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John Deere Motor Tier Ii Diagr. Elect. & DTC PDF
John Deere Motor Tier Ii Diagr. Elect. & DTC PDF
John Deere
Tier II Engine
Troubleshooting
31200371
Original
February 2, 2007
EFFECTIVITY PAGE
Section 1
Safety Practices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.1
1.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2
1.2 Disclaimer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2
1.3 Operation & Safety Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2
1.4 Do Not Operate Tags . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2
1.5 Safety Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.3
1.6 Safety Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.3
1.7 Safety Decals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.4
Section 2
General Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.1
2.1 Basic Engine Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.2
2.2 Pre-Troubleshooting Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.2
2.3 Electronic Control System Terminology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.3
2.4 Electronic Control System Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.4
2.5 Monitoring Engine Parameters. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.4
2.6 Electronic Control System Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.4
2.7 ECU Connector Legend . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.5
2.8 OEM Trim Option Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.6
Section 3
Function Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.1
3.1 Troubleshooting Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.2
3.2 Retrieving Fault Codes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.3
3.3 Engine Derate Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.5
3.4 Engine Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.6
3.5 ECU Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.12
3.6 CAN Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.14
3.7 Electrical Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.15
Section 4
Electrical Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.1
4.1 Wiring Schematics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.2
Contents
DANGER indicates an imminently hazardous situation LIFTING: NEVER lift a heavy object without the help of at
which, if not avoided, will result in death or serious injury. least one assistant or a suitable sling and hoist.
ENGINE: Stop the engine before performing any service TIRES: Always keep tires inflated to the proper pressure
unless specifically instructed otherwise. to help prevent tipover. DO NOT over-inflate tires.
VENTILATION: Avoid prolonged engine operation in NEVER use mismatched tire types, sizes or ply ratings.
enclosed areas without adequate ventilation. Always use matched sets according to machine
specifications.
SOFT SURFACES AND SLOPES: NEVER work on a
machine that is parked on a soft surface or slope. The MAJOR COMPONENTS: Never alter, remove, or
machine must be on a hard level surface, with the wheels substitute any items such as counterweights, tires,
blocked before performing any service. batteries or other items that may reduce or affect the
overall weight or stability of the machine.
FLUID TEMPERATURE: NEVER work on a machine
when the engine, cooling or hydraulic systems are hot. BATTERY: DO NOT charge a frozen battery.Charging a
Hot components and fluids can cause severe burns. frozen battery may cause it to explode. Allow the battery
Allow systems to cool before proceeding. to thaw before jump-starting or connecting a battery
charger.
FLUID PRESSURE: Before loosening any hydraulic or
diesel fuel component, hose or tube, turn the engine
1.7 SAFETY DECALS
OFF. Wear heavy, protective gloves and eye protection.
NEVER check for leaks using any part of your body; use Check that all safety decals are present and readable on
a piece of cardboard or wood instead. If injured, seek the machine. Refer to the Operation & Safety Manual
medical attention immediately. Diesel fluid leaking under supplied with machine for information.
pressure can explode. Hydraulic fluid and diesel fuel
leaking under pressure can penetrate the skin, cause
infection, gangrene and other serious personal injury.
Relieve all pressure before disconnecting any
component, part, line or hose. Slowly loosen parts and
allow release of residual pressure before removing any
part or component. Before starting the engine or applying
pressure, use components, parts, hoses and pipes that
are in good condition, connected properly and are
tightened to the proper torque. Capture fluid in an
Contents
2.1 BASIC ENGINE CHECKS • Crank position sensor that is not giving consistent
readings can cause hard starting, shutdown, erratic
throttle issues. This is a John Deere isssue. Just be aware
If the engine will not run or is running erratically, the fault may of the effect this sensor can have.
not be related to the electronic system. Ensure that the following
Check critical connectors for signs of looseness, corrosion,
points are checked before ECU troubleshooting.
damage, etc. The following connectors are critical:
• Travel Select Lever is in the (N) NEUTRAL position
• ECU Connector
• Park brake is set
• Crank position sensor at front of engine
• Throttle pedal has free range of motion without interuption
• Fuel pump solenoid connector
• Sufficient fuel in the fuel tank for engine operation
• Cam position sensor on block
• Fuel quality is of an acceptable rating
• ECU water temperature sensor on thermostat housing (not
• Battery power and ground connections are secure to be confused with the JLG/Gradall installed water
temperature sensor)
• Fuel tank vent hose is clear of obstructions
The order in which the steps should be taken are as follows:
• No restrictions in the exhaust or intake system
1. Check all fuel and air filters, water ingression into this
• No broken fins on turbo equipped models
system will promote fault codes. Daily draining of the fuel/
• No restrictions in fuel filters water separator is recommended.
• No water in the fuel system 2. Check the condition of the fuel lines from the tank to the
engine.
2.2 PRE-TROUBLESHOOTING CHECKS 3. Check the fuel tank cap vent.
The following is a basic checklist of items to check when 4. Check all engine fault codes and record them. Refer to
troubleshooting engine ECU issues on John Deere engines. Section 3.2, “Retrieving Fault Codes.”
Some of the reported issues have been engine shutdown, 5. Check all wiring and socket conditions. A check for ground
erratic running, and erratic throttle position. This list is not for and positive voltage supply at the John Deere, 9 pin
actual ECU troubleshooting, but rather external factors that may connector is also recommended. This would also detect a
affect ECU operation. Check fault codes prior to checking the harness issue on the JLG side.
following items. Refer to Section 3.2, “Retrieving Fault Codes,” 6. After all JLG/Gradall supplied items have been inspected,
for more information on fault codes. Some of the items below repaired, corrected and/or replaced, then the John Deere
may not show a fault code. Dealer should be called to install the latest version of ECU
• Check the female sockets in the engine harness plug that software. Refer to Section 2.8, “OEM Trim Option
attaches to the engine’s ECU. Use the proper tension Settings.”. The John Deere Dealer will need to file a
gauge or a male pin to ensure that the female socket is in DETAC case and request, the “OEM Trim Options”
good condition. If it is not, the socket will have to be payload replacement software.
replaced. Usage of dielectric grease on all connections is
required. 7. If the problem comes back, then the ECU will have to be
• Check bolt used to retain harness connector to ECU. If replaced with a new one that has been updated.
loose, it needs to be tightened. Check operation after
tightening bolt. Loctite® 242 should be applied to threads if
bolt is loose.
• Verify brass insert in ECU is not loose. In addition, it may
be possible in some situations that the brass insert may
not allow full seating of the connector bolt. If the connector
bolt is tight, and you are able to “wiggle” the connector, the
brass insert in the ECU is suspect. Contact your local John
Deere service dealer with full details.
• Verify ground cable attachment on engine and frame.
Check that bolts are tight; verify ground is clean and bare
for contact between ground connection and frame. ECU
primary supply ground wire must be properly secured in
the wedge connector.
• Verify positive cables are clean and tight. Primary ECU
power supply at the battery post is tight within the wedge
connection, that the fuse is supplied and working properly.
• Check the overall condition of the engine harness
including heat related damage and routing. Harness tie off
locations should leave a small amount of slack to the
individual sensors or ECU.
Term Definition
Actuator A device controlled by the (ECU) to perform a certain function.
Analog Signal which has a continuous range of possible voltages. Usually 0 to 5 volt or 0 to 12 volt
signals.
Boost Air charge pressure in the intake manifold.
CAN Controller Area Network. The electronic pathway network on vehicles that allows communication
between controllers.
DTC Diagnostic Trouble Code. A code which is stored in the ECU’s memory when the ECU detects a
problem in the electronic control system.
DST Diagnostic Scan Tool. This is a diagnostic software that is used to read engine parameters, check
DTC’s and run special tests. The DST consists of a Windows (‘95, ‘98, 2000) or NT compatible
computer and a hardware kit available from John Deere Distribution Service Center (DSC):
JDIS121 - ECU Communication Hardware Kit. The software is available to download from your
John Deere home page.
Digital A signal which consists of only two-volt levels - usually 0 volts and +5 volts.
ECT Engine Coolant Temperature (sensor). Measures the temperature of the engine coolant.
ECU Engine Control Unit. The computer which controls the fuel, air, and ignition systems on the engine.
FMI Failure Mode Identifier. The second part of a two-part code that identifies control system trouble
codes according to the SAE J1939 standard. The FMI identifies the type of failure that has
occurred. The first half of the code is the Suspect Parameter Number (SPN).
J1587-J1708 The Society of Automotive Engineers (SAE) standard for the electronic components of heavy duty
vehicles. J1587 is the software standard. J1708 is the hardware standard.
MAT Manifold Air Temperature (sensor). Measures the temperature of the air in the intake manifold.
PDM Parallel Data Module. Device used as part of the DST that allows communication with the ECU.
PROM Programmable, Read-Only Memory. The computer chip which contains the calibration information
for the engine control system.
PWM Pulse Width Modulation. A digital signal (not analog) which consists of a pulse generated at a fixed
frequency. When an actuator is controlled by a PWM signal, the on time of the signal is increased
or decreased (modulated) to increase or decrease the output of the actuator.
RAM Random Access Memory. The portion of computer memory within the ECU which changes as the
engine is running and is stored while the engine is off.
SAE Society of Automotive Engineers. Working with society to promote vehicle safety and maintenance
and energy resource conservation.
Sensor Device used by the ECU to monitor various engine parameters.
SPN Suspect Parameter Number. The first half of a two-part code that identifies control system fault
codes according to the SAE J1939 Standard. The SPN identifies the system of component that
has the failure. The second half of the code is the Failure Mode Identifier (FMI).
VBAT Battery voltage or unswitched voltage.
VSW Switch voltage
Contents
Manifold Air
Temperature (MAT)
Sensor
ECT Sensor
Loss of Coolant
Fuel Temperature Sensor
Sensor
Crank Position
Sensor
Electronic Control
Unit (ECU)
Pump Control
Solenoid Oil Pressure
Sensor
3.2 RETRIEVING FAULT CODES flash code 33 if there are any “stored” fault codes. If there
are no “stored” codes, the system will flash code 88.
1. Park the machine on a firm, level surface, level the 4. Once the code is retrieved, turn the ignition OFF.
machine, fully retract the boom, lower the boom, place the
Note: When the engine sensor inputs exceed normal
transmission control lever in (N) NEUTRAL and engage
operating ranges, the ECU will derate the amount of fuel that is
the park brake.
delivered to the engine. A fault code will always accompany a
2. Turn the ignition switch to “ON”. fuel derate. If the engine is running at a much lower rate, check
3. Push down and hold the reset button on the dash for 3-5 the fault codes first to see if the engine is experiencing an
seconds. The fault lamp will begin to flash a code number. internal problem.
