JOHN DEERE 644H Cargador F. Manual Taller Parte 1 2004 PDF

644H and 644H MH
Loader
Operation and Tests
TECHNICAL MANUAL
644H and 644H MH Loader
Operation and Test
TM1637 15JAN04 (ENGLISH)
For complete service information also see:

644H and 644H MH Loader Operation and
Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TM1637
644H and 644H MH Loader Repair . . . . . . . . TM1638
8.1 L Engine Repair . . . . . . . . . . . . . . . . . . . . CTM86
6.8 L and 8.1 L Engine Level 3 Electronic
Fuel Systems with Bosch In-Line Pump . . . CTM134
8.1 L Engine Level 9 Electronic Fuel
System With High Pressure Common
Rail . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CTM255
Alternators and Starting Motors . . . . . . . . . . CTM77
TeamMate III Axles . . . . . . . . . . . . . . . . . . . CTM150
Worldwide Construction
And Forestry Division
LITHO IN U.S.A.
Introduction
Foreword
This manual is written for an experienced technician.

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

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

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

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

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

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

sources covering basic theory of operation, fundamentals
of troubleshooting, general maintenance, and basic type
of failures and their causes.
TX,INTR,DU2141 –19–22MAR97–1/1
TM1637 (15JAN04) 644H and 644H MH Loader

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PN=2
Introduction
Technical Information Feedback Form
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TX,TM,FAX –19–03JUL01–1/1

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Introduction

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

Group 10—Operational Checkout Procedure
9005
SECTION 9010—Engine
Group 05—Theory Of Operation
Group 15—Diagnostic Information
Group 20—Adjustments
Group 25—Tests 9010
SECTION 9015—Electrical System

Group 05—System Information
Group 10—System Diagrams
Group 15—Sub-System Diagnostics
9015
Group 20—References
SECTION 9020—Power Train

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

9025
Group 25—Test
SECTION 9031—Heating And A/C

Group 15—Diagnostic Information 9031
Group 25—Tests
INDX
All information, illustrations and specifications in this manual are based on

the latest information available at the time of publication. The right is
reserved to make changes at any time without notice.
COPYRIGHT  2004
DEERE & COMPANY
Moline, Illinois
All rights reserved
A John Deere ILLUSTRUCTION Manual
Previous Editions
Copyright  1999, 2000, 2001
TM1637 (15JAN04) i 644H and 644H MH Loader

011504
PN=1
Contents
9000
9005
9010
9015
9020
9025
9031
INDX
TM1637 (15JAN04) ii 644H and 644H MH Loader

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9000
Section 9000
General Information
Contents
Page Page
Group 01—Safety Information Handle Fuel Safely—Avoid Fires. . . . . . . . .9000-01-11

4WD Loader Safety Features . . . . . . . . . . . .9000-01-1 Prepare for Emergencies. . . . . . . . . . . . . . .9000-01-11
Recognize Safety Information . . . . . . . . . . . .9000-01-2 Handle Starting Fluid Safely . . . . . . . . . . . .9000-01-12
Understand Signal Words . . . . . . . . . . . . . . .9000-01-2 Clean Trash from Machine . . . . . . . . . . . . .9000-01-12
Follow Safety Instructions . . . . . . . . . . . . . . .9000-01-2 Protect Against Flying Debris . . . . . . . . . . .9000-01-12
Avoid Injury from Rollover Accidents Wear Protective Clothing. . . . . . . . . . . . . . .9000-01-13
-------------------------------- Wear Your Seat Protect Against Noise . . . . . . . . . . . . . . . . .9000-01-13
Belt -------------------------------- Do Not Handle Chemical Products Safely . . . . . . . .9000-01-13
Attempt to Jump Clear of Tipping Use Safety Lights and Devices . . . . . . . . . .9000-01-14
Machine—Serious or Fatal Crushing Keep ROPS Installed Properly . . . . . . . . . .9000-01-14
Injuries Will Result -------------------------------- Warn Others of Service Work . . . . . . . . . . .9000-01-15
Machine Will Tip Over Faster Than You Practice Safe Maintenance . . . . . . . . . . . . .9000-01-16
Can Jump Free . . . . . . . . . . . . . . . . . . . . .9000-01-3 Support Machine Properly . . . . . . . . . . . . . .9000-01-16
Avoid Injury from Backover Accidents Remove Paint Before Welding or
------------------------------------ Before Moving Heating . . . . . . . . . . . . . . . . . . . . . . . . . .9000-01-17
Machine, Be Sure All Persons are Clear of Avoid Heating Near Pressurized Fluid
Area ------------------------------------ Always Be Lines . . . . . . . . . . . . . . . . . . . . . . . . . . . .9000-01-17
Alert for Bystanders Moving into the Work Avoid High-Pressure Fluids . . . . . . . . . . . . .9000-01-18
Area. Use Horn or Other Signal to Warn Clean the Machine Regularly . . . . . . . . . . .9000-01-18
Bystanders Before Moving Machine Service Cooling System Safely . . . . . . . . . .9000-01-19
------------------------------------ When Using a Store Attachments Safely . . . . . . . . . . . . . .9000-01-19
Signal Person, Keep Person in View at all Dispose of Waste Properly . . . . . . . . . . . . .9000-01-19
Times. Be Sure Signal Person is Clear
Before Backing Up. . . . . . . . . . . . . . . . . . .9000-01-4
Avoid Injury from Rollaway Accidents
------------------------------------ To Prevent
Rollaway, Always Make Sure Machine is
Properly Secured Before Leaving
Operator’s Seat ------------------------------------
Death or Serious Injury May Result if
You Attempt to Mount or Stop a Moving
Machine. . . . . . . . . . . . . . . . . . . . . . . . . . .9000-01-5
Inspect Machine . . . . . . . . . . . . . . . . . . . . . .9000-01-5
Use Handholds and Steps. . . . . . . . . . . . . . .9000-01-6
Prevent Machine Runaway . . . . . . . . . . . . . .9000-01-6
Use Seat Belt Properly . . . . . . . . . . . . . . . . .9000-01-6
Maintain Seat Belt . . . . . . . . . . . . . . . . . . . . .9000-01-7
Secondary Exits . . . . . . . . . . . . . . . . . . . . . .9000-01-7
Travel Safely . . . . . . . . . . . . . . . . . . . . . . . . .9000-01-8
Drive Machine Safely . . . . . . . . . . . . . . . . . .9000-01-8
Operate Machine with Caution . . . . . . . . . . .9000-01-9
Operating on Slopes . . . . . . . . . . . . . . . . . . .9000-01-9
Carrying Loads . . . . . . . . . . . . . . . . . . . . . .9000-01-10
Avoid Power Lines . . . . . . . . . . . . . . . . . . .9000-01-10
Beware of Exhaust Fumes . . . . . . . . . . . . .9000-01-10
Keep Riders Off Machine . . . . . . . . . . . . . .9000-01-11
TM1637 (15JAN04) 9000-1 644H and 644H MH Loader

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Contents
9000

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Group 01
Safety Information
9000
4WD Loader Safety Features 01
1
–19–04NOV98
T111699
TX,05,JC2303 –19–09NOV98–1/1
TM1637 (15JAN04) 9000-01-1 644H and 644H MH Loader

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Safety Information
9000
01 Recognize Safety Information
2
This is a safety-alert symbol. When you see this symbol

on your machine or in this manual, be alert to the
potential for personal injury.
–UN–07DEC88
Follow recommended precautions and safe operating
practices.
T81389
DX,ALERT –19–29SEP98–1/1
Understand Signal Words
A signal word—DANGER, WARNING, or CAUTION—is

used with the safety-alert symbol. DANGER identifies the
most serious hazards.
DANGER or WARNING safety signs are located near
–19–30SEP88
specific hazards. General precautions are listed on
CAUTION safety signs. CAUTION also calls attention to
safety messages in this manual.
TS187
DX,SIGNAL –19–03MAR93–1/1
Follow Safety Instructions
Carefully read all safety messages in this manual and on

your machine safety signs. Keep safety signs in good
condition. Replace missing or damaged safety signs. Be
sure new equipment components and repair parts include
the current safety signs. Replacement safety signs are
–UN–23AUG88
available from your John Deere dealer.
Learn how to operate the machine and how to use

controls properly. Do not let anyone operate without TS201
instruction.
Keep your machine in proper working condition.

Unauthorized modifications to the machine may impair the
function and/or safety and affect machine life.
If you do not understand any part of this manual and need

assistance, contact your John Deere dealer.
DX,READ –19–03MAR93–1/1

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Safety Information
9000
Avoid Injury from Rollover Accidents 01
3
--------------------------------
Wear Your Seat Belt
--------------------------------
Do Not Attempt to Jump Clear of Tipping
Machine—Serious or Fatal Crushing Injuries
Will Result
--------------------------------
Machine Will Tip Over Faster Than You Can
Jump Free
To avoid rollovers:
Be careful when operating on a slope.
Avoid sharp turns.
Balance loads so weight is evenly distributed and load is

stable.
–19–22FEB90
Carry tools and loads close to the ground to aid visibility
and lower center of gravity.
T7242EA
Reduce speed before turning or swinging load.
Know capacity of machine. Do not overload.
Be careful when operating at the edge of an excavation,

trench, or drop-off, and loading or unloading from a trailer.
Read and understand the operating instructions in this

operator’s manual.
TX,05,DH1525 –19–21JUN91–1/1

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Safety Information
9000
01 Avoid Injury from Backover Accidents
4
------------------------------------
Before Moving Machine, Be Sure All Persons
are Clear of Area
------------------------------------
Always Be Alert for Bystanders Moving into
–UN–21FEB90
the Work Area. Use Horn or Other Signal to
Warn Bystanders Before Moving Machine
------------------------------------
T7241AY
When Using a Signal Person, Keep Person in
View at all Times. Be Sure Signal Person is
Clear Before Backing Up
To avoid backover accidents:
Always look around before you back up. Be sure that

everyone is in the clear.
Keep bystanders away from pivot area of an articulated

machine.
Keep reverse warning alarm in working condition, if

equipped.
Use a signal person when backing up if view is

obstructed. Always keep signal person in view.
Learn the meaning of all flags, signs, and markings used

on the job, and who has the responsibility for signaling.
Keep windows, mirrors, and lights clean and in good

condition.
Dust, heavy rain, fog, etc., can reduce visibility. As

visibility decreases, reduce speed and use proper lighting.

TX,05,DH1573 –19–18MAR91–1/1

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Safety Information
9000
Avoid Injury from Rollaway Accidents 01
5
------------------------------------
To Prevent Rollaway, Always Make Sure
Machine is Properly Secured Before Leaving
Operator’s Seat
------------------------------------
–UN–21FEB90
Death or Serious Injury May Result if You
Attempt to Mount or Stop a Moving Machine
T7241AZ
To avoid rollaways:
Select level ground when possible to park machine.
Move transmission control lever to neutral "N", engage

neutral lock, and push park brake switch to ON.
Lower all equipment to ground.
Stop the engine.
Block all wheels if you must park on a grade. Position

machine to prevent rolling.
Park a reasonable distance from other machines.

TX,05,JC1888 –19–18FEB97–1/1
Inspect Machine
Inspect your machine carefully each day by walking

around it before you start it. (See Pre-Start Inspection
Chapter.) –UN–18OCT88
T6607AQ
T82,BHSA,CL –19–14MAR90–1/1

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PN=13
Safety Information
9000
01 Use Handholds and Steps
6
Falling is one of the major causes of personal injury.
When you get on and off the machine, always maintain a

three point contact with the steps and handrails, and face
–UN–15JUN89
the machine. Do not use the steering wheel or any
controls as handholds.
Never jump on or off the machine. Never mount or
T6981AN
dismount a moving machine.
Be careful of slippery conditions on platforms, steps, and

handrails when leaving the machine.
TX,05,DH553 –19–18MAR91–1/1
Prevent Machine Runaway
Avoid possible injury or death from a runaway machine.
DO NOT start engine by shorting across starter terminals.

Machine will start in gear if normal circuitry is bypassed.
–UN–20OCT88
Never start engine while standing on ground. Start engine
only from operator’s seat with transmission control lever
locked in neutral and park brake engaged.
T6642EB
TX,05,DH2281 –19–06OCT92–1/1
Use Seat Belt Properly
Overturns may occur if proper operating instructions are

not followed.
Use your seat belt.

–UN–23AUG88
TS175
TX,05,JC1044 –19–12JAN96–1/1

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Safety Information
9000
Maintain Seat Belt 01
7
It is important to use the seat belt on ROPS equipped

machines to minimize the chance of injury from an
accident such as an overturn. Keep the seat belt in good
condition.
The complete seat belt assembly should be replaced

after three years of usage, regardless of appearance.
Between replacement intervals:
Carefully examine buckle, webbing, and attaching

hardware.
Be sure that the retractor, if equipped, locks to prevent

belt extension after latching buckle.
Be sure that attaching hardware is in place. Tighten, if

necessary.
Replace the seat belt if it does not operate properly, or if it

is damaged, worn, or deteriorated.
TX,05,JC242 –19–03MAR95–1/1
Secondary Exits
Machines equipped with cabs are equipped with

secondary exits. For additional secondary exit information,
see “Opening Side Window/Secondary Exit” in chapter 10
of this manual.
TX,05,JC1753 –19–09DEC96–1/1

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Safety Information
9000
01 Travel Safely
8
Know the location of bystanders before moving the

machine.
Always keep the reverse warning alarm in working
–UN–20DEC88
condition. It warns people when the machine starts to
move in reverse.
Use a signal person when moving the machine in
T6964AD
congested areas. Coordinate hand signals before starting
the machine.
TX,05,DH496 –19–02AUG89–1/1
Drive Machine Safely
Walk around machine to clear all persons from area of

operation and machine movement.
Always check area to rear before shifting to reverse.
–UN–25OCT88
Drive carefully in congested areas, over rough ground,
near ditches for excavations, and on slopes or curves.
T6582AS
Keep machine in gear when going down hills.
Use accessory lights and devices to warn operators of

other vehicles.
TX,05,DH1931 –19–21JUN91–1/1

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PN=16
Safety Information
9000
Operate Machine with Caution 01
9
Check location of cables, gas lines, and water mains

before digging.
Keep loading area smooth.
–UN–18OCT88
Never lower a loaded bucket with the boom and bucket
control lever in the float position.
T6642EF
Increase the power gradually when pulling a heavy load or
when driving out of a ditch or excavation.
TX,05,DH1932 –19–06JUN91–1/1
Operating on Slopes
Avoid side slope travel whenever possible. Drive up slope

in forward and down in reverse. The danger of tipping is
always present.
In steep slope operation, do not allow engine to

overspeed. Select low gear speed before starting down
slope.
The grade of the slope you should attempt will be limited

by such factors as ground condition, and load being
handled.
–UN–03AUG89
T7050AB
TX,05,RR,171 –19–27APR89–1/1

011504
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Safety Information
9000
01 Carrying Loads
10
Carry loader bucket as low as possible for better stability

and visibility.
Handle only those loads which are properly arranged. Do
–UN–03AUG89
not overload.
Do not start, stop, or turn quickly when transporting a

load.
T7050AA
Do not change forward or reverse directions quickly when
carrying a load.
TX,05,RR,172 –19–03JUN92–1/1
Avoid Power Lines
Serious injury or death can result from contact with

electric lines.
Never move any part of the machine or load closer to
–UN–20JUN89
electric line than 3 m (10 ft) plus twice the line insulator
length.
T6642EG
02T,05,J18 –19–06JUN91–1/1
Beware of Exhaust Fumes
Prevent asphyxiation. Engine exhaust fumes can cause

sickness or death.
If you must operate in a building, be sure there is

–UN–18OCT88
adequate ventilation. Either use an exhaust pipe extension

to remove the exhaust fumes or open doors and windows
to bring enough outside air into the area.
T6458AO
TX,DH,2 –19–09FEB89–1/1

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Safety Information
9000
Keep Riders Off Machine 01
11
Only allow the operator on the machine. Keep riders off.
Riders on machine are subject to injury such as being

struck by foreign objects and being thrown off of the
machine. Riders also obstruct the operator’s view resulting
–UN–23AUG88
in the machine being operated in an unsafe manner.
TS290
DX,RIDER –19–03MAR93–1/1
Handle Fuel Safely—Avoid Fires
Handle fuel with care: it is highly flammable. Do not refuel

the machine while smoking or when near open flame or
sparks.
Always stop engine before refueling machine. Fill fuel tank
–UN–23AUG88
outdoors.
Prevent fires by keeping machine clean of accumulated

trash, grease, and debris. Always clean up spilled fuel.
TS202
DX,FIRE1 –19–03MAR93–1/1
Prepare for Emergencies
Be prepared if a fire starts.
Keep a first aid kit and fire extinguisher handy.
Keep emergency numbers for doctors, ambulance service,

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

TS291
DX,FIRE2 –19–03MAR93–1/1

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PN=19
Safety Information
9000
01 Handle Starting Fluid Safely
12
Starting fluid is highly flammable.
Keep all sparks and flame away when using it. Keep
starting fluid away from batteries and cables.
–UN–18OCT88
Remove container from machine if engine does not need
starting fluid.
T6464AV
To prevent accidental discharge when storing the
pressurized can, keep the cap on the container, and store
in a cool, protected location.
Do not incinerate or puncture a starting fluid container.
TX,05,FF2281 –19–22FEB91–1/1
Clean Trash from Machine
Keep engine compartment, radiator, batteries, hydraulic

lines, fuel tank, and operator’s station clean.
Temperature in engine compartment may go up

immediately after engine is stopped. BE ON GUARD FOR
–UN–23AUG88
FIRES DURING THIS PERIOD.
Open access door(s) to cool the engine faster, and clean

engine compartment.
TS227
02T,05,J33 –19–13JUN00–1/1
Protect Against Flying Debris
When you drive connecting pins in or out, guard against

injury from flying pieces of metal or debris; wear goggles
or safety glasses.
–UN–18OCT88
T6642DK
02T,05,J45 –19–30MAY90–1/1

011504
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Safety Information
9000
Wear Protective Clothing 01
13
Wear close fitting clothing and safety equipment

appropriate to the job.
Operating equipment safely requires the full attention of

the operator. Do not wear radio or music headphones
–UN–23AUG88
while operating machine.
TS206
DX,WEAR2 –19–03MAR93–1/1
Protect Against Noise
Prolonged exposure to loud noise can cause impairment

or loss of hearing.
Wear a suitable hearing protective device such as

earmuffs or earplugs to protect against objectionable or
–UN–23AUG88
uncomfortable loud noises.
TS207
DX,NOISE –19–03MAR93–1/1
Handle Chemical Products Safely
Direct exposure to hazardous chemicals can cause

serious injury. Potentially hazardous chemicals used with
John Deere equipment include such items as lubricants,
coolants, paints, and adhesives.
–UN–26NOV90
A Material Safety Data Sheet (MSDS) provides specific
details on chemical products: physical and health hazards,
safety procedures, and emergency response techniques.
Check the MSDS before you start any job using a TS1132
hazardous chemical. That way you will know exactly what
the risks are and how to do the job safely. Then follow
procedures and recommended equipment.
(See your John Deere dealer for MSDS’s on chemical

products used with John Deere equipment.)
DX,MSDS,NA –19–03MAR93–1/1

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PN=21
Safety Information
9000
01 Use Safety Lights and Devices
14
Operators of machines that travel below normal highway

speeds should take special precautions to avoid collision
with other vehicles.
–UN–10FEB89
Before driving on public roads, check state and local laws
that may apply to tractors, self-propelled machines, and
towed equipment. Additional lights, mirrors, SMV
emblems, or reflectors may be required.
N36564
Install and use all safety lights and devices necessary to
assure safe operation and local compliance. Keep these A—Lights
safety items in good condition. Replace missing or B—Slow Moving Vehicle Emblem
damaged parts immediately. C—Reflector Tape
D—Reflectors
TX,05,DH1729 –19–26JAN91–1/1
Keep ROPS Installed Properly
A damaged roll-over protective structure (ROPS) should

be replaced, not reused.
The protection offered by ROPS will be impaired if ROPS

is subjected to structural damage, is involved in an
overturn incident, or is in any way altered by welding,
bending, drilling, or cutting.
If ROPS was loosened or removed for any reason, inspect

it carefully before operating the machine again.
To maintain the ROPS:
• Replace missing hardware using correct grade

hardware.
• Check hardware torque.
• Check isolation mounts for damage, looseness or wear;
replace them if necessary.
• Check ROPS for cracks or physical damage.
TX,05,DH1846 –19–14MAY91–1/1

011504
PN=22
Safety Information
9000
Warn Others of Service Work 01
15
Unexpected machine movement can cause serious injury.
Before performing any work on the machine, attach a "DO

NOT OPERATE" tag to the steering wheel.
–19–22APR91
T7447AO
TX,05,DH1820 –19–14MAY91–1/1

011504
PN=23
Safety Information
9000
01 Practice Safe Maintenance
16
Understand service procedure before doing work. Keep

area clean and dry.
Never lubricate, service, or adjust machine while it is

moving. Keep hands, feet , and clothing from
power-driven parts. Disengage all power and operate
controls to relieve pressure. Lower equipment to the
ground. Stop the engine. Remove the key. Allow machine
to cool.
Securely support any machine elements that must be

raised for service work.
Keep all parts in good condition and properly installed. Fix

damage immediately. Replace worn or broken parts.
Remove any buildup of grease, oil, or debris.
On self-propelled equipment, disconnect battery ground

cable (-) before making adjustments on electrical systems
–UN–23AUG88
or welding on machine.
On towed implements, disconnect wiring harnesses from

tractor before servicing electrical system components or
TS218
welding on machine.
DX,SERV –19–17FEB99–1/1
Support Machine Properly
Always lower the attachment or implement to the ground

before you work on the machine. If the work requires that
the machine or attachment be lifted, provide secure
support for them. If left in a raised position, hydraulically
supported devices can settle or leak down.
–UN–23AUG88
Do not support the machine on cinder blocks, hollow tiles,

or props that may crumble under continuous load. Do not
work under a machine that is supported solely by a jack.
TS229
Follow recommended procedures in this manual.
When implements or attachments are used with a

machine, always follow safety precautions listed in the
implement or attachment operator’s manual.
DX,LOWER –19–24FEB00–1/1

011504
PN=24
Safety Information
9000
Remove Paint Before Welding or Heating 01
17
Avoid potentially toxic fumes and dust.
Hazardous fumes can be generated when paint is heated

by welding, soldering, or using a torch.
–UN–23AUG88
Remove paint before heating:
• Remove paint a minimum of 100 mm (4 in.) from area

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

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

fumes and dust away.
Dispose of paint and solvent properly.
DX,PAINT –19–24JUL02–1/1
Avoid Heating Near Pressurized Fluid Lines
Flammable spray can be generated by heating near

pressurized fluid lines, resulting in severe burns to
yourself and bystanders. Do not heat by welding,
soldering, or using a torch near pressurized fluid lines or
other flammable materials. Pressurized lines can be
–UN–15MAY90
accidentally cut when heat goes beyond the immediate

flame area.
TS953
DX,TORCH –19–03MAR93–1/1

011504
PN=25
Safety Information
9000
01 Avoid High-Pressure Fluids
18
Escaping fluid under pressure can penetrate the skin

causing serious injury.
Avoid the hazard by relieving pressure before
–UN–23AUG88
disconnecting hydraulic or other lines. Tighten all
connections before applying pressure.
Search for leaks with a piece of cardboard. Protect hands
X9811
and body from high pressure fluids.
If an accident occurs, see a doctor immediately. Any fluid

injected into the skin must be surgically removed within a
few hours or gangrene may result. Doctors unfamiliar with
this type of injury should reference a knowledgeable
medical source. Such information is available from Deere
& Company Medical Department in Moline, Illinois, U.S.A.
DX,FLUID –19–03MAR93–1/1
Clean the Machine Regularly
Remove any grease, oil, fuel, or debris build-up to avoid

possible injury or machine damage.
High pressure washing [greater than 1379 kpa (13.8 bar)
–UN–18OCT88
(200 psi)] can damage freshly painted finishes. Paint
should be allowed to air dry for 30 days minimum after
receipt of machine before cleaning with high pressure.
Use low pressure wash operations until 30 days have
elapsed. T6642EJ
Do not spray oil cooler fins at an angle. Fins may bend.
TX,05,FF2787 –19–27JUL94–1/1

011504
PN=26
Safety Information
9000
Service Cooling System Safely 01
19
Explosive release of fluids from pressurized cooling

system can cause serious burns.
Shut off engine. Only remove filler cap when cool enough
to touch with bare hands. Slowly loosen cap to first stop
–UN–23AUG88
to relieve pressure before removing completely.
TS281
DX,RCAP –19–04JUN90–1/1
Store Attachments Safely
Stored attachments such as dual wheels, cage wheels,

and loaders can fall and cause serious injury or death.
Securely store attachments and implements to prevent

falling. Keep playing children and bystanders away from
–UN–23AUG88
storage area.
TS219
DX,STORE –19–03MAR93–1/1
Dispose of Waste Properly
Improperly disposing of waste can threaten the

environment and ecology. Potentially harmful waste used
with John Deere equipment include such items as oil, fuel,
coolant, brake fluid, filters, and batteries.
–UN–26NOV90
Use leakproof containers when draining fluids. Do not use
food or beverage containers that may mislead someone
into drinking from them.
Do not pour waste onto the ground, down a drain, or into TS1133
any water source.
Air conditioning refrigerants escaping into the air can

damage the Earth’s atmosphere. Government regulations
may require a certified air conditioning service center to
recover and recycle used air conditioning refrigerants.
Inquire on the proper way to recycle or dispose of waste

from your local environmental or recycling center, or from
your John Deere dealer.
DX,DRAIN –19–03MAR93–1/1

011504
PN=27
Safety Information
9000
01
20

011504
PN=28
Section 9005
Operational Checkout Procedure
Contents 9005
Page
Group 10—Operational Checkout Procedure

Complete Machine Operational Checkout . . .9005-10-1
Engine Off Checks . . . . . . . . . . . . . . . . . . . .9005-10-2
Engine Running Checks . . . . . . . . . . . . . . . .9005-10-5
Monitor Indicator And Gauge Check—Engine
Running . . . . . . . . . . . . . . . . . . . . . . . . . . .9005-10-6
Brake System, Clutch Cutoff, And Differential
Lock Checks . . . . . . . . . . . . . . . . . . . . . . .9005-10-9
Driving Checks . . . . . . . . . . . . . . . . . . . . . .9005-10-16
Hydraulic System Checks . . . . . . . . . . . . . .9005-10-23
Steering System Checks . . . . . . . . . . . . . . .9005-10-33

011504
PN=1
Contents
9005

011504
PN=2
Group 10
Complete Machine Operational Checkout
This procedure is designed so technician can make a

quick check of the operation of machine while sitting in
operator’s seat.
9005
10
A location will be required which is level, has adequate 1
space to complete the driving checks and to work the unit.
The engine and all other major components must be at

operating temperature for some checks.
Complete the necessary visual checks (oil levels, oil

condition, external leaks, loose hardware, loose linkage,
etc.) prior to doing the checkout.
Before starting this operational checkout, check Diagnostic

Trouble Codes using the monitor or SERVICE ADVISOR
application. These Diagnostic Trouble Codes must be
corrected or cleared before starting this checkout.
No special tools or gauges are needed. Always start in

the left column and read completely, following this
sequence from left to right. Read each check completely
before performing.
At the end of each check, if no problem is found (YES:),

you will be instructed to go to next check. If problem is
indicated (NO:), you will be given repair required and
either group location, CTM number, or hyperlink if viewing
in electronic format. If verification is needed, you will be
given next best source of information:
Group 10 (System Operational Checks)
Group 15 (Diagnostic Information)
Group 20 (Adjustments)
Group 25 (Tests)
CTM (Component Technical Manual)
SERVICE ADVISOR is a trademark of Deere & Company LS10960,0000022 –19–05SEP02–1/1

011504
PN=31
1 Engine Off Checks
9005 – – –1/1
10
2
Battery Check Key Off. YES: Go to next check.
Press SELECT button and hold until battery volts are NO: Go to Monitor
displayed. Display Unit—Diagnostics
Menu— Battery Monitor
LOOK: Does battery volts read a minimum of 25.2 volts? (d 03). (Group 9015-15.)
Check voltage on each
NOTE: The hourmeter reading is also displayed and if battery before recharging.
T103154 –UN–10SEP96 you hold SELECT button down for 4 seconds the
odometer reading will be displayed. If one battery will not hold
a charge, replace both
batteries.
– – –1/1

011504
PN=32
Monitor Bulb And Gauge YES: Go to next check.

Check
NO: Check Monitor
Switched Power Fuse 5A.
See Fuse Specifications.
(Group 9015—10.)
9005
10
IF OK: Go to Monitor
3
T103151 –UN–18SEP96 Display Unit — Service
Diagnostics Menu —
Machine Model (S 01).
(Group 9015-15.)
T113686 –UN–20FEB98
Turn key on.

Observe monitor and note changes for first 3 seconds.
LOOK/LISTEN: Do all lights come ON and does alarm

sound?
Does Message Display and Basic Display window have

“8s” showing in every display?
T103154 –UN–10SEP96
Do all the gauge indicators point to approximately 12:00
O’ clock position?
Is backlighting of gauges ON?
After 4 seconds observe changes in Monitor.
LOOK: Do gauge indicators change from 12:00 O’clock

to normal readings?
Does Message Display show JOHN DEERE?
Does Basic Display show correct machine model for 3

seconds?
After 3 seconds observe Basic Display Window.
LOOK: Does Basic Display change to show gear, rpm,

hourmeter and battery voltage readings?
– – –1/1

011504
PN=33
Monitor Indicator Circuit YES: Go to next check.

And Key Switch Check
NO: Go to Monitor
Display Unit Circuit.
(Group 9015-15.)
9005
10
4
T103151 –UN–18SEP96
With key switch Off and bucket on ground, push brake pedal 30—50 times.
Turn key switch to Accessory position.
LISTEN: Does accessory relay “click”? Does monitor remain off?
Turn key switch to On.
LISTEN: Does accessory relay “click” when key is turned to On?
NOTE: Click of relay will come from fuse block in right rear side of side console, it may
be hard to hear if area is noisy.
After 10 seconds:
LOOK/LISTEN: Do the following indicators remain On: Flashing STOP light, Engine Oil
Pressure, Steering Pressure (If equipped), Park Brake and Brake Pressure?
– – –1/1
Cab System Checks Check the following for proper working order: YES: Go to next check.
• Seat Adjustment NO: Go to specific circuit

• Seat Belt See System Functional
• Tilt Wheel Counsel Schematic. (Group
• Front and rear work lights 9015-15.)
• Front and rear drive lights
• Turn signals
• Dome light
• Horn
• Front and rear windshield wiper and washer
• Four speed (five position) blower fan
• Door and window latches
• Side shield latches
• Grill housing door latch
• Radiator cap and Fuel door checks
• Cab Mount Ladder
• Boom Lock check
• Service Decal check
– – –1/1

011504
PN=34
Transmission Control Engine Off, key On. YES: Go to next check.

Lever And Neutral Lock
Latch Checks Push automatic transmission switch to Off position. NO: Monitor Display Unit
Circuit Operational
Move transmission control lever to Forward, Neutral and Information. (Group
Reverse positions. 9015-15.) and System
9005
Functional Schematic
10
LOOK: Does lever move into Forward, Neutral and SE23 Transmission
5
T106879 –UN–14FEB97
Reverse positions easily? Control Unit Input
Circuits. (Group 9015-10.)
Does lever stay in detented positions?
IF OK: Repair or replace
Does backup alarm sound? shift lever assembly.
Put neutral lock in LOCKED position.
Apply slight effort to move lever into forward (F) and

reverse (R).
LOOK: Does neutral lock stay engaged and lever stay in

neutral?
Twist lever to shift into each gear 1st, 2nd, 3rd and 4th.
LOOK: Does gear number align with pointer in each

detented position?
Does twist handle remain in detented positions?
Does Basic Display indicate correct gear and “N”

position? (1 N, 2 N, 3 N and 4 N)
– – –1/1
2 Engine Running Checks
– – –1/1

011504
PN=35
Neutral Start Circuit YES: Go to next check.

Check
NO: Go to Fuse
Specifications. (Group
9015—10.) Check Neutral
Start Fuse.
9005
10
IF OK: Go to Start
6
T103154 –UN–10SEP96 Circuit. (Group 9015-15.)
T7773BI1 –UN–05AUG92 T106879 –UN–14FEB97
Engine Off, key On.
Move neutral lock to UNLOCKED position.
Twist transmission control lever until 1st gear “N” is displayed.
Move transmission control lever to 1st gear forward (1F), turn key switch to START.
LISTEN: Starting motor must not run.
NOTE: Gear display will not display “F” for forward or “R” for reverse until engine is
started and park brake released.
Move transmission control lever to 1st gear reverse (1R), turn key switch to START.
LISTEN: Starting motor must not run. Backup alarm will sound.
With transmission control lever in neutral (1N), turn key switch to START
LISTEN: Does starting motor run with lever in neutral position only?
– – –1/1
3 Monitor Indicator And Gauge Check—Engine Running
– – –1/1

011504
PN=36
Engine Speed Check YES: Go to next check.
NO: Inspect linkage to

potentiometer under
pedal. Go to Analog
Throttle Position Sensor
9005
Adjustment. (Group
10
9010-20.) Slow and High
7
T103160 –UN–10SEP96 Idle.
NO: If engine speed out

of specifications, check to
see that Monitor is
programmed for correct
machine, 644H. Go to
Monitor Display Unit
Service Diagnostics.
(Group 9015-15.)
T106883 –UN–14FEB97
IF OK: Go to Diagnose
Engine Malfunctions.
Start engine and warm to normal operating temperature. (Group 9010-15.)
LOOK: Does engine speed read 900 ± 25 rpm?
Press accelerator pedal down until it hits the stop bolt.
LOOK: Does engine accelerate smoothy to high Idle

speed of 2350 ± 25 rpm?
T106881 –19–14FEB97
FEEL: Does accelerator pedal contact stop bolt?
– – –1/1

011504
PN=37
Monitor Basic Display, LOOK: Does hourmeter reading appear?

Alternator Output Check
And Seat Belt Indicator LOOK: Is battery volts reading 25.2—27.6?
Check
LOOK: Does engine speed read 0?
9005
2. Start engine and run at slow idle. Observe monitor display.
10
8
LOOK: Does seat belt indicator go Off 5 seconds after engine starts?
LOOK: Is battery voltage higher after engine starts?
T103154 –UN–10SEP96
T103160 –UN–10SEP96
T7747AH –UN–19MAY92
Stop engine.
1. Turn key switch to On and wait 10 seconds.
NOTE: It is normal for Engine Oil Pressure and Brake Pressure indicators to stay on 4
to 6 seconds after engine starts.
LOOK: Do all indicator lights go Off except for park brake? Park brake indicator light
will go Off when park brake is turned Off.
NOTE: If any indicators are On check to see if machine is equipped with that option
before doing diagnostics. If machine is not equipped with option it will have to be
turned Off in the Service Menu. Go to Monitor Display Unit—Service Menu—Enable
Options (S 06). (Group 9015-15.)
2. Increase engine speed to high idle and observe monitor display.
LOOK: Is engine speed 2350 ± 25?

– – –1/2

011504
PN=38
LOOK: Is hourmeter symbol flashing and hourmeter YES: Go to next check.

reading displayed?
NO: Go to Fuse
9015-15.) Check Monitor
and Transmission
9005
Controller Unswitched
10
Fuse 5A and Monitor
9
Switched Power Fuse
7.5A .
IF OK: Go to Monitor
Display Unit Circuit
Theory Of Operation.
(Group 9015-15.)
NO: Inspect linkage to

potentiometer under
pedal. Go to Analog
Throttle Position Sensor
Adjustment. (Group
9010-20.) Slow and High
Idle.
NO: If engine speed out

of specifications, check to
see that monitor is
programmed for correct
machine, 644H. Go to
Service Diagnostics.
(Group 9015-15.)
NO: If charging voltage is

not normal, go to
Charging Circuit Theory
of Operation. (Group
9015-15.) To check
Abnormal Voltage
Diagnostic Trouble
Codes.
–19– –2/2
4 Brake System, Clutch Cutoff, And Differential Lock Checks
– – –1/1

011504
PN=39
Park Brake Check YES: Go to next check.
NO: See Back-Up Alarm

And Park Brake Sensing
And Park Brake Release
Circuit Theory Of
9005
Operation. (Go to
10
9015-15.)
10
T103160 –UN–10SEP96 T103441 –UN–09SEP96
NO: If machine does not
stop within specified
CAUTION: Seat belt must be worn during this distance, see Repair Park
check to prevent possible injury from sudden Brake. (Group 1160.)
machine stops. TM1638 Repair Manual.
Engine running.
Fasten seat belt.

T103162 –UN–09SEP96
Release park brake and put transmission in 1st gear
forward.
Drive machine at 3 MPH and push park brake switch to

ON.
LOOK/FEEL: Does machine come to a stop within 1

meters (3 feet) when park brake is engaged at 3 MPH?
Does transmission shift to neutral?
– – –1/1
Park Brake Indicator YES: Go to next check.

Check
NO: Shift machine into
reverse (R) and listen for
back-up alarm. If alarm
does not sound, check
Park Brake and Back-up
Alarm Fuse 5A. See Fuse
T103441 –UN–09SEP96 Specifications. (Group
9015-10.)
IF OK: Go to Backup
Alarm, Park Brake
Sensing and Park Brake
Release Circuit. (Group
9015-15.)
T106884 –19–20FEB97
Start engine.
Release park brake by pushing park brake switch to OFF position and releasing back
to the Neutral position. See Park Brake Switch. (Group 30.) Operators Manual.
LOOK: Does park brake indicator go off when brake is released? Will machine move if
put into gear?
– – –1/1

011504
PN=40
Park Brake Transmission YES: Go to next check.

Lockout Check
NO: Go to Transmission
Control Unit Circuit or
Backup Alarm, Park
Brake Sensing and Park
9005
Brake Release Circuit.
10
(Group 9015-15.)
11
T103158 –UN–10SEP96 T103441 –UN–09SEP96 T7773BN –UN–05AUG92
CAUTION: Machine may move during this check. Perform check in an

open area.
Engine running.
Push park brake switch to ON.
CAUTION: Brakes may NOT hold the machine in 1st forward or 1st
reverse at high idle.
Place transmission in 3rd forward.
Slowly increase engine speed to high idle.
LOOK: Does machine remain stationary?
FEEL/LOOK: Does transmission remain in neutral (N)?
LISTEN/LOOK: Does STOP warning light flash and alarm sound, indicating park brake
is ON?
– – –1/1

011504
PN=41
Service Brake Check YES: Go to next check.
NO: Inspect brake linings

on brake disks. (Group
9020-20.)
9005
IF OK: Inspect for leaks
10
from brake system or
12
T103453 –UN–05SEP96 overfilling of standard
axle. Go to Diagnose
Service Brake
Malfunctions. (Group
9020-15.)
T113521 –UN–13FEB98
A—Service Brake Pedal

B—Service Brake Pedal
C—Clutch Cutoff Switch
Engine running.
Push Clutch Cutoff switch (C) to off position. Fully apply either (A) or (B) service brake
pedal, push park brake switch to OFF and put transmission in 2nd forward. Increase
engine speed to high idle.
LOOK: Does machine remain stationary or move very slowly?
Repeat check three times to ensure accurate results.
– – –1/1

011504
PN=42
Service Brake Pressure

Switch And Brake
Accumulator Precharge
9005
10
13
T103122 –UN–10SEP96
A—Service Brake Pedal

T108329D –UN–09APR97
C—Rear Brake Lights
NOTE: Axles and hydraulic oil must be at operating temperature.
In later machines (S.N. —574050) the boom lower circuit is connected to brake valve
inlet to provide oil for braking if engine quits and accumulator has discharged. Return
oil is available as long as bucket is off the ground to apply the brakes. Do the following
before performing this check:
• Engine running, lower bucket to ground and put boom lever in float position.
• Lower bucket to the ground.
• Stop engine.
CAUTION: Bucket will drop suddenly when pilot enable/boom down

switch is held to BOOM DOWN and control lever is moved to boom down
position.
Hold pilot enable/boom down switch to BOOM DOWN and cycle control lever in all
directions 20 times to bleed charge pressure from PRV/brake accumulator.
Key switch On. Do not start engine.
Press brake pedal (A) or (B) and record number of applications until brake pressure
indicator comes On.
Continue pushing brake pedal and counting applications until brake lights (C) fail to
come On.
– – –1/2

011504
PN=43
LOOK: YES: Go to next check.
NO: If fewer than 12

brake pedal applications
are required to turn brake
oil pressure indicator on,
9005
accumulator charge
10
pressure may be low. Go
14
to Brake Accumulator
Precharge Test. (Group
9025-25.)
NO: If brake oil pressure

indictor does not come
on, see Monitor Display
T7747AF –UN–19MAY92 Unit Circuit
Specifications—Switches
And Senders. (Group
Are at least 12 brake pedal applications needed before brake pressure indicator comes 9015-15.)
On?
LOOK: Are at least 30 brake pedal applications needed before brake lights fail to come
on?
–19– –2/2
Service Brake Linkage A—Service Brake Pedal YES: Go to next check.

