraulic oil filter base Return hydraulic filter . . . . . . . . . . . . . .9025-05-49 Hydraulic oil warmup procedure . . . . . . . . .9025-25-1 Hydraulic pump Flow test . . . . . . . . . . . . . . . . . . . . . . . .9025-25-12 Operation . . . . . . . . . . . . . . . . . . . . . . . .9025-05-2 Hydraulic pump case drain Test . . . . . . . . . . . . . . . . . . . . . . . . . . .9025-25-14 Hydraulic steering system Compensator valve manifold operation . . . . . . . . . . . . . . . . . . . . . .9025-05-11 Valve operation . . . . . . . . . . . . . . . . . . .9025-05-11 Hydraulic system Diagnose malfunctions . . . . . . . . . . . . . .9025-15-9 Loader operation. . . . . . . . . . . . . . . . . . .9025-05-1 Hydraulic system accumulators Discharge . . . . . . . . . . . . . . . . . . . . . . . .9025-25-2 Hydraulic system diagnose malfunctions Boom down does not work (engine off) diagnostic procedure . . . . . . . . . . . . . . . . . . . . .9025-15-19 Boom float function not working diagnostic procedure . . . . . . . . . . . . . . . . . . . . .9025-15-16 Constant steering required to maintain straight travel diagnostic procedure . . . . . . . .9025-15-22 Hydraulic function drifts down diagnostic procedure . . . . . . . . . . . . . . . . . . . . .9025-15-18 Hydraulic functions slow diagnostic procedure . . . . . . . . . . . . . . . . . . . . .9025-15-10 TM10229 (17MAR09)

Page

Hydraulic oil foams diagnostic procedure . . . . . . . . . . . . . . . . . . . . .9025-15-21 Hydraulic pump noisy diagnostic procedure . . . . . . . . . . . . . . . . . . . . .9025-15-13 Machine turns in opposite direction as steering wheel diagnostic procedure . . . . . . . .9025-15-27 No hydraulic functions diagnostic procedure . . . . . . . . . . . . . . . . . . . . . .9025-15-9 No steering functions diagnostic procedure . . . . . . . . . . . . . . . . . . . . .9025-15-15 Oil overheats diagnostic procedure . . . .9025-15-20 One hydraulic function not working diagnostic procedure . . . . . . . . . . . . . . . . . . . . .9025-15-17 Pin disconnect cylinders will not retract diagnostic procedure . . . . . . . . . . . . . . . . . . . . .9025-15-22 Secondary steering motor will not operate diagnostic procedure . . . . . . . . . . . . .9025-15-28 Secondary steering pump runs but will not steer machine diagnostic procedure . . . . . .9025-15-28 Slow steering wheel movement will not cause frame movement diagnostic procedure . . . . . . . . . . . . . . . . . . . . .9025-15-23 Steering erratic diagnostic procedure . . . . . . . . . . . . . . . . . . . . .9025-15-25 Steering jerky diagnostic procedure . . .9025-15-28 Steering valve binds or locks up diagnostic procedure . . . . . . . . . . . . . . . . . . . . .9025-15-26 Steering wheel free play diagnostic procedure . . . . . . . . . . . . . . . . . . . . .9025-15-25 Steering wheel kickback diagnostic procedure . . . . . . . . . . . . . . . . . . . . .9025-15-27 Steering wheel turns by itself diagnostic procedure . . . . . . . . . . . . . . . . . . . . .9025-15-27 Steering wheel turns without resistance and causes no frame movement diagnostic procedure . . . . . . . . . . . . . . . . . . . . .9025-15-24 Hydraulic system maximum pressure Test . . . . . . . . . . . . . . . . . . . . . . . . . . . .9025-25-9 Hydraulic system pressure Discharge . . . . . . . . . . . . . . . . . . . . . . . .9025-25-2 Hydraulic system schematic Neutral . . . . . . . . . . . . . . . . . . . . . . . . . .9025-15-2

I Intake manifold pressure test Turbocharger boost. . . . . . . . . . . . . . . . .9010-25-5