The light will flash the first digit then pause for a short time
and then flash the second digit. If there are “active” codes,
the system will first flash code 32. If there are no “active”
codes, the system will flash code 88. The system will then
30A
VBAT
12VDC
012D, RED
022C, RED
K1 A2
J2
A3 B3 C3 D3 E3 F3 G3 H3 J3 K3
050G, BLK
A2 B2 C2 D2 E2 F2 G2 H2 J2 K2
A1 B1 C1 D1 E1 F1 G1 H1 J1 K1
100
80
IGNITION
SWITCH
BATTERY
VSW
30A
VBAT
12VDC
012D, RED
022C, RED
K1 A2
J2
A3 B3 C3 D3 E3 F3 G3 H3 J3 K3
050G, BLK
A2 B2 C2 D2 E2 F2 G2 H2 J2 K2
A1 B1 C1 D1 E1 F1 G1 H1 J1 K1
Crank Sensor
Crank Position Connector
Sensor
Crank Position Return
B B
447, PURPLE
448, GRAY
B2 D2
A3 B3 C3 D3 E3 F3 G3 H3 J3 K3
A2 B2 C2 D2 E2 F2 G2 H2 J2 K2
A1 B1 C1 D1 E1 F1 G1 H1 J1 K1
The crank position sensor is located on the front of the c. Backprobe Terminal A and test for continuity between
crankshaft behind the pressed-on crank gear. It is an inductive Pin A on the same side of the connector.
type pickup sensor that detects teeth on the crank timing wheel. • If continuity is found, repeat step for the other
The ECU uses the crank position input to determine engine terminals of the connector
speed and precise piston position in relation to the firing order. • If continuity is not found, repair or replace the
The crank timing wheel is composed of 46 evenly spaced teeth connector
and 2 missing teeth. The missing teeth help the ECU to • If continuity is found on all terminals and both sides of
determine “Top-Dead-Center” (TDC). the connector, proceed to next step
1. Refer to Section 2, “General Troubleshooting” for initial 6. Check Crank Position sensor Input and Return Wiring
checks before moving on to the following steps. a. Ignition OFF
2. Recover any fault codes. Refer to Section 3.2, “Retrieving b. Crank Position sensor connector still disconnected
Fault Codes.” A fault code will result if the ECU detects that c. Disconnect ECU connector
engine speed exceeds 3400 rpm. The ECU will shut fuel d. Backprobe wire B2 on the ECU connector and test for
off until engine speed is below 2800 rpm. continuity between Terminal A of the Crank Position
3. Inspect the Crank Position sensor and Timing Wheel sensor connector.
a. Remove crank position sensor from injection pump. • If continuity is found, check the sensor return wire
b. Inspect sensor for cracks, corrosion, or any foreign • If continuity is not found, there is an open in the
material on the end of the sensor. sensor input wiring OR a faulty ECU connector.
c. Inspect the crank timing wheel notches for burrs or e. Backprobe wire D2 on the ECU connector and test for
chips. continuity between Terminal B of the ECT sensor
• If a fault is found in a part, repair or replace the part. connector.
4. Test the Crank Position sensor. • If continuity is found, proceed to next step.
3.4.4 Engine Misfires/Runs Irregularly 10. With engine running at a moderate engine rpm, loosen the
injector fuel supply hard lines one at a time. A drop in the
engine rpm would indicate the cylinder is OK. If there is no
change in engine rpm, contact your local John Deere
service distributor.
11. If all checks are completed and the engine still does not
operate properly, contact your local John Deere service
distributor.
MY1030
IGNITION
SWITCH
BATTERY
VSW
30A
VBAT
12VDC
012D, RED
022C, RED
K1 A2
J2
A3 B3 C3 D3 E3 F3 G3 H3 J3 K3
050G, BLK
A2 B2 C2 D2 E2 F2 G2 H2 J2 K2
A1 B1 C1 D1 E1 F1 G1 H1 J1 K1
IGNITION
SWITCH
BATTERY
VSW
30A
VBAT
12VDC
012D, RED
022C, RED
K1 A2
J2
A3 B3 C3 D3 E3 F3 G3 H3 J3 K3
050G, BLK
A2 B2 C2 D2 E2 F2 G2 H2 J2 K2
A1 B1 C1 D1 E1 F1 G1 H1 J1 K1
1. Refer to Section 2, “General Troubleshooting” for initial 5. If all checks are completed and the engine still does not
checks before moving on to the following steps. operate properly, contact your local John Deere service
2. Recover any fault codes. Refer to Section 3.2, “Retrieving distributor.
Fault Codes.” A fault code will result if the ECU detects
voltage is on the switched voltage input wire to the ECU.
3. Check the ECU Power Wiring
a. Ignition OFF
b. Disconnect ECU connector.
c. Backprobe wire K1 and wire J2 and check for 12 VDC.
• If the required voltage is found, test the A2 circuit
• If voltage is not found, there is an open in the ECU
Power wiring
d. Backprobe wire A2 and wire J2 and check for 12 VDC
with the ignition ON.
• If the required voltage is found, test the Engine
Cranking Speed
• If the required voltage is not found, there is an open
in the ECU Power wiring
4. Test the ECU connector
a. Ignition OFF
b. ECU connector still disconnected
c. Backprobe wire K1 on the ECU connector and check
for continuity with pin K1 on the harness end of the
connector.
• If continuity is found, repeat this step for the A2 and
J2 circuits of the ECU connector.
• If continuty is not found, there is a faulty ECU
connector.
• If continuity is found on all circuits, proceed to next
step.
F1 F2 F3
D D G1G2 G3
E C
C H1 H2 H3
J1 J2 J3
F A B E K1 K2 K3
G B SWITCHED VOLTAGE
J
H A STATIC GROUND
DIAGNOSTIC
CONNECTOR
B A
B
A
C
C MAN0020
A A MAT Input
463, Orange
914E, Yellow
D1 D3
A3 B3 C3 D3 E3 F3 G3 H3 J3 K3
A2 B2 C2 D2 E2 F2 G2 H2 J2 K2
A1 B1 C1 D1 E1 F1 G1 H1 J1 K1
The Manifold Air Temperature (MAT) sensor is a thermistor • If measurement is between 2500 and 3500 ohms,
(temperature sensitive resistor) mounted in the intake manifold. proceed to next step.
The MAT sensor is used to measure the temperature of the • If measurement is below 2500 ohms or above
intake air. The MAT sensor’s variable resistance causes the 3500 ohms, repair or replace the sensor.
input voltage to the ECU to vary. Higher intake air temperatures 4. Test MAT sensor connector
result in lower MAT input voltages to the ECU; lower
a. Ignition OFF
temperatures result in higher voltages.
b. MAT connector still disconnected
Note: For OEM applications, the high manifold air temperature c. Backprobe Terminal A and test for continuity between
input voltage specification is 4.9 volts. Low manifold air Pin A on the same side of the connector.
temperature voltage specification is 0.1 volts. • If continuity is found, repeat step for the other
Check the following items that can cause high intake air terminals of the connector
temperatures: • If continuity is not found, repair or replace the
connector
• Excessively high ambient air temperature
• If continuity is found on all terminals and both sides of
• Restricted, dirty, or damaged charge air cooler the connector, proceed to next step
• Loose cooling fan belt 5. Check MAT Sensor Input and Return Wiring
• Malfunctioning cooling fan a. Ignition OFF
• Restricted or damaged intake air piping b. MAT connector still disconnected
• Damaged cooling fan shroud c. Disconnect ECU connector
d. Backprobe wire D1 on the ECU connector and test for
1. Refer to Section 2, “General Troubleshooting” for initial continuity between Terminal A of the MAT sensor
checks before moving on to the following steps. connector.
2. Recover any fault codes. Refer to Section 3.2, “Retrieving • If continuity is found, check the sensor return wire
Fault Codes.” A fault code will result if the manifold air
• If continuity is not found, there is an open in the
temperature input voltage exceeds or goes below the sensor input wiring OR a faulty ECU connector.
sensor’s voltage specification.
e. Backprobe wire D3 on the ECU connector and test for
3. Check the MAT sensor continuity between Terminal B of the MAT sensor
a. Ignition OFF connector.
b. Disconnect MAT sensor connector • If continuity is found, proceed to next step.
c. Measure resistance between both terminals of the • If continuity is not found, there is an open in the
MAT sensor sensor return wiring OR a faulty ECU connector.
Fuel Temp
Fuel Temp Connector
Sensor
Sensor Ground
t B B
428, Gray
914E, Yellow
C3 D3
A3 B3 C3 D3 E3 F3 G3 H3 J3 K3
A2 B2 C2 D2 E2 F2 G2 H2 J2 K2
A1 B1 C1 D1 E1 F1 G1 H1 J1 K1
The fuel temperature sensor is a thermistor (temperature 4. Test Fuel Temperature sensor connector
sensitive resistor) located on the injection pump fuel outlet a. Ignition OFF
housing. The fuel temperature sensor’s variable resistance b. Fuel Temperature connector still disconnected
causes the input voltage to the ECU to vary. Higher fuel
c. Backprobe Terminal A and test for continuity between
temperatures result in lower fuel temperature input voltages to Pin A on the same side of the connector.
the ECU; lower temperatures result in higher voltages. The ECU
• If continuity is found, repeat step for the other
uses the fuel temperature sensor input to adjust the fuel delivery terminals of the connector
for the variations in fuel density caused by varying fuel
temperatures. • If continuity is not found, repair or replace the
connector
Note: For OEM engine applications, the high fuel temperature • If continuity is found on all terminals and both sides of
input voltage specification is 4.9 volts. Low manifold air the connector, proceed to next step
temperature voltage specification is 0.1 volts. The ECU will use 5. Check Fuel Temperature sensor Input and Return Wiring
a “limp-home” fuel temperature value of -20° C (-4° F) during
cranking, and 40° C (104° F) during running. a. Ignition OFF
b. Fuel Temperature connector still disconnected
1. Refer to Section 2, “General Troubleshooting” for initial c. Disconnect ECU connector
checks before moving on to the following steps.
d. Backprobe wire C3 on the ECU connector and test for
2. Recover any fault codes. Refer to Section 3.2, “Retrieving continuity between Terminal A of the Fuel Temperature
Fault Codes.” A fault code will result if the fuel temperature sensor connector.
input voltage goes above the sensor’s high voltage • If continuity is found, check the sensor return wire
specification. This voltage corresponds to a temperature • If continuity is not found, there is an open in the
that is lower than what is physically possible for fuel sensor input wiring OR a faulty ECU connector.
temperature.
e. Backprobe wire D3 on the ECU connector and test for
3. Check the Fuel Temperature sensor continuity between Terminal B of the Fuel Temperature
sensor connector.
a. Ignition OFF
b. Disconnect Fuel Temperature sensor connector • If continuity is found, proceed to next step.
c. Measure resistance between both terminals of the • If continuity is not found, there is an open in the
Fuel Temperature sensor sensor return wiring OR a faulty ECU connector.
• If measurement is between 2500 and 3500 ohms,
proceed to next step.