Check B—Service Brake Pedal
NO: Inspect for debris
Engine off. under brake pedal.
Move each pedal with hand to check “free travel”. Inspect brake pedal
linkage for damage.
FEEL/LISTEN: Does each pedal have about 6 mm (0.25
in.) free travel? IF OK: If linkage is OK,
T103453 –UN–05SEP96 go to Brake Valve
Leakage Test. (Group
9025-25.)
– – –1/1

011504
PN=44
Service And Driveline YES: Go to next check.

Bearing Park Brake
System Drag Checks NO: Inspect Service
Brake Disks. (Group
1160.) Repair Manual.
9005
NO: Inspect driveline
10
bearing park brake disk,
15
T103160 –UN–10SEP96 go to Park Brake
T6522CH –UN–19OCT88
Pressure Test. (Group
9020-25.)
Engine running.
Position unit on gradual slope with engine running in neutral.
Lower bucket approximately 30 cm (12 in.) from ground.
Push park brake switch to OFF position and remove foot from service brake pedal.
LOOK: Does machine move or coast?
NOTE: If unit does not move, check brake pedals to be sure they fully release with feet
are removed from them.
Drive unit at high speed for about five minutes. Brake drag is indicated if brake areas
in differential case are too hot to touch.
FEEL: Are brake areas of both differentials cool?
NOTE: If brake area of either differential is hot, service brake drag is indicated.
FEEL: Is driveline bearing park brake housing cool?
NOTE: If driveline bearing park brake is hot, driveline bearing park brake drag is
indicated.
– – –1/1
Differential Lock Check Park unit on a hard surface. YES: Go to next check.
Release brakes. NO: Go to Differential

Lock Pressure Test.
Push differential lock switch and steer unit left and right. (Group 9025-20.)
Release differential lock switch and steer unit 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.
LOOK: Do front wheels rotate in opposite directions with

differential lock switch released?
T103168 –UN–05SEP96
– – –1/1

011504
PN=45
Clutch Cutoff Check YES: Go to next check.
NO: See Fuse

9015-10.) Rocker,
Restriction, Radio Fuse
9005
7.5A .
10
16
T103170 –UN–05SEP96 IF OK: Go to Clutch
Cutoff Sensor Check.
A—Service Brake Pedal (Group 9005-10.)
T103453 –UN–05SEP96
Place clutch Cutoff switch in on position.
Release park brake.
Drive machine at half speed in 1st forward.
Push brake pedal (A) or (B).
T103441 –UN–09SEP96 FEEL: Does transmission disengage when either brake

pedal is pushed?
NOTE: Clutch Cutoff switch can be adjusted to operator

preference to match your loading needs by selecting one
of three operating functions in the monitor. Transmission
does not totally disengage, some effort to move by the
machine can be felt. Go to Monitor Display Unit—
Accessory Menu—Clutch Cutoff (A 01). (Group
9015-15.)
– – –1/1
5 Driving Checks
NOTE: Transmission oil must be at operating temperature for these checks.
– – –1/1

011504
PN=46
Transmission Oil Warm Engine running. YES: Go to next check.

Up Procedure
Press MENU to get Diagnostic Menu (d) displayed. NO: Apply service
brakes, and release park
Press SELECT to get (d 01) displayed, then press next brake
until (d 05) is displayed.
9005
Push Clutch Cutoff switch
10
Press SELECT to get (d 051) transmission oil to off position.
17
T103169 –UN–09SEP96 temperature.
Move transmission
LOOK: Is transmission temperature in 50—65 °C (120— selector lever to 3rd
150 °F) range? speed.
Increase engine speed to

high idle for 30 seconds.
Move transmission control

lever to neutral "N"
position and run for 15
seconds.
Repeat procedure until

transmission temperature
is in operating range.
– – –1/1
Transmission Noise Engine running. YES: Go to next check.

Check
Run engine at approximately 1600 rpm. NO: See Diagnose
Transmission Systems
Drive unit with transmission in each forward and reverse Malfunctions. (Group
speed. 9020-15.) Excessive
Transmission Noise
LISTEN: Is transmission quiet except for normal gear (under load or no load).
T7773BN –UN–05AUG92
noise, in all gears?
NO: See Diagnose
Does engine speed remain almost constant as machine Transmission System
is shifted between gears? Malfunctions. (Group
9020-15.) Machine will
Does transmission shift smoothly between gears and not shift correctly.
forward to reverse?
– – –1/1

011504
PN=47
Automatic Shift And NOTE: In the AUTO mode, transmission will shift to YES: Go to next check.
Speedometer Check highest gear selected as ground speed increases, or will
down shift to 2nd as ground speed decreases. NO: Monitor is
Transmission will never shift to 1st gear. In AUTO programmed for wrong
MODE TO FIRST the transmission will start in 1st when tire size. Go to Monitor
initially shifted from Neutral to Forward or Reverse. After Display Unit—Service
9005
the initial shift from Neutral, the transmission will Menu—Tire Size (S 03).
10
downshift no lower than 2nd unless a high load is (Group 9015-15.)
18
T103162 –UN–09SEP96 encountered. Transmission will upshift or downshift as
ground speed dictates. IF OK: Check
Transmission Output
Engine running. Shaft Speed Sensor. If
sensor has failed,
Automatic transmission switch to AUTO. speedometer will not
work, and transmission
Perform this check in an open area away from other will not shift above 2nd.
people and machinery. Go to Transmission
Control Unit Operating
Release park brake and shift to (4th) forward. Modes. (Group 9015-15.)
Drive machine on level ground and slowly accelerate to

high idle speed and note speed when shifts are made
until engaged in 4th gear. Reduce engine rpm to idle
and note speed when transmission makes each
downshift.
LOOK: Does the transmission shift at following

approximate speeds?
644H
Shift MPH Km/H
2nd-3rd 6 9
3rd-4th 10 16
4th-3rd 10 16
3rd-2nd 6 9
NOTE: In 4th Forward automatic the transmission starts

out in 2nd gear and up-shifts to 3rd then 4th. When
transmission downshifts it returns to 2nd. Transmission
will shift at different speeds depending on machine
loads. Use only as reference.
– – –1/1

011504
PN=48
Transmission Shift Mode

Check
9005
10
19
T103165 –UN–09SEP96 T103436 –UN–09SEP96
Engine running.
Turn Automatic Transmission Shift switch to off.
Press MENU until ACCESSORY shows in basic display,

then press SELECT.
Accessory will display in Message Display Window and

A 02 Quick Shift in Basic Display Window.
Press NEXT until A 021 Down/up displays, then press

SELECT.
Release park brake and shift to 3rd forward.
Drive machine at approximately 1600 rpm and press

Quick Shift Switch once.
LOOK/FEEL: Does transmission shift to and remain in

2nd gear?
T111398 –UN–19SEP97
Press Quick Shift Switch once more.
LOOK/FEEL: Does transmission shift back to 3rd gear?
NOTE: If Quick Shift Switch is pressed twice,

transmission will shift down one gear then immediately
back up to where it was. Quick Shift feature operates in
all gears.
In Basic Display Window with Quick Shift A 021

displayed, press NEXT to get Downshift A 022 Down
Only to display.
Press SELECT to enable Down Only shift mode.
Release park brake and shift to 4th forward.
Drive machine at approximately 1200 rpm and press

Quick Shift Switch once.

3rd gear?

2nd gear?

1st gear?
– – –1/2

011504
PN=49
LOOK/FEEL: Does transmission stay in 1st gear? YES: Go to next check.
NOTE: In DOWN ONLY mode pressing Quick Shift NO: Check Rocker,
Switch will not change gears once 1st gear is reached, Restriction, Radio
unless a direction or gear change is made. Switches Fuse 7.5A . Go
to Transmission Control
9005
Unit Circuit . (Group
10
9015-15.)
20
NO: Check Quick Shift
Switch. Go to
Transmission Control Unit
Circuit. (Group 9015-15.)
–19– –2/2
Forward, Reverse Clutch YES: Go to next check

Pack Drag Check
NO: If Torque Converter
Output speed is
excessively higher in one
direction, opposite
direction clutch pack drag
is indicated. See Remove
T7773BN –UN–05AUG92
And Install Transmission.
(Group 0350.)
IMPORTANT: Transmission must be warmed up for
this check. See Transmission Warm-up Procedure in
Group 9020-25.
Engine running.
1. Press MENU to display (d) in Basic Display Window.

2. Press SELECT to get (d 01) displayed, then press
NEXT until (d 05) is displayed.
T111406 –UN–16SEP97
3. Press SELECT, then NEXT to (d 054) Torque Output
Speed. Press SELECT.
4. With machine on LEVEL hard surface, shift to 1st.
forward.
Release park brake and service brakes.
5. Run engine at slow idle, do not put foot on
accelerator.
Observe Torque Converter Output Speed and note
rpm within 50 m (55 yd) of machine travel.
6. Shift to 1st reverse and observe Torque Converter
Output Speed and highest rpm within 50 m (55 yd) of
machine travel.
7. Repeat procedure in 2nd gear forward and reverse.
LOOK/FEEL: Is Torque Converter Output Speed within

400 rpm in each Forward and Reverse gear?
NOTE: If output speed differential is greater than 400

rpm, drive the machine the opposite direction across the
test course to insure the surface is level. Some
difference in rpm is normal. Machine has failed test only
if rpm differential is excessive.
– – –1/1

011504
PN=50
1st, 2nd, And 3rd Speed YES: Go to next check.

Clutch Pack Drag Check
NO: See Remove And
Install Transmission.
(Group 0350.) Repair
Manual
9005
10
21
T113485 –UN–13FEB98
A—Automatic Transmission Switch
Engine running.
Stop unit on a level, hard surface.
Push Automatic Transmission Switch (A) to OFF

position.
Run engine at slow idle.
Release park and service brakes.

T106879 –UN–14FEB97
Put transmission in 1st forward, 2nd forward, then 3rd
forward.
Note machine movement.
LOOK: Does machine roll ahead in each gear?
NOTE: If machine rolls ahead in one gear but not the

other two, drag is indicated in that clutch pack.
– – –1/1

011504
PN=51
Transmission Shift YES: Go to next check.

Modulation Check
NO: See Diagnose
Transmission System
9020-15.) Transmission
9005
shifts to fast or slow.
10
22
T106881 –19–14FEB97 T7773BN –UN–05AUG92
T113485 –UN–13FEB98
A—Automatic Transmission Switch
Engine running.
Push Clutch Cutoff Switch to off position.
Push Automatic Transmission Switch (A) off.
CAUTION: Fasten seat belt before performing this check. Machine will
change directions abruptly!
Shift transmission to 1st forward, increase engine speed to high idle, shift from forward
to reverse and reverse to forward several times, allowing machine to reach full speed
in forward and reverse before changing directions. Repeat check in 2nd gear.
LOOK: Does machine slow down and change direction smoothly?
Drive machine in 2nd gear at high idle, apply service brakes to slow engine down to
1800 rpm, then while still holding service brakes, shift to 1st gear.
LOOK/FEEL: Does transmission shift smoothly without jerking?

– – –1/1

011504
PN=52
Torque Converter and YES: Go to next check.

Engine Power Check
NO: If stall speed is
outside range, problem
may be engine power or
torque converter. Go to
9005
Engine Power Test Using
10
Engine Pulldown in group
23
T103169 –UN–09SEP96 9010-25.
Engine running and park brake released. IF OK: If power is ok, go

to Diagnose Transmission
Turn Clutch Cutoff Switch to off. System Malfunctions in
group 9020-15.
Transmission oil must be warm before performing this
check. See Transmission Oil Warm-up Procedure.
(Group 9020-25.)
T106883 –UN–14FEB97
Warm transmission oil to at least 83 °C (180 °F).
Apply service brakes so machine does not move.
Shift transmission to 3rd forward.
Push accelerator pedal until it touches stop bolt. Record

engine speed in basic display window.
LOOK: Is torque converter stall speed within following

range:
644H—Standard Cooling System
• No. 1 fuel: 2070—2190 rpm

• No. 2 fuel: 2100—2220 rpm
644H—High Ambient Cooling System
• No. 1 fuel: 2040—2170 rpm

• No. 2 fuel: 2070—2190 rpm
644H MH—High Ambient Cooling System
• No. 1 & 2 fuel: 2155—2185 rpm
Move transmission control lever to neutral "N" position

and run for 15 seconds to cool oil.
NOTE: 644H MH has same stall speed with both fuels

due to being electronically controlled with the controller.
Also is only offered with high ambient cooling package
– – –1/1
6 Hydraulic System Checks
– – –1/1

011504
PN=53
Pilot Controller Check YES: Go to next check.
NO: See Pilot Controller

Repair. (Group 3160.)
Repair manual
9005
10
24
T103171 –UN–09SEP96 T103173 –UN–06SEP96
Turn key switch to off position.
Move control lever to all positions and then release.
LOOK: Does lever return to neutral when released from all positions?
– – –1/1
Pilot Controller Lock YES: Go to next check.

Check
NO: Replace Pilot
Enable/Boom Down
Switch. Go to Load
Center Harness (W3)
Component Location
Detail C. (Group
T107029 –UN–04FEB97 T103429 –UN–09SEP96 9015-10.)
NOTE: Perform check in an open area, boom will raise

during check.
Start engine.
Push Pilot Enable/Boom Down Switch to LOCKED

position.
Move boom control lever to boom raise and hold.

T107028 –UN–04FEB97
Move Pilot Enable/Boom Down Switch to UNLOCK and

observe boom.
LOOK/FEEL: Does boom raise when switch is

UNLOCKED?
Move Pilot Enable/Boom Down Switch to LOCKED

position and observe boom.
LOOK/FEEL: Does boom stop when switch is LOCKED?
– – –1/1

011504
PN=54
Pilot Enable/Boom Down YES: Go to next check.

Solenoid (Key On) Check
NO: Check Pilot Enable
Fuse 7.5A. See Fuse
9015-10.)
9005
10
IF OK: See Pilot Enable
25
And Boom Down Circuit
T107030 –UN–04FEB97
Theory Of Operation.
(Group 9015-05.)
Engine running.
Raise boom to full height and roll bucket back half way.
Stop engine.
Turn key to on position.
T103427 –UN–09SEP96 Move Pilot Enable/Boom Down Switch to LOWER

position and hold it.
Move control lever to bucket dump position.
Move control lever to boom lower position.
LOOK: Does bucket dump and boom lower?
– – –1/1
Pilot Enable/Boom Down Raise boom to full height and roll bucket back half way. YES: Go to next check.
Solenoid (Key Off) Check
Stop engine. NO: Check Unswitched,
Boom Down, Radio and
With key switch off move Pilot Enable Switch to Lower Dome Light Fuse 5A .
position and hold it. See Fuse Specifications.
(Group 9015-10.)
Move control lever to bucket dump position.
T107030 –UN–04FEB97
IF OK: See Pilot Enable
Move control lever to boom lower position. And Boom Down Circuit
Theory Of Operation. (Go
LOOK: Does bucket dump and boom lower? to 9015-10.)
– – –1/1

011504
PN=55
Pilot Control Valve Boom YES: Go to next check.

Float Check
NO: See Pilot Control
Valve Pressure Test.
(Group 9025-25.)
9005
10
26
T107137 –UN–07FEB97 T103177 –UN–06SEP96 T6601AA –UN–19OCT88
Run engine at slow idle.
Push Ride Control Switch off.
Push Return To Carry Switch off.
With the bucket partially dumped, lower boom to raise

front of machine.
T103427 –UN–09SEP96
Push control lever to the float detent position and
release lever.
LOOK: Does front of machine lower to the ground and

valve remain in float position when lever is released?
– – –1/1
Return To Dig, Return To Check Return to Dig, Return to Carry, and Boom Height Kickout. YES: Go to next check.
Carry, and Boom Height
Kickout Checks See Return To Carry, Boom Height Kickout And Return To Dig Circuit Theory Of NO: If all three functions
Operation. (Group 9015-05.) are not working, check
fuse F15. See Fuse and
Are all systems working properly? Relay Specifications.
(Group 9015-10.)
IF OK: Adjust sensors.
See Return-To-Dig
Adjustment.
See Return-To-Carry
Kickout Adjustment.
See Boom Height Kickout

Adjustment.
– – –1/1

011504
PN=56
Pin Disconnect System Run engine at slow idle. YES: Go to next check.
Check (If Equipped)
Position bucket flat on the ground. NO: Hold a screwdriver
blade against the end of
Push and hold pin disconnect switch. the pin disconnect
solenoid valve and check
9005
LOOK: Does pin disconnect cylinder retract both pins, while switch is pressed? for magnetism with the
10
switch pushed.
27
NO: Check Differential
Lock and Pin Disconnect
5A Fuse. (Group
9015-10.) Check pin
disconnect switch.
IF OK: Go to group
9025-15 to correct a
hydraulic problem.
– – –1/1

011504
PN=57
Ride Control Check YES: Go to next check.

CAUTION: Boom will jump upward during this check. Make sure area
around bucket is clear. NO: Check Ride Control
7.5A Fuse. (Group
Start engine. 9015-10.) See Ride
Control Switch. (Group
9005 Push Ride Control Switch to off position. 9015-10.) See Ride
10 Raise boom to maximum height and hold control lever Control Pressure Switch.
28 over relief for 2 seconds. (Group 9015-10.) See
Ride Control Boom
Solenoid. (Group
9015-10.) See Ride
Control ON/OFF
Solenoid. (Group
T107137 –UN–07FEB97 9015-10.)
Lower boom and bucket to eye level. Observe loader IF OK: Ride control
boom as Ride Control Switch is switched to on. accumulator charge
LOOK/FEEL: Does boom jump upward 30 cm (12 in) or pressure.See Charge
more? Ride Control
Accumulator. (Group
Start engine. 9025-20.)
Push ride control switch to AUTO position. Switch will IF OK: Check valve or
illuminate. solenoid valve in ride
T107038 –UN–07FEB97
control manifold is stuck
open. See Inspect And
Raise boom to maximum height and hold control lever
Repair. (Group 3160.)
over relief for 2 seconds.
Lower boom and bucket to eye level and slowly

accelerate to 5 mph while watching speedometer and
bucket.
LOOK/FEEL: Does ride control come on at

T107037 –UN–07FEB97
approximately 3 mph and bucket raise slightly?
T103162 –UN–09SEP96
– – –1/1

011504
PN=58
Hydraulic Oil Warm-Up IMPORTANT: Hydraulic oil temperature must be in YES: Go to next check.
Procedure 50—65 °C (120—150 °F) range to get accurate test
results. NO: Release Park brake.
Engine running Hold bucket rollback

function and steer
9005
Press MENU to get Diagnostic Mode d displayed. machine stop-to-stop until
10
hydraulic temperature
29
T103164 –UN–09SEP96 Press SELECT to get d 01 displayed, then press NEXT reached operating range.
until d 06 is displayed.
Press SELECT get d 061 displayed to monitor hydraulic

system oil temperature.
LOOK: Is hydraulic temperature in 50—65 °C (120—150

°F) range?
– – –1/1
Hydraulic Oil Cool Down IMPORTANT: Hydraulic checks oil temperature must YES: Go to next check.
Procedure be below 104 °C (220 °F) to get accurate test results.
NO: Operate engine at
Engine running high idle. Cycle loader
boom and bucket
Press MENU on monitor until Diagnostic Mode d is cylinders full stoke until
displayed. hydraulic oil temperature
is below 104 °C (220 °F)
T103164 –UN–09SEP96 Press SELECT to get d 01 displayed, then press NEXT
until d 06 is displayed.
Press SELECT get d 061 displayed to activate hydraulic

system oil temperature.
LOOK: Is hydraulic oil temperature below 104 °C (220

°F)?
– – –1/1

011504
PN=59
Hydraulic Pump Press MENU on monitor until Accessory Mode a is displayed then press SELECT. YES: Go to next check
Performance Check
Press NEXT until a 05 STOP WATCH is displayed then press SELECT. NO: Go to Steering
System Leakage Check.
Press SELECT to start the stop watch and SELECT to stop it. Press NEXT to reset the (This group.)
stop watch.
9005
IF OK: See Loader
10
Run engine at slow idle. Hydraulic Pump Flow
30
Test. (Group 9025-25.)
Steer machine to either stop and hold steering wheel while boom is raising.
With bucket flat on ground, actuate boom raise and Press SELECT on Monitor at the
same time to measure boom raise time to full height. Press SELECT when boom stops
to record time.
LOOK: Does boom raise to full height in less than 20 seconds?
NOTE: Repeat boom raise three times to get average time.
– – –1/1
Load Performance A—LPM Mode Switch YES: Go to next check.

Management (LPM) B—LPM Switch
Check, If Equipped NO: Check fuse.
Run engine at high idle.
IF OK: Go To Load
Transmission in First Forward. Performance
Management (LPM)
Drive ahead in an open clear area Circuit Specifications.
T103451 –UN–05SEP96 (Group 9015-15)
Turn knob (A) to position 1 and turn Performance
Management switch (B) to ON position
Do bucket roll back and hold lever. Note engine rpm

drop as hydraulic system is at high standby pressure.
LOOK/LISTEN: Does engine rpm drop hydraulic system

goes to standby pressure?
NOTE: The engine rpm will remain at lower level until

transmission control lever is shifted through neutral
position or LPM switch is turned off.
Turn Performance Management switch to off position.
Do bucket roll back and hold lever. Note engine rpm

drop as hydraulic system is at high standby pressure.
Repeat for switch positions 2 ,3, 4 and 5.
The rpm drop in each positions Setting is:
• One—1900
• Two—1825
• Three—1750
• Four—1675
• Five—1600
LOOK/LISTEN: Does engine rpm stay higher?
– – –1/1

011504
PN=60
Control Valve Lift Check YES: Go to next check.
NO: See Repair Lift

Checks In Control Valve.
manual.
9005
10
31
T6601AA –UN–19OCT88
Run machine at slow idle.
Turn Ride Control switch to off if equipped.
With bucket partially dumped, lower boom to raise front

of machine.
Stop engine and turn key on.

T107030 –UN–04FEB97
Press pilot enable/boom down switch to Boom Down
Position and hold.
Slowly move boom control lever to boom lower position.
Slowly move bucket control lever to bucket dump

position.
LOOK: Does boom remain stationary and not allow front

wheels to drop to the ground.
Start engine.
Slowly move boom control lever to boom lower position.
Slowly move bucket control lever to bucket dump

position.
LOOK: Does front of machine raise without dropping

first?
– – –1/1
Bucket Rollback Circuit YES: Go to next check.

Relief Valve Check
NO: Go to Loader Relief
and Circuit Relief Valve
9025-25.)
T6564OD –UN–19OCT88
Position bucket at a 45° angle against an immovable

object.
Engage transmission in third speed forward.
Press accelerator to stop bolt and hold for 15 seconds.
LOOK: Does bucket angle remain the same?

T106883 –UN–14FEB97
– – –1/1

011504
PN=61
Bucket Dump Circuit YES: Go to next check.

Relief Valve Check CAUTION: Perform check in an open area
away from other people. NO: Go To Loader Relief
and Circuit Relief Valve
With bucket dumped at 45° raise front of machine off the Pressure Test. (Group
ground. 9025-25.)
9005
10 Drive the machine backwards with the front wheels off
32 the ground while observing bucket angle.
LOOK: Does bucket rollback less than 5-8 degrees?
– – –1/1
Boom Down Check Valve Heat hydraulic oil to operating temperature. See YES: Go to next check.
Leakage Check Hydraulic Oil Warm-up Procedure. (Group 9025-25).
NO: See Replace Boom
Position bucket flat on ground. Lower Check Valve.
Run engine at slow idle for two minutes. manual.
LOOK: Does bucket remain on the ground?

T7010AO –UN–15MAR89
– – –1/1
Boom And Bucket Set bucket flat on the ground and raise about 50 mm (2 YES: Go to next check.
Cylinder Drift Check in.).
NO: Go to Boom and
Stop engine. Observe bucket for 1 minute. Bucket Cylinder Leakage
LOOK: Does bucket remain in position? Bucket should To isolate cylinder or
not settle to the ground. valve leakage.
T6564NZ –UN–19OCT88
NOTE: Use good judgement to determine if the amount
of drift is objectionable for your loader application.
– – –1/1

011504
PN=62
Axle Disconnect Check YES: Go to next check.
NO: See Check

Differential Lock and Pin
Disconnect 5A Fuse.
(Group 9015-10.) See
9005
Check Axle Disconnect
10
Switch, and Axle
33
Disconnect Solenoid.
(Group 9015-10.)
IF OK: Go to Diagnose
Differential/Axle
T113524 –UN–13FEB98 9020-15.)
A—Axle Disconnect Switch
Operate machine in an open area away from bystanders.
With bucket partially dumped, lower boom to raise front

wheels off the ground.
Push Axle Disconnect Switch to on position.

Watch front wheels while operating the machine in
reverse. Front wheels must not rotate as machine moves
backwards.
LOOK: Do front wheels remain stationary while machine

moves backwards?
– – –1/1
7 Steering System Checks
– – –1/1

011504
PN=63
Steering Valve Check Transmission in Neutral. YES: See Steering Valve

Drift Test. (Group
Run engine at slow idle. 9025-25.)
Remove foot from brake pedal. NO: Go to next check.

9005
Release park brake.
10
34
Turn steering wheel until machine frames contact right
T6471AQ –UN–19OCT88
and left frame stops.
LOOK: Does machine steer smoothly in both directions?
NOTE: It is normal for machine frames to drift away from

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

wheel?
– – –1/1
Steering System Leakage Heat hydraulic oil to operating temperature. See YES: Go to next check.
Check Hydraulic Oil Warm-Up Procedure in this group. (Group
9025-25.) NO: Do Steering Valve
Leakage Test in Group
Run engine at high idle. 9025-25 and See
Steering Valve Drift Test.
Turn steering wheel rapidly until machine frame contacts (Group 9025-25.)
stop. Jerk steering wheel, and hold approximately 22 N
T6601AC –UN–19OCT88
(5 lb force) on steering wheel.
Count steering wheel revolutions for 1 minute. Repeat

test in opposite direction.
LOOK: Does steering wheel rotate less than 5 rpm?
NOTE: Steering wheel may rotate very little or even

faster than specification. Use good judgement, excessive
steering wheel rpm does not mean steering will be
affected.
A new valve may exceed specification but work OK for

your application.
– – –1/1

011504
PN=64
Secondary Steering YES: Go to next check.

System Check
NO: See Fuse
9015-10.)See Secondary
Steering. (Group
9005
9015-15.)
10
35
IF OK: If secondary
T7773BH1 –UN–05AUG92 T6601AC –UN–19OCT88
steering pump and motor
operate but machine does
IMPORTANT: Do not operate secondary steering pump for more than 15 seconds
not steer, go to
with the steering in neutral or damage to the pump and motor can occur.
Secondary Steering
Park unit on a hard level surface with machine frames straight. Pump Relief Valve
9025-25.)
Start engine.
IF OK: If secondary
steering pump and motor
operate, but machine
steers slow, go to
Secondary Steering
Manifold Primary Check
Valve Leakage Test.
(Group 9025-25.) orsee
Secondary Steering
Manifold Secondary
Check Valve Leakage
T114515B –UN–26MAR98
A—Engine Controller Switch Fuse
Remove Engine Controller Switch Fuse (A) from fuse box in cab on right side of
electrical load center. Engine will stop.
Secondary Steering will activate.
Steer unit to right and left.
LOOK: Does machine steer approximately half way to

stops in both directions? Does light in monitor come ON
and stay on until key is turned off?
T7747AJ1 –UN–24AUG92
– – –1/1

011504
PN=65
Secondary Steering Run engine at high idle. YES: Go to next check.

System Primary Check
Valve Test Turn steering wheel rapidly until machine frame is against steering stop. Hold NO: See Secondary
approximately 22 N (5 lb force) on steering wheel. Steering Manifold Primary
Check Valve Leakage
Actuate a hydraulic function and hold over relief. Return control lever to neutral. Test. (Group 9025-25.)
9005
10
FEEL: Is steering wheel "kickback" felt as hydraulic function is released?
36
NOTE: Steering wheel "kickback" is normal on units without secondary steering.
– – –1/1
Start Aid System Check YES: Go to next check.
NO: Check for empty

start aid can (A).
IF OK: See Fuse

9015-10.) See Check
T103442 –UN–09SEP96 Start Aid Solenoid.
(Group 9015-10.)
T113708 –UN–20FEB98
A—Start Aid Can
Start engine and run at slow idle.
Push Start Aid Switch.
LISTEN: Does engine speed increase slightly (25-50 rpm)?
– – –1/1

011504
PN=66
Section 9010
Engine
Contents
Page

6081 John Deere Engine—Use CTM86 9010
8.1 L Diesel Engines Base Engine. . . . . . .9010-05-1
6081 John Deere Engine—Use CTM134
Level 3 Electronic Fuel Systems with
Bosch In-Line Pump (S.N. —585560) . . . .9010-05-1
6081 John Deere Engine—Use CTM255
Level 9 Electronic Fuel System With
High Pressure Common Rail (S.N. 585561—
). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9010-05-1
Air Cleaner Operation . . . . . . . . . . . . . . . . . .9010-05-2
Engine Air Heater Circuit Operation . . . . . . .9010-05-4
Electronic Fuel Injection System
Operation. . . . . . . . . . . . . . . . . . . . . . . . . .9010-05-5

Engine Observable Symptom Diagnostics . . .9010-15-1
Injection Pump Fuel Rack Specifications
(S.N. —585560). . . . . . . . . . . . . . . . . . . . .9010-15-4
Bleed the Fuel System
6081 Engine . . . . . . . . . . . . . . . . . . . . . . .9010-20-1
Group 25—Tests
Fuel Line Leakage. . . . . . . . . . . . . . . . . . . . .9010-25-1
Air Intake System Leakage . . . . . . . . . . . . . .9010-25-2
Air Filter Restriction Indicator Switch . . . . . . .9010-25-3
Engine Power Test Using Engine
Pulldown . . . . . . . . . . . . . . . . . . . . . . . . . .9010-25-4

011504
PN=1
Contents
9010

011504
PN=2
Group 05
Theory Of Operation
6081 John Deere Engine—Use CTM86 8.1 L
Diesel Engines Base Engine
For additional engine information, the component technical

manual (CTM) is also required.
–UN–07SEP88
Use the CTM in conjunction with this machine manual.
M44215
9010
05
TX,9010,BA1886 –19–24JUL96–1/1 1
6081 John Deere Engine—Use CTM134 Level

3 Electronic Fuel Systems with Bosch In-Line
Pump (S.N. —585560)

–UN–07SEP88
M44215
CED,TX17864,23 –19–24MAR98–1/1
6081 John Deere Engine—Use CTM255 Level

9 Electronic Fuel System With High Pressure
Common Rail (S.N. 585561—)

–UN–07SEP88
M44215
TX17961,000007B –19–09APR02–1/1

011504
PN=69
Theory Of Operation
Air Cleaner Operation
(S.N. —585560)
A—Screen Plenum
B—Dust Unloading Valve
–UN–23MAR98
C—Primary Element
D—Secondary (Safety) Filter
T114480B
9010
05
2
–UN–23MAR98
T114481B
–UN–23MAR98
T114482B
Continued on next page CED,TX17864,24 –19–24MAR98–1/2

011504
PN=70
Theory Of Operation
(S.N. 585561—)
Under suction generated by the engine, unfiltered air flows

through screen plenum (A) and is forced into a high-speed
centrifugal motion by tilted fins in the element. By this
circulating action most of the dust and dirt particles are
–UN–07JUN02
separated from the air and collected in the dust unloading
valve (B).
The remaining dirt is removed as the air flows through the
T155817B
primary element (C) and the secondary (safety) filter (D) 9010
before being drawn into the engine. 05
3
The secondary (safety) filter ensure that no unfiltered air

is drawn into the engine when changing primary filter or if
the primary element fails.
B—Primary Element
–UN–07JUN02
C—Secondary Element
T155816B
CED,TX17864,24 –19–24MAR98–2/2

011504
PN=71
Theory Of Operation
Engine Air Heater Circuit Operation
IMPORTANT: DO NOT use fluid starting aid option Air heaters have a large amperage demand. Battery
with the engine air heater. Damage power is supplied to the Engine Air Heater Relay (K34)
to engine may occur. through a 125A Fuse (F36) located in the engine
compartment. See Engine Air Heater Harness (W7)
The engine air heater function allows for easier cold Component Location in Group 9015-10.
weather starting and also helps reduce black smoke
shortly after engine start-up. Air heater is controlled by Power to energize Engine Air Heater Relay (K34) coil
either the Chassis Control Unit (CCU) or Engine comes from the Engine Air Heater Coil Relay (K33)
9010 Control Unit (ECU). when commanded by the CCU. The CCU also send a
05 signal across the Controller Area Network (CAN) bus
4
Serial Number — 585560 to the monitor display unit to illuminate the engine
preheat indicator light.
When the key switch is turned on the Chassis Control
Unit (CCU) (A2) measures engine coolant temperature. Details for components in air heater circuit are in
The CCU calculates the air heater ON time for both system functional schematic section SE2. See System
preheat (before start-up) and postheat (after start-up) Functional Schematic in Group 9015-10.
based on the recorded coolant temperature. Engine
Preheat Indicator Light will come on in monitor display NOTE: Anytime the key is moved from Start to Run
when air heaters are on. Operator should wait for the position when engine does not start, a
light to go out before starting the machine. key-off/key-on cycle will be required before
preheating is allowed again.
ON times for preheat and postheat are independent of
one another. ON time is longer at colder temperatures. Serial Number 585561 —
Maximum preheat ON time is 30 seconds. Maximum
ON time for post heat is 60 seconds. Operation is identical to the earlier serial number with
two exceptions.
Coolant temperature has to be less than 10° C (50° F)
for air heaters to come on during preheat. Coolant • Engine Control Unit (ECU) controls the air heater
temperature has to be less than 20° C (68° F) for air instead of the CCU.
heaters to come on during postheat. • Manifold Air Temperature is used to determine ON
time instead of the coolant temperature.
If battery voltage drops below 20 V, the CCU will turn
off the air heaters. This allows air heaters to be OFF
during cranking. Air heaters will turn back ON then
when the battery voltage raises above 20 V.
CED,TX17864,25 –19–26JUN02–1/1

011504
PN=72
Theory Of Operation
Electronic Fuel Injection System Operation
Fuel injection system will be a Level 3 or a Level 9

Electronic fuel injection system. The term “level” is simply
a means to identify fuel systems. A Level 3 system meters
the fuel at the injection pump. A Level 9 system uses a
High Pressure Common Rail (HPCR) and meters fuel at
the injectors. See Distinguishing ECUs on 8.1 L Engines
in CTM134.
Level 3 (S.N. — 585560) 9010

05
5
The components within the fuel injection pump are:
• Injection pump
• Actuator solenoid
• Rack position sensor
• Primary speed sensor (S.N. —572976)
• Fuel shut-off solenoid
• Fuel temperature sensor
The remaining components: throttle potentiometer and

auxiliary speed sensor are appropriately located
throughout the loader.
The injection pump is an in-line pump with the mechanical

governor assembly replaced by the electronic governor.
The governor assembly includes the actuator solenoid to
move the control rack.
The engine start command uses a 24—volt signal to

indicate initial start of engine.
The throttle command is a variable 0—5 volt signal that

senses the percent of throttle travel by the operator in the
cab. This signal is sent to the chassis controller unit
where it is then sent to the engine controller unit across
the CAN Link.
The primary speed sensor (S.N. —572976) is a magnetic

pickup that generates voltage pulses to the engine
controller as the teeth on the speed ring passes it. The
auxiliary speed sensor is a magnetic pickup located on
the engine and serves as a back-up speed sensor in the
event of a complete failure of the primary speed sensor.
Continued on next page CED,TX17864,26 –19–26JUN02–1/2

011504
PN=73
Theory Of Operation
The primary speed (S.N. 572976—) sensor is a magnetic

pickup located on the engine
The rack position sensor supplies rack position

information to the engine controller so that a specific rack
position can be controlled.
The fuel temperature sensor is located at the rear of the

pump at the fuel inlet. It is used to determine the optimum
fuel delivery for starting, and is used to maintain constant
9010 power over a predetermined temperature range.
05
6
The fuel shut-off solenoid is located at the rear of the
pump. It will shut off fuel to the injection pump when the
key switch is turned off or when the engine controller
detects a rack position error above a preset engine speed.
The rack position command signal controls rack position

to vary fuel to the engine.
See Fuel System Overview in CTM134.
See Fuel Injection Pump Operation in CTM134
Level 9 (585561 — )
See Fuel System Operation in CTM255.
See Electronic Control System Overview in CTM255.
See Electronic Control System Operation in CTM255.
See High Pressure Fuel Pump Operation in CTM255.
See High Pressure Common Rail (HPCR) Operation in

CTM255.
CED,TX17864,26 –19–26JUN02–2/2

011504
PN=74
Group 15
Diagnostic Information
Engine Observable Symptom Diagnostics
To diagnose engine diagnostic trouble codes See Engine

Diagnostic Trouble Codes (DTCs) on Level 3 ECU or See
Engine Diagnostic Trouble Codes (DTCs) on Level 9
ECU. (Group 9015-20.)
See Distinguishing ECUs on 8.1 L Engines. (CTM134 or

CTM255.)
Symptom Problem Solution 9010

15
1
Engine Cranks/Won’t Start Engine Problem For engines with a Level 3 ECU, see
LEVEL 3 ECU - E1 - ENGINE
CRANKS/WON’T START
DIAGNOSTIC PROCEDURE in
Section 04, Group 150 of CTM134.
For engines with a Level 9 ECU, see

CRANKS/WON’T START
Engine Misfires/Runs Irregularly Engine Problem For engines with a Level 3 ECU, see
MISFIRES/RUNS IRREGULARLY

MISFIRES/RUNS IRREGULARLY
Engine Does Not Develop Full Engine Problem For engines with a Level 3 ECU, see
Power LEVEL 3 ECU - E3 ENGINE DOES
NOT DEVELOP FULL POWER

LEVEL 9 ENGINE DOES NOT
DEVELOP FULL POWER
Continued on next page RG40854,0000006 –19–08APR02–1/3

011504
PN=75
Symptom Problem Solution
Engine Emits Excessive White Engine Problem For engines with a Level 3 ECU, see
Exhaust Smoke LEVEL 3 ECU - E4 - ENGINE
EMITS EXCESSIVE WHITE
EXHAUST SMOKE DIAGNOSTIC
PROCEDURE in Section 04, Group
150 of CTM134.

9010 LEVEL 9 ECU - E4 - ENGINE
15 EMITS EXCESSIVE WHITE
2
EXHAUST SMOKE DIAGNOSTIC
150 of CTM255.
Engine Emits Excessive Black Or Engine Problem For engines with a Level 3 ECU, see
Gray Smoke LEVEL 3 ECU - E5 - ENGINE
EMITS EXCESSIVE BLACK OR
GRAY SMOKE DIAGNOSTIC
150 of CTM134.