J JDLink system Component location . . . . . . . . . . . . . . 9015-10-108

Index-4

544J Loader (S.N. 611800— ) 032409

PN=4

Index

Page

Connection procedure . . . . . . . . . . . . . .9015-20-19 Functional schematic . . . . 9015-10-26, 9015-10-28 GlobalTRACS terminal (GTT) harness (W29) wiring diagram . . . . . . . . . . . . . . . . . 9015-10-110 Machine information gateway (MIG) harness (W30) wiring diagram . . . . . . 9015-10-112, 9015-10-114

Monitor Operational check . . . . . . . . . . . . . . . . . .9005-10-3

N Neutral start check Operational check . . . . . . . . . . . . . . . . . .9005-10-5

L Legend Functional Schematic and Component Location. . . . . . . . . . . . . . . . . . . . . . . .9015-10-4 Load center harness (W3) Component location . . . . . . . . . . . . . . .9015-10-38 Wiring diagrahm . . . . . . . . . . . . . . . . . .9015-10-40 Load sense circuit Boom raise and bucket dump . . . . . . . .9025-05-37 Operation . . . . . . . . . . . . . . . . . . . . . . .9025-05-34 Steering . . . . . . . . . . . . . . . . . . . . . . . .9025-05-35 Steering and boom down . . . . . . . . . . .9025-05-36 Load sense circuit-steering . . . . . . . . . . . .9025-05-35 Load sense differential pressure Adjustment . . . . . . . . . . . . . . . . . . . . . . .9025-20-1 Load sense relief valve Operation . . . . . . . . . . . . . . . . . . . . . . .9025-05-40 Loader frame harness (W2) Component location . . . . . . . . . . . . . . .9015-10-30 Wiring diagram . . . . . . . . . . . . . . . . . . .9015-10-34 Loader hydraulic system Component location . . . . . . . . . . . . . . . .9025-15-4 Loader Hydraulic System Operation . . . . . . . . . . . . . . . . . . . . . . . .9025-05-1 Lube pressure test Transmission. . . . . . . . . . . . . . . . . . . . .9020-25-16

M Machine information gateway (MIG) harness (W30) Component location . . . . . . . . . . . . . . 9015-10-108 Wiring Diagram . . . . . . . 9015-10-112, 9015-10-114 Machine modifications Avoid . . . . . . . . . . . . . . . . . . . . . . . . . . .9000-01-2 Menu Structure-Service Mode CAN monitor unit (CMU) . . . . . . . . . . . .9015-20-20 Metal pins. . . . . . . . . . . . . . . . . . . . . . . . .9000-01-16 Metri-Pack connector Replace . . . . . . . . . . . . . . . . . . . . . . . .9015-20-66 Modulation circuit Transmission. . . . . . . . . . . . . . . . . . . . .9020-05-10 TM10229 (17MAR09)

O Oil clean-up Procedure . . . . . . . . . . . . . . . . . . . . . . . .9025-20-1 Oil cooler restriction test Transmission. . . . . . . . . . . . . . . . . . . . .9020-25-37 Oil filter, hydraulic Inspection procedure. . . . . . . . . . . . . . .9025-25-66 Operation Park brake . . . . . . . . . . . . . . . . . . . . . .9020-05-20 Torque converter. . . . . . . . . . . . . . . . . . .9020-05-4 Transmission. . . . . . . . . . . . . . . . . . . . . .9020-05-4 Outlet section Steering, loader in neutral . . . . . . . . . . .9025-05-32