• If measurement is below 2500 ohms or above
3500 ohms, repair or replace the sensor.
E2 E1 D3
A3 B3 C3 D3 E3 F3 G3 H3 J3 K3
A2 B2 C2 D2 E2 F2 G2 H2 J2 K2
A1 B1 C1 D1 E1 F1 G1 H1 J1 K1
The analog throttle position sensor is a variable resistor • If continuity is not found, there is an open in the
(potentiometer) used to measure the position of the throttle. The sensor supply circuit OR a faulty sensor connector
throttle input voltage normally varies between 1.0 and 4.0 volts OR a faulty ECU connector
depending on the throttle position. Analog throttle voltage at low 4. Check the Sensor Connector
idle will be approximately 0.500-1.0 VDC to 4.0-4.80 VDC at a. Ignition OFF
high idle. The ECU has the ability to learn different voltages for b. Disconnect the sensor connector
low and high idle, so the voltage range may change slightly c. Backprobe Terminal A and test for continuity between
between applications. Pin A on the same side of the connector.
1. Refer to Section 2, “General Troubleshooting” for initial • If continuity is found, repeat step for the other
checks before moving on to the following steps. terminals of the connector
2. Recover any fault codes. Refer to Section 3.2, “Retrieving • If continuity is not found, repair or replace the
Fault Codes.” connector
3. Check the Sensor Wiring • If continuity is found on all terminals and both sides of
the connector, proceed to next step
a. Ignition OFF
5. Check the Sensor Input and Return Wiring
b. Disconnect the ECU connector
c. Backprobe wire E2 on the ECU connector and check a. Ignition OFF
for continuity with Terminal D on the sensor side of the b. ECU connector still disconnected
connector. c. Backprobe wire E2 on the ECU connector and test for
• If continuity is found, proceed to step D. continuity between Terminal D of the sensor
connector.
• If continuity is not found, there is an open in the
sensor supply circuit OR a faulty sensor connector • If continuity is found, check the Analog Throttle Input
OR a faulty ECU connector to ECU wiring
d. Backprobe wire E1 on the ECU connector and check • If continuity is not found, there is an open in the
for continuity with Terminal C on the sensor side of the sensor supply wiring OR a faulty ECU connector
connector. d. Backprobe wire E1 on the ECU connector and test for
• If continuity is found, proceed to step E. continuity between Terminal C of the sensor
connector.
• If continuity is not found, there is an open in the
sensor supply circuit OR a faulty sensor connector • If continuity is found, check the sensor ground wiring
OR a faulty ECU connector • If continuity is not found, there is an open in the
e. Backprobe wire D3 on the ECU connector and check sensor Input to ECU wiring OR a faulty ECU
for continuity with Terminal A on the sensor side of the connector
connector.
• If continuity is found, repair or replace the Analog
Throttle sensor
Crank Sensor
Crank Position Connector
Sensor
Crank Position Return
B B
447, PURPLE
448, GRAY
B2 D2
A3 B3 C3 D3 E3 F3 G3 H3 J3 K3
A2 B2 C2 D2 E2 F2 G2 H2 J2 K2
A1 B1 C1 D1 E1 F1 G1 H1 J1 K1
• If voltage is between 2500 and 3500 ohms, proceed • If continuity is not found, there is an open in the
to next step. sensor return wiring OR a faulty ECU connector.
Pump
Solenoid Pump Solenoid
Connector
Solenoid Return
B B
A A Solenoid Input
491, Brown
493, Orange
K2 A3
A3 B3 C3 D3 E3 F3 G3 H3 J3 K3
A2 B2 C2 D2 E2 F2 G2 H2 J2 K2
A1 B1 C1 D1 E1 F1 G1 H1 J1 K1
B 5V Supply
C A Sensor Ground
914E, Yellow
467, Purple
911E, Brown
Oil Pressure Sender
D3 F3 E2
A3 B3 C3 D3 E3 F3 G3 H3 J3 K3
A2 B2 C2 D2 E2 F2 G2 H2 J2 K2
A1 B1 C1 D1 E1 F1 G1 H1 J1 K1
The oil pressure sender is a pressure transducer connected to • If continuity is not found, there is an open in the
the main oil galley. As engine oil pressure increases, the oil Supply Wiring
pressure sender input voltage increases. The ECU monitors oil 4. Check the ECU connector
pressure in order to protect the engine in case of a low oil a. Ignition OFF
pressure condition.
b. ECU connector still disconnected
Note: ECU uses a default oil pressure of 260 kPa (2.6 bar) c. Backprobe wire D3 on the ECU connector and check
(37.5 psi). For OEM applications, the high oil pressure input for continuity with pin D3 on the harness end of the
voltage is 4.9 volts. The low oil pressure input voltage connector
specification is 0.3 volts. • If continuity is found, repeat this step for the F3 and
E2 circuits of the ECU connector.
1. Refer to Section 2, “General Troubleshooting” for initial
checks before moving on to the following steps. • If continuity is not found, there is a faulty ECU
connector
2. Recover any fault codes. Refer to Section 3.2, “Retrieving
• If continuity is found on all circuits, proceed to next
Fault Codes.” A fault code will result if: step
• The oil pressure input voltage exceeds or drops 5. If all checks are completed and the engine still does not
below the sender’s voltage specification. operate properly, contact your local John Deere service
• ECU’s low oil pressure engine protection feature distributor.
disabled.
3. Check the Sender Wiring
a. Ignition OFF
b. Disconnect the ECU connector
c. Backprobe wire D3 on the ECU connector and check
for continuity between Terminal A on the Oil Pressure
Sender
• If continuity is found, check the Sender Input Wiring
• If continuity is not found, there is an open in the
circuit wiring OR a faulty ECU connector
d. Backprobe wire F3 on the ECU connector and check
for continuity between Terminal C on the Oil Pressure
Sender
• If continuity is found, check Sender Input Wiring
• If continuity is not found, there is an open in the
circuit wiring OR a faulty ECU connector
e. Backprobe wire E2 on the ECU connector and check
for continuity between Terminal B on the Oil Pressure
Sender
• If continuity is found, repair or replace the Oil
Pressure Sender
A1 A2 A3
ECT Sensor
ECT Sensor Connector
ECT Ground
t B B
A A ECT Input
461, Brown
914E, Yellow
B1 D3
A3 B3 C3 D3 E3 F3 G3 H3 J3 K3
A2 B2 C2 D2 E2 F2 G2 H2 J2 K2
A1 B1 C1 D1 E1 F1 G1 H1 J1 K1
The engine coolant temperature (ECT) is a thermistor 4. Test ECT sensor connector
(temperature sensitive resistor) mounted on the thermostat a. Ignition OFF
housing or in the rear of the cylinder head. It is used to measure b. ECT connector still disconnected
the coolant temperature. The ECT’s variable resistance causes
c. Backprobe Terminal A and test for continuity between
the input voltage to the ECU to vary. Higher coolant Pin A on the same side of the connector.
temperatures result in lower ECT input voltages to the Engine
• If continuity is found, repeat step for the other
Control Unit (ECU); lower temperatures result in higher terminals of the connector
voltages.
• If continuity is not found, repair or replace the
The ECU senses ECT on OEM applications about 118° C connector
(244° F).
• If continuity is found on all terminals and both sides of
Note: This engine is equipped with Engine protection with the connector, proceed to next step
different features: 5. Check ECT Sensor Input and Return Wiring
• With Shutdown Feature: The derate feature will go a. Ignition OFF
into effect when the code is set, and the engine will b. ECT connector still disconnected
shut down after 30 seconds.
c. Disconnect ECU connector
• With Derate Feature: On OEM applications, the d. Backprobe wire B1 on the ECU connector and test for
engine derates 60% per minute until the engine is continuity between Terminal A of the ECT sensor
running at 40% full power. connector.
1. Refer to Section 2, “General Troubleshooting” for initial • If continuity is found, check the sensor return wire
checks before moving on to the following steps.
• If continuity is not found, there is an open in the
2. Recover any fault codes. Refer to Section 3.2, “Retrieving sensor input wiring OR a faulty ECU connector.
Fault Codes.” e. Backprobe wire D3 on the ECU connector and test for
3. Check the ECT Sensor continuity between Terminal B of the ECT sensor
connector.
a. Ignition OFF
b. Disconnect ECT sensor connector • If continuity is found, proceed to next step.
c. Measure resistance between both terminals of the • If continuity is not found, there is an open in the
ECT sensor sensor return wiring OR a faulty ECU connector.
• If measurement is between 2500 and 3500 ohms,
proceed to next step.
• If measurement is below 2500 ohms or above
3500 ohms, repair or replace the sensor.
Loss of Coolant
Loss of Coolant Temperature Sensor
Temperature Connector
Sensor
Sensor Ground
t B B
A A Input
947, Purple
914E, Yellow
C1 D3
A3 B3 C3 D3 E3 F3 G3 H3 J3 K3
A2 B2 C2 D2 E2 F2 G2 H2 J2 K2
A1 B1 C1 D1 E1 F1 G1 H1 J1 K1
The loss of coolant temperature sensor is a thermistor 5. If continuity is found on all terminals and both sides of the
(temperature sensitive resistor) mounted in the rear of the connector, proceed to next stepCheck Loss of Coolant
cylinder head. It is used to measure the coolant temperature Temperature Sensor Input and Return Wiring
and to detect whether there is a loss of coolant. The sensor’s a. Ignition OFF
variable resistance causes the input voltage to the ECU to vary. b. Loss of Coolant sensor connector still disconnected
Higher coolant temperatures result in lower loss of coolant
c. Disconnect ECU connector
temperature input voltages to the ECU; lower temperatures
d. Backprobe wire C1 on the ECU connector and test for
result in higher voltages. continuity between Terminal A of the Loss of Coolant
1. Refer to Section 2, “General Troubleshooting” for initial Temperature sensor connector.
checks before moving on to the following steps. • If continuity is found, check the sensor return wire
2. Recover any fault codes. Refer to Section 3.2, “Retrieving • If continuity is not found, there is an open in the
Fault Codes.” A fault code will result if the loss of coolant sensor input wiring OR a faulty ECU connector.
temperature input voltage drops below 0.1 volts. This e. Backprobe wire D3 on the ECU connector and test for
voltage corresponds to a temperature that is higher than continuity between Terminal B of the Loss of Coolant
what is physically possible for engine coolant. Temperature sensor connector.
3. Check the Loss of Coolant Sensor • If continuity is found, proceed to next step.
a. Ignition OFF • If continuity is not found, there is an open in the
b. Disconnect Loss of Coolant sensor connector sensor return wiring OR a faulty ECU connector.
c. Measure resistance between both terminals of the 6. Test the ECU connector
Loss of Coolant sensor a. Ignition OFF
• If measurement is between 2500 and 3500 ohms, b. ECU connector still disconnected
proceed to next step. c. Backprobe wire C1 on the ECU connector and check
• If measurement is below 2500 ohms or above for continuity with pin C1 on the harness end of the
3500 ohms, repair or replace the sensor. connector.