EMITS EXCESSIVE BLACK OR
GRAY SMOKE DIAGNOSTIC
150 of CTM255.
Engine Will Not Crank Engine Problem For engines with a Level 3 ECU, see
LEVEL 3 ECU - E6 - ENGINE WILL
NOT CRANK in Section 04, Group
150 of CTM134.

LEVEL 9 ECU - E6 - ENGINE WILL
NOT CRANK in Section 04, Group
150 of CTM255.
Engine Idles Poorly Engine Problem For engines with a Level 3 ECU, see
LEVEL 3 ECU - E7 - ENGINE IDLES
POORLY in Section 04, Group 150
of CTM134.
Continued on next page RG40854,0000006 –19–08APR02–2/3

011504
PN=76
Symptom Problem Solution

LEVEL 9 ECU - E7 - ENGINE IDLES
POORLY in Section 04, Group 150
of CTM255.
Abnormal Engine Noise Engine Problem For engines with a Level 3 ECU, see
LEVEL 3 ECU - E8 - ABNORMAL
ENGINE NOISE in Section 04,
Group 150 of CTM134. 9010
15
3
LEVEL 9 ECU - E8 - ABNORMAL
ENGINE NOISE in Section 04,
Group 150 of CTM255.
Excessive Oil Consumption Engine Problem For 8.1L engines, see 8.1L - L1 -
EXCESSIVE OIL CONSUMPTION in
Engine Oil Pressure Low Engine Problem For 8.1L engines, see 8.1L - L2 -
ENGINE OIL PRESSURE LOW in
Engine Oil Pressure High Engine Problem For 8.1L engines, see 8.1L - L3 -
ENGINE OIL PRESSURE HIGH in
Engine Coolant Temperature Engine Problem For 8.1L engines, see 8.1L - C1 -
Above Normal ENGINE COOLANT
TEMPERATURE ABOVE NORMAL
in Section 04, Group 150 of CTM86.
Engine Coolant Temperature Engine Problem For 8.1L engines, see 8.1L - C2 -
Below Normal ENGINE COOLANT
TEMPERATURE BELOW NORMAL
in Section 04, Group 150 of CTM86.
Coolant In Oil or Oil In Coolant Engine Problem For 8.1L engines, see 8.1L - C3 -
COOLANT IN OIL OR OIL IN
COOLANT in Section 04, Group 150
of CTM86.
RG40854,0000006 –19–08APR02–3/3

011504
PN=77
Injection Pump Fuel Rack Specifications

(S.N. —585560)
NOTE: These are all nominal values, there will be slight

variations from machine to machine.
These values can be viewed using the d 045

Rack Position Display in the monitor display unit.
See Monitor Display Unit—Diagnostics Menu—
Engine Sensors (d 04) to access monitor display
9010 menus. (Group 9015-15)
15
4
Rack position value displayed in the monitor is
multiplied by 1000, so a display 11300 is actually
11.3 mm.
644H
Item Measurement Specification
Full Load Rated Speed (2200 rpm) Position (approximate) 11.3 mm

Voltage 2.75 volts
Slow Idle Position (approximate) 5.5 mm

Voltage 1.59 volts
High Idle Position (approximate) 8.75 mm

Voltage 2.25 volts
Start-up Position (approximate) 19.5—21.5 mm

Voltage 4.2—4.6 volts
644H MH—First Gear

Voltage 2.82 volts

Voltage 1.59 volts
High Idle Position (approximate) 8.75 mm

Voltage 2.25 volts

Continued on next page CED,TX17864,54 –19–07APR99–1/2

011504
PN=78
644H MH—Second, Third, And Fourth Gear

Voltage 2.97 volts

Voltage 1.59 volts
High Idle Position (approximate) 8.75 mm 9010

Voltage 2.25 volts 15
5

CED,TX17864,54 –19–07APR99–2/2

011504
PN=79
9010
15
6

011504
PN=80
Group 20
Adjustments
Bleed The Fuel System
Whenever the fuel system has been opened up for

service (lines disconnected or filters removed), it will be
necessary to bleed air from the system.
See Bleed the Fuel System in CTM134 for Level 3 fuel

systems (S.N —585560).
See Bleed the Fuel System in CTM255 for Level 9 fuel

systems (S.N. 585561— ). 9010
20
1
S11,0408,AC –19–11JUN02–1/1

011504
PN=81
Adjustments
9010
20
2

011504
PN=82
Group 25
Tests
Fuel Line Leakage Test
SPECIFICATIONS
Fuel System Test Pressure 69 kPa (0.7 bar) (10 psi)
SERVICE EQUIPMENT AND TOOLS

Pressure Regulator
Connections may allow air to enter the fuel system without

allowing fuel to leak out. Follow this procedure to find air
9010
leaks in the system.
25
1
1. Disconnect fuel supply and fuel return lines at fuel
tank.
2. Drain all fuel from system, including fuel supply pump,

fuel injection pump, and fuel filter(s).
3. Close end of fuel return line using a plug, cap, or a

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

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

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

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

minutes.
NOTE: For engines with an in-line fuel injection pump, an

internal leak path may allow air to enter the fuel
system. If an internal pump leak is suspected,
remove the pump and have a pressure test
performed by an authorized repair station.
TX,1025,MM,140 –19–17MAR98–1/1

011504
PN=83
Tests
Air Intake System Leakage Test
SPECIFICATIONS
Air Intake System Pressure 14—21 kPa (0.14—0.21 bar) (2—
3 psi)
–UN–23FEB89
ESSENTIAL TOOLS
JDE147 Manifold Pressure Kit
SERVICE EQUIPMENT AND TOOLS
T5906AP
9010 Pressure Regulator
25
2
OTHER MATERIAL
TY9370 U.S. Thread Lock and Sealer (Medium Strength)
242LOCTITE Thread Lock and Sealer (Medium Strength)
1. Remove air cleaner cover and main filter element.
–UN–19MAR98
2. Put large plastic bag into and over end of main filter
element as shown. Install main filter element and
cover.
T114427B
3. Remove plug from left side of intake manifold.
4. Connect air pressure regulator to manifold using hose

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

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

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

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

011504
PN=84
Tests
Air Filter Restriction Indicator Switch Test
SPECIFICATIONS
Restriction Indicator Light Must 4.98—7.48 kPa (0.05—0.075 bar)
Come On Pressure (20—30 in. water)
ESSENTIAL TOOLS
JT0652 Tee
JT0246 Coupler
0202-4-4 Coupler (Parker)
9010
25
SERVICE EQUIPMENT AND TOOLS 3
Barbed Fitting (1/8 in.)
Barb Fitting (1/4 in.)
0—15 kPa (0—150 mbar) (0—60 in. Water) Vacuum Gauge
1. Remove air restriction indicator switch.
2. Install parts as shown.
–UN–17DEC90
3. Start engine and slowly cover the air cleaner inlet with
a piece of paper or cardboard.
T7350EP
4. Air filter restriction indicator (light) must come on
according to specification. Engine speed may need to
be increased above low idle with intake covered to
reach high range of specification. A—Switch
B—Tee
Specification C—Barbed Fitting
Restriction Indicator Light Must D—Tube
Come On—Pressure ............................ 4.98—7.48 kPa (0.05—0.075 bar) E—Barbed Fitting
(20—30 in. water) F—Coupler
G—Gauge
5. If reading is not within specifications, install a new
indicator switch.
TX,9010,SS530 –19–07JAN93–1/1

011504
PN=85
Tests
Engine Power Test Using Engine Pulldown
SPECIFICATIONS 3. Apply service brakes and put transmission in 3rd

Hydraulic Oil Temperature 65 ± 5 °C (150 ± 10 °F) forward.
Transmission Oil Temperature 82 ± 6 °C (180 ± 10 °F)
Park Brake Switch Position Off 4. Run engine at high idle and stall the torque
converter and record lowest engine rpm readings.
Automatic Transmission Switch Off
Position
Specification
Clutch Cutoff Switch Position Off Engine—Speed ...................................................................... High Idle
Engine Speed High Idle 644H Standard Cooling System
9010
(No. 1 Fuel)—Torque Converter
25 644H Standard Cooling System 2070—2190 rpm
Stall—Speed ............................................................. 2070—2190 rpm
4 (No. 1 Fuel)—Torque Converter
644H Standard Cooling System
Stall Speed (No. 2 Fuel)—Torque Converter
644H Standard Cooling System 2100—2200 rpm Stall—Speed ............................................................. 2100—2200 rpm
(No. 2 Fuel)—Torque Converter 644H High Ambient Cooling
Stall Speed System (No. 1 Fuel)—Torque
644H High Ambient Cooling 2040—2170 rpm Converter Stall—Speed ............................................ 2040—2170 rpm
System (No. 1 Fuel)—Torque 644H High Ambient Cooling
Converter Stall Speed System (No. 2 Fuel)—Torque
Converter Stall—Speed ............................................ 2070—2190 rpm
644H High Ambient Cooling 2070—2190 rpm 644H MH—Torque Converter
System (No. 2 Fuel)—Torque Stall—Speed ............................................................. 2155—2185 rpm
Converter Stall Speed
644H MH—Torque Converter 2155—2185 rpm NOTE: 644H MH only has the high ambient cooling
Stall Speed package and the torque converter stall speed
is not dependent on fuel type.
1. Heat hydraulic oil and transmission oil to
specification. 5. If rpm is low, check for:
Specification • Engine malfunction. See Engine Does Not

Hydraulic Oil—Temperature .......................... 65 ± 5 °C (150 ± 10 °F)
Transmission Oil—Temperature .................... 82 ± 6 °C (180 ± 10 °F) Develop Full Power. (Group 9010-15)
2. Release park brake. Auto and clutch cutoff (Neutral) If rpm is high, check for:
switches must be in the “OFF” position.
• Low transmission oil level or aerated oil.
Specification • Transmission slippage or a failed torque
Park Brake Switch—Position .......................................................... Off converter freewheel clutch.
Automatic Transmission
Switch—Position ............................................................................. Off Also See Measure Intake Manifold Pressure (Turbo
Clutch Cutoff Switch—Position ....................................................... Off
Boost) in CTM86.
CED,TX17864,20 –19–17MAR98–1/1

011504
PN=86
Section 9015
Electrical System
Contents
Page Page
Group 05—System Information Blower/Air Conditioning Harness (W20)

Electrical Diagram Information. . . . . . . . . . . .9015-05-2 And Component Location Drawing. . . . . 9015-10-108
Converter and Power Plug Harness (W21)
Group 10—System Diagrams Component Location . . . . . . . . . . . . . . . 9015-10-111
Fuse Specifications . . . . . . . . . . . . . . . . . . . .9015-10-1 Secondary Steering Pump Motor Harness
System Functional Schematic (W23)
Legend . . . . . . . . . . . . . . . . . . . . . . . . . . .9015-10-2 Component Location . . . . . . . . . . . . . . . 9015-10-112 9015
Functional Schematic And Component Battery (Cables) Harness (W24)
Component Location . . . . . . . . . . . . . . . 9015-10-114
Location Legend (S.N. —585560) . . . . . . .9015-10-4
Sump Tank Harness (W31)
System Functional Schematic . . . . . . . . . . .9015-10-13
Functional Schematic And Component
Axle Disconnect Harness (W33)
Location Legend (S.N. 585561— ). . . . . .9015-10-28
System Functional Schematic . . . . . . . . . . .9015-10-36
Radio Harness (W34) Component
Loader Frame Harness (W2)
Location. . . . . . . . . . . . . . . . . . . . . . . . . 9015-10-118
Component Location . . . . . . . . . . . . . . . .9015-10-51
Electric Air Adjust Seat Harness (W36)
Load Center Harness (W3)
CAN Terminator Harness (W37)
Load Center Harness (W3) Component
Location (S.N. 585561—) . . . . . . . . . . . .9015-10-65
Front Console Harness (W4)
Group 15—Sub-System Diagnostics
Power Circuit
Engine Frame Harness (W5)
Theory of Operation. . . . . . . . . . . . . . . . . .9015-15-1
Charging Circuit
Engine Harness (W6)
Start Circuit
Engine Air Heater Harness (W7)
Engine Air Heater Circuit
Return-to-Dig Harness (W8)
Operation. . . . . . . . . . . . . . . . . . . . . . . . . .9015-15-8
Component Location . . . . . . . . . . . . . . . .9015-10-88 Starting Aid Circuit
Ride Control Harness (W9) Theory of Operation. . . . . . . . . . . . . . . . .9015-15-10
Component Location . . . . . . . . . . . . . . . .9015-10-89 Ride Control Circuit
Transmission Harness (W10) Specifications. . . . . . . . . . . . . . . . . . . . . .9015-15-11
Component Location . . . . . . . . . . . . . . . .9015-10-94 Operational Information . . . . . . . . . . . . . .9015-15-11
Rear Frame Harness (W13) Theory of Operation. . . . . . . . . . . . . . . . .9015-15-12
Component Location . . . . . . . . . . . . . . . .9015-10-96 Monitor Display Unit Circuit
LPM Mode Harness (W14) Specifications-Switches And Senders . . .9015-15-14
Component Location . . . . . . . . . . . . . . . 9015-10-100 Specifications-Gauge Sensors . . . . . . . . .9015-15-16
License Plate Light Harness (W15) Monitor Display Unit
Component Location . . . . . . . . . . . . . . . 9015-10-102 Specifications, Gauge Ranges . . . . . . . . .9015-15-19
Pin Disconnect Harness (W16) Monitor Display Unit Circuit
Component Location . . . . . . . . . . . . . . . 9015-10-103 Specifications-Diagnostic Menu
Secondary Steering Switch Harness (W17) Sensors . . . . . . . . . . . . . . . . . . . . . . . .9015-15-21
Component Location . . . . . . . . . . . . . . . 9015-10-105 Operational Information . . . . . . . . . . . . . .9015-15-22
Cab Work Lights Harness (W19)
Component Location . . . . . . . . . . . . . . . 9015-10-106 Continued on next page

011504
PN=1
Contents
Page Page
Theory Of Operation-Function . . . . . . . . .9015-15-23 Reconfiguration, Access Service

Theory Of Operation-Modes Of Menu . . . . . . . . . . . . . . . . . . . . . . . . . .9015-15-81
Operation . . . . . . . . . . . . . . . . . . . . . . .9015-15-24 Reconfiguration, Machine Model (S
Theory Of Operation-Caution And 01) . . . . . . . . . . . . . . . . . . . . . . . . . . . .9015-15-82
Warning Lights And Gauges. . . . . . . . .9015-15-26 Monitor Display Unit Reconfiguration—Tire
Theory Of Operation-Switches, Sensors Size (S 03) . . . . . . . . . . . . . . . . . . . . . . .9015-15-83
And Indicator Lights . . . . . . . . . . . . . . .9015-15-29 Monitor Display Unit Reconfiguration—
Functional Schematic. . . . . . . . . . . . . . . .9015-15-34 Enable Options (S 06) . . . . . . . . . . . . . . .9015-15-84
Monitor Display Unit Monitor Display Unit
Accessing Menus. . . . . . . . . . . . . . . . . . .9015-15-36 Reconfiguration, Delete Service
Monitor Display Unit--Normal Display Codes . . . . . . . . . . . . . . . . . . . . . . . . .9015-15-85
Normal Display . . . . . . . . . . . . . . . . . . . .9015-15-37 Chassis Computer Unit Circuit
Monitor Display Unit Operational Information . . . . . . . . . . . . . .9015-15-86
9015 Accessory Menu, Clutch Cutoff (A 01) . . .9015-15-39 Theory of Operation. . . . . . . . . . . . . . . . .9015-15-87
Monitor Display Unit—Accessory Chassis Computer Unit
Menu—Quick Shift Mode (A 02) . . . . . . .9015-15-43 Intermittent Wipers Circuit Signals . . . . . .9015-15-88
Monitor Display Unit—Accessory Menu— Turn and Flasher Light Signals . . . . . . . .9015-15-88
Auto Mode To First (A 03) . . . . . . . . . . . .9015-15-45 Drive Lights and Work Lights Signals . . .9015-15-89
Monitor Display Unit—Accessory Menu— Tail/Marker Lights Signals . . . . . . . . . . . .9015-15-89
Job Timer Mode (A 04) . . . . . . . . . . . . . .9015-15-46 Battery Monitoring Signals . . . . . . . . . . . .9015-15-90
Monitor Display Unit Chassis Computer Unit Circuit
Accessory Menu, Stop Watch Mode (A Functional Schematic. . . . . . . . . . . . . . . .9015-15-90
05) . . . . . . . . . . . . . . . . . . . . . . . . . . . .9015-15-46 Connector Signals (30-Pin Connector) . . .9015-15-91
Monitor Display Unit—Accessory Menu— Connector Signals (60-Pin Connector) . . .9015-15-93
0.1 Hour Meter Mode (A 06) . . . . . . . . . .9015-15-47 Load Performance Management (LPM)
Monitor Display Unit—Accessory Circuit
Menu—Metric Units Mode (A 07). . . . . . .9015-15-48 Specifications. . . . . . . . . . . . . . . . . . . . . .9015-15-96
Monitor Display Unit—Diagnostics Operational Information . . . . . . . . . . . . . .9015-15-97
Menu—Diagnostic Trouble Codes (d Theory of Operation. . . . . . . . . . . . . . . . .9015-15-98
01) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9015-15-48 Functional Schematic. . . . . . . . . . . . . . . .9015-15-99
Monitor Display Unit—Diagnostics Transmission Control Unit Circuit
Menu—Continuity Check (d 02) . . . . . . . .9015-15-51 Specifications. . . . . . . . . . . . . . . . . . . . . 9015-15-100
Monitor Display Unit—Diagnostics Operational Information . . . . . . . . . . . . . 9015-15-101
Menu—Battery Monitor (d 03) . . . . . . . . .9015-15-56 Theory of Operation. . . . . . . . . . . . . . . . 9015-15-103
Monitor Display Unit—Diagnostics Functional Schematic. . . . . . . . . . . . . . . 9015-15-105
Menu—Engine Sensors (d 04). . . . . . . . .9015-15-56 TCU Connector Signals . . . . . . . . . . . . . 9015-15-106
Monitor Display Unit—Diagnostics Transmission Control Valve Solenoid
Menu—Transmission Sensors (d 05) . . . .9015-15-61 Check . . . . . . . . . . . . . . . . . . . . . . . . . . 9015-15-110
Monitor Display Unit—Diagnostics Transmission
Menu—Hydraulic Sensors (d 06) . . . . . . .9015-15-65 Modes of Operation--Manual and
Monitor Display Unit—Diagnostics Automatic . . . . . . . . . . . . . . . . . . . . . . 9015-15-112
Menu—Fuel Sensor (d 07). . . . . . . . . . . .9015-15-68 Transmission Functions Set at Monitor
Monitor Display Unit Display Unit . . . . . . . . . . . . . . . . . . . . . . 9015-15-114
Diagnostics Menu, (d 08)-Not Used . . . . .9015-15-68 Transmission Shift Ranges in Automatic
Diagnostics Menu, LPM Mode (d 09). . . .9015-15-69 Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . 9015-15-120
Diagnostics Menu, Machine I.D. Mode Transmission Control Unit Operating
(d 10) . . . . . . . . . . . . . . . . . . . . . . . . . .9015-15-70 Modes . . . . . . . . . . . . . . . . . . . . . . . . . . 9015-15-123
Service Menu, Machine Model (S 01) . . .9015-15-74 Transmission Control Unit Response to
Service Menu, Tell-Tale Service Codes Malfunctions . . . . . . . . . . . . . . . . . . . . . 9015-15-125
(S 02). . . . . . . . . . . . . . . . . . . . . . . . . .9015-15-75 Transmission Control Unit Inputs and
Service Menu, Tire Size (S 03) . . . . . . . .9015-15-78 Outputs . . . . . . . . . . . . . . . . . . . . . . . . . 9015-15-127
Service Menu, Enable Options (S 06) . . .9015-15-79
Service Menu, Hitachi Mode (S 07) . . . . .9015-15-80 Continued on next page

011504
PN=2
Contents
Page Page
Back Up Alarm, Park Brake Sensing and Engine Controller Unit

Park Brake Release Circuit Input Signals . . . . . . . . . . . . . . . . . . . . . 9015-15-167
Specifications. . . . . . . . . . . . . . . . . . . . . 9015-15-128 Connector Signals-Cab Side . . . . . . . . . 9015-15-169
Back Up Alarm, Park Brake Sensing and Electronic Controllers Block Diagram . . . . 9015-15-172
Park Brake Release Circuit
Operational Information . . . . . . . . . . . . . 9015-15-129 Group 20—References
Theory of Operation. . . . . . . . . . . . . . . . 9015-15-131 Alternators and Starting Motors--Use
Functional Schematic. . . . . . . . . . . . . . . 9015-15-134 CTM77. . . . . . . . . . . . . . . . . . . . . . . . . . . .9015-20-1
Pilot Enable and Boom Down Circuit Diagnostic Trouble Code Quick Reference
Operational Information . . . . . . . . . . . . . 9015-15-135 List. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9015-20-2
Pilot Enable/Boom Down Circuit Transmission Diagnostic Trouble Codes
Theory of Operation. . . . . . . . . . . . . . . . 9015-15-136 (DTCs). . . . . . . . . . . . . . . . . . . . . . . . . . . .9015-20-5
Functional Schematic. . . . . . . . . . . . . . . 9015-15-137 Engine Related Diagnostic Trouble Codes
Return to Carry, Boom Height Kickout and (DTCs). . . . . . . . . . . . . . . . . . . . . . . . . . .9015-20-37 9015
Return to Dig Circuit Engine Diagnostic Trouble Codes (DTCs)
Operational Information . . . . . . . . . . . . . 9015-15-138 on Level 3 ECU (S.N. —585560). . . . . . .9015-20-46
Theory of Operation. . . . . . . . . . . . . . . . 9015-15-139 Engine Diagnostic Trouble Codes (DTCs)
Differential Lock, Pin Disconnect, and Axle on Level 9 ECU (S.N. 585561—). . . . . . .9015-20-55
Disconnect Circuit Steering and Brake Diagnostic Trouble
Functional Schematic. . . . . . . . . . . . . . . 9015-15-143 Codes . . . . . . . . . . . . . . . . . . . . . . . . . . .9015-20-65
Front Wiper Circuit Electrical System Diagnostic Trouble
Rear Wiper Circuit Hydraulic System Diagnostic Trouble
Secondary Steering Circuit Batteries
Specifications. . . . . . . . . . . . . . . . . . . . . 9015-15-146 Specifications. . . . . . . . . . . . . . . . . . . . . .9015-20-92
Operational Information . . . . . . . . . . . . . 9015-15-146 Check Controller . . . . . . . . . . . . . . . . . . . . .9015-20-93
Theory of Operation. . . . . . . . . . . . . . . . 9015-15-147 Batteries
Functional Schematic. . . . . . . . . . . . . . . 9015-15-148 Diagnose Malfunctions. . . . . . . . . . . . . . .9015-20-94
Horn Circuit Check Electrolyte Level and
Functional Schematic. . . . . . . . . . . . . . . 9015-15-149 Terminals . . . . . . . . . . . . . . . . . . . . . . .9015-20-95
Flasher and Turn Signal Procedure for Testing . . . . . . . . . . . . . . .9015-20-98
Functional Schematic. . . . . . . . . . . . . . . 9015-15-150 Alternator Check . . . . . . . . . . . . . . . . . . . . .9015-20-99
Tail and Marker Light Circuit Transmission Control Valve Solenoid
Theory of Operation. . . . . . . . . . . . . . . . 9015-15-151 Check . . . . . . . . . . . . . . . . . . . . . . . . . . 9015-20-100
Functional Schematic. . . . . . . . . . . . . . . 9015-15-152 Clutch Cutoff Sensor Check and
Drive Light Circuit Adjustment. . . . . . . . . . . . . . . . . . . . . . . 9015-20-101
Theory of Operation. . . . . . . . . . . . . . . . 9015-15-153 Engine Control Unit Temperature Sensors
Functional Schematic. . . . . . . . . . . . . . . 9015-15-154 Test (S.N. 585561—). . . . . . . . . . . . . . . 9015-20-103
Brake and Light Circuit Engine Control Unit
Specifications. . . . . . . . . . . . . . . . . . . . . 9015-15-155 Speed Sensors Test . . . . . . . . . . . . . . . 9015-20-104
Operational Information . . . . . . . . . . . . . 9015-15-155 Pressure Sensors and Solenoids
Theory Of Operation . . . . . . . . . . . . . . . 9015-15-155 Test . . . . . . . . . . . . . . . . . . . . . . . . . . 9015-20-105
Functional Schematic. . . . . . . . . . . . . . . 9015-15-156 Analog Throttle Position Sensor
Cab Work Light Circuit Adjustment. . . . . . . . . . . . . . . . . . . . . . . 9015-20-105
Operational Information . . . . . . . . . . . . . 9015-15-157 Adjustments
Theory of Operation. . . . . . . . . . . . . . . . 9015-15-157 Boom Height Kick Out . . . . . . . . . . . . . . 9015-20-107
Functional Schematic. . . . . . . . . . . . . . . 9015-15-158 Return To Carry . . . . . . . . . . . . . . . . . . 9015-20-109
Converter and Radio Circuit Return-To-Dig Adjustment . . . . . . . . . . . . . 9015-20-111
Functional Schematic. . . . . . . . . . . . . . . 9015-15-159 Continuity Check For Sensors With Two
Engine Controller Unit Circuit Wires . . . . . . . . . . . . . . . . . . . . . . . . . . . 9015-20-113
Theory of Operation. . . . . . . . . . . . . . . . 9015-15-161
Specifications. . . . . . . . . . . . . . . . . . . . . 9015-15-166 Continued on next page

011504
PN=3
Contents
Page
Continuity Check For Sensors With Three

Wires . . . . . . . . . . . . . . . . . . . . . . . . . . . 9015-20-114
Replace METRI-PACK Connectors. . . . . 9015-20-115
Replace DEUTSCH Connectors . . . . . . . 9015-20-116
Install DEUTSCH Contact. . . . . . . . . . . . 9015-20-117
Weather Pack Connectors
Replace . . . . . . . . . . . . . . . . . . . . . . . . . 9015-20-118
Install WEATHER PACK Contact . . . . . . 9015-20-119
Transmission Control Valve Connector Body
Remove and Install . . . . . . . . . . . . . . . . 9015-20-120
Transmission Control Valve Connector
Contact
Install. . . . . . . . . . . . . . . . . . . . . . . . . . . 9015-20-121
9015 Crimper Tool for Transmission Controller Unit
Connector
Operation. . . . . . . . . . . . . . . . . . . . . . . . 9015-20-124
Remove and Install Die Set . . . . . . . . . . 9015-20-125
Contact Support Adjustment . . . . . . . . . 9015-20-128
Crimping Procedure . . . . . . . . . . . . . . . . 9015-20-129
Crimp Height Inspection. . . . . . . . . . . . . 9015-20-131
Crimp Height Adjustment . . . . . . . . . . . . 9015-20-132
Transmission Controller Unit Connector
Terminals
Replace . . . . . . . . . . . . . . . . . . . . . . . . . 9015-20-133
Chassis Computer Unit Connector Terminals
Replace . . . . . . . . . . . . . . . . . . . . . . . . . 9015-20-134
Install CINCH Contact . . . . . . . . . . . . . . 9015-20-137
Remove Connector Body From Blade
Terminals. . . . . . . . . . . . . . . . . . . . . . . . 9015-20-138
Remove Blade Terminals From Fuse
Block . . . . . . . . . . . . . . . . . . . . . . . . . . . 9015-20-138
Pressure Switches
Remove and Install . . . . . . . . . . . . . . . . 9015-20-139

011504
PN=4
Group 05
System Information
9015
05
1

011504
PN=89
System Information
Electrical Diagram Information
9015
05
2
–UN–29FEB00
T128818
Continued on next page CED,TX17984,455 –19–07MAY01–1/6

011504
PN=90
System Information
1—Continuity Chart 4—Wire Identification 7—Section Number 10—Component Schematic

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

011504
PN=91
System Information
9015
05
4
–UN–29FEB00
T128819

011504
PN=92
System Information
1—Harness Connector Pin 3—Component Identification 6—Component Connector 9—Component Identification

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

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

011504
PN=93
System Information
T143000 –UN–21JUN01

011504
PN=94
System Information
1—Battery 25—Sensor with Normally 47—Variable Resistor 63—Momentary Switch

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

011504
PN=95
System Information
9015
05
8

011504
PN=96
Group 10
System Diagrams
Fuse Specifications
IMPORTANT: Install fuse with correct amperage

rating to prevent electrical system
damage from overload.
(S.N. —585560)
See Load Center Component Location—Detail B. (In this

group.)
CED,TX17864,31 –19–29MAR99–1/2
K25 K27 K17 Rear Wiper K13

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

Tail & Marker Light Lighter Down & Radio
Switched
F24 7.5 AMP Fuse F27 7.5 Amp Fuse F32 10 AMP Fuse F28 Unswitched
7.5 AMP Fuse 7.5 AMP Fuse F11
99M 7064 (ACC) 99M 7064 (BATT)
P39 P44 P48 57M 7121 (ACC) P14 99M 7064 (BATT) P25 99M 7064 (IGN)
K30 Ride K21 Secondary
Control Boom Diff Lock, Spare Rotary Beacon Converter Park Brake, Steering
F14 Pin Disc Solenoid F35 F26 F31 Unswitched Back-up Alarm F13
Solenoid 5 AMP Fuse
15 AMP Fuse
99M 7065
10 AMP Fuse
15 AMP Fuse 5 AMP Fuse
(Relay Coil)
57M 7121
Relay P42 57M 7125 (ACC) P35 (BATT) P41 (ACC) P16 99M 7065 (BATT) P26 57M 7125 (IGN) Relay
AT162863 Power for Rocker Engine Controller Alternator Monitor & Trans Controller Start Aid,
AT162863
F23 Switches F6 Unswitched F1 Excitation
F4 Unswitched Converter & Sec. Strg F2
5 AMP Fuse 10 AMP Fuse 7.5 AMP Fuse 5 AMP Fuse 10 AMP Fuse
P27 57M 7125 (ACC) P06 57M 7121 (BATT) J07 99M 7064 (IGN) P02 57M 7125 (BATT) P04 57M 7121 (IGN)
K6 K1 K5 K10 K4
–19–24OCT02
Accessory Neutral Start Accesory Back-Up Ignition

Relay #2 Relay Relay #1 Relay Relay
AT162863 AT162863 AT162863 AT162863 AT162863
T159002
T159002
(S.N. 585561—)
CED,TX17864,31 –19–29MAR99–2/2

011504
PN=97
System Diagrams
System Functional Schematic Section

Legend
NOTE: SE1—Battery, Ignition Power Circuit (24V System)
SE1 indicates section number of System

Functional Schematic where circuit is located.
Battery, Ignition Power Circuit (24V System)

indicates circuit name.
For later machines, See System Functional Schematic

Section Legend (S.N. 585561 —)
• SE1—Battery, Ignition Power Circuit (24V System)

9015 • SE2—Alternator and Engine Air Heater Circuits
10 • SE3—Starting Circuit
2 • SE4—Start Aid Circuit
• SE5—Ignition Power Circuit
• SE6—Ignition Power Circuit
• SE7—Accessory Power Circuit
• SE10—Ride Control Circuit
• SE11—Ride Control Circuit
• SE12—Electric Adjust Seat, Lighter and Spare Circuits
• SE13—Monitor Display Unit Circuit
• SE16—Chassis Controller Unit Circuit
• SE22—Transmission Controller Unit Input Circuits
• SE25—Pilot Enable and Boom Down Circuit
• SE26—Return to Carry Circuit
• SE27—Boom Height Kickout and Return to Dig Circuit
• SE28—Differential Lock, Pin Disconnect and Axle
Disconnect Circuit
• SE29—Front Wiper Circuit
• SE30—Rear Wiper Circuit
• SE31—Heater/Pressurizer Circuit
Continued on next page CED,TX17864,33 –19–23JUL02–1/2

011504
PN=98
System Diagrams
• SE32—Air Conditioning Circuit

• SE33—Secondary Steering and Horn Circuit
• SE34—Flasher and Turn Circuit
• SE35—Tail/Marker Light Circuit
• SE36—Drive Light and Rotary Beacon Circuit
• SE37—Brake Light and Dome Light Circuit
• SE38—Cab Work Light Circuit
• SE39—Converter and Radio Circuits
• SE40—Engine Controller Circuit
9015
10
3
CED,TX17864,33 –19–23JUL02–2/2

011504
PN=99
System Diagrams

Location Legend (S.N. —585560)
NOTE: A2—Chassis Computer Unit (SE18, SE19, W3)
A2 indicates component identification number.
Chassis Computer Unit indicates component

name.
SE18, SE19 indicates section numbers of

SYSTEM FUNCTIONAL SCHEMATIC where
component is located.
W3 is the identification number of the

9015 COMPONENT LOCATION and HARNESS
10 CONNECTOR (WITH WIRE AND PIN
4 LOCATION) drawings for the component. This
would indicate that the Chassis Computer Unit is
connected to W3 Load Center Harness.
• A1—Engine Controller Unit (SE41, W3)

• A2—Chassis Computer Unit (SE18, SE19, W3)
• A3—Transmission Controller Unit (SE23, W3)
• A4—Pilot Controller Unit (SE27, W3)
• A5—Radio (SE39, W34)
• B1—Not Used
• B2—Auxiliary Speed Sensor (SE42, W6)
• B3—Fuel Temperature Sensor (SE, W6)
• B4—Rack Position Sensor (SE42, W6)
• B5—Primary Speed Sensor (S.N. —572976) (SE42,
W6)
• B6—Not Used
• B7—Not Used
• B8—Hydraulic Pressure Sensor (SE16, W5)
• B9—Not Used
• B10—Not Used
• B11—Not Used
• B12—Not Used
• B13—Not Used
• B14—Analog Throttle Position Sensor (SE16, W3)
• B15—Hydraulic Oil Temperature Sensor (SE19, W5)
• B16—Engine Coolant Temperature Sensor (SE19, W6)
• B17—Fuel Level Sender (SE19, W5)
• B18—Engine Coolant Level Switch (S.N. —574739)
(SE20, W13)
Continued on next page CED,TX17864,32 –19–26JAN01–1/10

011504
PN=100
System Diagrams
• B19—Engine Air Filter Restriction Switch (SE20, W6)

• B20—Transmission Oil Filter Restriction Switch (SE20,
W10)
• B21—Hydraulic Oil Filter Restriction Switch (SE20, W5)
• B22—Not Used
• B23—Engine Oil Pressure Sensor (SE21, W6)
• B24—Not Used
• B25—Steering System Pressure Switch (SE21, W17)
• B26—Not Used
• B27—Service Brake Pressure Switch Accumulator
Charge (SE21, 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)
9015
• B31—Transmission Output Shaft Speed Sensor (SE22, 10
W10) 5
• B32—Transmission Oil Temperature Sensor (SE24,
W10)
• B33—Clutch Cutoff Sensor (SE24, W3)
• B34—Park Brake Pressure Switch (SE24, W2, W11)
• B35—Freeze Control Switch (SE32, W20)
• B36—A/C Low Pressure Switch (SE32, W20)
• B37—A/C High Pressure Switch (SE32, W20)
• B38—Low-Note Horn (SE33, W2)
• B39—Hi-Note Horn (SE33, W2)
• B40—Brake Light Pressure Switch (SE37, W3)
• B41—Ride Control Pressure Switch (SE10, W9)
• B42—Left Speaker (SE39, W34)
• B43—Right Speaker (SE39, W34)
• E1—Back-up Alarm Lamp (Hitachi Only) (SE22)

• E2—Left Front Turn Light (SE34, W2)
• E3—Left Rear Turn Light (SE34, W13)
• E4—Right Front Turn Light (SE34, W2)
• E5—Right Rear Turn Light (SE34, W13)
• E6—Left Front Marker Light (SE35, W2)
• E7—Right Front Marker Light (SE35, W2)
• E8—Left Tail Light (SE35, W13)
• E9—Right Tail Light (SE35, W13)
• E10—License Plate Light (SE35, W15)
• E11—Left Front Drive Light (SE36, W2)
• E12—Right Front Drive Light (SE36, W2)
• E13—(Not Used)
• E14—(Not Used)

011504
PN=101
System Diagrams
• E15—Rotary Beacon Light (SE36, W19)

• E16—Left Rear Brake Light (SE37, W13)
• E17—Right Rear Brake Light (SE37, W13)
• E18—Dome Light (SE37, W19)
• E19—Not Used
• E20—Left Front Work Light (SE38, W19)
• E21—Right Front Work Light (SE38, W19)
• E22—Left Rear Work Light (SE38, W19)
• E23—Right Rear Work Light (SE38, W19)
• E24—Lighter (Hitachi Only) (SE12, W3)
• E25—Engine Air Heater (SE2, W7)
• E26—Not Used
• E27—Not Used
• E28—No Used
• E29—Not Used
9015
10 • F1—Alternator Excitation 7.5A Fuse (SE2, W3)
6 • F2—Start Aid, Converter and Secondary Steering 10A
Fuse (SE4, W3)
• F3—Neutral Start 5A Fuse (SE3, W3)
• F4—Monitor and Transmission Controller, Unswitched
5A Fuse (SE14, W3)
• F5—Engine Controller Switched 15A Fuse (SE40, W3)
• F6—Not Used
• F7—Monitor, Switched Power 5A Fuse (SE14, W3)
• F8—Not Used
• F9—CCU 12V Battery, Unswitched 5A Fuse (SE20,
W3)
• F10—Power for Pressure Switches 5A Fuse (SE21,
W3)
• F11—CCU 28V Switched Power 7.5A Fuse (SE21, W3)
• F12—Transmission Controller Switched 5A Fuse (SE22,
W3)
• F13—Park Brake and Back-up Alarm 5A Fuse (SE22,
W3)
• F14—Differential Lock and Pin Disconnect 5A Fuse
(SE28, W3)
• F15—BHKO, RTC, and RTD 5A Fuse (SE26, W3)
• F16—Pilot Enable 7.5A Fuse (SE25, W3)
• F17—Front Wiper 10A Fuse (SE29, W3)
• F18—Rear Wiper 10A Fuse (SE30, W3)
• F19—Blower Motor 25A Fuse (SE31, W3)
• F20—Pressurizer Motor 7.5A Fuse (SE31, W3)
• F21—Horn 7.5A Fuse (SE33, W3)
• F22—Turn Signal/Flasher Light 7.5A Fuse (SE34, W3)

011504
PN=102
System Diagrams
• F23—Rocker, Restriction, Radio Switches 5A Fuse

(SE16, W3)
• F24—Tail/Marker Light 7.5A Fuse (SE35, W3)
• F25—Drive Light 10A Circuit Breaker (SE36, W3)
• F26—Rotary Beacon 10A Fuse (SE36, W3)
• F27—Brake Light 7.5A Fuse (SE37, W3)
• F28—Unswitched Boom Down, Radio and Dome Light
7.5A Fuse (SE37, W3)
• F29—Cab Work Light 10A Circuit Breaker (SE38, W3)
• F30—Ride Control 7.5A Fuse (SE10, W3)
• F31—Converter, Unswitched 15A Fuse (SE39, W3)
• F32—Electric Air Adjust Seat, & Lighter 10A Fuse
(SE12, W3)
• F33—Spare Accessory 5A Fuse (SE12, W3)
• F34—Spare Ignition 5A Fuse (SE12, W3)
• F35—Spare Battery 15A Fuse (SE12, W3)
9015
• F36—Engine Air Heater 125A Fuse (SE2, W7) 10
7
• G1—Batteries (SE1, W24)
• G2—Emergency Starting Terminal (SE1, W6)
• G3—55 Amp Bosch Alternator (SE2, W6)
• G5—12V Power Plug (SE39, W21)
• G6—24V to 12V Voltage Converter (SE39, W21)
• G7—24V to 12V Voltage Converter (Radio Only) (SE39,
W34)
• H1—Monitor Alarm (SE13, W4)

• H2—Monitor Display Unit (SE14, W4)
• H3—Back-Up Alarm (SE22, W13)
• K1—Neutral Start Circuit Relay (SE3, W3)