P Park brake Diagnose malfunctions . . . . . . . . . . . . .9020-15-39 Drag test . . . . . . . . . . . . . . . . . . . . . . . . .9020-25-4 Operation . . . . . . . . . . . . . . . . . . . . . . .9020-05-20 Pressure test. . . . . . . . . . . . . . . . . . . . . .9020-25-2 Park brake check Operational checkout . . . . . . . . . . . . . . .9005-10-6 Park brake diagnose malfunctions Park brake indicator light flashes during each shift diagnostic procedure . . . . . . . . . . . . .9020-15-41 Park brake indicator light flashes when shifting from fwd to rev diagnostic procedure . . . . . . . . . . . . . . . . . . . . .9020-15-41 Park brake indicator light will not go on diagnostic procedure . . . . . . . . . . . . . . . . . . . . .9020-15-43 Park brake overheats diagnostic procedure . . . . . . . . . . . . . . . . . . . . .9020-15-40 Park brake will not apply diagnostic procedure . . . . . . . . . . . . . . . . . . . . .9020-15-43 Park brake will not hold diagnostic procedure . . . . . . . . . . . . . . . . . . . . .9020-15-39 Pilot Control Operation . . . . . . . . . . . . . . . . . . . . . . .9025-05-22

Index-5

544J Loader (S.N. 611800— ) 032409

PN=5

Indx 5

Index

Indx 6

Page

Pilot control lever Adjustment . . . . . . . . . . . . . . . . . . . . . . .9025-20-2 Pilot control valve Pressure test. . . . . . . . . . . 9025-25-35, 9025-25-45 Pilot control valve boom float check Operational check . . . . . . . . . . . . . . . . .9005-10-14 Pilot control valve two lever Pressure test. . . . . . . . . . . . . . . . . . . . .9025-25-40 Pilot controller lock check Operational check . . . . . . . . . . . . . . . . .9005-10-13 Pilot enable circuit . . . . . . . . . . . . . . . . . .9015-15-12 Pilot enable/boom down solenoid check Operational check . . . . . . . . . . . . . . . . .9005-10-13 Pilot orifice check valve Control valve section. . . . . . . . . . . . . . .9025-05-24 Pin disconnect Operation . . . . . . . . . . . . . . . . . . . . . . .9025-05-20 Pin disconnect circuit . . . . . . . . . . . . . . . .9015-15-12 Pressure test. . . . . . . . . . . . . . . . . . . . .9025-25-58 Pin disconnect system check (if equipped) Operational check . . . . . . . . . . . . . . . . .9005-10-15 Power train Component location . . . . . . . . . . . . . . . .9020-15-6 Components . . . . . . . . . . . . . . . . . . . . . .9020-05-2 Power train component location . . . . . . . . .9020-15-6 Power train components . . . . . . . . . . . . . . .9020-05-2 Precharge test Boom down accumulator. . . . . . . . . . . .9025-25-49 Pressure and temperature analyzer, digital Installation. . . . . . . . . . . . . . . . . . . . . . . .9025-25-4 Pressure reducing valve Theory of operation. . . . . . . . . . . . . . . .9025-05-14 Pressure switches Remove and install . . . . . . . . . . . . . . . .9015-20-62 Pressure test Differential lock . . . . . . . . . . . . . . . . . . .9020-25-18 Fan pump . . . . . . . . . . . . . . . . . . . . . . .9025-25-60 Torque converter relief . . . . . . . . . . . . .9020-25-25 Torque converter-in. . . . . . . . . . . . . . . .9020-25-20 Torque converter-out. . . . . . . . . . . . . . .9020-25-22 Transmission clutch . . . . . . . . . . . . . . .9020-25-10 Transmission lube . . . . . . . . . . . . . . . . .9020-25-16 Transmission system . . . . . . . . . . . . . . .9020-25-8 Prevent unintended detonation of explosive devices . . . . . . . . . . . . . . . . . . . . . . . . .9000-01-13 Proportional fan check (if equipped) Operational check . . . . . . . . . . . . . . . . .9005-10-17 PRV Pressure reducing valve . . . . . . . . . . . .9025-05-14 Pump Load sense differential pressure test. . . .9025-25-5 Standby pressure test . . . . . . . . . . . . . . .9025-25-5

Pump flow test Transmission. . . . . . . . . . . . . . . . . . . . . .9020-25-6 Pump load sense differential and standby pressure Adjustment . . . . . . . . . . . . . . . . . . . . . . .9025-20-1 Pump operation Hydraulic. . . . . . . . . . . . . . . . . . . . . . . . .9025-05-2

TM10229 (17MAR09)