4. Test Loss of Coolant Temperature sensor connector • If continuity is found, repeat this step for the D3 circuit
of the ECU connector.
a. Ignition OFF
b. Loss of Coolant sensor connector still disconnected • If continuty is not found, there is a faulty ECU
connector.
c. Backprobe Terminal A and test for continuity between
Pin A on the same side of the connector. • If continuity is found on all circuits, proceed to next
step.
• If continuity is found, repeat step for the other
terminals of the connector 7. If all checks are completed and the engine still does not
operate properly, contact your local John Deere service
• If continuity is not found, repair or replace the
connector distributor.
Contents
15 AMP
FUSE
A A BAT-HN HN-AC
B B 15 AMP
GND-3 FUSE
C C
START 15 AMP
D D IGN-A FUSE
RELAY
OIL PRESS. FUEL
IGN-C PRK IGN PRK BRK 4X4 PWR
GAUGE GAUGE FWD/N/REV ENGINE SHUTDOWN
BAT
REV
FWD
SWITCH START-C 2/4 WHEEL SHUTDOWN OVERRIDE THROTTLE
IGN-A
BAT-HN
SHT IGN
SWITCH
START-A
DRIVE SWITCH LIGHT PEDAL
15 AMP
FUSE GND-3 473
GAUGE START-B
I ACC-A ACC-B PB LHT
LIGHT WATER TEMP. B A
VOLTMETER START-B
IGN-B
START-A AL
GAUGE PRK IGN
915
ST TE
918
OIL GAG
4X4 LHT
911A
911B
914C
XC
GND-6 -A
4X4
IGNITION PARK BRAKE
IGN-B SWITCH 4X4
LIGHT
GAUGE
LIGHT GND-3
ACC-C
OPEN
AUXLT
FUL GAG
CLT TMP
OPEN
ACC-C
Electrical Wiring
911A
915
914C
START-B
473
911B
918
534D-9 Tier II:
HOUR
534D-10 Tier II:
PRK IGN
START-C
CLT TMP
PRK BRK
OIL GAG
ALT EXC-A
GND-3
4X4
ACC-C
FUL GAG
HR MTR
ALT EXC-B
METER
ALT EXC-B
PB LHT
GND-3 OPEN GND-3
HR MTR
A B C D E F G H J K L M N P SPL-ACC ALTERNATOR C B A 6 5 4 3 2 1
WARNING LIGHT
GND-3
PS IGN
PARK BRAKE
OPEN
Before S/N 0160013979
LIGHT
ACC-B
SPL-ACC2
A B C D E F G H J K L M N P C B A 6 5 4 3 2 1
4X4
918
473
915
ALT EXC-A
911B
911A
914C
GND-3
WIRING SCHEMATICS
ACC-C
PRK IGN
OIL GAG
START-B
CLT TMP
60
ALT EXC-B
HR MTR
FUL GAG
START-C
ALT EXC-A
PRK BRK
SPL-ACC RESISTOR
SPL-ACC-2 HORN
BUTTON
ACC-C
HN-AC
4X4
TRC LOK
OPEN
GND-3
GND-2
GND-6
HORN
941
Before S/N 0160014009 (excluding S/N 0160013513)
B A
OPT.
SHUT
PRK BRK
GND-2
DOWN
B A
941
914C
911B
473
915
918
911A
CLT TMP
REV
OIL GAG
ALT EXC-B
PS IGN
4X4
FWD
HR MTR
HORN
BAT
FUL GAG
START-C
DIODE 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 P N M L K J H G F E D C B A
A B 4X4 TRC LOK
050C 050C
012C 012C
TRACTION LOCK 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 P N M L K J H G F E D C B A 904B 904B
SWITCH BAT 905B 905B
4X4
A B
REV
473
915
918
941
FWD
911A
914C
911B
HORN
020C 020C CAN
PS IGN
TRC LOK
HR MTR
DIAGNOSTIC
OIL GAG
START-C
CLT TMP
BACK-UP
FUL GAG
ALT EXC-B
ALARM 85 86
GND-10 START-C
GND-4 STRT SOL
911B
473
915
918
941
012B
911A
914C
B 30 87
J H G F E D C B A
J H G F E D C B A
A DIODE
HORN
FUL GAG
8 7 6 5 4 3 2 1
FUEL HORN STARTER
(#10)
LEVEL ST RELAY
A B
TRACTION SENDER RT
LOCK SO 914D 914D
BAT L 8 7 6 5 4 3 2 1 OIL
911D 911D
REV
VALVE
012C
(#000) PRESSURE
GND-5
473
915
918
941
SIGNAL
REV-B
PARK BRAKE 467 467
C B A
C B A
911B
911A
914C
012B
SOLENOID
(#12)
B 10 AMP
A 904C 904C
ALT BAT
(#000)
GND-3 FUSE
012D
050F
002A 002B CAN
(#12)
905C 905C
GND-4
914C
050F TERMINATOR
GND-5
914E 914D 020D 020D 020D
C B A
C B A
D-2
-1
A B
GND-3
D
911A
911B
GN
G
ALT EXC-B 911D
NEG POS
PS IGN
DIODE
GND-10 491 491 FUEL
4X4 493 493 INJECTION
B A
B A
VALVE CONTROL
911E
#1
050D
022A
012B
ALT BAT ALTERNATOR 39
BATT #2
904B
904C
905B
905C
020D
HR MTR
RESISTOR
SNSR 904E 904D
022C 904D 904D
947
050D
OIL GAG
(ON ENGINE)
CLT TMP
050G
POSITION
DIODE
FORWARD
REVERSE
OIL
REV-B
VALVE
WATER PRESSURE
TEMP. GAUGE
SENDER
491
022C
050G
473
904E
467
905E
911E
915
914E
448
428
947
918
447
461
493
012D
941
K3 K2 K1 J3 J2 J1 H3 H2 H1 G3 G2 G1 F3 F2 F1 E3 E2 E1 D3 D2 D1 C3 C2 C1 B3 B2 B1 A3 A2 A1
461 461
GND-8 COOLANT
415 415
B A
B A
TEMP
K3 K2 K1 J3 J2 J1 H3 H2 H1 G3 G2 G1 F3 F2 F1 E3 E2 E1 D3 D2 D1 C3 C2 C1 B3 B2 B1 A3 A2 A1
STAB-SW2
B
A ECU CONNECTOR
A B C D
A B C D
B
A
WHITE
BLUE
BLACK
RED
ORANGE
DIODE
+ -
STABILIZER
N.C.
N.O.
PROXIMITY
SENSOR
GND-7
STABILIZER
VALVE
MAN0180
Models 534D-9 Tier II & 534D-10 Tier II
15 AMP
FUSE
A A BAT-HN HN-AC
B B 15 AMP
GND-3 FUSE
C C
START 15 AMP
D D IGN-A FUSE
RELAY
OIL PRESS. FUEL
IGN-C PRK IGN PRK BRK 4X4 PWR
GAUGE GAUGE FWD/N/REV ENGINE SHUTDOWN
BAT
REV
FWD
SWITCH START-C 2/4 WHEEL OVERRIDE THROTTLE
IGN-A
SHUTDOWN
BAT-HN
SHT IGN
START-A
DRIVE SWITCH LIGHT SWITCH PEDAL
15 AMP
IGN-B
START-A AL
GAUGE PRK IGN
915
ST TE
918
OIL GAG
4X4 LHT
911A
911B
914C
XC
GND-6 -A
4X4
IGNITION PARK BRAKE
IGN-B SWITCH 4X4
LIGHT
GAUGE
LIGHT GND-3
ACC-C
OPEN
AUXLT
FUL GAG
CLT TMP
OPEN
ACC-C
534D-9 Tier II:
911A
915
914C
START-B
534D-10 Tier II:
473
911B
918
HOUR
PRK IGN
START-C
CLT TMP
PRK BRK
OIL GAG
ALT EXC-A
GND-3
4X4
ACC-C
FUL GAG
HR MTR
ALT EXC-B
ALT EXC-B
METER
PB LHT
GND-3 OPEN GND-3
HR MTR
A B C D E F G H J K L M N P SPL-ACC ALTERNATOR C B A 6 5 4 3 2 1
WARNING LIGHT
GND-3
PS IGN
S/N 0160013979 & After
PARK BRAKE
OPEN LIGHT
ACC-B
SPL-ACC2
A B C D E F G H J K L M N P C B A 6 5 4 3 2 1
4X4
918
473
915
ALT EXC-A
911B
911A
914C
GND-3
ACC-C
PRK IGN
OIL GAG
START-B
CLT TMP
ALT EXC-B
60
HR MTR
FUL GAG
START-C
ALT EXC-A
PRK BRK
SPL-ACC RESISTOR
SPL-ACC-2 HORN
BUTTON
ACC-C
HN-AC
4X4
TRC LOK
S/N 0160014009 & After (including S/N 0160013513)
OPEN
GND-3
GND-2
GND-6
HORN
B A 941
OPT.
SHUT
PRK BRK
GND-2
DOWN
B A
941
914C
911B
473
915
918
911A
CLT TMP
REV
OIL GAG
ALT EXC-B
PS IGN
4X4
FWD
HR MTR
HORN
BAT
FUL GAG
START-C
DIODE 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 P N M L K J H G F E D C B A
A B 4X4 TRC LOK
050C 050C
012C 012C
TRACTION LOCK 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 P N M L K J H G F E D C B A 904B 904B
SWITCH BAT 905B 905B
4X4
A B
REV
473
915
918
941
FWD
911A
914C
911B
HORN
020C 020C CAN
PS IGN
HR MTR
TRC LOK DIAGNOSTIC
OIL GAG
START-C
CLT TMP
FUL GAG
BACK-UP
ALT EXC-B
ALARM 85 86
GND-10 START-C
GND-4 STRT SOL
911B
473
915
918
941
012B
911A
914C
B 30 87
J H G F E D C B A
J H G F E D C B A
A DIODE
HORN
FUL GAG
8 7 6 5 4 3 2 1
FUEL HORN STARTER
(#10)
LEVEL ST RELAY
A B
TRACTION SENDER RT
LOCK SO 914D 914D
BAT L 8 7 6 5 4 3 2 1 OIL
911D 911D
REV
VALVE
012C
(#000) PRESSURE
GND-5
473
915
918
941
SIGNAL
REV-B
PARK BRAKE 467 467
C B A
C B A
911B
911A
914C
012B
(#12)
B 10 AMP
A 904C 904C
ALT BAT
(#000)
FUSE
012D
GND-3
050F
002A 002B CAN
(#12)
905C 905C
GND-4
914C
050F TERMINATOR
GND-5
914E 914D 020D 020D 020D
C B A
C B A
D-2
-1
914B
GND-3
A B
D
911A
911B
GN
914A
G
ALT EXC-B 911D
NEG POS
PS IGN
DIODE
GND-10 491 491 FUEL
4X4 493 493 INJECTION
B A
B A
CONTROL
911E
VALVE #1
050D
022A
012B
ALT BAT ALTERNATOR 39
BATT #2
904B
904C
905B
905C
020D
HR MTR
RESISTOR
SNSR 904E 904D
022C 904D 904D
947
050D
OIL GAG
(ON ENGINE)
CLT TMP
050G
POSITION
DIODE
FORWARD
REVERSE
OIL
REV-B
VALVE
WATER PRESSURE
TEMP. GAUGE
SENDER
491
022C
050G
473
904E
467
905E
911E
915
914E
448
428
947
918
447
461
493
012D
941
K3 K2 K1 J3 J2 J1 H3 H2 H1 G3 G2 G1 F3 F2 F1 E3 E2 E1 D3 D2 D1 C3 C2 C1 B3 B2 B1 A3 A2 A1
461 461
GND-8 COOLANT
914A 415
B A
B A
TEMP
K3 K2 K1 J3 J2 J1 H3 H2 H1 G3 G2 G1 F3 F2 F1 E3 E2 E1 D3 D2 D1 C3 C2 C1 B3 B2 B1 A3 A2 A1
STAB-SW2
B
A ECU CONNECTOR
A B C D
A B C D
B
A
WHITE
BLUE
BLACK
RED
ORANGE
DIODE
+ -
Electrical Wiring
STABILIZER
N.C.