• K2—Not Used
• K3—Start Relay (SE3, W3)
• K4—Ignition Power Relay (SE5, W3)
• K5—Accessory Power Relay #1 (SE7, W3)
• K7—Not Used
• K8—Not Used
• K9—Not Used
• K10—Back-Up Alarm Relay (SE22, W3)
• K11—Return to Carry Relay (SE26, W3)
• K12—Boom Height Kickout Relay (SE27, W3)
• K13—Return-to-Dig Relay (SE27, W3)
• K14—Not Used
• K15—Front Wiper (Return to Park) Relay (SE29, W3)

011504
PN=103
System Diagrams
• K16—Front Intermittent Wiper Relay (SE29, W3)

• K17—Rear Wiper (Return to Park) Relay (SE30, W3)
• K18—Rear Intermittent Wiper Relay (SE30, W3)
• K19—Blower Pressurizer Motor Relay (SE31, W3)
• K20—Not Used
• K21—Secondary Steering Relay (SE33, W3)
• K22—Horn Relay (SE33, W3)
• K23—Left Signal/Flasher Relay (SE34, W3)
• K24—Right Signal/Flasher Relay (SE34, W3)
• K25—Drive Light Relay (SE35, W3)
• K26—Not Used
• K27—(Not Used)
• K28—Brake Light Relay (SE37, W3)
• K29—Not Used
• K30—Ride Control Boom Relay (SE11, W3)
• K31—Ride Control On/Off Relay (SE11, W3)
9015
10 • K32—Detent Enable and Pilot Enable Relay (SE26,
8 W3)
• K33—Engine Air Heater Coil Relay (SE2, W3)
• K34—Engine Air Heater Relay (SE2, W7)
• M1—Starter Motor (SE1, W3, W6, W7, W23, W24)

• M2—Front Washer Pump (SE29, W31)
• M3—Front Wiper Motor (SE29, W4)
• M4—Rear Washer Pump (SE30, W31)
• M5—Rear Wiper Motor (SE30, W19)
• M6—Main Blower Motor (SE31, W20)
• M7—Pressurizer Blower Motor (SE31, W20)
• M8—Secondary Steering Pump Motor (SE33, W23)
• M9—Electric Air Adjust Seat Motor (SE12, W36)
• R1—CAN Termination Node (SE13, W3)

• R3—Blower Speed Resistor (SE31, W20)
• R4—Lighter Resistor (Hitachi Only) (SE12, W3)
• S1—Key Switch (SE1, W4)

• S2—Manual Battery Disconnect Switch (SE1, W24)
• S3—Start Aid Switch (SE4, W4)
• S4—Not Used
• S5—LPM Off/On Switch (SE16, W14)
• S6—Automatic Transmission Switch (SE22, W3)
• S7—Quick Shift Switch (SE22, W3)
• S8—Park Brake Release Switch (SE22, W4)
• S9—Not Used
• S10—Shifter Switch (SE23, W4)

011504
PN=104
System Diagrams
• S11—Clutch Cutoff Enable Switch (SE24, W3)

• S12—Pin Disconnect Switch (SE28, W3)
• S13—Differential Lock (Foot) Switch (SE28, W3)
• S14—Return to Carry Switch (SE26, W2)
• S15—Return to Carry (Enable) Switch (SE27, W3)
• S16—Boom Height Kickout Switch (SE27, W2)
• S17—Return-to-Dig Switch (SE27, W8)
• S18—Pilot Enable/Boom Down Switch (SE25, W3)
• S19—Front Wiper Switch (SE29, W3)
• S20—Rear Wiper Switch (SE30, W3)
• S21—Blower Speed Switch (SE31, W3)
• S22—A/C (On/Off) Switch (SE32, W3)
• S23—Horn Switch (On Steering Column) (SE33, W4)
• S24—4-Way Flasher Switch (SE34, W3)
• S25—Turn Switch (SE35, W4)
• S26—Drive and Tail/Marker Light Switch (SE35, W3)
9015
• S27—Rotary Beacon Switch (SE36, W3) 10
• S28—Dome Light Switch (SE37, W19) 9
• S29—Door Light Switch (SE37, W19)
• S30—Cab Work Light Switch (SE38, W3)
• S31—Ride Control Switch (SE10, W3)
• S32—Up/Down Electric Air Adjust Seat Switch (SE12,
W3)
• S33—LPM Mode Switch (SE 16, W14)
• S34—Not Used)
• S35—Axle Disconnect Switch (SE28, W3)
• V1—Starter Coil Suppression Diode 5A (SE1, W3)

• V2—Alternator Excitation Diode 5A (SE2, W6)
• V3—Start Aid Diode 1A (SE4, W13)
• V4—Not Used
• V5—Start Relay Coil Suppression Diode 1A (SE3, W3)
• V6—Not Used
• V7—Pin Disconnect Diode 1A (SE28, W16)
• V8—Differential Lock Diode(SE28, W5)
• V9—Pilot Enable/Boom Down Diode(SE25, W5)
• V10—Not Used
• V11—A/C Clutch Diode 1A (SE32, W6)
• V12—Ride Control Boom Diode 1A (SE11, W9)
• V13—Ride Control On/Off Diode 1A (SE11, W9)
• V14—Axle Disconnect Diode 1A (SE28, W33)
• V15—Engine Fuel Shutoff 5A Diode (Pull-In) (SE3, W6)
• V16—Engine Fuel Shutoff 1A Diode (Hold-In) (SE3,
W6)
• W1—Antenna (SE39, W34)

011504
PN=105
System Diagrams
• W2—Loader Frame Harness

• W3—Load Center Harness
• W4—Front Console Harness
• W5—Engine Frame Harness
• W6—Engine Harness
• W7—Engine Air Heater Harness
• W8—Return-to-Dig Harness
• W9—Ride Control Harness
• W10—Transmission Harness
• W11—Not Used
• W12—Not Used
• W13—Rear Frame Harness
• W14—LPM Mode Harness
• W15—License Plate Light Harness
• W16—Pin Disconnect Harness
• W17—Secondary Steering Switch Harness
9015
10 • W18—Not Used
10 • W19—Cab Work Light Harness
• W20—Blower/AC Harness
• W21—Converter and Power Plug Harness
• W22—Not Used
• W23—Secondary Steering Pump Motor Harness
• W24—Battery Harness (4 Battery Cables)
• W25—G01 Blk Ground for MDU, TCU, CCU at Starter
• W26—G02 Blk Ground for Grille and Engine Frame
Components by Starter
• W27—G03 Blk Ground for Engine Components at
Starter
• W28—G04 Blk Ground for Cab Components in Load
Center
• W29—G05 Blk Ground for Loader Frame Components
at Right Front Cab Leg
• W30—G08 Blk Ground for Front Dash Components in
Load Center
• W31—Sump Tank Harness
• W32—Not Used
• W33—Axle Disconnect Harness
• W34—Radio Harness
• W35—Not Used
• W36—Electric Air Adjust Seat Harness
• W37—CAN Terminator Harness (1 for Front Console
Harness, 1 for Load Center Harness)
• X1—Engine Frame Harness to Rear Frame Harness

Connector (W5, W13)

011504
PN=106
System Diagrams

Connector (W5, W13)
• X3—Loader Frame Harness to Pin Disconnect Harness
Connector (W2, W16)
• X4—Engine Frame Harness to Load Center Harness
Connector (W3, W5)
• X5—Load Center Harness to Engine Harness
Connector (W3, W6)
• X6—Load Center Harness to Transmission Harness
Connector (W3, W10)
• X7—Load Center to Loader Frame Harness Connector
(W2, W3)
(W2, W3)
(W2, W3)
9015
• X10—Loader Frame Harness to Ride Control Harness 10
Connector (W2, W9) 11
• X11—Return-to-Dig Harness to Loader Frame Harness
Connector (W2, W8)
• X12—Load Center Harness to LPM Mode Harness
Connector (W3, W14)
• X13—Front Console Harness to Load Center Harness
Connector (W3, W4)
• X14—Load Center Harness to Traction Control Harness
Connector (W3) (Not Used)
• X15—Rear Traction Control Harness to Load Center
Harness Connector (W3) (Not Used)
• X16—Rear Traction Control Harness to Load Center
Harness Connector (W3) (Not Used)
• X17—Cab Work Light Harness to Load Center Harness
Connector (W3, W19)
Connector (W3, W19)
• X19—Blower and AC Harness to Load Center Harness
Connector (W3, W20)
Connector (W3, W20)
Connector (W3, W20)
• X22—Not Used
• X23—Not Used
• X24—License Plate Harness to Rear Frame Harness
Connector (W13, W15)
• X25—Loader Frame Harness to Load Center Harness
Connector (W2, W3)

011504
PN=107
System Diagrams
• X26—Secondary Steering Switch Harness to Load

Center Harness Connector (W3, W17)
• X27—Converter and Power Plug Harness to Load
• X28—CAN Terminator Harness to Load Center Harness
and to Front Console Harness Connector (W3, W4,
W37)
• X29—Not Used
• X30—Loader Frame Harness to Axle Disconnect
Harness Connector (W2, W33)
• X31—Engine Frame Harness to Sump Tank Harness
Connector (W5, W31)
• X32—Chassis Controller Connector (Programming)
(Factory Only) (W3)
• X33—Chassis Controller Connector (30 pin) (W3)
9015
10 • X35—Spare (BATT) Connector (W3)
12 • X36—Spare (ACC) Connector (W3)
• X37—Spare (IGN) Connector (W3)
• X38—Transmission Controller Unit Connector (W3)
• X39—Monitor Display Unit Connector (Programming)
(Factory Only) (W4)
• X40—Not Used
• X41—Transmission Control Valve Connector (W10)
• X42—Engine Harness to Engine Air Heater Harness
Connector (W6, W7)
• X43—Engine Harness to Secondary Steering Pump
Motor Harness Connector (W6, W23)
• X44—Engine Frame Harness to Battery Harness
Connector (W5, W24)
• X45—Converter and Power Plug Harness to 12V
Accessory Connector (W21)
• X46—Not Used
• X47—Load Center Harness to Radio Harness
Connector (W3, W34)
• X48—Load Center Harness to Air Adjust Seat Harness
Connector (W3, W36)
• X49—Return to Carry Without Switch Connection (W3)
• X50—Engine Controller Unit Diagnostic Connector (W3)
• X51—Engine Controller Unit Connector (Engine Side)
(Part A) (W3)
(Part B) (W3)
• X53—TCU Diagnostic And Programming Connector (SN
573382—) (SE24, W3)

011504
PN=108
System Diagrams
• X54—SERVICE ADVISOR System Connector (S.N.

573733—) (W3)
• Y1—Transmission Control Solenoid (SE23, W10)

• Y7—Start Aid Solenoid (SE4, W13)
• Y8—Not Used
• Y9— (Not Used)
• Y13—Differential Lock Solenoid (SE28, W5)
9015
• Y14—Pilot Enable Solenoid (SE25, W5) 10
• Y15—Boom Down Solenoid (SE25, W5) 13
• Y16—A/C Compressor Clutch Solenoid (SE32, W6)
• Y17—Ride Control Boom Solenoid (SE11, W9)
• Y18—Ride Control On/Off Solenoid (SE11, W9)
• Y19—Park Brake Release Solenoid (SE24, W2)
• Y20—Pin Disconnect Solenoid (SE28, W16)
• Y21—Not Used
• Y22—Not Used
• Y23—Not Used
• Y24—Not Used
• Y25—Not Used
• Y26—Not Used
• Y28—Ride Control Rod End Solenoid (SE11, W9)
• Y29—Not Used
• Y30—Not Used
• Y31—Axle Disconnect Solenoid (SE28, W33)
• Y32—Rack Actuator Solenoid (SE40, W6)
• Y33—Secondary Fuel Shut-off Solenoid SE40, W6)
SERVICE ADVISOR is a trademark of Deere & Company CED,TX17864,32 –19–26JAN01–10/10
System Functional Schematic (S.N. —585560)
See System Functional Schematic (S.N. 585561 —) for

later machines.
Continued on next page CED,TX17864,34 –19–16FEB01–1/15

011504
PN=109
System Diagrams
T131680 –19–23JUN00

011504
PN=110
System Diagrams
T137490 –19–26JAN01
Start Aid, Ignition Power Circuits (SE4, SE5, SE6)

011504
PN=111
System Diagrams
T131682 –19–23JUN00

011504
PN=112
System Diagrams
T120958 –19–01APR99

011504
PN=113
System Diagrams
T113156 –19–31MAR98

011504
PN=114
System Diagrams
T137524 –19–20JAN01
Chassis Computer Input Circuits (SE16, SE17, SE18)

011504
PN=115
System Diagrams
T137495 –19–25JAN01
Chassis Computer Input Circuits (SE19, SE20, SE21)

011504
PN=116
System Diagrams
T138309 –19–15FEB01
Transmission Control Unit Input Circuits (SE22, SE23, SE24)

011504
PN=117
System Diagrams
T113160 –19–31MAR98

011504
PN=118
System Diagrams
T113161 –19–31MAR98

011504
PN=119
System Diagrams
T137523 –19–20JAN01
Heater, Pressurizer, Air Conditioner, Secondary Steering, and Horn Circuits (SE31, SE32, SE33)

011504
PN=120
System Diagrams
T113163 –19–31MAR98

011504
PN=121
System Diagrams
T137522 –19–20JAN01
Brake Light, Dome Light, Cab Work Light, Converter, and Radio Circuits (SE37, SE38, SE39)

011504
PN=122
System Diagrams
T131590 –19–13JUL00
CED,TX17864,34 –19–16FEB01–15/15

011504
PN=123
System Diagrams

Location Legend (S.N. 585561— )
NOTE: A2—Chassis Computer Unit (SE18, SE19, W3)
A2 indicates component identification number.
Chassis Computer Unit indicates component

name.
SE18, SE19 indicates section numbers of

SYSTEM FUNCTIONAL SCHEMATIC where
component is located.
W3 is the identification number of the

9015 COMPONENT LOCATION and HARNESS
10 CONNECTOR (WITH WIRE AND PIN
28 LOCATION) drawings for the component. This
would indicate that the Chassis Computer Unit is
connected to W3 Load Center Harness.
• A1—Engine Controller Unit (SE41, W3)

• A2—Chassis Computer Unit (SE18, SE19, W3)
• A3—Transmission Controller Unit (SE23, W3)
• A4—Pilot Controller Unit (SE27, W3)
• A5—Radio (SE39, W34)
• B3—Fuel Temperature Sensor (SE40, W6)

• B4—Engine Crank Sensor (SE40, W6)
• B5—Engine Cam Sensor (SE41, W6)
• B7—Intake Manifold Air Temperature Sensor (SE40,
W6)
• B8—Hydraulic System Pressure Sensor (SE16, W5)
• B9—Boom Position Sensor (SE17, W2)
• B14—Analog Throttle Position Sensor (SE16, W3)
• B15—Hydraulic Oil Temperature Sensor (SE19, W5)
• B16—Engine Coolant Temperature Sensor (SE40, W6)
• B17—Fuel Level Sender (SE19, W5)
• B19—Engine Air Filter Restriction Switch (SE20, W6)
• B20—Transmission Oil Filter Restriction Switch (SE20,
W10)
• B21—Hydraulic Oil Filter Restriction Switch (SE20, W5)
• B22—Return to Dig Switch (SE27, W8)
• B23—Engine Oil Pressure Sensor (SE21, W6)
• B25—Steering System Pressure Switch (SE21, W17)
• B27—Service Brake Pressure Switch Accumulator
Charge (SE21, W3)
Continued on next page TX17994,00003D6 –19–18AUG03–1/9

011504
PN=124
System Diagrams
• B28—Torque Converter Input Speed Sensor (Engine

Speed) (SE22, W10)
• B29—Torque Converter Output Speed Sensor (SE22,
W10)
• B30—Internal Clutch Speed Sensor (SE22, W10)
• B31—Transmission Output Shaft Speed Sensor (SE22,
W10)
• B32—Transmission Oil Temperature Sensor (SE24,
W10)
• B33—Clutch Cutoff Sensor (SE24, W3)
• B34—Park Brake Pressure Switch (SE24, W2)
• B35—Freeze Control Switch (SE32, W20)
• B36—A/C System Pressure Switch (SE32, W20)
• B38—Low-Note Horn (SE33,W2)
• B39—Hi-Note Horn (SE33, W2)
• B40—Brake Light Pressure Switch (SE37, W3)
9015
• B41—Bucket Dump Pressure Switch (SE11, W9) 10
• B42—Left Speaker (SE39, W34) 29
• B43—Right Speaker (SE39, W34)
• B48—Water In Fuel Sensor (SE40, W6)
• B49—Fuel Rail Pressure Sensor (SE41, W6)
• E2—Left Front Turn Light (SE34, W2)

• E3—Left Rear Turn Light (SE34, W13)
• E4—Right Front Turn Light (SE34, W2)
• E5—Right Rear Turn Light (SE34, W13)
• E6—Left Front Marker Light (SE35, W2)
• E7—Right Front Marker Light (SE35, W2)
• E8—Left Tail Light (SE35, W13)
• E9—Right Tail Light (SE35, W13)
• E10—License Plate Light (SE35, W15)
• E11—Left Front Drive Light (SE36, W2)
• E12—Right Front Drive Light (SE36, W2)
• E15—Rotary Beacon Light (SE36, W19)
• E16—Left Rear Brake Light (SE37, W13)
• E17—Right Rear Brake Light (SE37, W13)
• E18—Dome Light (SE37, W19)
• E20—Left Front Work Light (SE38, W19)
• E21—Right Front Work Light (SE38, W19)
• E22—Left Rear Work Light (SE38, W19)
• E23—Right Rear Work Light (SE38, W19)
• E25—Engine Air Heater (SE2, W7)
• F1—Alternator Excitation Fuse (SE2, W3)

• F2—Start Aid, Converter and Secondary Steering Fuse
(SE4, W3)

011504
PN=125
System Diagrams
• F3—Neutral Start Fuse (SE3, W3)

• F4—Monitor and Transmission Controller, Unswitched
Fuse (SE14, W3)
• F5—Engine Controller Switched Fuse (SE42, W3)
• F6—Engine Controller Unit Switched Fuse (SE42)
• F7—Monitor, Switched Power Fuse (SE14, W3)
• F9—Chassis Controller Unit Unswitched Fuse (SE20,
W3)
• F10—Steering and Service Brake Pressure Switch Fuse
(SE21, W3)
• F11—Chassis Controller Unit Switched Power Fuse
(SE21, W3)
• F12—Transmission Controller Switched Fuse (SE22,
W3)
• F13—Park Brake and Back-up Alarm Fuse (SE22, W3)
• F14—Differential Lock and Pin Disconnect Fuse (SE28,
9015
10 W3)
30 • F15—BHKO, RTC, and RTD Fuse (SE26, W3)
• F16—Pilot Enable Fuse (SE25, W3)
• F17—Front Wiper Fuse (SE29, W3)
• F18—Rear Wiper Fuse (SE30, W3)
• F19—Blower Motor Fuse (SE31, W3)
• F20—Pressurizer Motor Fuse (SE31, W3)
• F21—Horn Fuse (SE33, W3)
• F22—Turn Light Fuse (SE34, W3)
• F23—Rocker Switches and Radio Fuse (SE16, W3)
• F24—Tail/Marker Light Fuse (SE35, W3)
• F25—Drive Light Circuit Breaker (SE36, W3)
• F26—Rotary Beacon Fuse (SE36, W3)
• F27—Brake Light Fuse (SE37, W3)
• F28—Unswitched Boom Down, Radio and Dome Light
Fuse (SE37, W3)
• F29—Cab Work Light Circuit Breaker (SE38, W3)
• F30—Ride Control Fuse (SE10, W3)
• F31—Converter, Unswitched Fuse (SE39, W3)
• F32—Air Seat Adjust Fuse (SE12, W3)
• F33—Spare Accessory Fuse (SE12, W3)
• F34—Spare Ignition Fuse (SE12, W3)
• F35—Spare Battery Fuse (SE12, W3)
• F36—Engine Air Heater Fuse (SE2, W7)
• G1—Batteries (SE1, W24)

• G2—Emergency Starting Terminal (SE1, W6)
• G5—12V Power Plug (SE39, W21)

011504
PN=126
System Diagrams
• G6—24V to 12V Voltage Converter (SE39, W21)

• G7—24V to 12V Voltage Converter (Radio Only) (SE39,
W34)
• H1—Monitor Alarm (SE13, W4)

• H2—Monitor Display Unit (SE14, W4)
• H3—Back Up Alarm (SE22, W13)
• K1—Neutral Start Circuit Relay (SE3, W3)

• K3—Start Relay (SE3, W3)
• K4—Ignition Power Relay (SE5, W3)
• K10—Back Up Alarm Relay (SE22, W3)
• K13—Return-to-Dig Relay (SE27, W3)
• K15—Front Wiper (Return to Park) Relay (SE29, W3)
9015
• K16—Front Intermittent Wiper Relay (SE29, W3) 10
• K17—Rear Wiper (Return to Park) Relay (SE30, W3) 31
• K18—Rear Intermittent Wiper Relay (SE30, W3)
• K19—Blower and Pressurizer Motor Relay (SE31, W3)
• K21—Secondary Steering Relay (SE33, W3)
• K22—Horn Relay (SE33, W3)
• K23—Left Flasher Relay (SE34, W3)
• K24—Right Flasher Relay (SE34, W3)
• K25—Drive Light Relay (SE35, W3)
• K28—Brake Light Relay (SE37, W3)
• K30—Ride Control Boom Relay (SE10, W3)
• K31—Ride Control On/Off Relay (SE11, W3)
• K32—Detent Enable and Pilot Enable Relay (SE26,
W3)
• K33—Engine Air Heater Coil Relay (SE2, W3)
• K34—Engine Air Heater Relay (SE2, W7)
• M1—Starter Motor (SE1, W3, W6, W7, W23, W24)

• M2—Front Washer Pump (SE29, W31)
• M3—Front Wiper Motor (SE29, W4)
• M4—Rear Washer Pump (SE30, W31)
• M5—Rear Wiper Motor (SE30, W19)
• M6—Blower Motor (SE31, W20)
• M7—Pressurizer Blower Motor (SE31, W20)
• M8—Secondary Steering Pump Motor (SE33, W23)
• M9—Electric Air Adjust Seat Motor (SE12, W36)

• R3—Blower Speed Resistor (SE31, W20)

011504
PN=127
System Diagrams
• S1—Key Switch (SE1, W4)

• S2—Manual Battery Disconnect Switch (SE1, W24)
• S3—Start Aid Switch (SE4, W4)
• S5—Spin Control Switch (SE16, W3)
• S6—Automatic Transmission Switch (SE22, W3)
• S7—Quick Shift Switch (SE22, W3)
• S8—Park Brake Release Switch (SE22, W4)
• S10—Shifter Switch (SE23, W4)
• S11—Clutch Cutoff Enable Switch (SE24, W3)
• S12—Pin Disconnect Switch (SE28, W3)
• S13—Differential Lock (Foot) Switch (SE28, W3)
• S18—Pilot Enable/Boom Down Switch (SE25, W3)
• S19—Front Wiper Switch (SE29, W3)
• S20—Rear Wiper Switch (SE30, W3)
• S21—Blower Speed Switch (SE31, W3)
• S22—A/C (On/Off) Switch (SE32, W3)
9015
10 • S23—Horn Switch (SE33, W4)
32 • S24—4-Way Flasher Switch (SE34, W3)
• S25—Turn Switch (SE14, W4)
• S26—Drive and Tail/Marker Light Switch (SE35, W3)
• S27—Rotary Beacon Switch (SE36, W3)
• S28—Dome Light Switch (SE37, W19)
• S29—Door Light Switch (SE37, W19)
• S30—Cab Work Light Switch (SE38, W3)
• S31—Ride Control Switch (SE10, W3)
• S32—Air Seat Adjustment Switch (SE12, W3)
• S33—Spin Control Mode Switch (SE16, W14)
• S35—Axle Disconnect Switch (SE28, W3)
• V1—Starter Coil Suppression Diode 5A (SE1, W3)

• V2—Alternator Excitation Diode 5A (SE2, W6)
• V3—Start Aid Diode 1A (SE4, W13)
• V5—Start Relay Coil Suppression Diode 1A (SE3, W3)
• V8—Differential Lock Diode (SE28, W5)
• V9—Pilot Enable/Boom Down Diode (SE25, W5)
• V11—A/C Clutch Diode 1A (SE32, W6)
• W1—Antenna (SE39, W34)

• W2—Loader Frame Harness
• W3—Load Center Harness
• W4—Front Console Harness
• W5—Engine Frame Harness
• W6—Engine Harness
• W7—Engine Air Heater Harness
• W8—Return-to-Dig Harness
• W9—Ride Control Harness

011504
PN=128
System Diagrams
• W10—Transmission Harness
• W13—Rear Frame Harness
• W14—LPM Mode Harness
• W15—License Plate Light Harness
• W16—Pin Disconnect Harness
• W17—Secondary Steering Switch Harness
• W19—Cab Work Light Harness
• W20—Blower/AC Harness
• W21—Converter and Power Plug Harness
• W23—Secondary Steering Pump Motor Harness
• W24—Battery Harness (4 Battery Cables)
• W25—G01 Blk Ground for MDU, TCU, CCU at Starter
• W26—G02 Blk Ground for Grille and Engine Frame
Components by Starter
• W27—G03 Blk Ground for Engine Components at
Starter
9015
• W28—G04 Blk Ground for Cab Components in Load 10
Center 33
• W29—G05 Blk Ground for Loader Frame Components
at Right Front Cab Leg
• W30—G08 Blk Ground for Front Dash Components in
Load Center
• W31—Sump Tank Harness
• W33—Axle Disconnect Harness
• W34—Radio Harness
• W36—Electric Air Adjust Seat Harness
• W37—CAN Terminator Harness (1 for Front Console
Harness, 1 for Load Center Harness)

Connector (W5, W13)
Connector (W5, W13)
• X3—Loader Frame Harness to Pin Disconnect Harness
Connector (W2, W16)
• X4—Engine Frame Harness to Load Center Harness
Connector (W3, W5)
• X5—Load Center Harness to Engine Harness
Connector (W3, W6)
• X6—Load Center Harness to Transmission Harness
Connector (W3, W10)
(W2, W3)
(W2, W3)

011504
PN=129
System Diagrams

(W2, W3)
• X10—Loader Frame Harness to Ride Control Harness
Connector (W2, W9)
• X11—Return-to-Dig Harness to Loader Frame Harness
Connector (W2, W8)
• X12—Load Center Harness to Spin Control Mode
• X13—Front Console Harness to Load Center Harness
Connector (W3, W4)
• X14—A/C High Pressure Switch Jumper (SE32, W20)
Connector (W3, W19)
Connector (W3, W19)
9015
10 Connector (W3, W20)
34 • X20—Blower and AC Harness to Load Center Harness
Connector (W3, W20)
Connector (W3, W20)
• X24—License Plate Harness to Rear Frame Harness
Connector (W13, W15)
• X25—Loader Frame Harness to Load Center Harness
Connector (W2, W3)
• X26—Secondary Steering Switch Harness to Load
• X27—Converter and Power Plug Harness to Load
• X28—CAN Terminator Harness to Load Center Harness
and to Front Console Harness Connector (W3, W4,
W37)
• X30—Loader Frame Harness to Axle Disconnect
• X31—Engine Frame Harness to Sump Tank Harness
Connector (W5, W31)
• X32—Chassis Controller Connector (Programming)
(Factory Only) (W3)
• X35—Spare (BATT) Connector (W3)
• X36—Spare (ACC) Connector (W3)
• X37—Spare (IGN) Connector (W3)
• X38—Transmission Controller Unit Connector (W3)
• X39—Monitor Display Unit Connector (Programming)
(Factory Only) (W4)

011504
PN=130
System Diagrams
• X41—Transmission Control Valve Connector (W10)

• X42—Engine Harness to Engine Air Heater Harness
Connector (W6, W7)
• X43—Engine Harness to Secondary Steering Pump
Motor Harness Connector (W6, W23)
• X44—Engine Frame Harness to Battery Harness
Connector (W5, W24)
• X45—Converter and Power Plug Harness to 12V
Accessory Connector (W21)
• X47—Load Center Harness to Radio Harness
Connector (W3, W34)
• X48—Load Center Harness to Air Adjust Seat Harness
Connector (W3, W36)
• X49—Return to Carry Without Switch Connection (W3)
• X50—Engine Controller Unit Diagnostic Connector (W3)
9015
(Part A) (W3) 10
• X52—Engine Controller Unit Connector (Engine Side) 35
(Part B) (W3)
• X53—TCU Diagnostic And Programming Connector
(SE24, W3)
• X54—SERVICE ADVISOR System Connector (W3)

• Y7—Start Aid Solenoid (SE4, W13)
• Y8—Injection Pump Control Solenoid 1 (SE42, W6)
• Y9—Injection Pump Control Solenoid 2 (SE42, W6)
• Y13—Differential Lock Solenoid (SE28, W5)
• Y14—Pilot Enable Solenoid (SE25, W5)
• Y15—Boom Down Solenoid (SE25, W5)
• Y16—A/C Compressor Clutch Solenoid (SE32, W6)
• Y19—Park Brake Release Solenoid (SE24, W2)
• Y20—Pin Disconnect Solenoid (SE28, W16)
• Y21—Fuel Injector Solenoid 1 (SE42, W6)
SERVICE ADVISOR is a trademark of Deere & Company Continued on next page TX17994,00003D6 –19–18AUG03–8/9

011504
PN=131
System Diagrams

• Y31—Axle Disconnect Solenoid (SE28, W33)
TX17994,00003D6 –19–18AUG03–9/9
System Functional Schematic (S.N. 585561—)
See System Functional Schematic (S.N. — 585560) for

earlier machines.
Continued on next page TX17994,000032C –19–17JUN02–1/15
9015
10
36

011504
PN=132
System Diagrams
T156365 –19–22OCT02

011504
PN=133
System Diagrams
T156351 –19–24SEP02

011504
PN=134
System Diagrams
T156352 –19–24SEP02

011504
PN=135
System Diagrams
T156353 –19–24SEP02

011504
PN=136
System Diagrams
T156354 –19–24SEP02

011504
PN=137
System Diagrams
T157758 –19–24SEP02

011504
PN=138
System Diagrams
T156356 –19–24SEP02

011504
PN=139
System Diagrams
T156357 –19–24SEP02

011504
PN=140
System Diagrams
T161855 –19–03DEC02

011504
PN=141
System Diagrams
T161856 –19–22NOV02

011504
PN=142
System Diagrams
T156360 –19–24SEP02

011504
PN=143
System Diagrams
T156361 –19–24SEP02

011504
PN=144
System Diagrams
T156362 –19–16OCT02

011504
PN=145
System Diagrams
T156363 –19–22OCT02
TX17994,000032C –19–17JUN02–15/15

011504
PN=146
System Diagrams
Loader Frame Harness (W2) Component Location

T113168 –19–10FEB98
CED,TX17864,35 –19–02JUN00–1/4

011504
PN=147
System Diagrams
9015
10
52
–19–10FEB98
T113169

011504
PN=148
System Diagrams
9015
10
53

011504
PN=149
System Diagrams
T155793 –UN–28JUN02

011504
PN=150
System Diagrams
B9—Boom Position Sensor E11—Left Front Drive Light X9—Load Center to Loader X11—Return-to-Dig Harness to
B34—Park Brake Pressure E12—Right Front Drive Light Frame Harness Loader Frame Harness
Switch X3—Loader Frame Harness to Connector Connector
B38—Low-Note Horn Pin Disconnect Harness X25—Loader Frame Harness X30—Loader Frame Harness
B39—Hi-Note Horn Connector to Load Center Harness to Axle Disconnect
E2—Left Front Turn Light X7—Load Center to Loader Connector Harness Connector
E4—Right Front Turn Light Frame Harness Connector X10—Loader Frame Harness Y19—Park Brake Release
E6—Left Front Marker Light X8—Load Center to Loader to Ride Control Harness Solenoid
E7—Right Front Marker Light Frame Harness Connector Connector
CED,TX17864,35 –19–02JUN00–4/4
9015
10
55

011504
PN=151
System Diagrams
Load Center Harness (W3) Component Location (S.N. —585560)

T131456 –19–13JUL00
CED,TX17864,37 –19–26JAN01–1/9

011504
PN=152
System Diagrams
T137519 –19–20JAN01
Detail A
CED,TX17864,37 –19–26JAN01–2/9

011504
PN=153
System Diagrams
T137520 –19–20JAN01
Detail B
CED,TX17864,37 –19–26JAN01–3/9

011504
PN=154
System Diagrams
9015
10
59
–19–25JAN01
T137521
Detail C—Cab Units

011504
PN=155
System Diagrams
9015
10
60
–19–08JUN00
T131482
Detail C—Canopy Units (S.N. 575251—)

011504
PN=156
System Diagrams
T137518 –19–20JAN01
Harness Mating Connectors

011504
PN=157
System Diagrams
T131468 –19–06JUN00

011504
PN=158
System Diagrams
T137517 –19–20JAN01
Harness Connectors and Pin Location (2 of 3) (Rear View Shown)

011504
PN=159
System Diagrams
9015
10
64
–19–06JUN00
T131470
CED,TX17864,37 –19–26JAN01–9/9

011504
PN=160
System Diagrams
Load Center Harness (W3) Component

Location (S.N. 585561—)
See Fuse and Relay Specifications for fuse and relay

location.
Continued on next page TX17994,000034B –19–01OCT02–1/10
9015
10
65

011504
PN=161
System Diagrams
T159929 –UN–24OCT02

011504
PN=162
System Diagrams
A—Fuse and Relay Load X4—Engine Frame X20—Blower and AC X33—Chassis Controller
Center Harness-to-Load Center Harness-to-Load Center Connector (30 pin)
C—Side Console (See Detail Harness Connector Harness Connector X34—Chassis Controller
C) X5—Load Center X21—Blower and AC Connector (60 pin)
A1—Engine Controller Unit Harness-to-Engine Harness-to-Load Center X35—Spare (BATT) Connector
(ECU) Harness Connector Harness Connector X36—Spare (ACC) Connector
A2—Chassis Computer Unit X7—Load Center-to-Loader X25—Load Center X37—Spare (IGN) Connector
(CCU) Frame Harness Connector Harness-to-Loader X38—Transmision Controller
A3—Transmission Controller X8—Load Center-to-Loader Frame Harness Unit Connector
Unit (TCU) Frame Harness Connector Connector X51—Engine Controller Unit
A4—Pilot Controller Unit X9—Load Center-to-Loader X26—Load Center (A1) Connectors
B14—Analog Throttle Position Frame Harness Connector Harness-to-Secondary X52—Engine Controller Unit
Sensor X13—Front Console Steering Switch Harness (A1) Connectors
B27—Service Brake Harness-to-Load Center Connector X53—TCU Diagnostic and
Accumulator Charge Harness Connector X27—Converter and Power Programming Connector
Pressure Switch X17—Cab Work Light Plug Harness-to-Load X54—Engine Controller Unit
B33—Clutch Cut-Off Sensor Harness-to-Load Center Center Harness Connectors
B40—Brake Light Pressure Harness Connector Connector X55—Engine Controller Unit
Switch X18—Cab Work Light X28—CAN Terminator Connectors
K3—Start Relay Harness-to-Load Center Harness-to-Load Center X56—Service ADVISOR 9015
M1—Starter Motor Harness Connector Harness and to Front Connector 10
S7—Quick Shift Switch X19—Blower and AC Console Harness 67
V1—Starter Coil Suppression Harness-to-Load Center Connector
Diode Harness Connector X32—Chassis Controller
W29—Right Front Cab Leg Connector
Ground (Programming) (Factory
Only)

011504
PN=163
System Diagrams
9015
10
68
–UN–10OCT02
T159930

011504
PN=164
System Diagrams
1—Temperature Control S18—Pilot Enable/Boom Down S27—Rotary Beacon Switch (If X47—Load Center
S6—Automatic Transmission Switch Equipped) Harness-to-Radio
Switch S20—Rear Wiper Switch S30—Cab Work Light Switch Harness Connector
S11—Clutch Cut-Off Enable S21—Blower Speed Switch S31—Ride Control Switch X48—Load Center
Switch S22—A/C On/Off Switch X12—Load Center Harness-to-Electric Air
S12—Pin Disconnect Switch S24—4-Way Flasher Switch Harness-to-Spin Control Seat Adjust Harness
S15—Return-to-Carry (Enable) S26—Drive and Tail/Marker Mode Harness Connector
Switch Light Switch Connector
S16—Boom Height Kickout
Switch
9015
10
69

011504
PN=165
System Diagrams
T159931 –UN–19OCT02

011504
PN=166
System Diagrams
9015
10
71

011504
PN=167
System Diagrams
T159932 –UN–19OCT02

011504
PN=168
System Diagrams
X4—Engine Frame Harness to X13—Front Console Harness X19—Blower and AC Harness X27—Converter and Power
Load Center Harness to Load Center Harness to Load Center Harness Plug Harness to Load
Connector Connector Connector Center Harness
X5—Load Center Harness to X17—Cab Work Light Harness X20—Blower and AC Harness Connector
Engine Harness to Load Center Harness to Load Center Harness X28—CAN Terminator Harness
Connector Connector Connector to Load Center Harness
X6—Load Center Harness to X18—Cab Work Light Harness X21—Blower and AC Harness and to Front Console
Transmission Harness to Load Center Harness to Load Center Harness Harness Connector
Connector Connector Connector
9015
10
73

011504
PN=169
System Diagrams
T159933 –UN–10OCT02
Harness Components and Connector Pin Location (A)

011504
PN=170
System Diagrams
1—Temperature Control S11—Clutch Cutoff Enable S20—Rear Wiper Switch V5—Start Relay Coil
Switch Switch S21—Blower Speed Switch Suppression Diode
A5—Radio S12—Pin Disconnect Switch S22—A/C (On/Off) Switch X35—Spare (BATT) Connector
B14—Throttle Position Sensor S13—Differential Lock (Foot) S24—4-Way Flasher Switch X36—Spare (ACC) Connector
B27—Service Brake Pressure Switch S26—Drive and Tail/Marker X37—Spare (IGN) Connector
Switch S15—Return-to-Carry Switch Light Switch X48—Load Center Harness to
B33—Clutch Cutoff Sensor S16—Boom Height Kickout S27—Rotary Beacon Switch Air Adjust Seat Harness
B40—Brake Light Pressure Switch S30—Cab Work Light Switch Connector
Switch S18—Pilot Enable/Boom Down S31—Ride Control Switch X53—TCU Diagnostic And
K3—Start Relay Switch S35—Axle Disconnect Switch Programming Connector
M1—Starter Motor S19—Front Wiper Switch V1—Starter Coil Suppression
S6—Automatic Transmission Diode
Switch
9015
10
75
TX17994,000034B –19–01OCT02–10/10

011504
PN=171
System Diagrams
Front Console Harness (W4) Component Location

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

011504
PN=172
System Diagrams
T137515 –19–20JAN01
Harness Connector Pin Location (Rear View Shown)
TX,10,111518 –19–26JAN01–2/2

011504
PN=173
System Diagrams
Engine Frame Harness (W5) Component Location

T113180 –19–16FEB98
CED,TX17864,39 –19–26NOV02–1/4

011504
PN=174
System Diagrams
9015
10
79
–19–09FEB98
T113341
Continued on next page CED,TX17864,39 –19–26NOV02–2/4

011504
PN=175
System Diagrams
T161854 –UN–22NOV02
Continued on next page CED,TX17864,39 –19–26NOV02–3/4

011504
PN=176
System Diagrams
B8—Hydraulic System V3—Start Aid Diode X4—Engine Frame Harness to Y7—Start Aid Solenoid
Pressure Sensor V8—Differential Lock Diode Load Center Harness Y13—Differential Lock
B15—Hydraulic Oil V9—Pilot Enable/Boom Down Connector Solenoid
Temperature Sensor Diode X31—Engine Frame Harness Y14—Pilot Enable Solenoid
B17—Fuel Level Sender W26—Ground to Engine Frame to Sump Tank Harness Y15—Boom Down Solenoid
B21—Hydraulic Oil Filter X1—Engine Frame Harness to Connector
Restriction Switch Rear Frame Harness X44—Engine Frame Harness
M3—Front Washer Pump Connector to Battery (Cables)
M4—Rear Washer Pump X2—Engine Frame Harness to Harness Connector
Rear Frame Harness
Connector
CED,TX17864,39 –19–26NOV02–4/4
9015
10
81