Q Quick reference list Diagnostic Trouble Codes (DTCs). . . . . .9015-20-1

R Radio harness (W21) Component location . . . . . . . . . . . . . . 9015-10-116 Wiring diagram . . . . . . . . . . . . . . . . . . 9015-10-118 Reading diagnostic trouble codes Service ADVISOR. . . . . . . . . . . . . . . . .9015-20-16 Rear frame harness (W13) Component location . . . . . . . . . . . . . . .9015-10-90 Wiring diagram . . . . . . . . . . . . . . . . . . .9015-10-94 Reconfiguration electronic controller . . . . . . . . . . . . . . . .9015-20-86 Refrigerant cautions and proper handling . . . . . . . . . . . . . . . . . . . . . . . . .9031-25-3 Regulating circuit Transmission control valve . . . . . . . . . .9020-05-10 Relay Specifications . . . . . . . . . . . . . . . . . . . . .9015-10-2 Relief Load sense . . . . . . . . . . . . . . . . . . . . . .9025-05-40 Relief valve Pressure test. . . . . . . . . . . . . . . . . . . . .9025-25-16 Relief valve operation . . . . . . . . . . . . . . . .9025-05-38 Return-to-carry Adjustment . . . . . . . . . . . . . . . . . . . . . .9015-20-54 Return-to-carry and boom height kickout Adjustment . . . . . . . . . . . . . . . . . . . . . . .9025-20-1 Return-to-carry check Operational check . . . . . . . . . . . . . . . . .9005-10-14 Return-to-carry (RTC) circuit. . . . . . . . . . .9015-15-12 Return-to-dig Adjustment . . . . . . . . . . . . . 9015-20-56, 9025-20-1 Return-to-dig check Operational check . . . . . . . . . . . . . . . . .9005-10-14 Return-to-dig circuit . . . . . . . . . . . . . . . . .9015-15-12 Adjustment . . . . . . . . . . . . . . . . . . . . . .9015-20-55 Reverse fan check (if equipped) Operational check . . . . . . . . . . . . . . . . .9005-10-16

Index-6

544J Loader (S.N. 611800— ) 032409

PN=6

Index

Page

Reverse fan circuit . . . . . . . . . . . . . . . . . .9015-15-12 Ride control Operation . . . . . . . . . . . . . . . . . . . . . . .9025-05-53 Ride control accumulator Charge . . . . . . . . . . . . . . . . . . . . . . . . . .9025-20-6 Discharge . . . . . . . . . . . . . . .9025-20-3, 9025-20-6 Ride control accumulator charge . . . . . . . .9025-20-6 Ride control check Operational check . . . . . . . . . . . . . . . . .9005-10-16 Ride control circuit . . . . . . . . . . . . . . . . . .9015-15-12 Roads Operating or traveling . . . . . . . . . . . . . .9000-01-12 ROPS Inspect . . . . . . . . . . . . . . . . . . . . . . . . .9000-01-13 Maintain . . . . . . . . . . . . . . . . . . . . . . . .9000-01-13