N.O.
PROXIMITY
SENSOR
GND-7
STABILIZER
VALVE
MAN0190
4.3
4.4
4.1.2
N START
15 AMP
FUSE
A A BAT-HN HN-AC
B B 15 AMP
GND-3 FUSE
C C 15 AMP
START
D D RELAY IGN-A FUSE
OIL PRESS. FUEL
IGN-C PRK IGN PRK BRK 4X4 PWR SHUTDOWN
GAUGE GAUGE FWD/N/REV ENG.
BAT
SWITCH START-C SHUTDOWN OVERRIDE THROTTLE
BAT-HN
FWD
REV
2/4 WHEEL
SWITCH PEDAL
START-A
LIGHT
IGN-A
SHT IGN
15 AMP DRIVE SWITCH
FUSE GND-3 473
GAUGE ACC-A ACC-B START-B
LIGHT I
WATER TEMP. B A PB LHT
VOLTMETER START-B START-A
AL
IGN-B
GAUGE PRK IGN
915
918
TE
ST
4X4 LHT
911B
911A
914C
XC
4X4
GND-6 -A
IGNITION PARK BRAKE 4X4
IGN-B SWITCH LIGHT
GAUGE
OIL GAG
LIGHT GND-3
ACC-C
OPEN
AUXLT
FUL GAG
CLT TMP
OPEN
CLT TMP
ACC-C
Electrical Wiring
START-B
918
473
911B
915
914C
911A
HOUR
ALT EXC-B
PRK IGN
START-C
PRK BRK
ACC-C
FUL GAG
ALT EXC-A
4X4
GND-3
CLT TMP
ALT EXC-B
OIL GAG
HR MTR
METER OPEN
PB LHT
GND-3 GND-3
HR MTR
SPL-ACC
PS IGN
A B C D E F G H J K L M N P ALTERNATOR C B A 6 5 4 3 2 1
WARNING LIGHT
GND-3
PARK BRAKE
OPEN LIGHT
SPL-ACC2
ACC-B
A B C D E F G H J K L M N P C B A 6 5 4 3 2 1
4X4
918
473
915
60
ALT EXC-A
911B
911A
914C
GND-3
ACC-C
RESISTOR
PRK IGN
START-B
OIL GAG
START-C
ALT EXC-B
CLT TMP
PRK BRK
ALT EXC-A
HR MTR
FUL GAG
SPL-ACC
SPL-ACC-2 HORN
BUTTON
ACC-C
HN-AC
4X4
TRC LOK
OPEN
GND-2
GND-6
GND-3
B A 941
PRK BRK
HORN
OPT.
GND-2
SHUT
DOWN
B A
473
915
941
911A
914C
918
911B
ALT EXC-B
OIL GAG
PS IGN
REV
CLT TMP
BAT
4X4
FWD
FUL GAG
HORN
START-C
HR MTR
DIODE 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 P N M L K J H G F E D C B A
A B 4X4 TRC LOK
050C 050C
012C 012C
TRACTION LOCK 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 P N M L K J H G F E D C B A 904B 904B
SWITCH BAT
A B 905B 905B
941
918
915
473
4X4
REV
FWD
911A
914C
911B
CAN
HORN
020C 020C
PS IGN
TRC LOK DIAGNOSTIC
HR MTR
BACK-UP
OIL GAG
START-C
CLT TMP
FUL GAG
ALT EXC-B
ALARM 85 86
GND-10 START-C
GND-4 STRT SOL
012B
914C
918
941
915
911A
30 87
473
911B
A B
J H G F E D C B A
J H G F E D C B A
DIODE
HORN
FUL GAG
8 7 6 5 4 3 2 1
FUEL HORN STARTER
(#10)
A B ST RELAY
LEVEL RT
TRACTION SENDER SO 914D 914D
LOCK BAT L OIL
REV
8 7 6 5 4 3 2 1
012C
918
911A
012B
911B
914C
REV-B
STARTER
GND-5
SOLENOID VALVE SNSR
BATTERY MOTOR
4X4 (#000) STARTER 012B
- +
020C
SOLENOID
(#12)
B 10 AMP
ALT BAT
A
(#000)
GND-3 904C 904C
012D
FUSE
050F
(#12)
002A 002B 905C 905C CAN
GND-4
914C
TERMINATOR
050F
GND-5
914E 020D 020D 020D
C B A
914D
C B A
D-2
-1
911B
911A
GND-3
A B
D
N
914F
GN
G
GND-7 ALT EXC-B NEG POS 911D
GND-8 PS IGN
DIODE
GND-10 491 491 FUEL
4X4 493 493 INJECTION
B A
B A
VALVE CONTROL
#1
012B
ALTERNATOR
050D
022A
911E
HR MTR
BATT #2
020D
RESISTOR
SNSR 904E 904D
022C 904D 904D
947
STAB-SW1
STAB-PWR
PRESSURE SWITCH
CLT TMP
(ON ENGINE)
OIL GAG
050G
B POSITION
DIODE
A B C D A
FORWARD
REVERSE OIL
REV-B
VALVE 463 463
WATER PRESSURE A B C D CHARGE AIR
914F 914F
B A
B A
SENDER
A
WHITE
BLUE
BLACK
RED
ORANGE
DIODE
+ - 428 428
FUEL
415 415
B A
B A
TMP
N.O.
N.C.
491
022C
050G
473
904E
467
905E
911E
915
914E
448
463
428
947
918
447
461
493
012D
941
STABILIZER
PROXIMITY K3 K2 K1 J3 J2 J1 H3 H2 H1 G3 G2 G1 F3 F2 F1 E3 E2 E1 D3 D2 D1 C3 C2 C1 B3 B2 B1 A3 A2 A1
SENSOR
STABILIZER 461 461
VALVE COOLANT
415 415
B A
B A
TEMP
K3 K2 K1 J3 J2 J1 H3 H2 H1 G3 G2 G1 F3 F2 F1 E3 E2 E1 D3 D2 D1 C3 C2 C1 B3 B2 B1 A3 A2 A1
MAN0200
ECU CONNECTOR
BAT
START-C OVERRIDE THROTTLE
BAT-HN
SHUTDOWN
FWD
REV
SWITCH 2/4 WHEEL
SWITCH PEDAL
START-A
LIGHT
IGN-A
SHT IGN
15 AMP DRIVE SWITCH
FUSE GND-3 473
GAUGE ACC-A ACC-B START-B
LIGHT I
WATER TEMP. B A PB LHT
VOLTMETER START-B START-A
AL
IGN-B
GAUGE PRK IGN
915
918
TE
ST
4X4 LHT
911B
911A
914C
XC
4X4
GND-6 -A
IGNITION PARK BRAKE 4X4
IGN-B SWITCH LIGHT
GAUGE
OIL GAG
LIGHT GND-3
ACC-C
OPEN
AUXLT
FUL GAG
S/N 0160013976 & After
CLT TMP
OPEN
CLT TMP
ACC-C
START-B
918
473
911B
915
914C
911A
HOUR
ALT EXC-B
PRK IGN
START-C
PRK BRK
ACC-C
FUL GAG
ALT EXC-A
4X4
GND-3
CLT TMP
ALT EXC-B
OIL GAG
HR MTR
METER OPEN
PB LHT
GND-3 GND-3
HR MTR
SPL-ACC
PS IGN
A B C D E F G H J K L M N P ALTERNATOR C B A 6 5 4 3 2 1
WARNING LIGHT
GND-3
PARK BRAKE
OPEN LIGHT
SPL-ACC2
ACC-B
A B C D E F G H J K L M N P C B A 6 5 4 3 2 1
4X4
918
473
915
60
ALT EXC-A
911B
911A
914C
GND-3
ACC-C
RESISTOR
PRK IGN
START-B
OIL GAG
START-C
ALT EXC-B
CLT TMP
PRK BRK
ALT EXC-A
HR MTR
FUL GAG
SPL-ACC
SPL-ACC-2 HORN
BUTTON
ACC-C
HN-AC
4X4
TRC LOK
OPEN
GND-2
GND-6
GND-3
B A 941
PRK BRK
HORN
OPT.