011504
PN=177
System Diagrams
Engine Harness (W6) Component Location

T131433 –19–06JUN00
CED,TX17864,41 –19–26NOV02–1/4

011504
PN=178
System Diagrams
T131422 –19–06JUN00
CED,TX17864,41 –19–26NOV02–2/4

011504
PN=179
System Diagrams
T157693 –UN–31OCT02
CED,TX17864,41 –19–26NOV02–3/4

011504
PN=180
System Diagrams
B1—Engine Coolant B17—Fuel Level Sender V2—Alternator Excitation X55—Engine Air Heater Option
Temperature Sensor B19—Engine Air Filter Diode Relay Connector
B3—Fuel Temperature Sensor Restriction Switch V11—A/C Clutch Diode Y8—Injection Pump Control
B4—Engine Crank Position B23—Engine Oil Pressure X5—Load Center Harness to Solenoid 1
Sensor Sensor Engine Harness Y9—Injection Pump Control
B5—Injection Pump Position B48—Water In Fuel Sensor Connector Solenoid 2
Sensor B49—Fuel Rail Pressure X43—Engine Harness to Y16—A/C Compressor Clutch
B7—Intake Manifold Air Sensor Secondary Steering Solenoid
Temperature Sensor M1—Starter Motor Pump Motor Harness
Connector
CED,TX17864,41 –19–26NOV02–4/4
9015
10
85

011504
PN=181
System Diagrams
Engine Air Heater Harness (W7) Component Location
9015
10
86
–19–16FEB98
T113195

011504
PN=182
System Diagrams
9015
10
87
–19–10JAN97
T106074
CED,TX17864,43 –19–02JUN00–2/2

011504
PN=183
System Diagrams
Return-To-Dig Harness (W8) Component Location
9015
10
88
–19–05JUN00
T131085
CED,TX17864,45 –19–02JUN00–1/1

011504
PN=184
System Diagrams
Ride Control Harness (W9) Component Location

T132248 –19–06JUL00
CED,TX17864,47 –19–02JUN00–1/4

011504
PN=185
System Diagrams
9015
10
90
–19–30MAR98
T113347

011504
PN=186
System Diagrams
9015
10
91

011504
PN=187
System Diagrams
9015
10
92
–UN–23JUL02
T153147

011504
PN=188
System Diagrams
B41—Ride Control Pressure Y17—Ride Control Boom Y18—Ride Control On/Off Y34—Ride Control On/Off
Switch Solenoid Solenoid Solenoid
X10—Loader Frame Harness
to Ride Control Harness
Connector
CED,TX17864,47 –19–02JUN00–4/4
9015
10
93

011504
PN=189
System Diagrams
Transmission Harness (W10) Component Location

T132303 –19–07JUL00
TX,9015,111861 –19–26JAN01–1/2

011504
PN=190
System Diagrams
9015
10
95
–19–26JAN01
T137491
Harness Connectors
TX,9015,111861 –19–26JAN01–2/2

011504
PN=191
System Diagrams
Rear Frame Harness (W13) Component Location

T131416 –19–06JUN00
TX,9015,111863 –19–26JAN01–1/4

011504
PN=192
System Diagrams
9015
10
97
–19–20JAN01
T137513
Harness Connector Pin Locations (S.N. —585560)
Continued on next page TX,9015,111863 –19–26JAN01–2/4

011504
PN=193
System Diagrams
9015
10
98
–UN–19SEP02
T156827

011504
PN=194
System Diagrams
E3—Left Rear Turn Light E16—Left Rear Brake Light X1—Engine Frame Harness to X24—License Plate Harness to
E8—Left Tail Light E17—Right Rear Brake Light Rear Frame Harness Rear Frame Harness
E9—Right Tail Light H3—Backup Alarm Connector Connector
TX,9015,111863 –19–26JAN01–4/4
9015
10
99

011504
PN=195
System Diagrams
LPM Mode Harness (W14) Component Location (S.N. —585560)
9015
10
,100
–19–10MAR99
T120474

011504
PN=196
System Diagrams
9015
10
,101
–19–28JUL98
T113205
CED,TX17864,5 –19–01APR99–2/2

011504
PN=197
System Diagrams
License Plate Light Harness (W15) Component Location
9015
10
,102
–19–05JUN00
T131090
TX,9015,111866 –19–26NOV02–1/1

011504
PN=198
System Diagrams
Pin Disconnect Harness (W16) Component Location
9015
10
,103
–19–17FEB98
T113327

011504
PN=199
System Diagrams
9015
10
,104
–19–05SEP97
T110560
CED,TX17864,49 –19–31MAR98–2/2

011504
PN=200
System Diagrams
Secondary Steering Switch Harness (W17) Component Location
9015
10
,105
–19–05JUN00
T131091
CED,TX17864,51 –19–02JUN00–1/1

011504
PN=201
System Diagrams
Cab Work Lights Harness (W19) Component Location

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

011504
PN=202
System Diagrams
9015
10
,107
–19–05SEP97
T110564
TX,10,111547 –19–02JUN00–2/2

011504
PN=203
System Diagrams
Blower/Air Conditioning Harness (W20) And Component Location Drawing

T113184 –19–05MAR98
CED,TX03679,3533 –19–18MAR98–1/3

011504
PN=204
System Diagrams
A—Temperature Control F—Blower Motor 25A Fuse L—Expansion Valve S—Heating/Evaporator Core
Switch (F29) M—Air Conditioning Low T—Freeze Control Switch
B—Blower Speed Switch (S21) G—Receiver/Dryer Pressure Switch (B36) (B35)
C—Air Conditioning On/Off H—Air Conditioning Clutch 1A N—Heater Valve U—Air Ducts
Switch (S22) Diode (V11) O—Pressurizer Motor (M7) V—Blower Speed Resistor (R3)
D—Pressurizer Motor 7.5A I—Condenser P—Fresh Air Filter W—Main Blower Motor (M6)
Fuse (F20) J—Compressor Relief Valve Q—Recirculating Air Filter X—Service and Charge Port
E—Blower/Pressurizer Motor K—Air Conditioning R—Air Conditioning High
Relay (K19) Compressor Clutch (Y16) Pressure Switch (B37)
9015
10
,109

011504
PN=205
System Diagrams
9015
10
,110
–19–31JUL96
T101385
CED,TX03679,3533 –19–18MAR98–3/3

011504
PN=206
System Diagrams
Converter And Power Plug Harness (W21) Component Location
9015
10
,111
–19–05JUN00
T131099
TX,9015,111874 –19–03SEP97–1/1

011504
PN=207
System Diagrams
Secondary Steering Pump Motor Harness (W23) Component Location
9015
10
,112
–19–12FEB98
T113183

011504
PN=208
System Diagrams
9015
10
,113
–19–12FEB98
T113411
CED,TX17864,2 –19–02JUN00–2/2

011504
PN=209
System Diagrams
Battery (Cables) Harness (W24) Component Location
9015
10
,114
–19–10SEP97
T110566
TX,9015,111876 –19–03SEP97–1/1

011504
PN=210
System Diagrams
Sump Tank Harness (W31) Component Location
9015
10
,115
–19–10SEP97
T110567
Continued on next page TX,9015,111877 –19–02JUN00–1/2

011504
PN=211
System Diagrams
9015
10
,116
–19–05SEP97
T110568
TX,9015,111877 –19–02JUN00–2/2

011504
PN=212
System Diagrams
Axle Disconnect Harness (W33) Component Location
9015
10
,117
–19–06JUN00
T131436
CED,TX17864,1 –19–02JUN00–1/1

011504
PN=213
System Diagrams
Radio Harness (W34) Component Location
9015
10
,118
–19–10SEP97
T110569
Continued on next page TX,9015,111879 –19–28OCT02–1/3

011504
PN=214
System Diagrams
9015
10
,119
–19–09JUN00
T131311
Continued on next page TX,9015,111879 –19–28OCT02–2/3

011504
PN=215
System Diagrams
9015
10
,120
–19–22DEC00
T136669
Radio Harness (W34) Component Location (S.N. 578926—)
TX,9015,111879 –19–28OCT02–3/3

011504
PN=216
System Diagrams
Electric Air Adjust Seat Harness (W36) Component Location
9015
10
,121
–19–12FEB98
T113196
CED,TX17864,7 –19–11FEB98–1/1

011504
PN=217
System Diagrams
CAN Terminator Harness (W37) Component Location
9015
10
,122
–19–10FEB98
T113359
CED,TX17864,4 –19–10FEB98–1/1

011504
PN=218
Group 15
Sub-System Diagnostics
Power Circuit Theory Of Operation
See System Functional Schematic S.N. 585561 —) for

power circuit information on later machines. (Group
9015-10.)
Continued on next page TX,15,111716 –19–16SEP02–1/4
9015
15
1

011504
PN=219
T137531 –19–20JAN01
Power Circuit Functional Schematic

011504
PN=220
The power circuit includes batteries and main current (F16) then receives power through the detent enable
paths to primary distribution points. relay.
A manual battery disconnect switch (S2) is located in When key switch is in the On, Bulb Check, or Start
the negative cable between the batteries and starter position and the engine is running, power flows from
motor. When the battery disconnect switch is turned the IGN terminal of the key switch to energize the coils
Off, power is not supplied to any electrical circuits on of the Ignition Power Relay (K4). With Ignition Power
the machine. Relay energized, the following fuses receive power:
When the key switch (S1) is in the Off position, voltage • Park Brake/Backup Alarm 5A Fuse (F13)
is from the 12V center tap of the batteries to: • CCU 28V Switched Power 7.5A Fuse (F11)
• Monitor Switched Power 7.5A Fuse (F7)
• CCU 12V Battery Unswitched 5A Fuse (F9) • Spare Ignition 5A Fuse (F34)
• Converter, Secondary Steering and Start Aid 10A
When the key switch is in the Off position, voltage is Fuse (F2)
from the batteries to the key switch to the following: • Engine Controller Unit 20A Fuse (F5)
9015
15
• Spare Battery 15A Fuse (F35) When the key switch is in the On, Bulb Check, or Start 3
• Monitor and Transmission Controller Unswitched 5A position with the engine running, power flows from the
Fuse (F4) IGN terminal of the key switch through the Detent
• Blower Motor 25A Fuse (F19) Enable Relay (K32), which has been energized by the
• Left and Right Flasher 7.5A Fuse (F22) CCU. The Pilot Enable 7.5A Fuse (F16) then receives
• Drive Light 10A Circuit Breaker (F25) power though the detent enable relay. Fuse (F16)
• Brake Light 7.5A Fuse (F27) sends power to the Pilot Enable/Boom Down Switch
• Unswitched Boom Down, Radio and Dome Light (S18). When Pilot Enable/Boom Down Switch is in the
7.5A Fuse (F28) On position, power flows through the switch to power
• Converter Unswitched 15A Fuse (F31) following fuse:
When the key switch is in the Off position, voltage is • BHKO and RTD 5A Fuse (F15)
from batteries, to start motor to following:
When key switch is in the Start position, power flows
• Engine Air Heater 125 A Fuse (F36) from the ST terminal to:
When key switch is in the On, Bulb Check, or Start • Neutral Start 5A Fuse (F3)
position with the engine running, power flows from the
IGN terminal of the key switch to the following: When the key switch is in the On position, power flows
from the ACC terminal to power the following:
• Transmission Controller Switched 5A Fuse (F12)
• Ignition Power Relay (K4) • Cab Work Light 10A Circuit Breaker (F29)
The Pilot Enable/Boom Down 7.5A Fuse (F16) is When the key switch is in the On position, power flows
powered through the Detent Enable and Pilot Enable from the ACC terminal to energize coils of
Relay (K32). When key switch is in the On, Bulb Blower/Pressurizer Motor Relay (K19). With that relay
Check, or Start position with the engine running, power energized, power flows through Blower Motor 25A
flows from the IGN terminal of the key switch through Fuse (F19) through Blower Motor Pressurizer Relay
the Detent Enable Relay (K32), which has been (K19), through Blower Speed Switch (S21) to provide
energized by the CCU. The Pilot Enable 7.5A Fuse power to:

011504
PN=221
• Pressurizer Motor 7.5A Fuse (F20) • Horn 7.5A Fuse (F21)
When the key switch is in the ACC or ON position, With Accessory Relay #2 (K6) energized, the following
power flows from the ACC terminal to also energize fuses receive power:
the coils of Accessory Relay #1 (K5) and Accessory
Relay #2 (K6). These relays must be energized for all • Sec Steering, Park Brake, Service Brake Press
other systems to operate. Switch 5A Fuse (F10)
• Differential Lock, Pin Disconnect 5A Fuse (F14)
With Accessory Relay #1 (K5) energized, the following • Rocker Switches, Restriction Switches and Radio 5A
fuses receive power: Fuse (F23)
• Ride Control 7.5A Fuse (F30)
• Alternator Excitation 7.5A Fuse (F1) • Front Wiper 10A Fuse (F17)
• Rotary Beacon 10A Fuse (F26) • Rear Wiper 10A Fuse (F18)
• Electric Air Adjust Seat and Lighter 10A Fuse (F32) • Tail/Marker Light 7.5A Fuse (F24)
• Spare Accessory 5A Fuse (F33)
9015
15
4
TX,15,111716 –19–16SEP02–4/4

011504
PN=222
Charging Circuit Theory Of Operation

T131701 –19–23JUN00
TX,15,111718 –19–16SEP02–1/2

011504
PN=223
See System Functional Schematic S.N. 585561 —) for With the engine NOT running and the key On, the
charging circuit information on later machines. (Group battery voltage indicator will come on when battery
9015-10.) voltage is too high or too low.
The charging circuit consists of the batteries, a 24 volt, There are five different diagnostic trouble codes that
55 amp Bosch Alternator (G3) or a 24 volt, 80 amp can register when system voltage is abnormal.
Bosch Alternator (G4), an Alternator 7.5A Fuse (F1),
and Alternator Excitation 5A Diode (V2), Key Switch See Group 9015—20 for additional information on
(S1) and an indicator on the Monitor Display Unit (H2). diagnostic trouble codes.
The alternator provides power to all machine circuits Abnormal Voltage Diagnostic Trouble Codes
and charges the batteries when the engine is running. Code Cause
F1658 Battery voltages differ by more
The alternator B+ terminal is connected to battery than 0.6 volts
voltage at all times. F1660 System voltage above 29.6 with
engine running (Recorded at
9015
The alternator D+ terminal gets power from the CCU)
15
6 energized Accessory Power Relay #1 (K5) (S.N. — F1661 System voltage below 26.4 with
571785) or Ignition power relay (K4) (S.N. 571786—). engine running (Recorded at
CCU)
The Alternator Excitation Diode (V2) will prevent F1662 System voltage above 30 with
current from feeding back from the alternator if the engine OFF, Key ON
(Recorded at CCU)
alternator circuitry is improperly connected or there is a
major failure of the alternator. F1663 System voltage below 24.8 with
engine OFF, Key ON
(Recorded at CCU)
During normal machine operation, the monitor display
unit will show battery voltage in the basic display
window.
With the engine running, the battery voltage indicator

will come on when alternator voltage is too high or low.
TX,15,111718 –19–16SEP02–2/2

011504
PN=224
Start Circuit Theory Of Operation
When the key switch is in the On, Bulb Check or Start

position, power flows through the Transmission Controller
Switched 5A Fuse (F12) to energize the Shifter Switch
(S10).
–UN–15NOV02
When the key switch is in the START position and the
shifter switch is in the Neutral position, power flows from
the shifter switch to energize the coil of the Neutral Start
T160666
Circuit Relay (K1). When that relay is energized, power
flows from the key switch ST terminal, through the Neutral
Start 5A Fuse (F3) and the Neutral Start Circuit Relay
(K1) to energize the Start Relay (K3).
When the start relay is energized, battery power goes to

9015
the starter motor coil through the E01 White wire. The coil 15
in the Starter Motor (M1) is energized and direct battery 7
power is then sent to the starter motor.
The purpose of the Starter Coil Suppression Diode (V1)

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

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

011504
PN=225
Engine Air Heater Circuit Operation
9015
15
8
–19–30JUL97
T110238

011504
PN=226
IMPORTANT: DO NOT use fluid starting aid option The coolant temperature has to be less than 10° C
with the engine air heater. Damage (50° F) for the air heaters to come on during preheat.
to engine may occur. The coolant temperature has to be less than 20° C
(68° F) for the air heaters to come on during postheat.
The following conditions must be met for the engine air
heater circuit to operate. The chassis computer unit also monitors the system
battery voltage. If voltage drops below 20V the chassis
• Key switch in the On or Start position computer unit gives the signal to turn off the air
• Battery voltage higher than 20 volts heaters. This allows the air heaters to be OFF during
• Temperature below 20° C (68° F) cranking. The air heaters will turn back ON then when
• Power to chassis computer unit (CCU) the battery voltage raises above 20V.
The engine air heater function allows for easier cold Unswitched power flows from the batteries to the
weather starting and also helps reduce black smoke Starter Motor (M1), through the Engine Air Heater
shortly after engine start-up. When the key switch is 125A Fuse (F36) to the Engine Air Heater Relay (K34).
turned on the Chassis Computer Unit goes through an
9015
initialization. During Chassis Computer Unit When the key switch is in the On, Bulb Check, Or 15
initialization the Chassis Computer Unit (A2) measures Start position, power flows through the IGN terminal to 9
and records the engine coolant temperature. The energize the coil of the Ignition Power Relay (K4).
Chassis Computer Unit then calculates the air heater Then power flows from the relay, through the Start Aid
ON time for both preheat (before start-up) and post 10A Fuse (F2), to the Engine Air Heater Relay (K33).
heat (after start-up) based on the recorded coolant
temperature. The Engine Preheat Indicator Light will The chassis computer unit sends power to energize
come on in the monitor display when the air heaters the coils of Engine Air Heater Relay (K33). Power
are on. The operator should wait for the light to go out flows through that relay to energize coils of the Engine
before attempting to start the machine. Air Heater Relay (K34), then on to energize the air
heater. The chassis computer unit also send a signal
The ON times for preheat and postheat are across the CAN link to the monitor display unit to
independent of one another and are controlled by the illuminate the engine preheat indicator light.
Chassis Computer Unit based on coolant temperature.
The ON time is longer at colder temperatures and NOTE: Anytime the key is moved from Start to Run
shorter at warmer temperatures. The maximum position when engine does not start, a
preheat ON time is 30 seconds. The maximum ON key-off/key-on cycle will be required before
time for post heat is 60 seconds. preheating is allowed again.
CED,TX17864,25 –19–24MAR98–2/2

011504
PN=227
Starting Aid Circuit Theory Of Operation
9015
15
10
–19–30JUL97
T110239

011504
PN=228
IMPORTANT: DO NOT use starting aid option with When the Start Aid Switch (S3) is pushed, the Start
the engine air heater option. Damage Aid Solenoid (Y7) is energized. This allows starting
to engine may occur. fluid to be injected into the fuel system.
When the Key Switch (S1) is in the START or ON The purpose of the Start Aid 1A Diode (V3) is to limit
position, current will flow from the key switch IGN voltage spikes as the start aid solenoid de-energizes.
terminal, through the Ignition Power Relay (K4) and
through the Converter, Secondary Steering and Start
Aid 10A Fuse (F2) to the Start Aid Switch (S3).
TX,15,111728 –19–25JAN97–2/2
Ride Control Circuit Specifications

9015
Item Measurement Specification 15
11
Ride Control Pressure Switch Opening Pressure 414 kPa (4 bar) (60 psi)
(Normally Closed) Closing Pressure 276 kPa (2.7 bar) (40 psi)
TX,15,111145 –19–24AUG96–1/1
Ride Control Circuit Operational Information
NOTE: ( S.N. —581778) If the ride control switch is in the

On or Auto position when the key is turned On,
the ride control will not be On. The Ride Control
Switch must be cycled to the Off position before
ride control will function according to the switch
positions.
The following conditions must exist for the ride control

function to operate:
• Battery Disconnect Switch (S2) On

• Power to the Ride Control Switch (S31)
• Power through closed Ride Control Pressure Switch
(B41)
• Ride Control Switch in the “On” or “Auto” position (See
Note above)
• Power to Chassis Computer Unit (A2)
• Ride Control (S 064) enabled (turned On) in the Monitor
Display Unit Service Menu
TX,15,111731 –19–24AUG96–1/1

011504
PN=229
Ride Control Circuit Theory Of Operation

T195526 –19–22OCT03
TX,15,111147 –19–23AUG02–1/2

011504
PN=230
When Key Switch is ON, power is supplied to Ride dumping bucket. See Ride Control Operation—In the
Control Switch (S31) and relays K30 and K31 through “ON” Position-Bucket Dump for hydraulic operation.
fuse F30. (Group 9025-05.)
Ride Control Switch “On” Position: With Ride Ride Control Switch AUTO Position: With Ride
Control Switch (S31) on, voltage is sent to the CCU Control Switch (S31) in AUTO, ride control functions
through J02 wire. This tells CCU that ride control is same as on position with one exception. When ground
activated. CCU then supplies power to energize Ride speed is at specification or less, ride control is turned
Control On/Off Relay (K31) through J06 wire and Ride off. Ride control will activate after ground speed
Control Boom Relay (K30) through J04 wire. This exceeds specification. CCU controls this by switching
energizes relays Y18 and Y34 to activate ride control. power supplied to relay K31 through J06 wire.
Power is also available at pressure switch B41 when Specification

S31 is ON. This pressure switch is located in the Ride Control Switch AUTO
Position—Speed .......................................... 6 km/h (3.5 mph) or less
bucket dump pilot circuit and will close when the
bucket bump function is activated. With B41 closed,
Ride control also functions this way if machine is 9015
solenoid Y17 is energized. This blocks boom rod end 15
started with ride control switch in ON or AUTO.
oil to tank and prevents boom from dropping when 13
TX,15,111147 –19–23AUG02–2/2

011504
PN=231
Monitor Display Unit Circuit Specifications—

Switches And Senders
ENGINE COOLANT LEVEL SWITCH

(B18) (S.N. —574739)
Closes when fluid level drops by Height 10 ± 3mm (0.39 ± 0.118 in.)
ENGINE AIR FILTER RESTRICTION

SWITCH (B19)
Normally open. Closes on Pressure 4.98—7.48 kPa G (20—30 in. of

9015 increasing pressure at water)
15
14
TRANSMISSION OIL FILTER
RESTRICTION SWITCH (B20)
Normally open; Closes at Pressure 345 ± 69 kPa (3.4 ± 0.7 bar) (50 ±
10 psi)
HYDRAULIC OIL FILTER

RESTRICTION SWITCH (B21)
Normally Open; Closes when Pressure 345 ± 69 kPa (3.4 ± 0.7 bar) (50 ±
differential pressure above 10 psi)
STEERING SYSTEM PRESSURE

SWITCH (SECONDARY STEERING)
(B25)
Normally open; Closed during Pressure 240 kPa (2.4 bar) (35 psi)
normal operation and opens when
steering pressure drops below
SERVICE BRAKE PRESSURE

SWITCH (ACCUMULATOR
CHARGE) (B27)
Normally open; Closed during Pressure 2068 ± 193 kPa (21 ± 1.9 bar) (300
normal operation and opens when ± 28 psi)
brake pressure drops below

011504
PN=232
PARK BRAKE PRESSURE SWITCH

(B34)
Normally Closed; Opens on Pressure 1241 ± 69 kPa (12 ± 0.7 bar) (180 ±
increasing pressure at 10 psi)
Closes on decreasing pressure at Pressure 1034 ± 103 kPa (10 ± 1 bar) (150 ±
15 psi)
TX,15,111149 –19–26JAN01–2/2
9015
15
15

011504
PN=233
Monitor Display Unit Circuit Specifications—

Gauge Sensors
Hydraulic System Pressure Sensor Normal Operating Range 4826—24132 kPa (48.3—241.3 bar)
(B8) (644H MH Only) (700—3500 psi)
Full Operating Range 4826—24132 kPa (48.3—241.3 bar)
(700—3500 psi)
Normal Operating Voltage 0.5—4.5 volts
Engine Oil Pressure Sensor (B23) Normal Operating Range 0—704 kPa (0—7.03 bar) (0—102
(On Engine) psi)
9015 Normal Operating Voltage 0.5—4.5 volts
15 Full Operating Range 0—704 kPa (0—7.03 bar) (0—102
16 psi)
Indicator light turns On at 82.7 kPa (0.83 bar) (12 psi)
Indicator light turns Off at 89.6 kPa (0.89 bar) (13 psi)
Engine Coolant Temperature Sensor Normal operating range 85°—107° C (185°—225° F)

(B16) (Also See Output Full operating range -40°—+125° C (-40°—+257° F)
Specifications) Indicator light turns On at 107° C (225° F)
Indicator light turns Off at 106° C (223° F)
Hydraulic Oil Temperature Sensor Normal operating range 25°—104° C (77°—219° F)

(B15) (Also See Output Full operating range -40°—+125° C (-40°—+257° F)
Hydraulic Oil Temperature Sensor Resistance at 15° C (59° F) 4441—4699 ohms

(B15)—Continued Resistance at 85° C (185° F) 284—293 ohms
Resistance at 90° C (194° F) 242—250 ohms
Transmission Oil Temperature Normal operating range 85°—110° C (185°—230° F)

Sensor (B32) (Also See Output Full operating range -40°—+125° C (-40°—+257° F)

011504
PN=234
Transmission Oil Temperature Resistance at 15° C (59° F) 4441—4699 ohms

Sensor (B32)—Continued Resistance at 85° C (185° F) 284—293 ohms
Fuel Level Sender (B17) Resistance Empty tank 10 Ohms

Resistance Half full tank 100 Ohms
Resistance Full Tank 180 Ohms
9015
15
17

011504
PN=235
Temperature Sensor Output Voltage at -40° C (-40° F) 4.973—4.977 V

Voltage at -35° C (-31° F) 4.963—4.968 V
Voltage at -30° C (-22° F) 4.949—4.956 V
Voltage at -25° C (-13° F) 4.931—4.941 V
Voltage at -20° C (-3° F) 4.907—4.920
Voltage at -15° C (-5° F) 4.877—4.893 V
Voltage at -10° C (14° F) 4.839—4.859 V
Voltage at -5° C (23° F) 4.791—4.816 V
Voltage at 0° C (32° F) 4.732—4.762 V
Voltage at 5° C (41° F) 4.659—4.696 V
Voltage at 10° C (50° F) 4.571—4.616 V
Voltage at 15° C (60° F) 4.467—4.520 V
Voltage at 20° C (68° F) 4.346—4.407 V
Voltage at 25° C (77° F) 4.206—4.276 V
9015
15 Voltage at 30° C (86° F) 4.049—4.126 V
18 Voltage at 35° C (95° F) 3.874—3.959 V
Voltage at 40° C (104° F) 3.682—3.774 V
Voltage at 45° C (113° F) 3.478—3.574 V
Voltage at 50° C (122° F) 3.262—3.362 V
Voltage at 55° C (131° F) 3.040—3.142 V
Voltage at 60° C (140° F) 2.816—2.917 V
Voltage at 65° C (149° F) 2.592—2.691 V
Voltage at 70° C (158° F) 2.373—2.469 V
Voltage at 75° C (167° F) 2.162—2.253 V
Voltage at 80° C (176° F) 1.961—2.046 V
Voltage at 85° C (185° F) 1.772—1.850 V
Voltage at 90° C (194° F) 1.596—1.667 V
Voltage at 95° C (203° F) 1.434—1.498 V
Voltage at 100° C (212° F) 1.285—1.344 V
Voltage at 105° C (221° F) 1.149—1.205 V
Voltage at 110° C (230° F) 1.025—1.080 V
Voltage at 115° C (239° F) 0.915—0.967 V
Voltage at 120° C (248° F) 0.816—0.865 V
Voltage at 125° C (257° F) 0.729—0.775 V
CED,TX17864,60 –19–01APR98–3/3

011504
PN=236
Monitor Display Unit Circuit Specifications—Gauge Ranges
9015
15
19
–19–19SEP96
T102066
Continued on next page TX,15,111151 –19–09MAY00–1/2

011504
PN=237
Engine Oil Pressure Gauge Range (A) Red 16 kPa (0.14 bar) (2 psi)
Range (B) Red 82.7 kPa (0.83 bar) (12 psi)
Range (C) Green 100 kPa (1.03 bar) (15 psi)
Range (D) Green 500 kPa (5.03 bar) (73 psi)
Range (E) Green 704 kPa (7.03 bar) (102 psi)
Engine Coolant Temperature Gauge Range (A) Green Temp 38° C (100° F)
Range (B) Green Temp 60° C (140° F)
Range (C) Green Temp 99° C (210° F)
Range (D) Red Temp 107° C (225° F)
Range (E) Red Temp 121° C (250° F)
9015
15 Item Measurement Specification
20
Hydraulic Oil Temperature Gauge Range (A) Green Temp 27° C (81° F)
Range (B) Green Temp 49° C (120° F)
Transmission Oil Temperature Range (A) Green Temp -20° C (-4° F)

Gauge Range (B) Green Temp 60° C (140° F)
Fuel Level Gauge Range (A) Red 0% Tank Empty

Range (B) Green 5% Tank Full
Range (C) Green 50% Tank Full
Range (D) Green 100% Tank Full
TX,15,111151 –19–09MAY00–2/2

011504
PN=238
Monitor Display Unit Gauge Sensor

Specifications and Diagnostic Display
MONITOR CIRCUIT SPECIFICATIONS
COMPONENT MONITORED SPECIFICATION DISPLAY WINDOW MESSAGE
Engine Sensors
Engine Coolant Temperature Sensor (B16) Normal Operating Range: 85°— 107° C d 041 Engine Coolant Temperature
(185° — 225° F
Full Operating Range: -40°—+125° C (-40—
+257° F)
Engine Oil Pressure Sensor (B23) Measurement Range: 0—703.3 kPa (0— d 042 Engine Oil Pressure
7.033 bar) (0—102 psi)
Voltage Range: 0.5—4.5 volts
Analog Throttle Position Sensor (B14) Voltage Range: 0.5—4.5 volts d 043 Throttle
Fuel Temperature Sensor (B3) Temperature Range: -40°—+190° C (-40°— d 044 Fuel Temperature
374° F) 9015
15
Rack Position Sensor (B4) Range: 0—31.375 mm d 045 Rack Position 21
Transmission Sensors (d 05)
Transmission Oil Temperature Sensor (B32) Normal Operating Range: 85°— 110° C d 051 Oil Temperature Sensor
(185° — 230° F
+257° F)

Clutch Cutoff Sensor (B33) Level Ground Set Point to Release Clutch: d 052 Clutch Cutoff Pressure
500 kPa (5 bar) (72.5 psi) 0.32 volts
Level Ground Set Point to Apply Clutch: 200
kPa (2 bar) (29 psi) 0.16 volts
Small Slope Set Point to Release Clutch:
860 kPa (8.6 bar) (124.7 psi) 0.48 volts
Small Slope Set Point to Apply Clutch: 520
kPa (5.2 bar) (75.4 psi) 0.25 volts
Steep Slope Set Point to Release Clutch: 1
400 kPa (14 bar) (203 psi) 1.08 volts
Steep Slope Set Point to Apply Clutch: 1
100 kPa (11 bar) (159.5 psi) 0.84 volts
Torque Converter Input Speed Sensor (B28) Normal Operating Range of Speed: 900— d 053 Torque Input Speed Sensor
2350 rpm
Torque Converter Output Speed Sensor (B29) Normal Operating Range of Speed: 0—2350 d 054 Torque Output Speed Sensor
rpm
Internal Clutch Speed Sensor (B30) Normal Operating Range of Speed: 900— d 055 Internal Clutch Speed Sensor
2350 rpm
Transmission Output Shaft Speed Sensor Varies according to ground speed d 056 Output Shaft Speed Sensor
(B31)

011504
PN=239

Hydraulic Sensors (d 06)
Hydraulic Oil Temperature Sensor (B15) Normal Operating Range: 25°— 104° C d 061 Oil Temperature Sensor
(77° — 219° F)
+257° F)
Hydraulic System Pressure Sensor (B8) Normal Operating Range: 4826—24132 kPa d 062
(48.26—241.3 bar) (700—3500 psi)
Full Operating Range: 4826—24132 kPa
(48.26—241.3 bar) (700—3500 psi)
Normal Operating Voltage: 0.5—4.5 volts
Fuel Level Sender (B17) Empty Resistance: 10 Ohms d 07 Fuel Sensor
Half Full Resistance: 100 Ohms
Full Resistance: 180 Ohms
9015
15
22
CED,TX17864,61 –19–09MAY00–2/2
Monitor Display Unit Circuit Operational

Information
The following conditions must exist for display monitor to

function.
• Battery disconnect switch On

• Key switch in On position
Unswitched power must be present at terminal G of

monitor display unit 10-pin connector when key switch is
Off.
Switched power must be present at terminal J of monitor

display unit 10-pin connector when key switch is On.
Input signals received from chassis computer unit and

transmission control unit by way of CAN link.
TX,15,111153 –19–03SEP96–1/1

011504
PN=240
Monitor Display Unit Circuit Theory Of Operation—Function
9015
15
23
–19–13FEB97
T107329
A—Engine Coolant Level H—CAUTION Light P—Hydraulic Oil Temperature V—Engine Coolant
Indicator Light I—Right Turn Signal Q—Message Display (Deluxe Temperature Gauge
B—Engine Air Filter Indicator J—Park Brake On Indicator Monitor Only) W—Hydraulic Oil Temperature
Light K—Brake Pressure Indicator R—Transmission Service Gauge (Deluxe Monitor
C—Engine Oil Pressure L—Steering Pressure Indicator Indicator Only)
Indicator Light (Secondary Steering) S—Transmission Filter X—Transmission Oil
D—Engine Preheat Indicator M—Work Lights Indicator Indicator Temperature Gauge
E—Left Turn Indicator N—Fasten Seat Belt Indicator T—Battery Voltage Indicator Y—Fuel Gauge
F—STOP Light O—Hydraulic Oil Filter U—Engine Oil Pressure Gauge Z—Basic Display
G—High Beams On Indicator Indicator (Deluxe Monitor Only)
Light (Not Used)
NOTE: See Diagnostic Trouble Code Interpretation in (terminal G of ten pin connector) when the key switch
Group 9015—20 for additional information on is OFF. Power is supplied directly from the batteries.
the monitor display unit diagnostics.
The monitor switched power 7.5A fuse (F7) provides
The monitor display unit is used to indicate the status power to the monitor (terminal J of ten pin connector)
of machine functions. It is controlled by signals when the key switch is ON. Power is supplied from the
received from the transmission controller unit (A3) and batteries, through the key switch and through the
chassis computer unit (A2) along the CAN link. energized ignition relay (K4).
The monitor and transmission controller unswitched 5A

fuse (F4) provides power to the monitor display unit
TX,15,111802 –19–25AUG97–1/1

011504
PN=241
Monitor Display Unit Circuit Theory Of

Operation—Modes Of Operation
The monitor display unit (H2) has following modes of

operation:
Power Up from Unswitched Power: Press and hold

down SELECT on the monitor display unit keypad. The
monitor display unit will display the system battery voltage
and the accumulated engine hours on the basic display.
The engine hours will be retrieved from memory and the
battery voltage will be the system battery voltage read by
the monitor display unit (at pin G of the 8-pin connector).
Power will be supplied only to the gear indicator display

9015 and its lighting. The voltmeter/odometer line of the display
15 will show the following sequence, changing every 4
24 seconds: volts, miles, kilometers, repeat. When the switch
is released, the monitor display unit will immediately
power down.
Specification
Sequence Changes Every—Time .............................................. 4 seconds
Bulb Check: When the key switch is in the ON position

and the engine is not running, the Bulb Check mode will
be on for five seconds. During the Bulb Check mode, all
warning lights, the red STOP light and the yellow
CAUTION light are turned on solid. All indicators will go to
12 o’clock position. During the Bulb Check mode, the
audible alarm will sound for 1/2 second once every
second.
If the monitor display unit gets a signal that the engine

speed is greater than 300 rpm or engine oil pressure is
not low, it determines that the engine has started, and the
Bulb Check mode will be suspended.
CAN messages received by the monitor display unit

during Bulb Check will be saved and displayed or
indicated after the Bulb Check is complete.
Continued on next page TX,15,111155 –19–01APR98–1/2

011504
PN=242
Power Up from Switched Power: At power up from

switched power, the monitor display unit will initialize all
internal memory and set up all interfaces for normal
operation. No information will be displayed for the first
second to allow time for inputs to stabilize. The display
will be in Bulb Check mode for four seconds, then the
machine model will be shown for three seconds.
After this "power on" time delay, the gauges, lighted

displays and indicators will display the appropriate
information based on whether or not the engine is
running.
The fasten seat belt light will be turned on for the first five
seconds after the engine has started. If during the first 5
seconds the engine dies, the fasten seat belt light will be
9015
turned off. If the engine is restarted, the fasten seat belt 15
light will be turned on again for 5 seconds. 25
Monitor Display Unit Operation at Power Down: When

the monitor display unit detects that system battery
voltage at the switched power input (pin J) is less than
17.5 + or - 0.5 volts, the monitor display unit will assume
that a power down is in progress. If the monitor is in the
process of writing to memory, it will send a signal to the
on-board relay. This relay will be energized and provide
unswitched power to the monitor display unit so that the
write to memory can be completed.
When the write is complete, or after 2 seconds have

passed, the signal to the relay will stop, the relay will
de-energize and the monitor display unit will power down.
All the gauges, lighted displays, indicators, CAN
messages and all other functions will be suspended
during such a power down.
TX,15,111155 –19–01APR98–2/2

011504
PN=243

Operation—Caution And Warning Lights And
Gauges
IMPORTANT: When a critical warning is being

displayed, the STOP light will flash and
the display monitor audible alarm will
sound. The machine must be stopped
immediately or serious damage could
result.
When the red STOP indicator flashes,

machine must be stopped immediately.
When the audible alarm sounds,

9015 machine and engine should be stopped
15 immediately. This alerts the operator to
26 a critical diagnostic trouble code
condition indicated on the display.
When the yellow CAUTION indicator

light flashes, machine must be checked
or serviced as soon as possible.
The monitor display unit contains a speedometer and the

following gauges:
• Engine Oil Pressure

• Engine Coolant Temperature
• Hydraulic Oil Temperature
• Transmission Oil Temperature
• Fuel Level
Each of the above listed gauge sensors is an analog input

to the chassis computer unit. The chassis computer unit
will then excite the sensor and read the temperature, fuel
level or pressure value. A message is sent to the monitor
display unit by way of the CAN link.
After the monitor display unit receives the temperature,

fuel level, or pressure reading it displays the value on the
appropriate gauge by mapping the value to a needle
position and turns on the indicator light, if applicable.

011504
PN=244
When the engine oil pressure falls lower than 63 ± 13 kPa

(0.63 ± 0.13 bar) (9.137 ± 1.885 psi), the indicator light
will come On, the red STOP light will flash and the audible
alarm will sound.
Specification
Indicator Light Will Come On, The
Red Stop Light Will Flash And
The Audible Alarm Will Sound
When The Engine Oil Pressure
Falls Lower Than—Pressure ......................... 82.7 kPa (0.83 bar) (12 psi)
If the transmission oil temperature exceeds 120° C (248°

F), the indicator light will come On, the red STOP light will
flash and the audible alarm will sound.
If the hydraulic oil temperature exceeds 104° C (219° F),

9015
the indicator light will come On, the red STOP light will 15
flash and the audible alarm will sound. 27
If the engine coolant temperature exceeds 107° C (225°

F), the indicator light will come On, the red STOP light will
flash and the alarm will come on.
The engine oil pressure gauge, transmission oil

temperature gauge and engine coolant temperature
gauges will turn on the flashing red STOP light and the
audible alarm will sound when the pointer is in the red
zone.
All of the temperature, pressure and fuel gauges will

deflect to the far left of the scale whenever CAN
communications is lost or when a sensor error is active.