Sensor Circuit Check . . . . . . . . . . . . . . . . . . . . . . . . . .9015-20-57 Service ADVISOR Diagnostic application overview . . . . . .9015-20-13 Reading diagnostic trouble codes . . . . .9015-20-16 Service ADVISOR connection procedure . . . . . . . . . . . . . . . . . . . . . . .9015-20-14 Service brake Accumulator operation . . . . . . . . . . . . .9025-05-16 Bleeding procedure . . . . . . . . . . . . . . . . .9020-20-1 Diagnose malfunctions . . . . . . . . . . . . .9020-15-34 Leakage . . . . . . . . . . . . . . . . . . . . . . . .9025-25-58 Service brake check Operational check . . . . . . . . . . . . . . . . . .9005-10-7 Service brake diagnose malfunctions Brake warning light on diagnostic procedure . . . . . . . . . . . . . . . . . . . . .9020-15-37 Brakes aggressive diagnostic procedure . . . . . . . . . . . . . . . . . . . . .9020-15-35 Brakes chatter diagnostic procedure . . .9020-15-37 Brakes dragging diagnostic procedure . . . . . . . . . . . . . . . . . . . . .9020-15-36 Brakes lock up diagnostic procedure. . .9020-15-36 Brakes poor or do not apply diagnostic procedure . . . . . . . . . . . . . . . . . . . . .9020-15-34 Service brake inspection, external . . . . . . .9020-20-2 Service brake pessure switch and brake accumulator precharge . . . . . . . . . . . . . . . . . . . . . . .9005-10-12 Service brake valve Leakage test . . . . . . . . . . . . . . . . . . . . .9025-25-55 Operation . . . . . . . . . . . . . . . . . . . . . . .9025-05-18 Pressure test. . . . . . . . . . . . . . . . . . . . .9025-25-52 Servie Brake Hydraulic system operation . . . . . . . . . .9025-05-15 Solenoids activated Transmission clutch engagement . . . . . .9020-05-1 Specifications Electrical components . . . . . . . . . . . . . .9015-20-47 Fuse . . . . . . . . . . . . . . . . . . . . . . . . . . . .9015-10-2 Relay . . . . . . . . . . . . . . . . . . . . . . . . . . .9015-10-2 Stall speed test Torque converter. . . . . . . . . . . . . . . . . .9020-25-31 Standard differential Operation . . . . . . . . . . . . . . . . . . . . . . .9020-05-16 Standby pressure Adjustment . . . . . . . . . . . . . . . . . . . . . . .9025-20-1 Standby pressure adjustment . . . . . . . . . . .9025-25-5 Starting circuit Theory of operation. . . . . . . . . . . . . . . . .9015-15-1 Steering Valve operation . . . . . . . . . . . . . . . . . . .9025-05-10 Steering system component Operation . . . . . . . . . . . . . . 9025-05-9, 9025-05-11

S Safety Add cab guarding for special uses . . . . .9000-01-3 Follow safety instructions . . . . . . . . . . . .9000-01-1 Inspect machine . . . . . . . . . . . . . . . . . . .9000-01-3 Operate only if qualified . . . . . . . . . . . . .9000-01-2 Operator’s seat . . . . . . . . . . . . . . . . . . . .9000-01-7 Recognize safety information . . . . . . . . .9000-01-1 Stay clear of moving parts . . . . . . . . . . .9000-01-3 Wear protective equipment . . . . . . . . . . .9000-01-2 Schematic Electrical, JDLink system functional. . . . . . . . . . . . 9015-10-26, 9015-10-28 Hydraulic system, neutral . . . . . . . . . . . .9025-15-2 Information . . . . . . . . . . . . . . . . . . . . . . .9015-05-2 Sealed switch module (SSM) Diagnostic trouble codes (DTC) . . . . . . .9001-50-1 Sealed Switch Module (SSM) Remove and install . . . . . . . . . . . . . . . .9015-20-83 Seat belt Use and maintenance . . . . . . . . . . . . . . .9000-01-7 Seat control Operational check . . . . . . . . . . . . . . . . . .9005-10-2 Secondary steering circuit . . . . . . . . . . . .9015-15-12 Secondary steering harness (W17) Component location . . . . . . . . . . . . . . .9015-10-96 Secondary steering inlet manifold Operation . . . . . . . . . . . . . . . . . . . . . . .9025-05-12 Secondary steering manifold Primary check valve leakage test . . . . .9025-25-32 Secondary steering pump Relief valve pressure test . . . . . . . . . . .9025-25-30 Secondary steering system check (if equipped) Operational check . . . . . . . . . . . . . . . . .9005-10-18 TM10229 (17MAR09)