GND-2
SHUT
DOWN
B A
473
915
941
911A
914C
918
911B
ALT EXC-B
OIL GAG
PS IGN
REV
CLT TMP
BAT
4X4
FWD
FUL GAG
HORN
START-C
HR MTR
DIODE 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 P N M L K J H G F E D C B A
A B 4X4 TRC LOK
050C 050C
012C 012C
TRACTION LOCK 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 P N M L K J H G F E D C B A 904B 904B
SWITCH BAT
A B 905B 905B
941
918
915
473
4X4
REV
FWD
911A
914C
911B
CAN
HORN
020C 020C
PS IGN
TRC LOK DIAGNOSTIC
HR MTR
BACK-UP
OIL GAG
START-C
CLT TMP
FUL GAG
ALT EXC-B
ALARM 85 86
GND-10 START-C
GND-4 STRT SOL
012B
914C
918
941
915
911A
30 87
473
911B
A B
J H G F E D C B A
J H G F E D C B A
DIODE
HORN
FUL GAG
8 7 6 5 4 3 2 1
FUEL HORN STARTER
(#10)
A B ST RELAY
LEVEL RT
TRACTION SENDER SO 914D 914D
LOCK BAT L OIL
REV
8 7 6 5 4 3 2 1
012C
918
911A
012B
911B
914C
REV-B
STARTER
GND-5
SOLENOID VALVE SNSR
BATTERY MOTOR
4X4 (#000) STARTER 012B
- +
020C
SOLENOID
(#12)
B 10 AMP
ALT BAT
A
(#000)
GND-3 904C 904C
012D
FUSE 914B
050F
(#12)
002A 002B 905C 905C CAN
GND-4
914A
914C
TERMINATOR
050F
GND-5
914E 020D 020D 020D
C B A
914D
C B A
D-2
-1
911B
911A
GND-3
A B
D
N
914F
GN
G
GND-7 ALT EXC-B NEG POS 911D
GND-8 PS IGN
DIODE
GND-10 491 491 FUEL
4X4 493 493 INJECTION
B A
B A
VALVE CONTROL
#1
012B
ALTERNATOR
050D
022A
911E
HR MTR
BATT #2
020D
RESISTOR
SNSR 904E 904D
022C 904D 904D
947
STAB-SW1
STAB-PWR
PRESSURE SWITCH
CLT TMP
(ON ENGINE)
OIL GAG
050G
B POSITION
DIODE
A B C D A
FORWARD
REVERSE OIL
REV-B
VALVE 463 463
WATER PRESSURE A B C D CHARGE AIR
914F 914F
B A
B A
SENDER
A
WHITE
BLUE
BLACK
RED
ORANGE
DIODE
+ - 428 428
FUEL
914B 415
B A
B A
TMP
N.O.
N.C.
491
022C
050G
473
904E
467
905E
911E
915
914E
448
463
428
947
918
447
461
493
012D
941
STABILIZER
PROXIMITY K3 K2 K1 J3 J2 J1 H3 H2 H1 G3 G2 G1 F3 F2 F1 E3 E2 E1 D3 D2 D1 C3 C2 C1 B3 B2 B1 A3 A2 A1
SENSOR
MAN0210
STABILIZER 461 461
VALVE COOLANT
914A 415
B A
B A
TEMP
K3 K2 K1 J3 J2 J1 H3 H2 H1 G3 G2 G1 F3 F2 F1 E3 E2 E1 D3 D2 D1 C3 C2 C1 B3 B2 B1 A3 A2 A1
Electrical Wiring
ECU CONNECTOR
4.5
John Deere Engine 4.6
MY1060 KEY BAT PWR
S
B
KEY IGN
FUL LVL (D BLU, 18 GA GXL)
I
A
DASH GND
4
1
(BLK, 18 GA GXL)
CLT TMP (D BLU, 18 GA GXL)
GAGE PWR (RED, 18 GA GXL)
G
FAULT LT/473
BEEDE GAUGE
(D BLU, 18 GA GXL)
3
2
3
2
(RED, 18 GA GXL)
TRANS TMP SW
(RED, 18 GA GXL)
ST RLY
ON
SHIFT PWR 1
OFF
ON
HORN
(BLK, 18 GA GXL)
OFF
PK BRK SOL
HR MTR
SHTDN OVR
CHECK ENG
HD34-24-31ST
OIL PSI
LEFT DASH PANEL
OVR SUP/911
STEER/SWAY PWR
OVR SGN/918 STR AW
FAULT LT/473
TRAN/BRK PWR TRAN/BRK PWR
PLUGGED
PLUGGED
3
2
1
3
2
1
PLUGGED
+
PLUGGED
OFF
CRAB
ON
ALL WHL
PLUGGED
-
6
5
4
7
PLUGGED
HR MTR
6
5
4
7
PK BRK SOL
PARK BRAKE
STEER MODE
PLUGGED ST RLY
PLUGGED PK BRK SOL
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31
SHIFT PWR 1
DASH GND
DASH GND
F4
F3
F2
F1
N4
N3
N2
N1
R4
R3
R2
R1
GEAR
SW3
SW1
R
F
1
4
N
TRANS SOL Y1
2
3
TRANS SOL Y3
TRANS SOL Y5
TRANS SOL Y4
SHIFT PWR 1
KEY START
Y2, Y6
Y1, Y6
TRANS SOL Y2
Y2, Y3, Y6
Y1, Y3, Y6
PK BRK SOL
3
2
HOBBS
1 2 3 4 5 6 7 8
4
1
N
R
F
TRANSMISSION LEGEND
SW4
SW2
TO CHASSIS ASSEMBLY
THR SGN/915
THR RTN/914
OVR SUP/911
PLUGGED
PLUGGED
WILLIAMS
PLUGGED
A B C D E F
(SUSPENDED)
TWIST
THROTTLE
12 TURNS
PER FOOT
TRANS SOL Y1
TRANS SOL Y2
TRANS SOL Y3
TRANS SOL Y4
TRANS SOL Y5
PLUGGED PLUGGED 3 87a
KEY START TRAN/BRK PWR 1 30
SHIFT PWR 1 REVERSE 4 87
PK BRK SOL TRANS SOL Y2 5 86
RELAY
TRAN/BRK PWR
SHIFTER GND
OVR SUP/911
THR SGN/915
THR RTN/914
SP BAT PWR
SP ACCY PWR
SP CAB GND 1 PLUGGED 3 87a
SP CAB GND 2 SHIFTER GND 1 30
HD34-24-31PT
SP-1 TRANS TMP SW 4 87
SHIFTER HARNESS
SP-2 KEY START 5 86
SP-3 SHIFTER GND 2 85
TRANS TMP SW
TEST RELAY
WARN LIGHT
AC CLUTCH
STAB/TILT PWR
TILT UP
TILT DN
SP BAT PWR
STAB/TILT PWR
PLUGGED
PLUGGED STD JOY PWR
TILT
RED YEL
PLUGGED
SPEED
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31
STAB/TILT PWR
SHIFTER GND
TILT UP
TILT DN TILT UP RED
1 2 3 4
DT06-4S
TILT
UP
ROLLER OPTION
SHIFTER HARNESS
TILT DN BLU
TO TILT ON JOYSTICK
TILT
JOYSTICK
DOWN
PLUGGED PLUG
STANDARD
PLUGGED PLUG
1 2 3 4 5 6
SP BAT PWR
SP ACCY PWR
SP-3
SP-2
SP-1
SP CAB GND 2
SP CAB GND 1
SEE AC CLUTCH
SHEET 2
Cab Schematic
Models G10-55A & G12-55A 4.1.3
Electrical Wiring
John Deere Engine
WINDSHIELD
CAB LIGHTS WASHER DASH BLOWER HEATER M WIPER MOTOR
STOPLIGHT DOME
BEACON LEFT RIGHT MOTOR FAN MOTOR VALVE RIGHT DASH PANEL
AUX HYD PANEL OPTIONS VEC SWITCH LIGHT M
WIPER HEATER/BLOWER M M
F1 20 WIPER PWR M WORKLIGHTS BEACON WIPER
A
F5 20 HEATER PWR 1 2 3 4 5 6 7 8 9 10 OFF OFF
87a
87
86
85
30
87a
30
87
86
85
B
KEY ACC 1 4
C H
F7 10 BCN PWR 2 5 2 L
D W B
F8 10 D FAN PWR 3 6 3
AUX ELEC E P
AUX ELEC
GREEN-4
LIGHTS BCN/FAN F6 20
F
DOME LT A A B A B A B ON ON
SWING 7 MAST
7 CAB LT PWR A B A B C D
G
EMPTY
EMPTY
EMPTY
EMPTY
EMPTY
EMPTY
EMPTY
1 4 1
87a
30
87
86
85
4
87a
30
87
86
85
H
S/W LT PWR
2 5 2 5
BCN LT
AUX ELEC1
CAB LTS
WORK LT
BCN PWR
3 6 3 6
S/W LT PWR
SW1 86
CAB LT PWR
HEATER GND
HTR CNTRL B
HEATER PWR
A
EMPTY
EMPTY
87a
30
87
86
85
OPTION (15A) OPTION (25A) HEATER GND
WIPER HI
B
WASHER
WIPER HI
WIPER LO
WIPER LO
WIPER PARK
87a
30
87
86
85
87a
30
87
86
85
WIPER PARK
D
DOME/BCN GND
AUX ELEC2
AUX RLYS PWR
BLUE-3
E
STOP LT
S/W LT PWR
DOME/BCN GND
DOME LT
BCN LT
DOME/BCN GND
CAB LTS
CAB LT GND
CAB LTS
CAB LT GND
WASHER
HEATER HI
HEATER MED
HEATER LOW
HEATER GND
D FAN PWR
D FAN GND
SW1 87A
87a
30
87
86
85
F
F4
F3
F2
G
SW2 86
H
SW2 87A
25
15
15
BLACK-1 GRAY-2 HEATER HI
H G F E D C B A H G F E D C B A HEATER MED
HEATER LOW
HTR TEMP BLOWER
8K OHM
M H
L B
24 KOHM,1W
SWING
EXTRA
SW2 87A
SW2 86
MAST
SW1 87A
SIDESHIFT
SW1 86
AUX SW GND
PLUGGED
PLUGGED
PLUGGED
RESISTOR LOCATED
25A OPT
C
STOP LT
S/W LT PWR
BCN PWR
DOME LT
DOME/BCN GND
CAB LT PWR
CAB LT GND
WORK LT
PLUGGED
PLUGGED
15A OPT 2
15A OPT 1
OPT GND 1
OPT GND 2
APPROX 10" BEHIND
OPT PWR 1
OPT PWR 2
OPT PWR 3
OPT PWR 4
D FAN GND
AUX
AUX SW GND
25A OPT GND
WORKLIGHT/ HEATER TEMP SWITCH A B C
D FAN PWR
HEATER PWR
WIPER PWR
HEATER GND
D FAN GND
PLUGGED
OPTIONS HARNESS
FAN SW C
15A OPT 1
HEATER PWR
A OPTION 1
15A OPT 1 GND B 15 A
MAST
EXTRA
SWING
SW2 86
SW1 86
A B C D E F ENCLOSED CAB
SW2 87A
SW1 87A