011504
PN=245
NOTE: If the speedometer seems to be not calibrated

correctly, check machine model on monitor
display unit at start up. Also, check the tire size in
the Service menu (S 03).
See Monitor Display Unit Reconfiguration—

Machine Model (S 01) and Reconfiguration—Tire
Size (S 03), in this group.
The transmission output shaft speed sensor sends a

signal to the transmission controller unit, representing the
speed of the shaft. This is transmitted to the monitor
display unit in rpm’s by way of the CAN link. The monitor
unit then displays the wheel speed reading on the
speedometer.
9015
15
28
TX,9015,111908 –19–17SEP97–3/3

011504
PN=246

Operation—Switches, Sensors And Indicator
Lights
The monitor display unit (H2) receives diagnostic trouble

code messages by way of the CAN link from the chassis
computer unit (A2) (pins D3, E2 and E3 of the 60-pin
connector) and from the transmission control unit (A3)
(pins 2, 25, and 26).
The monitor display unit inputs these messages to

determine the indicator lights and warning level to turn on.
Engine Air Filter Indicator Light:The engine air filter

restriction switch (B19) is a normally open switch that
closes to machine ground when a restriction is sensed 9015
with the engine running. An input signal is sent to the 15
chassis computer unit (pin Y2 of the 60-pin connector) 29
through the CAN link, to the monitor display unit. The
CAUTION light and indicator light will come ON.
Transmission Filter Indicator Light:The transmission oil

filter restriction switch (B20) is a normally open switch that
closes to machine ground when a restriction is sensed
with the engine running. An input signal is sent to the
chassis computer unit (pin X1 of the 60-pin connector)
CAUTION light and the indicator light will come On.
Hydraulic Oil Filter Indicator Light:The hydraulic oil filter

restriction switch (B21) is a normally open switch that
closes to machine ground when a restriction is sensed
with the engine running. An input signal is sent to the
chassis computer unit (pin Y3 of the 60—pin connector)
CAUTION light and indicator light will come On.
Engine Preheat Indicator:Indicator will light when key

switch is turned clockwise to the ON position. Light will
turn off after approximately 15—45 seconds, depending
on engine temperature, indicating that preheating is
completed. Light will turn off while cranking engine.

011504
PN=247
IMPORTANT: If the “S 065” Engine Oil Pressure

Sensor option is set “On” or “Off”
incorrectly, the Engine Oil Pressure
Indicator will be On, the “STOP” light
will flash and the warning alarm will
sound when the engine is idling.
Diagnostic Trouble Code 0478 will be
active. Access Monitor Display Unit
Service Menu and reset the Engine Oil
Pressure Sensor option to correct
setting. See Monitor Display Unit
Reconfiguration—Enable Options (S 06)
for procedure to reset the S 065 option.
See Monitor Display Unit
Reconfiguration—Delete Diagnostic
Trouble Codes for procedure to delete
9015
15 Diagnostic Trouble Code 0478.
30
Engine Oil Pressure Indicator Light:The engine oil
pressure sensor (B23) sends a signal to the chassis
computer unit (pins P2, P3 and R3), then through the
CAN link to the monitor display unit.
When the engine oil pressure falls lower than 63 ± 13 kPa

(0.63 ± 0.13 bar) (9.137 ± 1.885 psi), the indicator light
will come On, the red STOP light will flash and the audible
alarm will sound.
Specification
Indicator Light Will Come On, The
Red Stop Light Will Flash And
The Audible Alarm Will Sound
When The Engine Oil Pressure
Falls Lower Than—Pressure ......................... 82.7 kPa (0.83 bar) (12 psi)
Hydraulic Oil Temperature Indicator Lights:The

hydraulic oil temperature sensor (B15) is an analog input
to the CCU. The CCU will then excite the sensor and read
the temperature. A message is sent to the monitor display
unit by way of the CAN link.

011504
PN=248
Engine Coolant Level Indicator Light: The engine

coolant level switch (B18) (S.N. —574739) is normally
open switch that closes to machine ground when a low
fluid level is sensed with or without the engine running. An
input signal is sent to the chassis computer unit (pin Y1 of
the 60-pin connector). The CCU then signs a signal by the
way of the CAN link to the monitor display unit. The
CAUTION light and indicator light will come On.
Battery Voltage Indicator Light:With the engine running,

the battery voltage indicator will come on when alternator
voltage is too high or low.
With the engine NOT running and key On, the battery
voltage indicator will come On when battery voltage is too
high or too low.
9015
15
A signal is sent from the chassis computer by way of the 31
CAN link, to the monitor display unit. The CAUTION light
and indicator light will come On.
Left Turn Signal/Hazard Indicator Light:The chassis

computer unit receives a signal (pin W3 of the 60—pin
connector) from the four-way flasher switch (S24). A
signal is sent from the chassis computer unit (pin C1 of
30—pin connector) to energize the left flasher relay (K23)
and turn on the appropriate lights.
Then a signal is sent from the chassis computer by way of

the CAN link, to the monitor display unit. The monitor
display unit turns on the left turn signal indicator. If either
of the turn signal switches is On, then the opposite turn
signal bulb will burn steady (On but not flashing). When
turn signal switch is turned Off, both turn signal bulbs will
again flash in synchronization—hazard mode.
Right Turn Signal/Hazard Indicator Light:The chassis

computer unit receives a signal (Pin W3 of the 60-pin
connector) from the four-way flasher switch (S24). A
signal is sent from the chassis computer unit (pin D1 of
30-pin connector) to energize the right flasher relay (K24)
and turn on the appropriate lights.

011504
PN=249
Then a signal is sent from the chassis computer by way of

the CAN link, to the monitor display unit. The monitor
display unit turns on the right turn signal indicator. If either
of the turn signal switches is On, then the opposite turn
signal bulb will burn steady (On but not flashing). When
turn signal switch is turned Off, both turn signal bulbs will
again flash in synchronization--hazard mode.
High Beams On Indicator Light:This indicator light is not

used.
Park Brake On Indicator Light:The park brake pressure

switch (B34) is a normally closed switch.
The switch closes when the brake pressure is below 1034

± 103 kPa (10 ± bar) (150 ± 15 psi). When the switch is
9015
15 closed, the park brake is applied and the indicator light in
32 the monitor display unit is On. A signal is sent from the
chassis computer unit by way of the CAN link, to the
monitor display unit.
Specification
Park Brake Pressure Switch
(B34) Closes When Brake
Pressure Is Below—Pressure .............. 1034 ± 103 kPa (10 ± bar) (150 ±
15 psi)
The shifter switch (S10) sends an “in gear” or “neutral”

message to the transmission controller. The transmission
controller sends this message to the monitor display unit
by way of the CAN link.
The monitor display unit then determines the appropriate

warning level, based on the park brake pressure switch
status and the “in gear” or “neutral” status. If the machine
is in “neutral,” the park brake indicator light will come on.
If the machine is “in gear,” the park brake indicator light
and red STOP light will flash.
The park brake pressure switch will open when brake

pressure is above 1 241 + or -69 kPa (12 + or -0.7 bar)
(180 + or - 10 psi), and the park brake releases. The light
in the monitor display unit will be turned off.

011504
PN=250
Specification
(B34) Opens When Park Brake
Releases And Brake Pressure Is
Above—Pressure...................................... 241 + or -69 kPa (12 + or -0.7
bar) (180 + or - 10 psi)
Brake Pressure Indicator Light:The service brake

pressure switch (accumulator charge) (B27) is held open
hydraulically. It closes when the service brake pressure is
no higher than 2 620 kPa (26 bar) (380 psi). It opens
when service brake pressure is less than 2 068 ± 193 kPa
(21 ± 1.9 bar) (300 ± 28 psi) and sends a signal to the
chassis computer unit (pin W1, of the 60-pin connector).
Then a signal is sent from the chassis computer unit by
way of the CAN link, to the monitor display unit.
9015
Specification
15
Service Brake Pressure Switch
33
(Accumulator Charge) (B27)
Closes When The Service Brake
Pressure Is No Higher Than—
Pressure ....................................................... 2 620 kPa (26 bar) (380 psi)
Service Brake Pressure Switch
(Accumulator Charge) (B27)
Opens When Service Brake
Pressure Is Less Than—Pressure ........... 2 068 ± 193 kPa (21 ± 1.9 bar)
(300 ± 28 psi)
If the engine is running, the monitor display unit turns on

the brake pressure light, the flashing red STOP light, and
the audible alarm.
If the engine is not running, the monitor display unit turns

on the brake pressure light and the flashing red STOP
light with no audible alarm.
Work Lights Indicator Light:The chassis computer unit

receives a signal (pin B1 of 60-pin connector) from the
cab work lights switch (S30). The chassis computer unit
sends the work lights On signal to the monitor display unit

011504
PN=251
Steering Pressure Light:The steering system pressure

switch (B25) (secondary steering) is closed during normal
operation. The switch opens when steering pressure is
less than 240 kPa (2.4 bar) (35 psi) and sends a signal to
the chassis computer (pin X2 , of the 60-pin connector). A
signal is sent from the chassis computer unit by way of
the CAN link to the monitor display unit.
Specification
Steering Pressure Light Switch
Opens When Steering Pressure
Is Less Than—Pressure ................................... 240 kPa (2.4 bar) (35 psi)
If the engine is running, the monitor display unit turns on

the steering pressure light, the flashing red STOP light,
and the audible alarm.
9015
15 If the engine is not running, the monitor display unit turns
34 on the steering pressure light and the flashing red STOP
light with no audible alarm.
Transmission Service Indicator Light:This indicator will

come on only if transmission clutch slippage occurs.
When the transmission detects a slippage, the indicator

comes on and stays on. the diagnostic trouble code resets
when the machine is shut down.
Fasten Seat Belt Indicator Light:The seat belt light is

controlled by the monitor display unit. The light is not
directly associated with any switch inputs. The fasten seat
belt indicator light will be on for the first five (5) seconds
after starting the machine.
TX,9015,111899 –19–01APR98–6/6
Monitor Display Unit Circuit Functional

Schematic
See Monitor Display Unit Circuit in System Functional

Schematic (SE13, SE14, SE 15). (Go to Group 9015-10)

011504
PN=252
T113156 –19–31MAR98
CED,TX17864,62 –19–26JAN01–2/2

011504
PN=253
Monitor Display Unit—Accessing Menus
9015
15
36
–19–13FEB97
T107094
The monitor display unit has a basic digital LCD Diagnostics menu provides a limited set of tools, and
display window (B) and also a 12 character is intended to be used by service personnel and
alpha-numeric message display (A) that provides a text machine operators for diagnostic and troubleshooting
description of the currently displayed mode. This functions.
message display supplements the information that is
shown on the basic display window. The four main Service menu is for service personnel and requires a
menus are: special procedure to gain access. This mode provides
an additional and more sophisticated set of tools for
• Normal Display diagnostics and troubleshooting.
• Accessory
• Diagnostics The monitor display unit keypad is used to scroll
• Service through the different menus and modes of operation.
Key names and general functions are as follows:
Normal menu is displayed when the machine is first
turned on, and no special diagnostic functions are • MENU (C) provides initial entry into the accessories
selected and diagnostics system. Each time MENU is
pressed, display will cycle to the next menu. Once a
Accessory menu allows the operator to make changes main menu has been selected, pressing MENU
to various operating conditions of the machine. again will return to the Normal Display Menu.
Continued on next page TX,9015,111881 –19–01JUL02–1/2

011504
PN=254
• BACK (D) will back out of a menu, one item each Diagnostics modes, SELECT will activate the
time the key is pressed. currently chosen menu.
• NEXT (E) will move to the next selection within a On machines with deluxe display monitor, press
menu or mode. SELECT to toggle battery voltage and sensor
• SELECT (F) switches between volts/kilometers/hours readings between basic digital LCD display window
during normal operation. In the Accessories or and alpha-numeric message display window.
TX,9015,111881 –19–01JUL02–2/2
Monitor Display Unit—Normal Display

9015
When key switch is turned on, all lights on display monitor 15
will come on, alarm will sound and stop and caution lights 37
will flash.
–19–17FEB98
The basic display window will show the bulb check mode.
The window will contain numerical digit 8’s and will be
shown for approximately 5 seconds.
T113526
Then the machine model number will show in the basic
display window.

011504
PN=255
Approximately five seconds later, the Normal display will

be shown.
NOTE: Press SELECT to alternate between Odometer

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

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

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

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

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

011504
PN=256
On U.S. and Hitachi export machines, the display rotates

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

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

miles (or 999,999 if the decimal point is disregarded).
From 0 to 62,111.7 miles (0 to 99,937.7 km), the
odometer displays both miles and kilometers in tenths.
From 62,111.8 to 99,999.9 miles (99,937.8 to 160,889.8
km) miles are displayed in tenths and kilometers in ones.
From 100,000 miles (160,900 km) on, both miles and
9015
kilometers are displayed in ones. The odometer runs only 15
when the engine is on. 39
When the 0.1 Hour Meter Mode is turned On in the

Accessory Menu (A 06), machine hours will be displayed
in tenths of hours in the volts/miles/km display. Press
SELECT to toggle between hours and the volts/miles/km
display.
TX,15,111807 –19–01JUL02–3/3
Monitor Display Unit—Accessory Menu—

Clutch Cutoff (A 01)
At Normal Mode display, press MENU once. Display

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

indicating Clutch Cutoff Mode.
T101986
Clutch Cutoff Menu (A 01)

011504
PN=257
In the Clutch Cutoff Mode of operation, there are three

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

NEXT again to A 013 Steep Slope Setting. Press SELECT
9015
15 to choose a setting and disable the other two settings.
40
Level Ground (A 011): When the Level Ground function
is turned “On” in the monitor display unit, the clutch cutoff
enable switch (S11) turned “On”, and the brake pedal is
pressed down, the clutch cutoff sensor (B33), which is a
rotary potentiometer, will sense the position of the brake
pedal linkage by the voltage reading. When it senses
voltage higher than the low voltage set point, the
transmission will “disengage” (release clutch) and
modulate to neutral. In this position the machine will still
roll slightly.
In “Auto” mode, the transmission will “re-engage” (apply

clutch) and modulate into the appropriate gear (based on
ground speed) if the Clutch Cutoff Sensor (B33) voltage
reaches the engagement set point. This voltage is lower
than the clutch cutoff set point.
The transmission will also re-engage if the clutch cutoff

enable switch is turned to the “Off” position.

011504
PN=258
Small Slope (A 012): When the Small Slope function is

turned “On” in the monitor display unit, the clutch cutoff
enable switch turned “On”, and the brake pedal is pressed
down, the Clutch Cutoff Sensor (B33), which is a rotary
potentiometer, will sense the position of the brake pedal
linkage by the voltage reading. When it senses voltage
higher than the medium voltage set point, the
roll slightly.

9015
15
The transmission will also re-engage if the clutch cutoff 41
Steep Slope (A 013): When the Steep Slope is turned

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



011504
PN=259
DISPLAY WINDOW MESSAGE COMPONENT MONITORED SPECIFICATION

d 052 Clutch Cutoff Pressure Clutch Cutoff Sensor (B33) Level Ground Set Point to Release Clutch:
1.20 volts
Level Ground Set Point to Apply Clutch: 1.18
volts
1.64 volts
Small Slope Set Point to Apply Clutch: 1.60
volts
Steep Slope Set Point to Release Clutch:
2.00 volts
Steep Slope Set Point to Apply Clutch: 1.94
volts
9015
15
42
TX,9015,111882 –19–01JUL02–4/4

011504
PN=260

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

between Down/Up and Down Only shift functions when
the transmission is in manual or automatic operation.
Down/Up: When this function is turned “On”, the

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

transmission will electronically shift up one gear again.
9015
Down Only—Transmission in Manual Operation:When 15
this function is turned “On”, each time the quick shift 43
switch (at top of pilot controller handle) is pressed down,
the transmission will shift down one gear (regardless of
selected gear).
If the operator presses down on the quick shift switch

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

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

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

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

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

011504
PN=261
Down Only works basically the same in automatic as in

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

gear displayed in basic display window until shifter switch
is moved to Neutral. This will cancel down shift mode and
transmission will go back to fully automatic mode.
TX,9015,111895 –19–01JUL02–2/5
Press SELECT at the A 02 Quick Shift display.

9015
15
44
–19–04SEP97
T110758
Quick Shift Menu (A 02)
TX,9015,111895 –19–01JUL02–3/5
If the A 021 Down/Up display shows OFF, press SELECT

to turn Down/Up shift function On and disable the Down
Only function.
To choose the Down Only shift function, press NEXT.

–19–04SEP97
T110759
Quick Shift Menu—Down/Up Mode

011504
PN=262
At A 022 Down Only display, press SELECT to turn Down

Only shift function “On” and to disable Down/Up function.
–19–09SEP97
T110760
Quick Shift Menu—Down Only Mode
9015
15
45
TX,9015,111895 –19–01JUL02–5/5

Auto Mode To First (A 03)
In Auto Mode to First, the transmission will shift to first

gear if a high load is sensed while the transmission is
actually in second gear. This shift change is made
–19–02SEP97
independent from shifter switch selection.
A direction change during normal conditions will not cause

the transmission to shift down into first gear. If a direction
T110761
change is made during high transmission load conditions,
the transmission will shift down into first gear.
Auto Mode to First Menu (A 03)
Press SELECT at the A 03 display.
Press SELECT again to either turn this option “On” or

“Off”.
TX,15,111810 –19–01JUL02–1/1

011504
PN=263
Monitor Display Unit—Accessory Menu—Job

Timer Mode (A 04)
The job timer is a resetable hour meter that can be used

to time tasks to the nearest tenth of an hour.
–19–15AUG96
At the A 04 display, press SELECT.
Then press SELECT again to turn the timer “On” or “Off”.
T101991
When the timer is “Off”, press NEXT to reset the timer.
Job Timer Mode Menu (A 04)
9015
15
46
TX,15,111812 –19–01JUL02–1/1

Stop Watch Mode (A 05)
The stop watch is a resetable timer that is used to

measure time in seconds and tenths of seconds.
–19–15AUG96
Then press SELECT again to turn the timer “On” or “Off”.
T101992
When the timer is “Off”, press NEXT to reset the timer.
Stop Watch Mode Menu (A 05)
TX,15,111813 –19–01JUL02–1/1

011504
PN=264
Monitor Display Unit—Accessory Menu—0.1

Hour Meter Mode (A 06)
Then press SELECT again to turn the 0.1 Hour Meter
–19–15AUG96
Mode “On” or “Off”.
T101993
0.1 Hour Meter Mode Menu (A 06)
9015
15
47
TX,15,111814 –19–01JUL02–1/2
When the 0.1 Hour Meter Mode is turned “On”, the hour
meter reading can be accessed during normal machine
operation by pressing SELECT. The odometer reading will
switch to the voltmeter reading, and then to the hour
meter reading (A) in hours and tenths of hour.
–19–28AUG96
When the 0.1 Hour Meter Mode is turned “Off”, only the
odometer reading and voltmeter are available.
The 0.1 Hour Meter Mode “On” or “Off” position stays set
T101994
after machine shut down.
0.1 Hour Meter Mode Menu (A 06)
TX,15,111814 –19–01JUL02–2/2

011504
PN=265

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

and English unit displays.
–19–15AUG96
Press SELECT to turn Metric Units display “On” or “Off”.
T101995
When Metric Units mode is “On”, all values will be shown
in metric. When Metric Units mode is “Off”, all values will Metric Units Mode Menu (A 07)
be shown in English units.
9015
15
48
TX,15,111815 –19–01JUL02–1/1
Monitor Display Unit—Diagnostics Menu—

Diagnostic Trouble Codes (d 01)

a Service Code. The term DTC conforms with the
standards set by the Society of Automotive
–19–02SEP97
Engineers (SAE).
This mode displays the eight highest priority diagnostic

trouble codes (DTC) which have occurred on the machine.
T110762
At the d 01 display, press SELECT.
Diagnostic Trouble Codes Menu (d 01)

011504
PN=266
An F is shown in the display window to indicate diagnostic

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

trouble code (DTC), press SELECT again.
–19–02SEP97
T110763
DTC Menu (d 01)
9015
15
49
TX,9015,111885 –19–01JUL02–2/6
NOTE: Diagnostic Trouble Codes (DTC) can be deleted

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

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

011504
PN=267

last occurrence of the diagnostic trouble code and the
total number of occurrences.
–19–15AUG96
T101998
DTC Menu (d 01)
9015
15
50
TX,9015,111885 –19–01JUL02–4/6
To move to the second diagnostic trouble code, press

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

011504
PN=268
Continue to scroll through diagnostic trouble codes (DTC)

using this sequence until END is shown in the display
window.
NOTE: When F END shows in display window, technician

can access Service Menu. This menu is NOT to
–19–15AUG96
be used by the operator—only by service
technicians. Press SELECT and hold down for at
least five seconds. An S in the display window
indicates Service Menu.
T101999
See Monitor Display Unit—Service Menu in this
DTC Menu (d 01)
group for detailed instructions on using this menu.
9015
15
51
TX,9015,111885 –19–01JUL02–6/6

Continuity Check (d 02)
In this diagnostic mode, sensors and circuits connected to

the chassis computer unit (CCU) are monitored for a
"state of change." Examples of "state of change" are
switches going from open to closed or closed to open,
circuit shorts and opens, high rate of change from analog
sensors, and changes in digital speed sensor outputs.
TX,9015,111886 –19–01JUL02–1/6
Two different "continuity check" modes are provided.

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

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

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

T110764
except the digital speed sensors. This mode is useful

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

011504
PN=269
After one of the continuity check modes is selected, the

display window will be in a waiting position until a "state of
change" is detected.
–19–15AUG96
T102000
Continuity Check Menu (d 02)
9015
15
52

011504
PN=270
Whenever a "change of state" is detected, the warning

horn will "beep" to inform the technician of the change
The circuit device component number and section number
as it appears on the system functional schematic will
show on the basic display window.
–19–15AUG96
Press SELECT to display sensor data and units in the
message display window. Press SELECT again or BACK
to remove the information from the message window.
Press NEXT to move to the next sensor display.
T102001
The audible alarm can be used to verify that a switch is
Continuity Check Menu (d 02)
changing state when it is activated (or is not changing
state when it should be, if there is no beep.) Also, by
moving a potentiometer type control slowly through its
operating range, a break or "bad spot" can be detected.
9015
15
Following is a listing of components that can be “continuity 53
checked” in the monitor display unit Diagnostics menu.
Component Identification No. and Name Message Display In Monitor Display Unit Functional Schematic and Wiring Harness
Location
B8 Hydraulic System Pressure Sensor Hydraulic Pressure Sensor Circuit SE16
W5 Engine Frame Harness
B14 Analog Throttle Position Sensor Throttle Sensor Circuit SE16
Load Center Harness (W3)
B15 Hydraulic Oil Temperature Sensor Hydraulic Oil Temperature Sensor Circuit SE19
B16 Engine Coolant Temperature Sensor Engine Coolant Temperature Sensor Circuit SE19
W6 Engine Harness
B17 Fuel Level Sender Fuel Level Sensor Circuit SE19
B18 Engine Coolant Level Switch (S.N. — Engine Coolant Level Switch Circuit SE20
574739) W13 Rear Frame Harness
B19 Engine Air Filter Restriction Switch Engine Air Filter Switch Circuit SE20
W6 Engine Harness
B20 Transmission Oil Filter Restriction Switch Transmission Oil Filter Switch Circuit SE20
Transmission Harness (W10)
B21 Hydraulic Oil Filter Restriction Switch Hydraulic Oil Filter Switch Circuit SE20
B23 Engine Oil Pressure Sensor Engine Oil Pressure Circuit SE21
W6 Engine Harness

011504
PN=271
Location
B25 Steering System Pressure Switch Steering Pressure Switch Circuit SE21
W17 Secondary Steering Switch Harness
B27 Service Brake Pressure Switch Brake Pressure Switch Circuit SE21
Accumulator Charge W3 Load Center Harness
B28 Torque Converter Input Speed Sensor Torque Input Speed Sensor Circuit SE22
W10 Transmission Harness
B29 Torque Converter Output Speed Sensor Torque Output Speed Sensor Circuit SE22
B30 Internal Clutch Speed Sensor Internal Clutch Speed Sensor Circuit SE22
B31 Transmission Output Shaft Speed Output Speed Sensor Circuit SE22
Sensor W10 Transmission Harness
B32 Transmission Oil Temperature Sensor Transmission Oil Temperature Sensor Circuit SE24
9015
B33 Clutch Cutoff Sensor Clutch Cutoff Pressure Sensor Circuit SE24
15
W3 Load Center Harness
54
B34 Park Brake Pressure Switch Park Brake Pressure Switch Circuit SE24
W2 Loader Frame Harness
W11 Loader Frame Harness
B40 Brake Light Pressure Switch Brake Light Pressure Switch Circuit SE37
F11 CCU 28V Switched Power 7.5A Fuse MDU System Voltage Circuit SE21

011504
PN=272
Location
S5 LPM Off/On Switch LPM Mode Rocker Circuit SE16
W14 LPM Mode Harness
S6 Automatic Transmission Switch Auto Rocker Circuit SE22
S8 Park Brake Release Switch Park Brake Rocker Circuit SE22
W4 Front Console Harness
S19 Front Wiper Switch Front Wiper Switch Circuit SE29
S20 Rear Wiper Switch Rear Wiper Switch Circuit SE30
S24 4-Way Flasher Switch Hazard Light Rocker Circuit SE34
S25 Turn Switch Left Turn Switch Circuit SE35
9015
S25 Turn Switch Right Turn Switch Circuit SE35
15
55
S26 Drive and Tail/Marker Light Switch Drive Light Rocker Switch SE35
S26 Drive and Tail/Marker Light Switch Marker Light Rocker Circuit SE35
S30 Cab Work Light Switch Work Light Rocker Switch SE38
S31 Ride Control Switch Ride Control On Rocker Circuit SE10
S31 Ride Control Switch Ride Control Auto Rocker Circuit SE10
S35 LPM Mode Switch LPM Mode Select Circuit SE16
W14 LPM Mode Harness
S34 Not Used
TX,9015,111886 –19–01JUL02–6/6

011504
PN=273

Battery Monitor (d 03)
This mode allows the technician to view the current

voltage of the left and right batteries.
–19–28AUG96
Battery voltage will be displayed in basic display window.
T102003
Battery Monitor Menu (d 03)
9015
15
56
TX,15,111818 –19–01JUL02–1/2
Press SELECT again to display reading in the

alpha-numeric message display. Pressing SELECT will
toggle the reading in and out of the alpha-numeric
window.
–19–02SEP97
T110767
Battery Monitor Menu (d 03)
TX,15,111818 –19–01JUL02–2/2

Engine Sensors (d 04)
This mode allows the technician to monitor all engine

sensors that are accessible to the computer system.

011504
PN=274
Press SELECT at the d 04 display.
–19–02SEP97
T110766
Engine Sensor Diagnostic Menu (d 04)
9015
15
57
CED,TX17864,64 –19–01JUL02–2/13
The d 041 display for Engine Coolant Temperature will be

shown. Temperature will be displayed in °C or °F
(depending on setting selected in A 07 mode) and sensor
voltage will be displayed.
–19–15AUG96
T102004
Coolant Temperature Menu (d 041)

011504
PN=275

toggle reading in and out of the alpha-numeric window.
Press NEXT.
–19–02SEP97
T110769
Coolant Temperature Menu (d 041)
9015
15
58
CED,TX17864,64 –19–01JUL02–4/13
The d 042 display for Engine Oil Pressure will be shown.

Pressure will be displayed in kPa or psi and sensor
voltage will be displayed.
–19–15AUG96
T102027
Engine Oil Pressure Menu (d 042)

011504
PN=276

toggle reading in and out of alpha-numeric window.
Press NEXT.
–19–02SEP97
T110771
Engine Oil Pressure Menu (d 042)
9015
15
59
CED,TX17864,64 –19–01JUL02–6/13
The d 043 display for Throttle sensor voltage will be

shown.
–19–02SEP97
T110772
Throttle Sensor Menu (d 043)
CED,TX17864,64 –19–01JUL02–7/13

Press NEXT.
–19–17FEB98
T113547

011504
PN=277
The d 044 display for Fuel Temperature will be shown.
–19–31MAR98
T114614
CED,TX17864,64 –19–01JUL02–9/13

9015 alpha-numeric message display. Pressing SELECT will
15 toggle reading in and out of alpha-numeric window.
60
Press NEXT.
–19–31MAR98
T114615
CED,TX17864,64 –19–01JUL02–10/13
NOTE: Rack Position will only be displayed on earlier

models (S.N. — 585560).
NOTE: Rack Position will only display in mm values. The

values are multiplied by 10000, so 00300 is
actually 00.300 mm.
–19–31MAR98
The d 045 display for Rack Position will be shown.
T114616
CED,TX17864,64 –19–01JUL02–11/13

Press NEXT.
–19–10MAR99
T120485

011504
PN=278
The d 047 display for Intake Manifold Air Temperature will BOOM POSITION
be shown.

–19–01JUL02
T156458
- +
VOLTS
SPECIFICATIONS
Engine Sensors (d 04)
9015
d 041 Engine Coolant Temperature Engine Coolant Temperature Sensor (B16) Normal Operating Range: 85°— 110° C 15
(185° — 230° F 61
+257° F)
Normal Operating Voltage: 1.772—1.025
volts
d 042 Engine Oil Pressure Engine Oil Pressure Sensor (B23) Measurement Range: 68.9—703.3 kPa
(0.689—7.033 bar) (10—102 psi)
Voltage Range: 0.906—4.566 volts
d 043 Throttle Sensor Voltage Analog Throttle Position Sensor (B14) Normal Operating Voltage: Low Side: 0.6 ±
0.1 volts. High Side: Greater than 4.1 volts.
d 044 Fuel Temperature Fuel Temperature Sensor (B3) Full Operating Temperature: -40—+190° C
(-40—+374° F)
d 045 Rack Position Rack Position Sensor (B4) Full Operating Position: 0—31.345 mm (0—
1.235 in.)
d 047 Intake Manifold Air Temperature Intake Manifold Air Temperature Sensor (B7) Normal Operating Temperature: 10—50° C
(50—122° F)
CED,TX17864,64 –19–01JUL02–13/13

This mode allows the technician to monitor all

transmission sensors that are accessible to the computer
system.

011504
PN=279
–19–05AUG97
T110773
Transmission Sensors Diagnostic Menu (d 05)
9015
15
62
TX,15,111820 –19–01JUL02–2/5
The d 051 Oil Temperature Sensor display will show the

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

011504
PN=280

Press NEXT.
–19–02SEP97
The d 052 Clutch Cutoff Sensor display will show the
Clutch Cutoff Sensor (B33) voltage.
Press NEXT.
T110775
The d 053 Torque Input Speed Sensor display will show
the speed in rpm. Oil Temperature Menu (d 051)
Press NEXT.
9015
The d 054 Torque Output Speed Sensor display will show 15
the speed in rpm. 63
Press NEXT.
The d 055 Internal Clutch Speed Sensor display will show

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

the speed in rpm.

011504
PN=281
SPECIFICATIONS
d 051 Oil Temperature Sensor Transmission Oil Temperature Sensor (B32) Normal Operating Range: 85°— 110° C
(185° — 230° F
+257° F)
d 052 Clutch Cutoff Pressure Clutch Cutoff Sensor (B33) Level Ground Set Point to Release Clutch:
1.20 volts
volts
1.64 volts
Small Slope Set Point to Apply Clutch: 1.60
volts
9015 Steep Slope Set Point to Release Clutch:
15 2.00 volts
64 Steep Slope Set Point to Apply Clutch: 1.94
volts
SPECIFICATIONS
d 053 Torque Input Speed Sensor Torque Converter Input Speed Sensor (B28) Normal Operating Range of Speed: 900—
2350 rpm
d 054 Torque Output Speed Sensor Torque Converter Output Speed Sensor (B29) Normal Operating Range of Speed: 0—2350
rpm
d 055 Internal Clutch Speed Sensor Internal Clutch Speed Sensor (B30) Normal Operating Range of Speed: 900—
2350 rpm
d 056 Output Shaft Speed Sensor Transmission Output Shaft Speed Sensor Varies according to ground speed
(B31)
TX,15,111820 –19–01JUL02–5/5

011504
PN=282

This mode allows the technician to monitor all hydraulic

sensors that are accessible to the computer system.
–19–02SEP97
T110776
Hydraulic Sensors Diagnostic Menu (d 06)
9015
15
65
CED,TX17864,65 –19–01JUL02–1/8
The d 061 Oil Temperature Sensor display will show the

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

–19–15AUG96
Press NEXT.
T102008
Oil Temperature Menu (d 061)
CED,TX17864,65 –19–01JUL02–2/8
The d 062 Pump Output Pressure display (Material

Handler only) will show the pressure in kPa or psi
voltage.
–19–17FEB98
T113559

011504
PN=283

Press NEXT.
–19–17FEB98
T113565
CED,TX17864,65 –19–01JUL02–4/8
The d 063 Boom Position Volt Sensor display will show INTAKE MANIFOLD
9015 voltage at the sensor (depending upon boom position).
15
66 Press SELECT again to display reading in the
–19–01JUL02
T156451
SPECIFICATIONS
d 061 Oil Temperature Sensor Hydraulic Oil Temperature Sensor (B15) Normal Operating Range: 85°— 110° C
(185° — 230° F)
+257° F)
volts)
d 062 Pump Output Pressure Hydraulic System Pressure Sensor (B8) Normal Operating Range: 4826—20685 kPa
(48.3—207 bar) (700—3000 psi)
Maximum: 22753 kPa (227 bar) (3300 psi)
Normal Operating Voltage: (0.5—4.5 volts)
d 063 Boom Position Volt Sensor (B9) Normal Operating Voltage: (0.6—3.7 volts)

011504
PN=284
Two different fan speed test modes are provided from the
d 064 menu:
Pressing SELECT once will enter into fan speed high test
–UN–29OCT02
mode (d 0641).
Pressing NEXT will enter into fan speed low test mode (d
0642).
T161033
CED,TX17864,65 –19–01JUL02–6/8
This mode enables the proportional fan to test fan speed

at highest setting (0 volts to proportional coil). 9015
15
67
–UN–29OCT02
T161034
CED,TX17864,65 –19–01JUL02–7/8
This mode enables the proportional fan to test fan speed

at slowest setting (12 volts to proportional coil).
–UN–29OCT02
T161035
CED,TX17864,65 –19–01JUL02–8/8

011504
PN=285

Fuel Sensor (d 07)
This mode allows the fuel level sensor to be monitored.
Press SELECT at the d 07 Fuel Sensor display.
–19–09SEP97
The Fuel Sensor display will show fuel level in gal or L
voltage.
T110780
Deluxe Monitor Display Unit
9015
15
68
TX,9015,111893 –19–01JUL02–1/2

–19–09SEP97
T110781
Deluxe Monitor Display Unit
SPECIFICATIONS
d 07 Fuel Sensor Fuel Level Sender (B17) Empty Resistance: 10 Ohms
Half Full Resistance: 100 Ohms
Full Resistance: 180 Ohms
TX,9015,111893 –19–01JUL02–2/2
Monitor Display Unit—User Diagnostics

Menu—(d 08)—Not Used
CED,TX17864,9 –19–01APR98–1/1

011504
PN=286

Menu—LPM Mode (d 09)
This mode allows the technician to monitor the Load

Performance Management (LPM) operation.
–19–17FEB98
The LPM Mode display will show the LPM number and
the LPM rotary sensor voltage.
T113578
TX,9015,MM3002 –19–01APR98–1/2

alpha-numeric message display. Pressing SELECT will 9015
toggle reading in and out of the alpha-numeric window. 15
69
–19–17FEB98
T113579
SPECIFICATIONS
d 09 Load Performance Management (LPM) LPM Mode Switch (S33) Position 1: 0.0—0.15 volts
Mode
Position 2: 0.15—0.53 volts
TX,9015,MM3002 –19–01APR98–2/2

011504
PN=287

Menu—Machine I.D. Mode (d 10)
This mode provides the technician with machine

identification information for hour meter readings, part
numbers and serial numbers of the monitor display unit,
–19–09SEP97
transmission controller unit, and chassis controller unit.
T110784
Machine I.D. Mode Menu (d 10)
9015
15
70
TX,9015,111894 –19–01APR98–1/9
The d 101 MDU Original display will show the monitor

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

011504
PN=288
Press NEXT.
The d 102 CCU Original display will show the chassis

controller unit hour meter reading and the original chassis
controller serial number.
–19–12SEP96
T102012
CCU Original Display
9015
15
71
TX,9015,111894 –19–01APR98–3/9
Press NEXT.
The d 103 MDU Part Number display will show the

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

011504
PN=289
Press NEXT.
The d 104 CCU Part Number display will show the

chassis controller unit part number and serial number.
–19–02SEP97
T110786
CCU Part Number Display
9015
15
72
TX,9015,111894 –19–01APR98–5/9
Press NEXT.
The d 105 MDU Software Number display will show the

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

011504
PN=290
Press NEXT.
The d 106 CCU Software Number display will show the

chassis controller unit software number.
–19–02SEP97
T110788
CCU Software Display Number
9015
15
73
TX,9015,111894 –19–01APR98–7/9
Press NEXT.
The d 107 TCU Serial Number display will show the

transmission controller unit serial number.
–UN–22OCT97
T111711
TX,9015,111894 –19–01APR98–8/9
Press NEXT.
The d 108 TCU Software Number display will show the

transmission controller unit software number.
–UN–22OCT97
T111712
TX,9015,111894 –19–01APR98–9/9

011504
PN=291
Monitor Display Unit—Service Menu—

Machine Model (S 01)
IMPORTANT: Whenever a monitor display unit (MDU),

chassis computer unit (CCU), or
transmission control unit (TCU) is
–19–02SEP97
replaced, the monitor display unit must
be “reconfigured.” This reconfiguration
procedure is performed in the Service
Menu. See Monitor Display Unit
T110790
Reconfiguration in this group for
procedure to set machine model, tire
size and to enable appropriate machine Service Menu Display
options.
9015 NOTE: The Service Menu is for dealer and factory

15 personnel only. This menu can be accessed from
74 the Diagnostics Menu, Diagnostic Trouble Codes
(d 01) mode. When F END shows in the display
window, press SELECT and hold down for at least
five seconds. An S in the display window indicates
the Service Menu.
At the S display, press SELECT.
TX,9015,111888 –19–01APR98–1/3
At the S 01 display, press SELECT again.
–19–02SEP97
T110791
Machine Model Display (S 01)

011504
PN=292
This mode initially will display the current machine model

that was programmed at the factory. Press SELECT to
verify that correct machine model is displayed. This model
will be stored and “Done” will be displayed to confirm the
selection.
–19–17FEB98
If the incorrect machine model is displayed, see Monitor
Display Unit Reconfiguration—Machine Model (S 01) in
this group for instructions to change model setting.
T113585
TX,9015,111888 –19–01APR98–3/3
Monitor Display Unit—Service Menu—

Tell-Tale Diagnostic Trouble Codes (S 02) 9015
15
75
This mode stores and displays the seven highest priority
tell-tale diagnostic trouble codes which have occurred on
the machine. Tell-tale diagnostic trouble codes are a
limited set of special service conditions that are used to
provide historical information on service and warranty
related items.
NOTE: See Diagnostic Trouble Code Interpretation in

Group 9015—20 for additional information on
Tell-Tale Diagnostic Trouble Codes.
The tell-tale diagnostic trouble codes are:
• 0300 Trans. Oil Temperature High Long

• 0400 Eng. Oil Pressure Low Duration
• 0500 Eng. Coolant Temp. High Long
• 1647 Machine Odometer Bad
• 1648 Machine Hourmeter Bad
• 1649 CCU Hourmeter Bad
• 2100 Hydraulic Oil Temperature High Long
The diagnostic trouble code list will show the most recent
codes at the top and the oldest codes being removed
from the bottom of the list. A running total of occurrences
over the life of the machine is kept for each diagnostic
trouble code in the set, and this total is part of the
diagnostic trouble code that is transmitted over the CAN.