Index-7

544J Loader (S.N. 611800— ) 032409

PN=7

Indx 7

Index

Page

Steering valve Drift test . . . . . . . . . . . . . . . . . . . . . . . .9025-25-28 Neutral leakage test . . . . . . . . . . . . . . .9025-25-24 Operation . . . . . . . . . . . . . . . . . . . . . . .9025-05-10 Steering valve check Operational check . . . . . . . . . . . . . . . . .9005-10-17 Steps use . . . . . . . . . . . . . . . . . . . . . . . . . .9000-01-7 Switches, pressure Remove and install . . . . . . . . . . . . . . . .9015-20-62 System Functional Schematic Electrical . . . . . . . . . . . . . . . . . . . . . . . .9015-10-10 System functional schematic Information . . . . . . . . . . . . . . . . . . . . . . .9015-05-2 System pressure Maximum . . . . . . . . . . . . . . . . . . . . . . . .9025-25-9 System pressure test Transmission. . . . . . . . . . . . . . . . . . . . . .9020-25-8

Charging circuit . . . . . . . . . . . . . . . . . . . .9015-15-1 Controller Area Network (CAN) . . . . . . . .9015-15-4 Engine Control Unit (ECU) . . . . . . . . . . .9015-15-6 Flex Load Controller (FLC) . . . . . . . . . .9015-15-12 Hydraulic fan drive . . . . . . . . . . . . . . . . .9025-05-4 Pilot Control . . . . . . . . . . . . . . . . . . . . .9025-05-22 Pressure reducing valve . . . . . . . . . . . .9025-05-14 Ride control . . . . . . . . . . . . . . . . . . . . .9025-05-53 Starting circuit . . . . . . . . . . . . . . . . . . . . .9015-15-1 Transmission Control Unit (TCU) . . . . .9015-15-28 Thermal bypass valve Pressure test. . . . . . . . . . . . . . . . . . . . .9020-25-35 Temperature test. . . . . . . . . . . . . . . . . .9020-25-32 Torque converter Operation . . . . . . . . . . . . . . . . . . . . . . . .9020-05-4 Transmission torque converter stall speed test . . . . . . . . . . . . . . . . . . . . . . . . . .9020-25-31 Transmission torque converter-in pressure test . . . . . . . . . . . . . . . . . . . . . . . . . .9020-25-20 Transmission torque converter-out flow test . . . . . . . . . . . . . . . . . . . . . . . . . .9020-25-27 Transmisson torque converter relief pressure test . . . . . . . . . . . . . . . . . . . . . . . . . .9020-25-25 Transmisson torque converter-out pressure test . . . . . . . . . . . . . . . . . . . . . . . . . .9020-25-22 Torque converter and engine power check Operational check . . . . . . . . . . . . . . . . .9005-10-11 Torque converter relief pressure test . . . .9020-25-25 Torque converter stall speed test . . . . . . .9020-25-31 Torque converter-in pressure test . . . . . . .9020-25-20 Torque converter-out flow test . . . . . . . . .9020-25-27 Torque converter-out pressure test. . . . . .9020-25-22 Tranmission Modulation circuit . . . . . . . . . . . . . . . . .9020-05-10 Tranmssion Clutch modulation . . . . . . . . . . . . . . . . .9020-05-13 Transmission Clutch pressure test . . . . . . . . . . . . . . .9020-25-10 Control system . . . . . . . . . . . . . . . . . . . .9020-15-4 Element leakage test . . . . . . . . . . . . . .9020-25-14 Filter bypass valve . . . . . . . . . . . . . . . . .9020-05-9 Lube pressure test . . . . . . . . . . . . . . . .9020-25-16 Oil cooler restriction test . . . . . . . . . . . .9020-25-37 Operation . . . . . . . . . . . . . . . . . . . . . . . .9020-05-4 Pump flow test . . . . . . . . . . . . . . . . . . . .9020-25-6 System pressure test . . . . . . . . . . . . . . .9020-25-8 Torque converter relief pressure test. . .9020-25-25 Torque converter stall speed test . . . . .9020-25-31 Torque converter-in pressure test . . . . .9020-25-20 Torque converter-out flow test. . . . . . . .9020-25-27 Torque converter-out pressure test . . . .9020-25-22 Warmup procedure . . . . . . . . . . . . . . . . .9020-25-1 Transmission clutch calibration . . . . . . . . . .9020-20-5