HEATER GND
HTR CNTRL A
15A OPT 2
HEATER PWR
PLUGGED
PLUGGED
PLUGGED
STOP LT
A OPTION 2 OPTION
DOME LT
WORK LT
SIDESHIFT
BCN PWR
15A OPT 2 GND
(RED)
S/W LT PWR
CAB LT PWR
B 15 A
CAB LT GND
AUX SW GND
DOME/BCN GND
25A OPT A
25A OPT GND B
OPTION
25 A
PLUGGED
D FAN GND
D FAN PWR
WIPER PWR
HEATER GND
HEATER PWR
A/C SWITCH
(BLACK)
Options Schematic
(RED/WHITE)
OPTIONS
FUSE LEGEND
F1 20A WIPER PWR THERMOSTATIC
F2 15A 15A OPTION 1 PWR SWITCH A/C PRESSURE SWITCH
F3 15A 15A OPTION 2 PWR
PRS SW AC SW
F4 25A 25A OPTION PWR
F5 20A HEATER/BLOWER PWR
F6 20A LIGHT PWR
F7 10A BEACON PWR
F8 10A DASH FAN PWR
25A OPT GND
KEY ACC
AUX RLYS PWR
STOP LT
WORK LT
PLUGGED
PLUGGED
MAST
OPT PWR 1
SIDESHIFT
OPT PWR 2
SWING
OPT PWR 3
EXTRA
OPT PWR 4
PLUGGED
OPT GND 1
PLUGGED
OPT GND 2
PLUGGED
RLY 87
AC SW
A
RLY 87
B
25A OPT GND
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 86 87a 87
OPTIONS HARNESS CONDENSER FANS
A/C M 17A M
AC CLUTCH
HD36-24-19PE (ON ROOF)
RELAY
TO CHASSIS ASSEMBLY 85 30
25A OPT GND
25A OPT
MY1070
SEE SHEET 1
Electrical Wiring
4.7
4.8
(OPT)
(OPT) (OPT) REVERSE (OPT) AUXILIARY
TAIL LIGHT ALARM TO OPTIONS HARNESS A/C TILT-ON ELECTRIC
FRONT RIGHT HORN TO DASH PANEL HARNESS TO CAB ASSEMBLY
WORKLIGHT 8-SHT3-REV BLK AND BOM COMPRESSOR JOYSTICK A S LT RT TM FUEL
BU STOP TAIL HD36-24-31PT TO SHIFTER HARNESS
VALVE SNDR
CHASSIS HARNESS HD36-24-31ST HD34-24-19SE
CHASSIS HARNESS CHASSIS HARNESS M
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19
BLK
YEL
BLU
RED
ORG
POWER DISTRIBUTION
(-)
EMPTY
A B
BLK
GRN
RED
A B A B A B
PLUGGED
FUSE/BREAKER LEGEND
Electrical Wiring
SP-1
SP-2
SP-3
A B A B C D
SP-3
SP-2
SP-1
HORN
CB2 20A OPTIONS POWER 4
MAST
HORN
ST RLY
OIL PSI
A B C D E F
SWING
EXTRA
STR AW
TILT UP
TILT DN
FUL LVL
HR MTR
KEY IGN
LT GND
CLT TMP
KEY ACC
STR CRB
CB3 20A OPTIONS POWER 1
STOP LT
KEY ACC
WORK LT
PLUGGED
PLUGGED
PLUGGED
PLUGGED
PLUGGED
PLUGGED
PLUGGED
PLUGGED
REVERSE
PLUGGED
PLUGGED
PLUGGED
PLUGGED
SP GND 1
SP GND 2
REVERSE
PLUGGED
PLUGGED
PLUGGED
PLUGGED
PLUGGED
DASH GND
GAGE PWR
SIDESHIFT
KEY START
HORN PWR
OPT GND 1
OPT GND 2
OPT PWR 1
OPT PWR 2
OPT PWR 3
OPT PWR 4
CB4 20A OPTIONS POWER 2
AC CLUTCH
PK BRK SOL
KEY START
PK BRK SOL
AC CLUTCH
SP BAT PWR
SP BAT PWR
SHIFT PWR 1
OVR SUP/911
SHIFT PWR 1
THR RTN/914
OVR SGN/918
FAULT LT/473
OVR SUP/911
THR SGN/915
SP BAT PWR
TRANS SOL Y1
TRANS SOL Y2
TRANS SOL Y3
TRANS SOL Y4
TRANS SOL Y5
SP ACCY PWR
TRANS TMP SW
TRAN/BRK PWR
STAB/TILT PWR
TRAN/BRK PWR
TRANS TMP SW
AUX RLYS PWR
FUL LVL
F2 5A ALTERNATOR EXCITE
FUL/STAB GND
REMOVE DIODES
STEER/SWAY PWR
LT GND
REVERSE
STOP LT
WORK LT
LT GND
WORK LT
F3 10A ENGINE ECU IGN PWR FOR OPTIONAL
ROLLER TILT NEGATIVE CABLE
ON JOYSTICK TO CAB FIREWALL
F4 10A GAGE (INST PANEL) PWR AND INSTALL
"EMPTY" PLUG
TILT DN
TILT UP
F5 15A SPARE ACCESSORY PWR
MAST
SIDESHIFT
AUX ELEC GND
SWING
EXTRA
PLUGGED
FUL/STAB GND
FUL/STAB GND
F6 10A AUX ELECTRIC PWR
F7 15A HORN PWR
F8 25A SPARE BATTERY PWR
F9 10A ENGINE ECU BAT PWR
F10 10A STEER/SWAY PWR
F11 10A R. AXLE STAB/TILT PWR
F12 15A KEY BATTERY PWR
+ -
12 VDC
ALL WHEEL 1
STR AW BATTERY
STEER 2
STR/SWAY GND
MODE POSITIVE CABLE
1
STR CRB
VALVE TO STARTER
2
STR/SWAY GND
CRAB AND ALTERNATOR
NEGATIVE CABLE
TO ENG BLOCK
NEGATIVE CABLE
FLAG TO
12 TURNS CHASSIS FRAME
PER FOOT
TWIST ECU IGN/012 1
ECU BAT/022 2
BAT GND
BAT GND
BAT POS
BAT POS
ECU GND/050 3
ENG GND 4
CLT TMP 5
PK BRK SOL 6
POWER DIST OVR SGN/918 7
A C A C FAULT LT/473 8
BLACK-6 GRAY-5 VEC ALT EXC 9
OVR SUP/911 10
THR SGN/915 11
A
DASH GND
THR RTN/914 12
F2 5 ALT EXC
B ST RLY
ACCY-2 IGNITION-2 F5 15 SP ACCY PWR 13
C HR MTR
F6 10 AUX RLYS PWR 14
87a
30
87
86
85
87a
30
87
86
85
D OIL PSI
OPT GND 1 15
E GAGE PWR
KEY ACC 16
GREEN-4
F TRANS TMP SW
F1 15 TRAN/BRK PWR 17
HD34-24-29PE
G PLUGGED
OPT GND 2 18
IGNITION-1 ACCY-1
CHASSIS HARNESS
H TRANS SOL Y1 19
PLUGGED
87a
30
87
86
85
87a
30
87
86
85
SP CAB GND 1 20
Chassis/Boom Schematic
A TRANS SOL Y2
SP CAB GND 2 21
B TRANS SOL Y3
TO POWER UNIT ASSEMBLY
SP GND 1 22
C PLUGGED
SP GND 2 23
D PLUGGED
AUX ELEC GND 24
E
CB4
F8
F3
CB3
F4
F9
CB1
F7
F10
CB2
F11
F12
TRANS SOL Y4
BLUE-3
LT GND 25
F TRANS SOL Y5
STR/SWAY GND 26
20
20
20
20
G PLUGGED
25
10
10
10
15
10
10
15
FUL/STAB GND 27
H PLUGGED 28
PLUGGED 29
BLACK-1 GRAY-2
H G F E D C B A H G F E D C B A
6A 6A
KEY IGN
ENG GND
OPT PWR 2
OPT PWR 1
GAGE PWR
OPT PWR 3
OPT PWR 4
HORN PWR
STAB/TILT PWR
STAB/TILT PWR
STAB VLV
FUL/STAB GND
ECU IGN/012
SP BAT PWR
ECU BAT/022
ECU GND/050
SHIFTER GND
KEY BAT PWR
STAB VLV
FUL/STAB GND
STAB VLV
FUL/STAB GND
STAB/TILT PWR
STEER/SWAY PWR
A B C D
STEER/SWAY PWR
STEER/SWAY PWR
SWAY ENABLE
STR/SWAY GND
SWAY ENABLE
MINUS 15
PLUG
STR/SWAY GND
SWAY ENABLE
PLUG
PLUS 15
STR/SWAY GND
SWAY LT
STR/SWAY GND
SWAY LOCK
STR/SWAY GND
SWAY LOCK
STR/SWAY GND
SWAY LOCK
STR/SWAY GND
SWAY RT
STR/SWAY GND
BLU
WHT
RED
ORG
BLK
A B C D
1 2 3 4 1 2 3 4 A B A B
STR/SWAY GND
MINUS 15
SWAY RT
STEER/SWAY PWR
STR/SWAY GND
PLUS 15
SWAY LT
STEER/SWAY PWR
1 2 1 2 1 2 1 2 1 2
BLU
BLK
RED
WHT
ORG
+
1
3
1
3
RED
YELLOW
GREEN
BLACK
RED
YELLOW
GREEN
BLACK
STABILIZER PROXIMITY
85 2
86 5
87 4
30
85 2
86 5
87 4
30
STABILIZER
87a
87a
MY1080
(-)15 DEG RLY (+)15 DEG RLY
SWAY PROXIMITY
SWITCH
A B A B A B A B A B C A B
F4 Y1, Y6
POSITIVE CABLE
TO BATTERY (3/0 AWG, RED)
R1 Y2, Y3, Y4, Y6
CLT/461
RELAY
INJ A/491
INJ B/493
30
R3 Y2, Y3, Y6 ST RLY PWR
OIL PRS/467
THR RTN/914
THR RTN/914
MAN TMP/463
THR RTN/914
THR RTN/914
CRANK A/447
OVR SUP/911
FUEL TMP/428
CRANK B/448
STRT SOL 87
R4 Y2, Y6 ST RLY 86
ENG GND 85
12 TURNS
PER FOOT N1 Y6 (ONLY IF PARK BRAKE OFF)
TWIST (3/0 AWG, RED)
1
ECU IGN/012
N4 Y6 (ONLY IF PARK BRAKE OFF)
2
ECU BAT/022
3
ECU GND/050 STRT SOL M
4
ENG GND
5
CLT TMP
6
PK BRK SOL
ST RLY PWR
7
OVR SGN/918
(3/0 AWG, RED)
8
FAULT LT/473
6A/400V
(4 AWG, RED)
9
ALT EXC
10
OVR SUP/911
11
THR SGN/915
12
THR RTN/914
13
ST RLY
ALTERNATOR
14
HR MTR (4 AWG, RED)
OIL PSI B+
15
HD36-24-29SE
G
16
GAGE PWR ALT EXC A
TRANS TMP SW A D+
6A/400V
TO CHASSIS ASSEMBLY
19
TRANS SOL Y1
20
PLUGGED
21
TRANS SOL Y2
TRANS SOL Y3 GAGE PWR 5 PSI ENGINE OIL
22 A
PLUGGED HR MTR PRESSURE
23 B
PLUGGED SWITCH