011504
PN=293
At the Tell-Tale Diagnostic Trouble Code display (S 02),

press SELECT.
–19–02SEP97
T110792
Tell-Tale Diagnostic Trouble Codes Display (S 02)
9015
15
76
TX,15,111825 –19–01APR98–2/6
An F is shown in the display window to indicate diagnostic

trouble code mode. This first diagnostic trouble code
number is shown.

NEXT.
–19–15AUG96
To obtain additional information about the first diagnostic
trouble code, press SELECT again.
T102019

011504
PN=294
This display window will show the hour meter reading at

first occurrence of the diagnostic trouble code.
To obtain additional information about the diagnostic

trouble code, press NEXT.
–19–15AUG96
T102020
9015
15
77
TX,15,111825 –19–01APR98–4/6

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

011504
PN=295

BACK until the Fxxxx display is shown.
Then press NEXT.
Continue to scroll through the diagnostic trouble codes
–19–15AUG96
using this sequence until End is shown in the display
window.
T102019
9015
15
78
TX,15,111825 –19–01APR98–6/6
Monitor Display Unit—Service Menu—Tire

Size (S 03)
At the S 03 display, press SELECT.
–19–02SEP97
T110794
Tire Size Display (S 03)

011504
PN=296
This mode initially will display the current machine tire

size that was programmed at the factory. The tire size will
be stored and “Done” will be displayed to confirm the
selection.
If the incorrect machine tire size is displayed, see Monitor
–19–02SEP97
Display Unit Reconfiguration—Set Tire Size (S 03) in this
group for instructions to change tire size.
T110795
Tire Size Display (S 03)
9015
15
79
TX,15,111826 –19–01APR98–2/2
Monitor Display Unit—Service Menu—Enable

Options (S 06)
The Enable Options mode allows the technician to turn

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

• (S 062) LPM (Material Handlers Only)
• (S 063) Engine Air Heater
• (S 064) Ride Control
• (S 065) Engine Oil Pressure Sensor
• (S 066) Material Handler

011504
PN=297
At the S 06 display, SELECT.
–19–02SEP97
T110797
Enable Options Display (S 06)
9015
15
80
TX,9015,111897 –19–01JUL02–2/3
The S 061 Secondary Steering mode will show in display

window. Display will show whether that option is “On” or
“Off”. To change a setting, follow procedure in Monitor
Display Unit, Reconfiguration—Enable Options (S 06), in
this group.
–19–09SEP97
Press NEXT to move from one option to the next.
T110796
Secondary Steering Display (S 061)
TX,9015,111897 –19–01JUL02–3/3
—Service Menu—Hitachi Mode (S 07)
Press SELECT at the S 07 display. The message display

will show HITACHI. Pressing SELECT will toggle between
the “On” and the “Off” position.
This mode used when spare parts are shipped to Hitachi.
TX,15,111828 –19–01JUL02–1/1

011504
PN=298
Monitor Display Reconfiguration—Access

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

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

come on, alarm will sound and stop and caution lights
will flash. The basic display window will show the bulb
check mode. The window will contain numerical digit
8’s and will be shown for approximately 5 seconds. 9015
15
2. Then the machine model will show in the basic display 81
window.
3. Approximately 5 seconds later, the Normal Gear LCD

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

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

indicating Diagnostics Menu.

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

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

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

diagnostic trouble code (DTC) number.
9. Continue to press NEXT key until “F End” shows in the

display window. Press and hold SELECT for at least 5
seconds until “S” is displayed, which indicates Service
Menu. The Service Menu is to be used only by
service technicians.
TX,9015,111914 –19–01APR98–1/1

011504
PN=299
Monitor Display Unit Reconfiguration—

Machine Model (S 01)
NOTE: The park brake MUST be set (indicator light will

be On) and the shifter switch MUST be in Neutral
for reconfiguration procedure.
1. Apply the park brake. Move shifter lever to Neutral

position. Once the Service Menu is accessed, press
SELECT and “S 01” will be displayed.
2. At the “S 01” display, press SELECT again, to see the

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

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

to “S 03.”
TX,9015,111849 –19–29AUG97–1/1

011504
PN=300
Monitor Display Unit Reconfiguration—Tire

Size (S 03)

be On) and the shifter switch MUST be in Neutral
for reconfiguration procedure.
1. At the Service Menu “S 03” Tire Size mode, press

SELECT to see the currently configured tire size. If
correct tire size is shown, press SELECT to confirm it.
If this screen does not show the correct tire size, press
NEXT to scroll through the different size options until
the correct tire size is displayed. Then press SELECT.
2. If reconfiguration is successful, DONE will be 9015

displayed. If reconfiguration is not successful, FAIL will 15
be displayed (about two seconds), and procedure must 83
be repeated.
3. Press BACK to “S 03.”
4. Press NEXT until “S 06” displays.
TX,9015,111909 –19–01JUL02–1/1

011504
PN=301
Monitor Display Unit Reconfiguration—

Enable Options (S 06)

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

successful, all options in this menu will be turned
“Off.” These must be reset to “On”.
If an option already shows “On” cycle it to “Off”

then back to “On.” This is a verification to make
sure monitor display unit is receiving the latest
information from the chassis computer unit, and
9015 the option is definitely set to “On.”
15
84 1. At the Service Menu “S 06” Enable Options mode,
press SELECT to display “S 061” Secondary Steering
option.
2. Press SELECT again to enable (turn “On”) or disable

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

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

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

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

key to return to Normal Gear LCD display.

011504
PN=302
IMPORTANT: After the reconfiguration procedure is

complete, key switch must be turned
“Off” then back “On” before the
transmission control unit (TCU) will
allow the transmission to shift into
gear.
6. Turn key switch “Off” and then back “On.”
TX,9015,111851 –19–01JUL02–2/2
Monitor Display Unit Reconfiguration—Delete

Diagnostic Trouble Codes (DTC) 9015
15
85
NOTE: After reconfiguration procedure is done,
Diagnostic Trouble Code (DTC) F0478 and/or F
1699 may be displayed. If so, clear these
diagnostic trouble codes.
1. At Normal Gear LCD display (with key switch “On”),

press MENU key twice to get into the Diagnostics
menu.
2. At the “d 01” display, press SELECT.
3. An F is shown in the display window to indicate

diagnostic trouble code (DTC) mode and the first
diagnostic trouble code (DTC) number is shown. Press
NEXT to view each successive diagnostic trouble code
DTC).
4. If F 0478 and/or F 1699 are displayed, clear these

diagnostic trouble codes; press and hold SELECT for
at least three seconds while each code is displayed.
5. Press MENU key again to return to Normal Gear LCD

display. Turn key switch “Off”.
TX,9015,111910 –19–01JUL02–1/1

011504
PN=303
Chassis Computer Unit Circuit Operational

Information
The following conditions must exist for the chassis

computer unit to function:
• Key Switch (S1) in On or Start position

• Ignition Power Relay (K4) energized
• Power from CCU 28V Switched Power 7.5A Fuse (F11)
to pin K1 and A3 of 30—Pin Connector and pin A1 of
60—Pin Connector
• Power from Battery 12V Center Tap and CCU 12 V
Battery Unswitched 5A Fuse (F9) to pin A3 of 60—Pin
Connector
• Signal from pin C1 of 60—Pin connector and K2 and K3
9015 of 30—Pin Connector to Single Point Ground on Starter
15 Motor (M1)
86
TX,15,111830 –19–26AUG97–1/1

011504
PN=304
Chassis Computer Unit Circuit Theory Of

Operation
The basic functions of the chassis computer unit are:
• Monitor machine functions

• Control monitor display unit
• Transfer hydraulic/transmission systems
communications
Following is the list of functions that work in conjunction

with the chassis computer unit:
• Ride Control Circuit (See Ride Control Circuit Theory of

Operation, this group)
• Secondary Steering Circuit (See Secondary Steering 9015
Circuit Theory of Operation, this group.) 15
• Engine Air Heater Circuit (See Engine Air Heater Circuit 87
Theory of Operation, this group.)
• Gauge and Indicators Circuits (See Monitor Display Unit
• Brake and Light Circuit (See Brake and Light Circuit
• Load Performance Management (LPM) Circuit (See
Load Performance Management Circuit Theory of
Operation, this group.)
• Intermittent Wipers Circuit (See Chassis Computer
Unit—Intermittent Wipers Circuit Signals, this group.)
• Turn Signals/Flasher Circuit (See Chassis Computer
Unit—Turn and Flasher Light Signals, this group.)
• Drive Lights/Work Lights Circuit (See Chassis Computer
Unit—Drive Lights and Work Lights Signals, this group.)
• Tail and Marker Lights Circuit (See Chassis Computer
Unit—Tail and Marker Lights Signals, this group.)
• Pilot Enable/Boom Down Circuit (See Pilot
Enable/Boom Down Circuit Theory of Operation, this
group.)
• Battery Monitoring (See Chassis Computer Unit—
Battery Monitoring Signals, this group.)
• Boom Height Kickout (Boom Position Sensor B9) (S.N.
585561—) (See Return To Carry, Boom Height Kickout
And Return To Dig Circuit Theory Of Operation)
TX,15,111831 –19–01APR98–1/1

011504
PN=305
Chassis Computer Unit—Intermittent Wipers

Circuit Signals
Front Wipers Intermittent Switch Input to CCU:The

chassis computer unit (pin T2 of 60—pin connector)
receives a digital signal input from the front wiper switch
(S19) when it is in the I (Intermittent) position.
Rear Wipers Intermittent Switch Input to CCU:The

chassis computer unit (pin T3 of 60—pin connector)
receives a digital signal input from the rear wiper switch
(S20) when it is in the I (Intermittent) position.
Front Wipers Output from CCU to Relay:The chassis

computer unit (pin J1 of 30-pin connector) sends an
9015 output signal to energize the front intermittent wiper relay
15 (K16).
88
Rear Wipers Output from CCU to Relay:The chassis
computer unit (pin F3 of 30-pin connector) sends an
output signal to energize the rear intermittent wiper relay
(K18).
TX,15,111732 –19–01APR98–1/1
Chassis Computer Unit—Turn And Flasher

Light Signals
Flasher Signal On/Off Switch Input to CCU:The chassis

computer unit (pin W3 of 60—pin connector) receives a
signal input from the 4—way flasher switch (S24).
Left Turn Signal Output from CCU to Relay:The

chassis computer unit (pin C1 of 30—pin connector)
sends an output signal to energize the left flasher relay
(K23).
Right Turn Signal Output from CCU to Relay:The

chassis computer unit (pin D1 of 30—pin connector)
sends an output signal to energize the right flasher relay
(K24).
TX,15,111191 –19–01APR98–1/1

011504
PN=306
Chassis Computer Unit—Drive Lights And

Work Lights Signals
Cab Work Lights On/Off Switch Input to CCU:The

chassis computer unit (pin B1 of the 60—pin connector)
receives a signal input from the Cab Work Light Switch
(S30).
Drive Lights On/Off Switch Input to CCU:The chassis

computer unit (pin T1 of the 60—pin connector) receives a
signal input from the Drive and Tail/Marker Light Switch
(S26).
9015
15
89
TX,15,111733 –19–01APR98–1/1
Chassis Computer Unit—Tail/Marker Lights

Signals
Tail/Marker Lights On/Off Switch Input to CCU:The

chassis computer unit (pin B2 of the 60—pin connector)
receives a signal input from the Drive and Tail/Marker
Light Switch (S26).
TX,15,111734 –19–01APR98–1/1

011504
PN=307
Chassis Computer Unit—Battery Monitoring

Signals
There is a 12-volt tap between the batteries, which

powers the CCU 12V Battery Unswitched 5A Fuse (F9).
The fuse sends an input signal to chassis computer unit
(pin A3 of 60-pin connector). The CCU will read this value
and transmit the voltage to the monitor display unit by way
of the CAN link.
Using the 12-volt measurement from CAN and the system

battery voltage value displayed on the voltmeter, the MDU
will calculate the voltage level of the second battery.
System battery voltage minus 12-volt measurement from
CAN equals voltage
9015
15 There are five different diagnostic trouble codes that can
90 register when system voltage is abnormal.
See Diagnostic Trouble Code Verification in Group 9015—

20 for additional information on diagnostic trouble codes.
SERVICE CODES
Code Cause
F1658 Battery voltages differ by more than 0.6 volts
F1660 System voltage above 29.6 with engine running (Recorded at CCU)
F1661 System voltage below 26.4 with engine running (Recorded at CCU)
F1662 System voltage above 30 with engine Off, Key On (Recorded at
CCU)
F1663 System voltage below 24.8 with engine Off, Key On (Recorded at
CCU)
TX,9015,111890 –19–01APR98–1/1
Chassis Computer Unit Circuit Functional

Schematic
See Chassis Computer Circuit Functional Schematic in

System Functional Schematic (SE16, SE17, SE18, SE19,
SE20, SE21). (Go to Group 9015-10.)
CED,TX17864,66 –19–01APR98–1/1

011504
PN=308
Chassis Computer Unit Circuit Connector Signals For 30—Pin Connector (S.N. — 585560)
9015
15
91
–19–10FEB98
T113219

011504
PN=309
CCU 30-PIN CONNECTOR SIGNALS

PIN WIRE COLOR FUNCTIONAL DESCRIPTION
A1 E13 Wht To Engine Air Heater Relay (K33)
A2 Plug
A3 P25 Red From CCU 28V Switched Power 7.5A Fuse, Common with pin K1 of 30-pin and pin A1 of
60-pin connector
B1 J06 Tan To Ride Control On/Off Relay (K31)
B2 J04 Tan To Ride Control Pressure Switch (B41) (Monitors Pilot "Dump" Pressure)
B3 M18 Pur Signal for PWM Throttle from Engine Controller Unit (A1)
C1 L08 Brn To Left Flasher Relay (K23)
C2 Plug
C3 H25 Grn To Detent Enable Relay (K32)
D1 L11 Brn To Right Flasher Relay (K24)
D2 H14 Grn To Secondary Steering Relay (K21)
9015
D3 Plug
15
92 E1 P52 Red Not Used
E2 H17 Grn Not Used
E3 A31 Org Not Used

F1 P53 Red Not Used
F2 H18 Grn Not Used
F3 A29 Org To Rear Intermittent Wiper Relay (K18)
G1 P54 Red Not Used
G2 H19 Grn Not Used
G3 Plug
H1 P55 Red Not Used
H2 H20 Grn Not Used
H3 Plug
J1 A27 Org To Front Intermittent Wiper Relay (K16)
J2 Plug
J3 Z11 Gry Boot Strap Mode (Factory Use Only)
K1 P25 Red From CCU 28 V Switched Power 7.5A Fuse (F11) (Common with pin K1 of 30-pin and pin
A1 of 60-pin connector)
K2 G01 Blk To Programming Pins (For Factory Use Only) and to Single Point Ground on Starter Motor
(M1), Common with pin K3
K3 G01 Blk To Programming Pins (For Factory Use Only) and to Single Point Ground on Starter Motor
(M1), Common with pin K2
CED,TX17864,67 –19–01APR98–2/2

011504
PN=310
Chassis Computer Unit Circuit Connector Signals For 60—Pin Connector (S.N. — 585560)
9015
15
93
–19–10FEB98
T113219

011504
PN=311

A1 P25 Red CCU 24V Switched Power 7.5A Fuse (F11)
A2 Plug
A3 P31 Red From Battery 12V Center Tap and CCU 12V Battery Unswitched 5A Fuse (F9)
B1 L02 Brn From Cab Work Light Switch (S30) / Turn On Cab Work Lights
B2 L06 Brn From Tail and Marker Light Switch (S26)/Tail and Marker Lights
B3 H16 Grn Not Used
C1 G01 Blk To Single Point Ground on Starter Motor (M1) and Ground for Programming Pins
Connector (Factory Use Only)
C2 Plug
C3 Plug
D1 Plug
D2 Plug
9015
D3 M12 Pur To MDU CAN Link
15
94 E1 A30 Org Not Used
E2 R02 Blk To MDU CAN Link
E3 M13 Pur To MDU CAN Link
F1 H10 Grn From LPM Switch (S5) (On Position)
F2 Plug
F3 Z09 Gry Programming Pins (For Factory Use Only)
G1 Plug
G2 Plug
G3 Z10 Gry Programming Pins (For Factory Use Only)

011504
PN=312

H1 M32 Pur Not Used
H2 P50 Red Not Used
H3 R17 Blk Not Used
J1 M29 Pur Not Used
J2 M30 Pur Not Used
J3 M31 Pur Not Used
K1 Plug
K2 Plug
K3 P21 Red To Hydraulic System Pressure Sensor (B8)
L1 Plug
L2 H11 Grn From LPM Mode Switch (S33)
L3 N05 Yel From Hydraulic System Pressure Sensor (B8)
9015
M1 Plug 15
M2 M20 Pur Not Used 95
M3 P51 Red To Analog Throttle Position Sensor (B14)

N1 Plug
N2 E12 Wht From Analog Throttle Position Sensor (B14)
N3 M33 Pur Not Used
P1 R13 Blk Ground Signal for Hydraulic System Pressure Sensor (B8) and Analog Throttle Position
Sensor (B14)
P2 R01 Blk Ground for: Hydraulic Oil Temperature Sensor (B15) Engine Coolant Temperature Sensor
(B16) Engine Oil Pressure Sensor (B23) Fuel Level Sender (B17)
P3 P13 Red To Engine Oil Pressure Sensor (B23)
R1 X01 Yel To Hydraulic Oil Temperature Sensor (B15)
R2 X04 Yel To Engine Coolant Temperature Sensor (B16)
R3 N02 Yel From Engine Oil Pressure Sensor (B23)
S1 J02 Tan From Ride Control Switch (S31) "On" Position
S2 J05 Tan Front Ride Control Switch (S31) "Auto" Position
S3 Y02 Yel To Fuel Level Sender (B17)

011504
PN=313

T1 L17 Brn From Drive and Tail/Marker Light Switch (S26)/For Drive Lights
T2 A26 Org From Front Wiper Switch (Intermittent) (S19)
T3 A28 Org From Rear Wiper Switch (Intermittent) (S20)
W1 N07 Yel From Service Brake Pressure Switch, Accumulator Charge (B27) (Closed during normal
operation)
W2 Plug
W3 L20 Brn From 4-Way Flasher Switch (S24)
X1 N03 Yel To Transmission Oil Filter Switch (B20)
X2 N08 Yel From Steering System Pressure Switch (B25) (Closed during normal operation)
X3 L03 Brn From Brake Light Pressure Switch (B40)
Y1 Y01 Yel From Engine Coolant Level Switch (B18) (S.N. —574739)
Y2 M06 Pur From Engine Air Filter Restriction Switch (B19)
9015
Y3 N01 Yel To: Hydraulic Oil Filter Restriction Switch (B21) Hydraulic Oil Filter Restriction Switch (B22)
15
Transmission Oil Filter Restriction Switch (B20)
96
CED,TX17864,68 –19–01APR98–4/4
Load Performance Management (LPM) Circuit

Specifications (S.N. — 585560)
SPECIFICATIONS
d 09 Load Performance Management (LPM) LPM Mode Switch (S33) Position 1: 0.0—0.15 volts
Mode
TX,15,MM3096 –19–25SEP96–1/1

011504
PN=314

Operational Information (S.N. — 585560)
The following conditions must exist for the load

performance management circuit to operate:
• Key switch On
• LPM switch (S5) On
• LPM mode switch (S33) powered by chassis computer
unit
• Machine in first gear
• LPM mode switch turned in any position
• LPM mode selected (or turned On) in the monitor
display unit Service Diagnostics Menu (S 062)
9015
15
97
CED,TX17864,69 –19–01APR98–1/1

011504
PN=315

Theory Of Operation (S.N. — 585560)
The load performance management (LPM) circuit reduces

engine rpm under high hydraulic pressure to reduce the
pushing force going into a pile, so the boom can lift
easier. As engine rpm decreases the rim pulling force at
the wheel also decreases, however hydraulic lifting force
remains fairly constant over the selected rpm droop levels.
The five position LPM mode switch sends five different
voltages to the chassis controller unit, which in turn
dictates the proper engine rpm. The hydraulic pressure is
sensed by the Hydraulic System Pressure Sensor (B8).
The circuit is powered by the Rocker Switch, Restriction

9015 Switch and Radio 7.5A fuse (F23).
15
98 When the LPM On/Off Switch (S5) is turned to the On
position, a signal is sent to the chassis computer unit (A2)
(pin F1 of 30-pin connector).
The LPM Mode Switch (S33) is a five position switch.
LPM Mode Switch is powered from chassis computer unit

(A2), (pin M3 of 60-pin connector). LPM Mode Switch
sends signal to pin L2 of 60-pin connector.
Switch Position Engine rpm

1 1750
2 1675
3 1600
4 1525
5 1450
CED,TX17864,70 –19–01APR98–1/1

011504
PN=316
Load Performance Management (LPM) Circuit Functional Schematic (S.N. — 585560)
9015
15
99
–19–24FEB98
T113627
CED,TX17864,71 –19–01APR98–1/1

011504
PN=317
Transmission Control Unit Circuit

Specifications
SPECIFICATIONS
d 051 Oil Temperature Sensor Transmission Oil Temperature Sensor (B32) Normal Operating Range: 85°— 110° C
(185° — 230° F
+257° F)
volts)
d 052 Clutch Cutoff Sensor Clutch Cutoff Sensor (B33) Level Ground Set Point to Release Clutch:
1.20 volts
volts
9015 Small Slope Set Point to Release Clutch:
15 1.64 volts
,100 Small Slope Set Point to Apply Clutch: 1.60
volts
Steep Slope Set Point to Release Clutch:
2.00 volts
Steep Slope Set Point to Apply Clutch: 1.94
volts
SPECIFICATIONS
d 053 Torque Input Speed Sensor Torque Converter Input Speed Sensor (B28) Normal Operating Range of Speed: 900—
2350 rpm
d 054 Torque Output Speed Sensor Torque Converter Output Speed Sensor (B29) Normal Operating Range of Speed: 0—2350
rpm
d 055 Internal Clutch Speed Sensor Internal Clutch Speed Sensor (B30) Normal Operating Range of Speed: 900—
2350 rpm
d 056 Output Shaft Speed Sensor Transmission Output Shaft Speed Sensor Varies according to ground speed
(B31)
TX,15,111737 –19–01APR98–1/1

011504
PN=318
Transmission Control Unit Circuit

Operational Information
The following conditions must exist for the transmission to

shift into gear.
• Shifter Switch (S10) in Neutral position to allow engine

to start
• Engine running
• Park brake released
• Clutch cutoff Not activated
• Brake pedal Not pressed down
• Shifter switch moved to desired gear
Clutch Cutoff, Down/Up, Down Only, and Automatic to

First functions work in conjunction with the transmission 9015
controller. The following conditions must exist for these 15
functions to operate: ,101
Clutch Cutoff
• One of the three Clutch Cutoff settings (A 011, A 012,

or A 013) turned On in the monitor display unit
Accessory menu
• Clutch Cutoff Enable Switch (S11) turned On
• Brake pedal pressed down
Down And Up
• Quick Shift (A 02) selected in the monitor display unit

Accessory menu
• Down/Up shift function (A 021) turned on in the monitor
display unit
• Quick Shift Switch pressed down once to shift down
one gear—once to shift back up one gear.
Down Only
• Quick Shift function (A 02) selected in the monitor

display unit Accessory menu
• Down Only shift function (A 022) turned On in the
monitor display unit
• Quick Shift Switch pressed down; each time it is
pressed will shift down one gear
Continued on next page TX,15,111198 –19–24AUG96–1/2

011504
PN=319
Automatic To First
• Automatic to First Mode of operation (A 03) selected in

the monitor display unit Accessory menu
• Transmission will shift into first gear if a high load is
sensed while transmission is in second gear or when
shifting out of neutral.
TX,15,111198 –19–24AUG96–2/2
9015
15
,102

011504
PN=320
Transmission Control Unit Circuit Theory Of

Operation
NOTE: The Transmission Controller (A3) also sends

signals to operate the Back Up Alarm Circuit, the
Park Brake Sensing Circuit and the Park Brake
Release Circuit.
See Back Up Alarm/Park Brake Sensing Circuit in

this group for additional information.
See Diagnostic Trouble Code Interpretation in

Group 9015—20 for information on Transmission
Control Unit Circuit diagnostic trouble codes.
When the Key Switch (S1) is Off, battery power flows from 9015
the Transmission Controller Unswitched 5A Fuse (F4) to 15
pins 23 and 68 of the transmission controller. ,103
IMPORTANT: After reconfiguration procedure is done

on the monitor display unit, the key
switch must be turned “Off” then back
to “On” before the transmission control
unit (TCU) will allow the transmission to
shift into gear.
When the key switch is in the On or Start position, power

flows from the IGN terminal of the key switch, through the
Transmission Controller Switched 5A Fuse (F12) to pin 45
of the transmission controller. The transmission controller
runs a diagnostic check for approximately one second
upon initial start up. The shifter switch must be in Neutral
position for a few seconds after machine is started or
machine will not move.
If shifter switch is not in neutral at start up, it must be

moved back to neutral, and then to the desired gear
before the machine will move.
When the shifter switch is moved to Forward, Neutral or

Reverse, an input signal is sent to the transmission
controller. The transmission controller will then activate
the appropriate solenoids in the transmission control valve
for the desired movement. When the Clutch Enable
Switch (S11) is turned On and there is input voltage from
the Clutch Cutoff Sensor (B33) to Pin 38, the transmission
will be in Neutral.
Continued on next page TX,15,111797 –19–10MAR99–1/3

011504
PN=321
There are four speed sensors in the transmission control

circuit.
Torque Converter Input Speed Sensor (Engine) (B28):

This sensor is located on the right side of the transmission
and monitors torque converter input shaft speed.
Torque Converter Output Speed Sensor (B29): This

sensor is located on the right side of the transmission and
monitors torque converter out speed.
Internal Clutch Speed Sensor (Transmission) (B30):

This sensor is located on the right side of the transmission
and monitors the speed that the clutch packs are turning.
Output Shaft Speed Sensor (Transmission) (B31) This

9015
15 sensor is located on the right side of the transmission
,104 control valve and monitors transmission output shaft
speed.
These sensors send signals to the transmission controller.

The transmission controller then, sends varying electrical
signals based on speed and load to the proportional
solenoids in the transmission control valve. This controls
the speed of clutch engagement during a shift. All of the
proportional solenoid valves are identical
• Y1 solenoid engages reverse clutch pack

• Y2 solenoid engages forward high-range clutch pack
• Y3 solenoid engages first speed clutch pack
• Y4 solenoid engages third speed clutch pack
• Y5 solenoid engages forward low-range clutch pack
• Y6 solenoid engages second speed clutch pack
The transmission controller will limit downshifting of the

transmission if the machine is moving too fast as indicated
by the magnetic pickup. If the machine is moving faster
than 20% higher than the next higher gear at wide open
throttle, then the transmission will not downshift.

011504
PN=322
With the machine coasting in neutral, the transmission

controller will not allow the transmission to engage too low
of a gear to cause engine overspeed. The gear
appropriate for the ground speed will be engaged, and
then the transmission will downshift to the selected gear.
If the machine is coasting in neutral at a speed greater
than fourth gear wide open throttle, only fourth gear will
engage.
If the machine is in fourth gear and going downhill, it will

automatically shift up to fourth gear as ground speed
dictates, regardless of engine speed
If the machine is operating faster than 20% greater than

wide open throttle in the gear engaged, a downshift or
reversal will not be permitted.
9015
15
,105
TX,15,111797 –19–10MAR99–3/3
Transmission Control Unit Circuit Functional

Schematic
See Transmission Control Unit Circuit in System

Functional Schematic (SE22, SE23, SE24). (Go to Group
9015-10)
TX,15,111745 –19–24AUG96–1/1

011504
PN=323
Transmission Control Unit Connector Signals
9015
15
,106
–19–13APR99
T121159

011504
PN=324
TCU CONNECTOR SIGNALS

PIN WIRE COLOR SIGNAL DESCRIPTION
1,2 G01 Blk Single Point Ground on Starter Motor
To R02 Blk to MDU CAN Link
3 R19 Blk Internal Clutch Speed Sensor (B30)
Torque Converter Output Speed Sensor (B29)
Torque Converter Input Speed Sensor (Engine Speed) (B28)
4 R22 Blk Transmission Output Shaft Speed Sensor (B31)
7 M28 Pur Back Up Alarm Relay (K10)
8 R18 Blk Park Brake Release Solenoid (Y19)—Common with Pin 53)
9 T07 Blu Transmission Control Valve Solenoid (Y5)
12 R14 Blk Ground for Transmission Control Valve Solenoids (Y1—Y6)
13 R14 Blk Ground for Transmission Control Valve Solenoids (Y1—Y6)
9015
19 M07 Pur Torque Converter Input Speed Sensor (Engine) (B28) 15
20 T12 Blu Shifter Switch (B3 Signal) (S10) ,107
21 T18 Blu Park Brake Release Switch (S8)

23 P02 Red Monitor and Transmission Controller Unswitched Fuse (F4)—(Common with Pin 68)

011504
PN=325
TCU CONNECTOR SIGNALS

PIN WIRE COLOR SIGNAL DESCRIPTION
24 R16 Blk Clutch Cutoff Sensor (B33)
25 M12 Pur To MDU CAN Link
26 M13 Pur To MDU CAN Link
28 Not Used
29 T16 Blu Automatic Transmission Switch (S6)
30 T02 Blu Park Brake Pressure Switch (B34)
31 T21 Blu Park Brake Release Switch (S8)
33 T09 Blu Park Brake Release Solenoid (Y19)
37 P60 Red Clutch Cutoff Sensor (B33)
38 T20 Blu Clutch Cutoff Sensor (B33)
39 P23 Red Transmission Oil Temperature Sensor (B32)
9015
15 41 M08 Pur Torque Converter Output Speed Sensor (B29)
,108 42 M09 Pur Internal Clutch Speed Sensor (B30)
43 T13 Blu Shifter Switch (Forward Signal) (S10)
44 T17 Blu Quick Shift Switch (S7)
45 P24 Red Transmission Controller Switched 5A Fuse (F12)
Shifter Switch (S10) Power
46 X06 Yel Transmission Oil Temperature Sensor (B32)
53 R18 Blk Park Brake Release Solenoid (Y19)—(Common with Pin 8)
62 M10 Pur Transmission Output Shaft Speed Sensor (B31)
63 T10 Blu Shifter Switch (B1 Signal) (Engine) (S10)
64 T14 Blu Shifter Switch (Reverse Signal) (S10)
65 T11 Blu Shifter Switch (B2 Signal) (Turbine) (S10)
66 T19 Blu Clutch Cutoff Enable Switch (S11)
67 E02 Wht Shifter Switch (Neutral) (S10)
Neutral Start Relay (K1)
68 P02 Red Monitor and Transmission Controller Unswitched Fuse (F4) (Common with Pin 33)
TX,15,111749 –19–14APR99–3/3

011504
PN=326
9015
15
,109

011504
PN=327
Transmission Control Valve Solenoid Check
9015
15
,110
–19–27AUG97
T110956
Continued on next page TX,15,111260 –19–13FEB97–1/2

011504
PN=328
Following is a simple test to check electrical operation terminal as shown.

of the transmission control valve solenoids:
Specification
1. Disconnect the X6 Transmission Harness to Load Control Valve Solenoid—
Resistance ...................................................................... 15—20 ohms
Center Harness Connector. (See Transmission
Harness (W10) Component Location in Group
3. This check can also be done at the X41
9015—10 for location on machine.)
Transmission Control Valve Connector.
2. Using an ohmmeter, check the resistance between
the common pin terminal (pin V) and each solenoid
TX,15,111260 –19–13FEB97–2/2
9015
15
,111

011504
PN=329
Transmission Modes Of Operation—Manual

And Automatic
The transmission has two basic modes of operation:

Manual Mode and Automatic Mode.
Manual Mode
The shifter is in 1st, 2nd, 3rd, or 4th gear. The following

rules apply:
1. When shifting from neutral to 1st, 2nd, 3rd, 4th

Forward or Reverse, the selected gear will be
immediately engaged.
2. When shifting from 1st to 3rd in the same direction, the
9015 transmission controller will shift from 1st to 2nd, and
15 then to 3rd.
,112 3. If 3rd or 4th gear is engaged in either direction with the
machine moving accordingly and a direction change is
made, the machine will automatically shift down to 2nd
gear incrementally and then change direction. The
machine will then shift back up incrementally.
Automatic Mode
The Auto Transmission Switch (S6) in the side console

must be turned to the On position, sending a signal to pin
29 of the transmission controller.
The machine will automatically select 2nd, 3rd, or 4th gear

according to the machine ground speed. The following
rules apply:
1. When shifting from Neutral to any forward gear

(automatic), the transmission controller will engage the
gear appropriate for the ground speed.
2. The transmission will shift based on transmission load
and ground speed. If the machine is accelerated in the
gear engaged, then the transmission will up shift. If the
machine is decelerated in the gear engaged, then the
transmission will down shift.
3. If selector is in fourth gear and going downhill, machine
will automatically shift up to fourth gear as ground
speed dictates, regardless of engine speed.
4. Reversals will be controlled by checking the ground
speed against the allowed reversal speed set in the
transmission controller.

011504
PN=330
5. If 2nd gear is engaged and shifter switch is moved to

Reverse position, the machine will reverse
immediately. However, if a 3rd to 2nd automatic shift
has already been started, the transmission controller
will complete that automatic downshift first, before
changing to reverse direction.
6. If 3rd or 4th gear is engaged and shifter switch is
moved to Reverse position, the machine will
automatically shift down to 2nd gear Forward and than
into 2nd gear reverse direction.
TX,15,111201 –19–31AUG96–2/2
9015
15
,113

011504
PN=331
Transmission Functions Set At Monitor

Display Unit
NOTE: See Monitor Display Unit—Accessing Menus

(Group 9015-15) for more detailed instructions on
scrolling through menus and modes.
Clutch Cutoff
The Clutch Cutoff function can be set at the monitor

display unit in the Accessory menu. In the Clutch Cutoff
mode of operation, there are three different settings to
choose from:
• Level Ground
9015 • Small Slope
15 • Steep Slope
,114
By turning one of these settings On, the other two are
automatically turned Off.
Level Ground (A 011): When the Level Ground function

is turned On in the monitor display unit, the Clutch Cutoff
Enable Switch (S11) turned On, and the brake pedal is
pressed down, the Clutch Cutoff Sensor (B33), which is a
voltage higher than the low voltage set point, the
roll slightly.


enable switch is turned to the Off position.

011504
PN=332
Small Slope (A 012): When the Small Slope function is

turned On in the monitor display unit, the Clutch Cutoff
voltage higher than the medium voltage set point, the
roll slightly.

9015
15
The transmission will also re-engage if the clutch cutoff ,115
Steep Slope (A 013): When the Steep Slope function is

turned On in the monitor display unit, the Clutch Cutoff
voltage higher than the high voltage set point, the
modulate into neutral. In this position the machine will still
roll slightly.


Quick Shift
The Quick Shift function can be set at the monitor display

unit in the Accessory menu. In the Quick Shift mode of
operation, there are two different functions to choose
from:

011504
PN=333
• Down/Up
• Down Only
When one of them is selected and turned On, the other is

automatically turned Off.
This mode allows the operator to choose between

Down/Up and Down Only shift functions when the
transmission is in manual or automatic operation.
Down/Up: When this function is turned On, the

transmission will down shift one gear when the Quick Shift
down once. It is not possible to down shift more than one
gear.
9015
15 When the quick shift switch is pressed down again, the
,116 transmission will electronically shift up one gear again.
Down Only—Transmission in Manual Operation: When

this function is turned On, each time the Quick Shift
down, the transmission will shift down one gear
(regardless of selected gear).

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

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

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

switch, the transmission will not shift up again unless a
direction or gear change is made.

011504
PN=334
Down Only—Transmission in Automatic Operation:If

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

manual, with the following exception.
Once a downshift is made by pressing the quick shift

switch, the transmission will shift up again (if ground
speed and/or load requires it). For example, if downshift is
made from third to second, it will automatically shift up
again to second, but no higher than second.
9015
Auto Mode To First 15
,117
In the monitor display unit menu, select Auto Mode to
First (A 03) to turn it On.
With the transmission running in Automatic Mode and the

Auto Mode to First turned on in the monitor display unit,
the transmission will automatically shift to 1st gear under
two conditions:
NOTE: The directional lever has to remain in neutral for a

predetermined amount of time before the
transmission will start out in 1st gear. The
transmission will not shift to 1st gear when making
reversals and the directional lever passes through
neutral. If there is a high load on a direction
change (high speed, full throttle, and possibly a
load in the bucket) the transmission will downshift
to 1st.
• When shifting out of neutral to either forward or reverse,

the transmission will start out in 1st gear
• If the machine is running in 2nd gear and a high load is
encountered, the transmission will automatically shift to
1st gear.

011504
PN=335
When the gear selector is shifted out of neutral to either

forward or reverse, the transmission will start in 1st gear.
As ground speed increases the transmission will up-shift
to 2nd gear. The transmission will now operate
automatically between gears 2 through 4 in forward and 2
through 3 in reverse, depending on the position of the
speed selector. Once the transmission shifts out of 1st
gear it will not automatically shift into 1st gear again,
unless the machine is under a high load.
When the transmission is running in 2nd gear and a high

load is encountered, (such as loading the bucket) the
transmission will automatically shift to 1st gear. The
transmission will stay in 1st gear until ground speed
increases. As ground speed increases, the transmission
will up-shift to 2nd gear. The transmission will now
9015
15 operate automatically in gears 2 through 4 in forward and
,118 2 through 3 in reverse depending upon the position of the
speed selector.
Once the transmission shifts out of 1st gear it will not

automatically shift into 1st gear again, unless, the
machine detects another high load condition.
TX,15,111748 –19–10MAR99–5/5

011504
PN=336
9015
15
,119

011504
PN=337
Transmission Shift Ranges In Automatic

Mode
The following charts show the response of the

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

Auto Mode to First Enabled by the Operator
Transmission has not shifted to the higher range due to low ground speed.
— Refers to all gears in between (i.e. 4F—1F is the same as 4F, 3F, 2F and 1F)
Gear Selector Position Actual Working Range After first push of button After second push of
button
1F(A) 1F(A) 1F no change 1F(A)
2F(A) 1F(A) 1F 1F 2F(A) speed depend 2F—
9015 1F
15
,120 2F(A) 2F(A) 2F—1F 1F 2F(A) speed depend 2F—
1F
1F
3F(A) 2F(A) 2F—1F 1F 3F(A) speed depend 3F—
1F
3F(A) 3F(A) 3F—1F 2F—1F 3F(A) speed depend 3F—
1F
1F
1F
1F
1F

011504
PN=338
Down/Up (Quickshift)—Transmission in Automatic Mode

Auto Mode to First Not Enabled By the Operator
Transmission has not shifted to the higher range due to low ground speed
—Refers to all gears in between (i.e. 4F— is the same as 4F, 3F, 2F and 1F)
Gear Selector Position Actual Working Range After first push of button After second push of
button
2F(A) 2F(A) 2F 1F 2F(A) speed depend 2F
2F
2F
2F
2F
4F(A) 4F(A) 4F—2F 3F—2F 4F(A) speed depend 4F— 9015
2F 15
,121
Down Only (Quickshift)—Transmission in Automatic Mode

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

011504
PN=339
Down Only (Quickshift)—Transmission in Automatic Mode

Auto Mode to First Not Enabled by the Operator
<>Refers to all gears in between (i.e. 4F— 1F is the same as 4F, 3F, 2F and 1F)
Gear Selector Actual Working Range After first push of After second push of After third push of
Position button button button
2F(A) 2F(A) 21F 1F no change no change
3F(A) 3F(A) 3F—2F 2F 1F no change
4F(A) 3F(A) 3F—2F 2F 1F no change
4F(A) 4F(A) 4F—2F 3F—2F 2F 1F
9015
15
,122
TX,15,111203 –19–30AUG96–3/3

011504
PN=340
Transmission Control Unit Operating Modes
Normal:
In the Normal mode, following conditions exist:
• No transmission “Service Light” on

• No failure detected in the transmission system or
• If there is a failure detected, it has no effect or slight
effect on transmission control
• Transmission control unit will work primarily without
limitation; in special cases with minimal limitations (Also
see Transmission Control Unit Response to
Malfunctions, this group.)
Substitute Clutch Control:

9015
15
In the Substitute Clutch Control mode, following conditions ,123
exist:
• Transmission can not change the gears or the direction

under the control of the normal clutch programmed
modulation.
• One of the speed sensors has failed or is disconnected.
• Transmission controller unit will default to a “Timed
Shift” for clutch pack engagement. All shift modulations
are only time controlled.
Limp Home:
When the transmission control unit detects a failure in the

system that affects transmission control, the transmission
will allow only one gear in each direction. In some cases
only one direction may be possible.
Output Speed Less Than Transmission Control Unit

Programmed Value— Slippage is measured in clutch
pack engagement, and damage to transmission can
occur.