Indx 8

TCU diagnostic trouble codes . . . . . . . . . . . . .9001-30-1 Test Alternator . . . . . . . . . . . . . . . . . . . . . . .9015-20-63 Axle breather . . . . . . . . . . . . . . . . . . . .9020-25-41 Axle circulation dual pump flow . . . . . . .9020-25-39 Cycle time. . . . . . . . . . . . . . . . . . . . . . .9025-25-46 Differential lock pressure. . . . . . . . . . . .9020-25-18 Fan motor rpm . . . . . . . . . . . . . . . . . . .9025-25-61 Fan pump pressure. . . . . . . . . . . . . . . .9025-25-60 Park brake drag . . . . . . . . . . . . . . . . . . .9020-25-4 Park brake pressure . . . . . . . . . . . . . . . .9020-25-2 Pilot control valve pressure . . . . . . . . . .9025-25-35 Service brake valve pressure . . . . . . . .9025-25-52 Torque converter relief pressure . . . . . .9020-25-25 Torque converter stall speed. . . . . . . . .9020-25-31 Torque converter-in pressure . . . . . . . .9020-25-20 Torque converter-out flow . . . . . . . . . . .9020-25-27 Torque converter-out pressure . . . . . . .9020-25-22 Transmission clutch pressure . . . . . . . .9020-25-10 Transmission element leakage . . . . . . .9020-25-14 Transmission lube pressure . . . . . . . . .9020-25-16 Transmission oil cooler restriction . . . . .9020-25-37 Transmission oil cooler thermal bypass valve pressure . . . . . . . . . . . . . . . . . . . . . .9020-25-35 Transmission oil cooler thermal bypass valve temperure . . . . . . . . . . . . . . . . . . . . .9020-25-32 Transmission pump flow . . . . . . . . . . . . .9020-25-6 Transmission system pressure . . . . . . . .9020-25-8 Theory of operation CAN monitor unit (CMU) . . . . . . . . . . . .9015-15-32 TM10229 (17MAR09)

Index-8

544J Loader (S.N. 611800— ) 032409

PN=8

Index

Page

Transmission clutch engagement Solenoids activated . . . . . . . . . . . . . . . . .9020-05-1 Transmission control circuit First forward . . . . . . . . . . . . . . . . . . . . . .9020-15-2 Transmission control unit (TCU) diagnostic trouble codes . . . . . . . . . . . . .9001-30-1 Transmission Control Unit (TCU) Remove and install . . . . . . . . . . . . . . . .9015-20-82 Theory of operation. . . . . . . . . . . . . . . .9015-15-28 Transmission control valve Components . . . . . . . . . . . . . . . . . . . . .9020-05-10 Regulating circuit . . . . . . . . . . . . . . . . .9020-05-10 Transmission Control Valve Solenoid Check . . . . . . . . . . . . . . . . . . . . . . . . . .9015-20-52 Transmission controller Clutch calibration . . . . . . . . . . . . . . . . . .9020-20-5 Transmission gear shift switch and neutral lock latch checks Operational checks Steering column mounted . . . . . . . . . .9005-10-4 Transmission gear shift switch checks Operational checks Hydraulic control lever mounted . . . . .9005-10-4 Transmission harness (W10) Component location . . . . . . . . . . . . . . .9015-10-86 Wiring diagram . . . . . . . . . . . . . . . . . . .9015-10-88 Transmission oil cooler Restriction test . . . . . . . . . . . . . . . . . . .9020-25-37 Thermal bypass valve pressure test . . .9020-25-35 Thermal bypass valve temperature test . . . . . . . . . . . . . . . . . . . . . . . . . .9020-25-32 Transmission oil cooler thermal bypass valve pressure test . . . . . . . . . . . . . . . . . . . . .9020-25-35 Transmission oil cooler thermal bypass valve temperature test . . . . . . . . . . . . . . . . . .9020-25-32 Transmission operation First gear forward . . . . . . . . . . . . . . . . . .9020-05-6 Transmission pump Flow test . . . . . . . . . . . . . . . . . . . . . . . . .9020-25-6 Transmission shift mode check Operational check . . . . . . . . . . . . . . . . . .9005-10-9 Transmission shift modulation check Operational check . . . . . . . . . . . . . . . . .9005-10-10 Transmission system Diagnose malfunctions . . . . . . . . . . . . . .9020-15-9 Transmission system diagnose malfunctions Machine creeps in neutral diagnostic procedure . . . . . . . . . . . . . . . . . . . . .9020-15-20 Machine power and acceleration low diagnostic procedure . . . . . . . . . . . . . . . . . . . . .9020-15-25 Machine vibrates diagnostic procedure . . . . . . . . . . . . . . . . . . . . .9020-15-24