011504
PN=341
At the first occurrence of this failure, the transmission

control unit will shift the transmission to Neutral. The
operator must then shift the control lever to Neutral, then
to Forward or Reverse to get the machine to move in
“Limp Home” mode of 2nd gear. The basic display window
of monitor display unit will show the gear as FF for
Forward and FR for Reverse. Service codes will be
available for viewing in (d) diagnostic menu of the monitor
display unit.
Output Speed More than TCU Programmed Value—

Sensor is failed or there is over speeding of transmission
due to ground or engine speed. The transmission will shift
to Neutral.
The operator must then stop the machine and shift control
9015
15 lever to Neutral before shifting machine into Forward or
,124 Reverse “Limp Home” 2nd gear. The basic display
window of the monitor display unit will show the gear as
FF for Forward or FR for Reverse. The transmission
service light will be On and diagnostic trouble codes will
be available for viewing in (d) diagnostic menu of the
monitor display unit.
Transmission Shutdown:
Severe Failure That Disables Control of

Transmission—The TCU will shut off the solenoid valves
in the control valve for the clutches and the common
power supply. The transmission will shift to Neutral and
the park brake will be disengaged. The operator will have
to stop the machine with service brakes and machine will
not shift into a “Limp Home” mode.
Severe Failure That Disables Control of System—The

TCU will shut off all solenoids in the control valve and
also both common power supplies. The park brake will be
engaged and the transmission will remain in Neutral. No
“Limp Home” mode will be available.
TX,15,111747 –19–29AUG96–2/2

011504
PN=342
Transmission Control Unit Response To

Malfunctions
DETECTED MALFUNCTION TCU RESPONSE OPERATION MODE
Malfunction of Shifter Switch (S10) (Direction TCU Shifts Transmission to Neutral Transmission Shutdown
Select Signal)
Malfunction of Shifter Switch (S10) (Gear The Malfunction Cannot be Detected in Normal
Range Signal) Systems with DW2 Gear Selector
Malfunction Clutch Cutoff Input Clutch Cutoff not Possible Normal
Malfunction Park Brake System TCU Shifts Transmission to Neutral Transmission Shutdown
Malfunction Engine Speed Input Clutch Modulation Fixed Time (Nominal), Substitute Clutch Control
Engine Overspeed Protection Operates With
Turbine Speed Input
Malfunction Turbine Speed Input Clutch Modulation Fixed Time (Nominal) Substitute Clutch Control
Backup Clutch Modulation
Malfunction Internal Speed Input Clutch Modulation Time Controlled Substitute Clutch Control 9015
Malfunction Output Speed Input Clutch Modulation Time Controlled, Mode for Substitute Clutch Control 15
Output Speed Sensor Failure ,125
Malfunction Temperature Sensor Input Replacement Value for Temperature 80° C Normal
(176° F)
Malfunction Low/High Power at Battery TCU Will Shut Off All Valve Solenoids, TCU Shutdown
Transmission to Neutral
Malfunction Backup Alarm Relay (K10), Short No Response Normal
to Ground

011504
PN=343
DETECTED MALFUNCTION TCU RESPONSE OPERATION MODE

Failure Park Brake Release Solenoid (Y19) Park Brake Engaged by Shut Off of Power Machine Not Moveable
Short Circuit to Ground Supply
Open Circuit, Short Circuit to Battery TCU Shifts Transmission to Neutral Transmission Shutdown
Malfunction Clutch C1 Solenoid (Y3), Short TCU Will Shift One Gear (Selected Gear Limp Home
Circuit to Ground, Open Circuit, Short Circuit Depends on Clutch Failure)
to Battery
to Battery
to Battery
Malfunction High-Range Clutch Solenoid TCU Will Shift One Gear (Selected Gear Limp Home
(Y1), Short Circuit to Ground, Open Circuit, Depends on Clutch Failure)
Short Circuit to Battery
9015 Malfunction Low-Range Clutch Solenoid (Y5) TCU Will Shift One Gear (Selected Gear Limp Home
15 Short Circuit to Ground, Open Circuit, Short Depends on Clutch Failure)
,126 Circuit to Battery
Malfunction Reverse Clutch Solenoid (Y2), Only One Direction Possible, TCU Will Shift Limp Home
Short Circuit to Ground, Open Circuit, Short One Gear (Selected Gear Depends on
Circuit to Battery Clutch Failure)
More Than One Malfunction, Short Circuit to TCU Shifts Transmission to Neutral Transmission Shutdown
Ground at Clutch Solenoids
Malfunction at Communication on CAN TCU Will Shut Off All Valve Solenoids, TCU Shutdown
Transmission to Neutral
TX,15,111261 –19–25SEP96–2/2

011504
PN=344
Transmission Control Unit Inputs And Outputs

T121167 –19–14APR99
TX,15,111207 –19–14APR99–1/1

011504
PN=345
Back-Up Alarm And Park Brake Sensing And

Park Brake Release Circuit Specifications
Park Brake Pressure Switch (B34) Opening Pressure (Park Brake 1241 ± 69 kPa (12 ± 0.7 bar) (180 ±
(Normally Closed) Releases) 10 psi)
Closing Pressure (Park Brake 1034 ± 103 kPa (10 ± 1 bar) (150 ±
Applied) 15 psi)
TX,15,111750 –19–24AUG96–1/1
9015
15
,128

011504
PN=346

Park Brake Release Circuit Operational
Information
The back-up alarm, park brake sensing, and park brake

release circuit work in conjunction with the transmission
controller.
Back-Up Alarm Circuit
The following conditions must exist for this circuit to

function:
• Key Switch (S1) On

• Shifter Switch (S10) in Reverse position
• Back-Up Alarm Relay (K10) energized 9015
• Signal to pin 7 of Transmission Controller (A3) 15
,129
Park Brake Sensing Circuit

function:
• Park Brake Pressure Switch (B34) closed when park

brake is On; indicator light in MDU will come On
• Park Brake Pressure Switch (B34) open when park
brake is released; indicator light in MDU will go out
• Signal to pin 30 of Transmission Controller (A3)
Park Brake Release Circuit
NOTE: If the transmission controller does not sense

engine rpm, it will not release the park brake.
If rpm is displayed on the monitor display unit

(MDU), the torque converter input speed sensor is
working.
The park brake is a spring-applied, hydraulically-released

brake. It is applied when the following condition exists (or
whenever key switch is in the Off position):
• Key On, Park Brake Release Switch (S8) On
If the engine stops with the key switch On, park brake
applies when following conditions exist:
• Engine speed lower than 50 rpm (dead engine)

011504
PN=347
• Ground speed less than 0.5 km/hr (0.31 mph)
The park brake is released when the following sequence

of conditions exist:
• Park Brake Release Switch (S8) in Park Brake Release

(Momentary) position; signal to pins 31 and 21 of
Transmission Controller.
• Park Brake Release Switch in center (detented)
position; signal to pin 21 of Transmission Controller
• Signal from Torque Converter Input Speed Sensor
(B28) greater than 50 rpm
9015
15
,130
TX,9015,111911 –19–24AUG96–2/2

011504
PN=348

Park Brake Release Circuit Theory Of
Operation
NOTE: These circuits work in conjunction with the

Transmission Controller Unit (A3).
Back-Up Alarm
Power flows from the Park Brake and Back Up Alarm 5A

Fuse (F13) to energize the Back Up Alarm Relay (K10).
When the Shifter Switch (S10) is moved to the Reverse
position, the relay is grounded through the Transmission
Controller (pin 7) and power flows to the Back Up Alarm
(H3) (and Back Up Light (E1) on Hitachi machines.)
9015
Park Brake Sensing Circuit 15
,131
NOTE: The Park Brake Pressure Switch (B34) senses
hydraulic brake pressure but does not directly
indicate the status of the Park Brake Release
Switch (S8). This circuit functions in any gear
selection.
The park brake pressure switch (B34) is a normally closed

switch, which is powered by the Secondary Steering, Park
Brake and Service Brake Pressure Switches 5A Fuse
(F10).
The switch closes when brake pressure is below 1 034 ±

103 kPa (10 ± 1 bar) (150 ± 15 psi). When the switch is
closed, the park brake is applied and the indicator light in
the monitor display unit is on. A signal is sent to chassis
computer unit (pin X3, of 60-pin connector). Then a signal
is sent from the chassis computer unit by way of the CAN
link, to the monitor display unit.
Specification
Closes When Brake Pressure is
Below—Pressure ......................................... 1 034 ± 103 kPa (10 ± 1 bar)
(150 ± 15 psi)
The shifter switch (S10) sends an “in gear” or “neutral”

message to the transmission controller. The transmission
controller sends this message to the monitor display unit

011504
PN=349
The monitor display unit then determines the appropriate

warning level, based on park brake pressure switch status
and the “in gear” or “neutral” status. If the machine is in
“neutral,” the park brake indicator light will come on. If the
machine is “in gear” the park brake indicator light and red
STOP slight will flash.
The park brake pressure switch will open when brake

pressure is above 1 241 ± 69 kPa (12 ± 0.7 bar) (180 ±
10 psi), and the park brake releases. The light in the
monitor display unit will be turned off.
Specification
Opens When Brake Pressure is
Above—Pressure........................................ 1 241 ± 69 kPa (12 ± 0.7 bar)
9015 (180 ± 10 psi)
15
,132 Park Brake Release Circuit
The Park Brake Release Rocker Switch (S8) has three

positions:
• Park Brake On, Detented Position

• Neutral, Center Detented Position
• Park Brake Release, Momentary Position
To release the park brake, Park Brake Release Switch

(S8) must be moved to the Park Brake Release
Momentary position, then to the Neutral, Center Detented
position. The switch will send a signal to the Transmission
Controller (pins 31 and 21). If engine rpm is greater than
50 rpm, the Torque Converter Input Speed Sensor (B28)
sends a signal to the Transmission Controller Unit (A3)
(pins 3 and 19). The controller then sends a signal to
energize the Park Brake Release Solenoid (Y19) and
allows hydraulic release of the park brake.
If the Transmission Controller Unit does not sense engine

rpm, it will not release the park brake. If rpm is displayed
on the Monitor Display Unit (MDU), the torque converter
input sensor is working.
To apply the park brake, Park Brake Switch must be

moved from the Neutral, Center Detented position to the
Park Brake On, detented position. The Transmission
Controller will send a signal to de-energize the Park Brake
Release Solenoid and the park brake will apply.

011504
PN=350
The park brake also applies when the key switch is in the
Off position.
If the engine stops with the key switch On, park brake
applies when following conditions exist:
• Engine speed lower than 50 rpm (dead engine)

• Ground speed less than 0.5 km/hr (0.31 mph)
TX,9015,111928 –19–07AUG97–3/3
9015
15
,133

011504
PN=351
Back-Up Alarm And Park Brake Sensing And Park Brake Release Circuit Functional
Schematic
T110621 –19–23JUL97
TX,15,111767 –19–07AUG97–1/1

011504
PN=352
Pilot Enable And Boom Down Circuit

Operational Information

function if the pilot enable/boom down switch (S18) is in
the "Momentary Boom Lower" position.
• Key switch in the Off position

• Power to the Unswitched Boom Down, Radio and Dome
Light Fuse (F28)
If the pilot enable/boom down switch (S18) is in the On

position:
• Key switch in On, Bulb Check or Start position and

engine running 9015
• Chassis computer unit energized 15
• Power to the Pilot Enable 7.5A fuse (F16) ,135
• Service brake accumulator pressure switch (B27) closed
(S.N. 574051—)
CED,TX02661,129 –19–11JUL00–1/1

011504
PN=353
Pilot Enable And Boom Down Circuit Theory

Of Operation
This circuit allows the operator to lower the boom with the
engine off.
The pilot enable/boom down switch (S18) has two

positions: On and Momentary Boom Lower.
Pilot Enable/Boom Down Switch "On" Position:
The key switch must be in On, Bulb Check, or Start

position and the engine running. The chassis computer
unit (A2) (pin C3 of 30-pin connector) sends a signal to
energize the detent enable relay (K32). In later machines
9015 (S.N. 574051—), the accumulator pressure switch (B27)
15 must be closed before the CCU will energize relay K32.
,136 Power from the energized ignition relay (K4) flows through
the detent enable relay to the pilot enable 7.5A fuse
(F16).
From the pilot enable fuse, power flows through the pilot
enable boom down switch to activate the boom down
solenoid (Y15) and pilot enable solenoid (Y14). A pilot
enable/boom down 1A diode (V9) functions to limit the
voltage spike back to the switch contacts when the
solenoids are energized and de-energized.
When the pilot enable/boom down switch (S18) is

powered in the On position, the BHKO and RTD 5A fuse
(F15) is also powered.
Pilot Enable/Boom Down Switch "Momentary Boom

Lower" Position:
With the key switch in the Off position, power flows from
the unswitched boom down, radio, and dome light fuse
(F28) to the pilot enable/boom down switch. When the
switch is in the Momentary Boom Lower position, power
flows through the switch to energize the pilot enable
solenoid and the boom down solenoid. A pilot
enable/boom down 1A diode functions to limit the voltage
spike back to the switch contacts when the solenoids are
energized and de-energized.
See Pilot Enable And Boom Down Circuit Functional

Schematic for individual circuit schematic.
TX,15,111213 –19–11JUL00–1/1

011504
PN=354
Pilot Enable And Boom Down Circuit Functional Schematic
9015
15
,137
–19–28JAN97
T106269
TX,15,111214 –19–20AUG96–1/1

011504
PN=355
Return To Carry, Boom Height Kickout And

Return To Dig Circuit Operational
Information
The pilot controller is a manually-operated, hydraulic valve

that controls the boom and bucket motions. Solenoids
inside the pilot controller engage the float, boom height
kickout and return to dig detents.
The engine must be running for these circuits to function.
TX,15,111215 –19–17AUG96–1/1
9015
15
,138

011504
PN=356
Return To Carry, Boom Height Kickout And Return To Dig Circuit Theory Of Operation
T120486 –19–10MAR99
TX,15,111774 –19–10MAR99–1/4

011504
PN=357
S.N. — 585560 The boom height kickout detent coil in the pilot
controller (A4) is powered when the boom is below the
The return to carry, boom height kickout and return to boom height kickout position. If the pilot controller lever
dig circuits are powered through the pilot enable/boom is pulled fully to the boom up position, the boom height
down switch (S18) when the switch is in the On kickout detent will hold the lever in that position. The
position and the engine is running. When the switch is boom will raise until the boom height kickout switch
in the Off position, with engine running, the return to aligns with the boom height kickout actuator plate.
carry, boom height kickout and return to dig circuits will Then the boom height kickout switch will close, the
not be powered. boom height kickout detent coil will de-energize, the
pilot controller will return to center position, and the
The float electromagnetic detent coil is powered boom will stop in the boom height kickout position.
whenever the engine is running and the return to carry
enable switch (S15) is Off, and the pilot controller (A4) The return to dig switch (S17) closes when the bucket
lever is pushed fully forward. The boom will lower to is moved below the dig position. The dig position is
the float position, and the detent coil will hold the lever determined by the location of the actuator bar.
in that position. However, it can be manually
9015
15 disengaged by pulling back on the control lever. On The return to dig detent coil in the pilot controller is
,140 machines without return-to-carry enable switch, a powered when the bucket is below the dig position. If
jumper wire harness is required between the P11 Red the pilot controller lever is pulled fully to the bucket
wire and the H12 GRN wire for float position. rollback position, the return to dig detent will hold the
lever in that position. The bucket will move until the
An optional return to carry function is also available. actuator bar passes by the return to dig switch. The
When the return to carry enable switch (S15) is in the return to dig switch (S17) will open or the return to dig
On position and the pilot controller in the float position, switch (S33) will close. Then the return to dig detent
the boom will float down until it reaches a preset coil will de-energize, the pilot controller will return to
height. The magnetic detent will release when the the center position, and the bucket will stop in the dig
boom reaches the preset position and the return to position. The detent can be manually released by
carry switch (S14) on the boom will open. The return moving the control lever to the right.
to carry height position is determined by the location of
the return to carry actuator plate. To adjust these functions, see Group 9025—20 for:
The boom height kickout switch (S16) closes when the • Boom Height Kickout Adjustment
boom is raised above the boom height kickout position. • Return-to-Carry Kickout Adjustment
The boom height kickout position is determined by the • Return-to-Dig Adjustment
location of the boom height kickout actuator plate.

011504
PN=358
T159429 –19–17OCT02

011504
PN=359
S.N. 585561 — the center position, and the bucket will stop in the dig
position. The detent can be manually released by
The return to carry, boom height kickout and return to moving the control lever to the right.
dig circuits are powered through the pilot enable/boom
down switch (S18) when the switch is in the On See Return to Dig Adjustment to adjust return to dig
position and the engine is running. When the switch is position. (Group 9015-20.)
in the Off position, with engine running, these circuits
will not be powered. Boom Height Kickout and Return to Carry
Float Position Both boom height kickout and return to carry are
controlled by the Chassis Controller (CCU). The
The float electromagnetic detent coil is powered operator sets these positions using the Boom Height
whenever the engine is running and the return to carry Kickout Switch (S16) and Return to Carry Switch
enable switch (S15) is Off, and the pilot controller (A4) (S15).
lever is pushed fully forward. The boom will lower to
the float position, and the detent coil will hold the lever The CCU receives a signal from the Boom Position
9015
15 in that position. However, it can be manually Sensor (B9). This sensor varies voltage based on
,142 disengaged by pulling back on the control lever. boom position, which the CCU uses to determine
boom position. The CCU stores the voltage output
Return to Dig from this sensor when the operators sets height and
carry kickout positions. These voltage value will be
The return to dig switch (S17) closes when the bucket stored until the operator resets them.
is moved below the dig position. The dig position is
determined by the location of the actuator bar. When the pilot controller is moved to the full boom
raise or lower position, detent magnets in the pilot
The return to dig detent coil in the pilot controller is control will hold the lever until to boom reaches the
powered when the bucket is below the dig position. If position set by the operator. The CCU will de-energize
the pilot controller lever is pulled fully to the bucket detent coil, the pilot controller will return to center
rollback position, the return to dig detent will hold the position, and the boom will stop in the set positions.
lever in that position. The bucket will move until the
actuator bar passes by the return to dig switch. The See Boom Height Kickout Adjustment or
return to dig switch (S17) will open or the return to dig Return-To-Carry Kickout Adjustment for adjustment
switch (S33) will close. Then the return to dig detent procedures. (Group 9015-20.)
coil will de-energize, the pilot controller will return to
TX,15,111774 –19–10MAR99–4/4

011504
PN=360
Differential Lock, Pin Disconnect, And Axle Disconnect Circuit Functional Schematic
9015
15
,143
–19–05SEP97
T110242
TX,15,111218 –19–28JAN97–1/1

011504
PN=361
Front Wiper Circuit Functional Schematic
9015
15
,144
–19–05SEP97
T110243
TX,15,111777 –19–19AUG97–1/1

011504
PN=362
Rear Wiper Circuit Functional Schematic
9015
15
,145
–19–05SEP97
T110244
TX,15,111779 –19–19AUG97–1/1

011504
PN=363
Secondary Steering Circuit Specifications
B25 Steering System Pressure

Switch (Secondary Steering)
Closed during normal operation; Pressure 240 kPa (2.4 bar) (35 psi)
Opens when steering pressure is
less than
CED,TX17864,72 –19–01APR98–1/1
Secondary Steering Circuit Operational

9015 Information
15
,146
The following conditions must exist for the secondary
steering function to operate.
• Battery disconnect switch on

• Engine running
• Steering pressure lower than 240 kPa (2.4 bar) (35 psi)
• Secondary Steering mode selected (or turned On) in the
monitor display unit Service Diagnostics Menu (S 061)
CED,TX17864,73 –19–01APR98–1/1

011504
PN=364
Secondary Steering Circuit Theory Of

Operation
With the key switch in the ACC or On position power

flows through the energized Accessory Relay #2 to the
Secondary Steering, Park Brake and Service Brake
Pressure Switches 5A Fuse.
The secondary steering pressure switch is closed when

the steering pressure is normal. When the steering
pressure is lower than 240 kPa (2.4 bar) (35 psi), the
switch will open and send a signal to the chassis
computer unit (pin X2 of the 60-pin connector).
The chassis computer unit will then send a signal (pin D2

of the 30-pin connector) to energize the secondary 9015
steering relay. Power flows through the Converter, 15
Secondary Steering and Start Aid 7.5A Fuse, through the ,147
secondary steering relay to energize a relay in the
secondary steering pump motor. Battery power is then
sent to the pump motor from the starter motor, and the
pump motor will operate.
CED,TX17864,74 –19–01APR98–1/1

011504
PN=365
Secondary Steering Circuit Functional Schematic
9015
15
,148
–19–24FEB98
T113680
CED,TX17864,75 –19–01APR98–1/1

011504
PN=366
Horn Circuit Functional Schematic
9015
15
,149
–19–28JAN97
T106352
TX,15,111226 –19–28JAN97–1/1

011504
PN=367
Flasher And Turn Signal Functional Schematic
9015
15
,150
–19–28JAN97
T106275
TX,15,111227 –19–28JAN97–1/1

011504
PN=368
Tail And Marker Light Circuit Theory Of

Operation
The Chassis Computer Unit (A2) reads the digital input of

the Drive and Tail/Marker Light Switch (S26) every 20
mSec ± 10 mSec and determines if the status of the
switch changes and if it is consistent for at least three
readings.
The status of the Drive and Tail/Marker Light Switch will

be transmitted from the CCU to turn on the following
lights:
• Left Front Marker Light (E6)

• Right Front Marker Light (E7)
• Left Tail Light (E8) 9015
• Right Tail Light (E9) 15
• License Plate Light (E10) ,151
• Panel Light (Above Right Panel) (E19)
TX,15,111228 –19–24AUG96–1/1

011504
PN=369
Tail And Marker Light Circuit Functional Schematic
9015
15
,152
–19–09SEP97
T110247
TX,9015,111896 –19–19AUG97–1/1

011504
PN=370
Drive Light Circuit Theory Of Operation
The Chassis Computer Unit (A2) reads the digital input of

the Drive and Tail/Marker Light Switch (S26) every 20
mSec ± 10 mSec and determines if the status of the
switch changes and if it is consistent for at least three
readings.
When the Drive and Tail/Marker Light Switch is in the

Drive Light position, the Drive Light Relay (K25) becomes
energized with power provided from the Drive and
Tail/Marker switch. The Front Drive Lights (E11 and E12)
are then powered from the normally closed contacts of the
Hi-Beam Relay (K27).
9015
15
,153
TX,15,111230 –19–24AUG96–1/1

011504
PN=371
Drive Light Circuit Functional Schematic

T110248 –19–19SEP97
TX,15,111785 –19–19AUG97–1/1

011504
PN=372
Brake And Light Circuit Specifications
BRAKE LIGHT PRESSURE SWITCH

(B40) (Normally Open)
Closes at Pressure 415 ± 275 kPa (6 ± 1.4 bar) (80 ± 20

psi)
TX,15,111232 –19–31JUL96–1/1
Brake And Light Circuit Operational

Information 9015
15
,155
function:
• Key switch On
• Power to the chassis computer
• Brakes applied
• Signal received at chassis computer from closed brake
light pressure switch
TX,15,111233 –19–31JUL96–1/1
Brake And Light Circuit Theory Of Operation
Power flows from the key switch BATT terminal, through

the brake light 7.5A fuse to the brake light relay.
When the brakes are applied, the brake light pressure

switch closes at 414 ± 275 kPa (6 ± 1.4 bar) (80 ± 20 psi)
and sends a signal to the chassis computer unit (pin X3 of
60-pin connector). This will allow the brake light relay to
energize. Power is then sent to the left and right rear
brake lights and they will come on.
TX,15,111234 –19–31JUL96–1/1

011504
PN=373
Brake And Light Circuit Functional Schematic
9015
15
,156
–19–05SEP97
T110249
TX,15,111786 –19–13FEB97–1/1

011504
PN=374
Cab Work Light Circuit Operational

Information
The following conditions must exist for the cab work light
circuit to function:
• Key switch (S1) in the On position

• Power to the cab work light 10A circuit breaker (F29)
• Cab work light switch (S30) turned to On position
TX,15,111236 –19–21AUG96–1/1
Cab Work Light Circuit Theory Of Operation

9015
The chassis computer unit (A2) reads the digital input of 15
the cab work light switch (S30) every 20 mSec ± 10 mSec ,157
and determines if the status of the switch changes and if it
is consistent for at least three readings.
The On or Off status of the cab work light switch will be

transmitted to the monitor display unit (H2) by way of the
CAN link, to turn the work light indicator on the monitor
On or Off.
The status of the cab work light switch will be transmitted

from the chassis computer unit to turn the work lights
(E20, E21, E22, E23) On or Off.
TX,15,111237 –19–21AUG96–1/1

011504
PN=375
Cab Work Light Circuit Functional Schematic
9015
15
,158
–19–26AUG97
T106274
TX,15,111788 –19–19AUG97–1/1

011504
PN=376
Converter And Radio Circuit Functional Schematic
9015
15
,159
–19–26AUG97
T106273
Converter and Radio Circuit Functional Schematic (S.N. —578925)


011504
PN=377
9015
15
,160
–19–17JAN01
T136542
Converter and Radio Circuit Functional Schematic (S.N 578926—)
TX,15,111789 –19–19AUG97–2/2

011504
PN=378
Engine Controller Unit Circuit Theory Of Operation

T131590 –19–13JUL00
CED,TX17864,78 –19–01APR98–1/5

011504
PN=379
S.N. — 585560 from B3 fuel temperature sensor, B5 primary speed

sensor, and B2 auxiliary speed sensor. Controlling the
NOTE: See Electronic Controllers Block Diagram at rack position in this way improves cold starting and
end of this group for additional information how black smoke is greatly reduced during hot starting.
engine controller unit interacts with the other This starting mode is activated either by the controller
electronic controllers. sensing the key switch in the START position or an
engine speed greater than 60 rpm. The starting fuel
The A1 engine controller unit is powered when the S2 quantity is not affected by the throttle position.
battery disconnect switch is ON, and the S1 key switch
is in the ON or START position. When the key switch With engine running, the engine controller will vary fuel
is turned to the ON position, power is sent from the delivery to the engine based on throttle and engine
key switch through B03 RED wire to energize K4 speed inputs. Throttle input, generated by the operator,
Ignition Power Relay. Power then flows through B10 is first received by the chassis computer unit where it
RED to F5 Engine Controller Unit 15A Fuse. Power is transferred to the ECU by way of the CAN link. Rack
continues to flow through P08 RED until it arrives at position is controlled by the engine controller adjusting
the ECU. The ECU then sends power to the Y16 the current level to the actuator solenoid until the rack
9015
15 Secondary Fuel Shutoff Solenoid which open the fuel position signal from the injection pump matches the
,162 valve and allows fuel to reach the pump. commanded signal. The controller turns off current to
the educator solenoid, when no fuel is desired. If a
When the key switch is turned to the START position situation occurs where the controller cannot control the
the controller sends power to Y15 Rack Actuator rack position, the fuel shut-off solenoid will be turned
Solenoid which moves the rack to starting fuel off in addition to the actuator solenoid.
positions based on engine controller input received

011504
PN=380
T131590 –19–13JUL00

011504
PN=381
S.N. 585561 — Fuel Temperature Sensor (B6)
See Electronic Control System Terminology for engine Engine control unit uses the fuel temperature sensor
sensor definitions. (B6) to calculate fuel density and adjust fuel delivery
accordingly.
The engine control unit (ECU) (A1) converts analog
voltage signals from various sensors into digital signals For information on sensor testing, see Engine Control
the central processing unit can understand. Unit Temperature Sensors Test. (Group 9015-20.)
The central processing unit performs computations to Water In Fuel Sensor (B48)
control injection fuel quantity and injection timing. It
communicates the desired fuel quantity and timing to Water In Fuel Sensor (B48) sends a signal to engine
the high pressure fuel pump and electronic injectors. control unit when water is detected in the fuel.
See Electronic Control System Operation. (CTM255.)
See Water In Fuel (WIF) Sensor theory for more
The ECU controls engine speed according to position information. (CTM225.)
9015
15 of Throttle Position Sensor (B14) attached to the
,164 accelerator pedal. This signal is sent to the ECU from Fuel Rail Pressure Sensor (B49)
the Chassis Computer Unit (CCU) over the CAN.
Fuel Rail Pressure Sensor (B49) controls the amount
Coolant Sensor (B16) and timing of fuel transferred from the high pressure
fuel pump.
Coolant overheat sensor (B16) is a temperature
sensitive variable resistor. ECU sends 5 volts to the See Measuring Pressure for theory on all engine
sensor, monitors voltage drop across the sensor and pressure sensors for more information. (CTM255.)
compares voltage drop to pre-programmed values to
determine temperature. For information on sensor testing, see Engine Control
Unit Pressure Sensors and Solenoids Test. (Group
For information on sensor testing, see Engine Control 9015-20.)
Unit Temperature Sensors Test. (Group 9015-20.)
Engine Crank Speed Sensor (B4)
Manifold Air Temperature Sensor (B5)
Engine Crank Speed Sensor (B4) is an inductive type
See Measuring Temperature. (CTM255.) pickup sensor that detects teeth on the timing wheel.
ECU uses the crank position input to determine engine
Manifold air temperature sensor (B5) is a temperature speed and precise piston position in relation to firing
sensitive voltage resistor. ECU sends 5 volts to the order. The crank timing wheel is composed of evenly
sensor, monitors voltage drop across the sensor and spaced teeth, with two ground off. The ground teeth
compares voltage drop to pre-programmed values to help the ECU determine when cylinder #1 is at
determine temperature. ECU uses this sensor to top-dead-center.
monitor manifold air temperature.
See Measuring Engine Speed theory on all engine
For information on sensor testing, see Engine Control speed sensors for more information. (CTM225.)
Unit Temperature Sensors Test. (Group 9015-20.)

011504
PN=382
For information on sensor testing, see Engine Control signal to the solenoids to regulate delivery of fuel to
Unit Speed Sensors Test. (Group 9015-20.) the high pressure common rail. When the solenoids
are energized, fuel is discharged from the high
Engine Cam Speed Sensor (B5) pressure fuel pump to the high pressure common rail.
Engine Cam Speed Sensor (B5) is an inductive type See Pump Control Valves (PCV’s) theory for more
pickup sensor that detects notches on the auxiliary information.
gear of the high pressure fuel pump camshaft. The
auxiliary gear is composed of evenly spaced notches For information on solenoid testing, see Engine Control
with one additional notch offset to tell the ECU that Unit Pressure Sensors and Solenoids Test. (Group
cylinder #1 is approaching top-dead-center. 9015-20).
See Measuring Engine Speed theory on all engine Electronic Fuel Injectors (Y11—Y16)
speed sensors for more information. (CTM225.)
ECU controls start of injection and amount of fuel
For information on sensor testing, see Engine Control injected by energizing and de-energizing the two-way
9015
Unit Speed Sensors Test. (Group 9015-20.) valve on the injectors. For additional information, see 15
Electronic Injector (EI) Operation. (CTM255.) ,165
High Pressure Fuel Pump (Solenoid 1) (Y8) and
High Pressure Fuel Pump (Solenoid 2) (Y9)
Solenoids (Y8 and Y9) are located on the high

pressure fuel pump. The ECU sends an electronic
CED,TX17864,78 –19–01APR98–5/5

011504
PN=383
Engine Controller Unit Circuit Specifications

(S.N. — 585560)
Specification
Primary Speed Sensor (B5)—
Normal Range Resistance .............................................. 600—1500 ohms
Specification
Auxiliary Speed Sensor (B2)—
Normal Range Resistance ............................................ 2500—3500 ohms
Specification
Rack Position Sensor (B4)—
Normal Range Resistance .................................................... 14—26 ohms
NOTE: See also Output Specifications
9015 Specification
15 Fuel Temperature Sensor (B3)—
,166 Normal Range Resistance .............................................. 50—50000 ohms
Fuel Temperature Sensor Output Specifications

Temperature (C°) Temperature (F°) Resistance (ohms)
-20 -4 15300
0 32 5840
20 68 2500
40 104 1180
60 140 600
80 386 327
100 212 188
CED,TX17864,76 –19–01APR98–1/1

011504
PN=384
Engine Controller Unit—Input Signals

(S.N. — 585560)
Fuel Temperature Sensor (B3)
The Fuel Temperature Sensor is located in the top of the

injection pump. This sensor monitors temperature of fuel
entering the injection pump. The ECU uses this signal to
compensate fuel delivery as fuel temperature and density
varies.
Primary Speed Sensor (B5) (S.N. — 572975)
This sensor is located inside the rear of the injection

pump. The ECU uses this signal to compare to the
command signal given by the operator input. The ECU 9015
relies on this sensor to know if the engine speed matches 15
the speed required by the throttle input. ,167
Auxiliary Speed Sensor (B2)
This sensor is mounted at the right hand side of the timing

gear cover (viewed from the rear of the engine.) It
monitors the teeth on the camshaft gear to detect engine
speed.
For early machines (S.N. — 572975), this sensor is

backup for the primary speed sensor and is only used in
the event of a primary speed sensor failure.
Later machines (S.N. 572976—) use this sensor as the

primary speed sensor. The ECU uses this signal to
compare to the command signal given by the operator
input. The ECU relies on this sensor to know if the engine
speed matches the speed required by the throttle input.
Rack Position Sensor (B4)
This sensor is located inside the rear of the injection

pump. It monitors the position of the injection pump fuel
rack to detect if rack position matches the command given
to the rack actuator solenoid.
Key Switch (S1)

011504
PN=385
During start up the key switch sends a signal to the ECU

to tell it the engine is in the process of starting. When this
happens the ECU moves the rack to starting fuel positions
based on engine controller input received from B3 fuel
temperature sensor, B5 primary speed sensor, and B2
auxiliary speed sensor. This function will override all
signals received from the throttle position sensor
generated by operator input.
CAN Link
During normal operation, all throttle inputs are received by

the ECU from the chassis controller unit through the CAN
link.
9015
15
,168
CED,TX17864,79 –19–01APR98–2/2

011504
PN=386
Engine Controller Unit Connector Signals (S.N. — 585560)
9015
15
,169
–19–13JUL00
T132472

011504
PN=387
ENGINE CONTROLLER UNIT (A1) CONNECTOR SIGNALS

(PART A OF CONNECTOR)
A1 P08 Red Power from Engine Controller Unit 20 A Fuse (F5)
B1 G01 Black To Single Point Ground on Starter Motor (M1)
C1 G01 Black To Single Point Ground on Starter Motor (M1)
D1 P12 Red Power to Rack Position Sensor (B4)
E1 Plug
F1 X02 Yellow Input from Fuel Temperature Sensor (B3)
G1 Plug
H1 R07 Ground for Rack Position Sensor (B4)
J1 Plug
K1 Plug
A2 E06 White Signal to Rack Actuator Solenoid (Y15)
9015
15 B2 Plug
,170 C2 M13 Purple To MDU CAN Link
D2 R08 Black Ground for Auxiliary Speed Sensor (B2), Fuel Temperature Sensor (B3), and Primary
Speed Sensor (B5)
E2 Plug
F2 Plug
G2 Plug
H2 Plug
J2 M02 Purple Input from Auxiliary Speed Sensor (B2)
K2 Plug
A3 E06 White Signal to Rack Actuator Solenoid (Y15)
B3 E07 White Power to Secondary Fuel Shut-Off Solenoid
C3 M04 Purple Signal from Rack Position Sensor
D3 M12 Purple To MDU CAN Link
E3 Plug
F3 Plug
G3 Plug
H3 Plug
J3 M03 Purple Input from Primary Speed Sensor (B5)
K3 Plug

011504
PN=388
ENGINE CONTROLLER UNIT (A1) CONNECTOR SIGNALS

(PART B OF CONNECTOR)
A1 Plug
B1 Plug
C1 Plug
D1 Plug
E1 Plug
F1 Plug
A2 Plug
B2 Plug
C2 Plug
D2 Plug
E2 Plug
9015
F2 Plug 15
A3 Plug ,171
B3 Plug
C3 P01 Red Power from 5 A Neutral Start Fuse (F3)
D3 Plug
E3 Plug
F3 Plug
CED,TX17864,81 –19–01APR98–3/3

011504
PN=389
Electronic Controllers Block Diagram
9015
15
,172
–19–10MAR99
T120487
TX,9015,HH949 –19–01APR99–1/1

011504
PN=390

JOHN DEERE 644H Cargador F. Manual Taller Parte 1 2004 PDF

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644H and 644H MH

For complete service information also see:

This manual is written for an experienced technician.

Live with safety: Read the safety messages in the

This is the safety-alert symbol. When you see this

Technical manuals are divided in two parts: repair and

Information is organized in groups for the various

Technical Manuals are concise guides for specific

Fundamental service information is available from other

TM1637 (15JAN04) 644H and 644H MH Loader

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TM1637 (15JAN04) 644H and 644H MH Loader

TM1637 (15JAN04) 644H and 644H MH Loader

SECTION 9005—Operational Checkout Procedure

SECTION 9015—Electrical System

SECTION 9020—Power Train

SECTION 9025—Hydraulic System

SECTION 9031—Heating And A/C

All information, illustrations and specifications in this manual are based on

TM1637 (15JAN04) i 644H and 644H MH Loader

TM1637 (15JAN04) ii 644H and 644H MH Loader

Group 01—Safety Information Handle Fuel Safely—Avoid Fires. . . . . . . . .9000-01-11

TM1637 (15JAN04) 9000-1 644H and 644H MH Loader

TM1637 (15JAN04) 9000-2 644H and 644H MH Loader

TM1637 (15JAN04) 9000-01-1 644H and 644H MH Loader

This is a safety-alert symbol. When you see this symbol

Understand Signal Words

A signal word—DANGER, WARNING, or CAUTION—is

DANGER or WARNING safety signs are located near

Follow Safety Instructions

Carefully read all safety messages in this manual and on

Learn how to operate the machine and how to use

Keep your machine in proper working condition.

If you do not understand any part of this manual and need

TM1637 (15JAN04) 9000-01-2 644H and 644H MH Loader

Be careful when operating on a slope.

Avoid sharp turns.

Balance loads so weight is evenly distributed and load is

Know capacity of machine. Do not overload.

Be careful when operating at the edge of an excavation,

Read and understand the operating instructions in this

TM1637 (15JAN04) 9000-01-3 644H and 644H MH Loader

To avoid backover accidents:

Always look around before you back up. Be sure that

Keep bystanders away from pivot area of an articulated

Keep reverse warning alarm in working condition, if

Use a signal person when backing up if view is

Learn the meaning of all flags, signs, and markings used

Keep windows, mirrors, and lights clean and in good

Dust, heavy rain, fog, etc., can reduce visibility. As

Read and understand the operating instructions in this

TM1637 (15JAN04) 9000-01-4 644H and 644H MH Loader

Select level ground when possible to park machine.

Move transmission control lever to neutral "N", engage

Lower all equipment to ground.

Stop the engine.

Block all wheels if you must park on a grade. Position