Machine will not engage in low gear diagnostic procedure . . . . . . . . . . . . . . . . . . . . .9020-15-14 Machine will not move in either direction diagnostic procedure . . . . . . . . . . . . . . . . . . . . .9020-15-11 Machine will not shift correctly diagnostic procedure . . . . . . . . . . . . . . . . . . . . .9020-15-15 Oil aerated diagnostic procedure. . . . . .9020-15-24 Oil ejected from dipstick diagnostic procedure . . . . . . . . . . . . . . . . . . . . .9020-15-24 Torque converter stall rpm diagnostic procedure . . . . . . . . . . . . . . . . . . . . .9020-15-27 Transmission clutch slippage diagnostic procedure . . . . . . . . . . . . . . . . . . . . . .9020-15-9 Transmission excessive noise diagnostic procedure . . . . . . . . . . . . . . . . . . . . .9020-15-22 Transmission hydraulic system overheats diagnostic procedure . . . . . . . . . . . . .9020-15-21 Transmission pressure is low (one or two gear ranges) diagnostic procedure . . . . . .9020-15-17 Transmission shifts too fast diagnostic procedure . . . . . . . . . . . . . . . . . . . . .9020-15-19 Transmission shifts too slow diagnostic procedure . . . . . . . . . . . . . . . . . . . . .9020-15-17 Transmission system pressure is low in neutral diagnostic procedure . . . . . . . . . . . . .9020-15-16 Traveling On public roads. . . . . . . . . . . . . . . . . . .9000-01-12 Turbocharger boost pressure test . . . . . . . .9010-25-5 Turn signal light circuit . . . . . . . . . . . . . . .9015-15-12

TM10229 (17MAR09)

V Valve Anticavitation Operation . . . . . . . . . . . . . . . . . . . . .9025-05-48 Load sense relief operation. . . . . . . . . .9025-05-40 Loader control. . . . . . . . . . . . . . . . . . . .9025-05-25 Transmission filter bypass. . . . . . . . . . . .9020-05-9 Valve leakage test Service brake . . . . . . . . . . . . . . . . . . . .9025-25-55 Indx 9

W Warmup procedure Hydraulic oil . . . . . . . . . . . . . . . . . . . . . .9025-25-1 Transmission oil . . . . . . . . . . . . . . . . . . .9020-25-1 Washer pump circuit. . . . . . . . . . . . . . . . .9015-15-12 Waste disposal . . . . . . . . . . . . . . . . . . . . . .9000-01-6 Welding repairs . . . . . . . . . . . . . . . . . . . .9000-01-16 Wiper motor circuit . . . . . . . . . . . . . . . . . .9015-15-12

Index-9

544J Loader (S.N. 611800— ) 032409

PN=9

Index

Page

Wiring diagrahm Load center harness (W3). . . . . . . . . . .9015-10-40 Wiring diagram Cab roof harness (W19) . . . . . . . . . . . 9015-10-102 GlobalTRACS terminal (GTT) harness (W29) . . . . . . . . . . . . . . . . . . . . . . . 9015-10-110 Information . . . . . . . . . . . . . . . . . . . . . . .9015-05-2 Machine information gateway (MIG) harness (W30) . . . . . . . . . . . . 9015-10-112, 9015-10-114 Work light circuit. . . . . . . . . . . . . . . . . . . .9015-15-12 4-way flasher circuit . . . . . . . . . . . . . . . . .9015-15-12

Indx 10

TM10229 (17MAR09)

Index-10

544J Loader (S.N. 611800— ) 032409

PN=10