24
25
TRANS SOL Y4
26
TRANS SOL Y5
27
PLUGGED
28
PLUGGED
29
PLUGGED CLT TMP CLT TEMP
RESISTOR LOCATED SENDER
Power Unit Schematic
SHIELDED
ECU HARNESS
CAN TERMINATOR CABLE PK BRK SOL 1 PARK
ENG GND 2 BRAKE
A
(CAN H/904, YELLOW)
(CAN L/905, GREEN) VALVE
B
120 OHM C
(SHIELD/020)
SHIELDED
CAN TERMINATOR
CABLE
A
(CAN H/904, YELLOW)
B
(CAN L/905, GREEN)
120 OHM C
(SHIELD/020)
12 TURNS
PER FOOT
TWIST
SHIELDED
CABLE
TRANS SOL Y1
ENG GND
TRANS SOL Y2
ENG GND
TRANS SOL Y3
ENG GND
TRANS SOL Y4
ENG GND
TRANS SOL Y5
ENG GND
PK BRK SOL
ENG GND
TRANS TMP SW
ENG GND
SHTDN/941
ECU IGN/012
INJ B/493
CLT/461
CRANK A/447
OVR SGN/918
HI LO/947
PLUGGED
FUEL TMP/428
MAN TMP/463
CRANK B/448
THR RTN/914
THR SGN/915
OVR SUP/911
PLUGGED
CAN L/905
PLUGGED
OIL PRS/467
CAN H/904
PLUGGED
FAULT LT/473
PLUGGED
PLUGGED
PLUGGED
PLUGGED
ECU GND/050
PLUGGED
ECU BAT/022
INJ A/491
PLUGGED
A B A B A B A B A B A B A B
J1
A1
F1
E1
C1
G1
J2
J3
A2
A3
B1
D1
K1
H1
F2
F3
E2
E3
C2
C3
G2
G3
B2
B3
D2
D3
K2
K3
H2
H3
ECU GND/050
ECU IGN/012
(CAN H/904, YELLOW)
(CAN L/905, GREEN)
(SHIELD/020)
PLUGGED
PLUGGED
PLUGGED
PLUGGED
Y1 Y2 Y3 Y4 Y5 Y6 250 F
DEERE ENGINE ECU
TRANSMISSION
A B C D E F G H J
DIAGNOSTIC
MY1090
CONNECTOR
Electrical Wiring
4.9
4.10
FUEL
H
9 8
CHECK
5 6
36830B
CLUSTER GAUGE
ORANGE-16
BLACK-16
P
A
B
A
B
ORANGE-16
BLACK-16
38200C-4
GROUND
ENGINE TO
MAINFRAME
PIN 86 IS GROUND
ON ALL RELAYS 4.1.4
6 7 BOOM ENGINE ENGINE FUEL INCLUDED IN UPPER INCLUDED IN INTERMEDIATE FUEL LEVEL 30
TRANS
WATER FAULT EXTEND PARK WATER I G HARNESS 66944D HARNESS 66961D GA SEND CONNECT BATT GRD
LOCK BRAKE TEMP CONNECTS UNDER SEAT BOX CONNECTS UNDER SEAT BOX TO LOWER STARTER
5 8 P29317
7 TRANS OIL MOUNTING BOLT
36804X POWER
HOURMETER TEMP
4 9 12 1 4 S STARTER 65724A
LAMPS BRAKE MOTOR
REAR PRESS
ENGINE BATTERY NEG. CABLE 2/0 BLACK 86 85
3 10 OSC OIL VOLTAGE 66982A 87A
LOCK TRANS
GRD DISC PRESSURE D TRANSMISSION TEMP 4923233 DASH HARNESS 'O' 4923232 ENGINE HARNESS 'A'
10 CONNECTS TO ENGINE HARNESS CONNECTS UNDER SEAT BOX 38200C-3
2 11 11 SOLENOID GROUND
87
OIL UNDER THE SEAT BOX PINS 18 - 29 PLUGGED 35646A
HOUR + BATTERY - OPER COMP TO
METER 1 12 POS. CABLE 12V MAINFRAME
G R B G Y V W T P O
+ - R E L R E I H A I R BLACK-10 2/0 RED
1 SEE SHEET 3
E D A A L O I N N A RELAY SOCKE
E 1 C Y L L T 1 K N 2 SEE SHEET 3
F N 6 K 1 O E E 6 1 G 3 SEE SHEET 3 TOP VIEW
1 1 6 W T 1 6 E 4 PLUGGED WHITE-10
6 6 1 1 6 1
5 SEE SHEET 3 38200C-5
6 6 6
6 PLUGGED R
SEE SHEET 3 E
7
STARTER D RED-12
8 SEE SHEET 3 YELLOW-14
RELAY 6 >> A (SHEET 4)
9 67789A
10 SEE SHEET 3
RED-12
>> B (SHEET 4)
11 SEE SHEET 3 RED-14 S B+
12 SEE SHEET 3 RED-12
13 PLUGGED ALTERNATOR >> C (SHEET 4)
Electrical Wiring
BOSCH
14 SEE SHEET 3
Model 1044C-54
95 AMP RED-12
15 SEE SHEET 3 D+ >> D (SHEET 4)
16 SEE SHEET 3
17 SEE SHEET 3 4923247
RED-12
WIRE W/DIODE >> E (SHEET 4)
PINS 4,
ENGINE 38094A THROTTLE
WILLIAMS 6, 13 &
3 3
FAULT O/R TRANSMISSION (SUSPENDED) 18 - 29
2 (RESET) 2 DISCONNECT
R PLUGGED
A WHITE-12
SWITCH 7 SWITCH B
C - + 66679A SPST-N.O., 250 PSI 67062A SPST-N.O., 250 PSI RED-12
Q B D PLUGGED BRAKE PRESSURE SWITCH ON MACHINES W/ROADWAY LIGHTS
E PLUGGED
F PLUGGED N ON DIAGNOSTIC PANEL
OPTION
67063A SPST-N.O., 1000 PSI 67064A SPST-N.O., 1000 PSI BACK-UP
TAN-16 B BLACK-16 CIRCUIT LIGHT
ON MACHINES W/DRY DISC BRAKES ON MACHINES W/DRY DISC BRAKES BREAKERS
RED-16 A RED-16
& ROADWAY LIGHTS 40 AMP
P29694
T
WHITE-16 D BLUE-16 BACK-UP
66680A DPST-N.C. SWITCH, 850 PSI ALARM
RED-16 C BLACK-16 P13774
LOW BRAKE PRESSURE SWITCH
BLACK-16 B YELLOW-16
- ON DIAGNOSTIC PANEL + -
YELLOW-16 A BROWN-16 +
USE 67065A SPST-N.C. SWITCH, 1800 PSI A
+ -
ON MACHINES WITH DRY DISC BRAKES B
M 66891C (10366981)
CIRCUIT BOARD 38329A COIL
10 AMP
2-WAY SOLENOID VALVE ON
A BOOM ANGLE GREATER THAN 40° NO
VIOLET-14 SV3 REAR AXLE STABILIZER VALVE
BLACK-14 ON REAR STABILIZER CYLINDER BOOM ANGLE LESS THAN 40° NC
A IGN. P11092 B
ENERGIZED W/BOOM BELOW 40° 37115X PROXIMITY SENSOR IS N. O.
ACC. IGNITION ON TRANSFER CARRIAGE
ST. SWITCH
10 AMP BAT.
VIOLET-16 1 STAB. SOL. SV3 (1.2 AMP INRUSH) VIOLET-16
38329A COIL
PINK-16 2 BACK-UP ALARM (.6 AMPS) PINK-16 SOLENOID VALVE ON BROWN BLACK
TO PARKING BRAKE J14 A REAR AXLE STABILIZER
BLACK-16 3 GROUND (9.6 AMPS AT INRUSH) BLACK-16 POWER
RELAY TERM 85 SV1 POWER
CONTROL VALVE(ENERGIZED IN
(SEE SHEET 2). B OUT
YELLOW-14 4 START RELAY(.41-.48 AMPS) YELLOW-14 W/BOOM BELOW 20°)
E2 BLACK-14
ORANGE-16 5 STAB. SOL. SV1 (1.2 AMP INRUSH) ORANGE-16 GROUND
RED-16 A 38329A COIL BLUE
BLACK-16 6 GROUND (2.4 AMPS) BLACK-16
BLUE-16 B J15 A 3-WAY SOLENOID VALVE ON
BLUE-16 7 STAB. SOL. SV2 (1.2 AMP INRUSH) BLUE-16 REAR AXLE STABILIZER CONTROL
66941A DPST-N.C. SWITCH,100 PSI - + SV2
VALVE ON VALVE PLATE
GRAY-14 8 HORN (6 AMPS MAX.) GRAY-14 B
PARKING BRAKE PRESSURE SWITCH ENERGIZED W/BOOM BELOW 40° OR
UNDER DASH PANEL GREEN-16 9 40° SWITCH POWER OUT BLACK-14 BOOM ABOVE 40° & FOOT BOOM ANGLE GREATER THAN 20° NO
+ - BOOM ANGLE LESS THAN 20° NC
SWITCH DEPRESSED
PINK-16 A TRANSMISSION BOOM/ TRANSFER RED-16 10 12 VOLTS 37115X PROXIMITY SENSOR IS N. O.
REAR OSC.
EXTEND LOCKOUT J2 ON TRANSFER CARRIAGE
BLACK-16 B LOCK DISCONNECT BLACK-16 11 PROXIMITY SWITCH GROUND
TO PARKING BRAKE 4 SECTION BOOM ONLY HORN
WHITE-16 12 20° SWITCH POWER OUT P13707
E1 RELAY TERM 86
(SEE SHEET 2). 13 BROWN BLACK
LAMP #10 LAMP #11 LAMP #9 14 POWER
POWER
IN
OUT
WHITE-16 A LAMP #10 A WHITE-16 GREEN-16 D GREEN-16 D
RED-16 C RED-16 C GROUND
VIOLET-16 B LAMP #11 B VIOLET-16 INTERMEDIATE HARNESS, 66961D
BLACK-16 B BLACK-16 B BLUE
TAN-16 C LAMP #9 C TAN-16 CONNECTS UNDER SEAT BOX
WHITE-16 A WHITE-16 A
BLUE-16 D DECLUTCH D BLUE-16
J16
WHITE-12 FROM ENGINE HARNESS, UNSWITCHED POWER
WHITE-14
L STUD ON BOARD
HORN 6K MACHINES)
TRANS. & PROXIMITY SWITCHES.
RELAY
F 85 87A 87
10 AMP
F4 RED-16
R BACK-UP ALARM
J7 STUD ON BOARD BLUE-16
15 AMP SWITCHED POWER FOR OPTIONS A B A B
F5 39510B HARNESS
R
BOOM PROX. SWITCH RELAYS
J J4 38329A COIL
MAN0260
RED-16
>> F (SHEET 4)
Before S/N 0160016632
RELAY K11 RELAY K12 RELAY K13 RELAY K14 RELAY K15 RELAY K16 RELAY K17
NOTES:
MAN0270
1. DIODE MODULES #1 AND #2 ARE IN TRANS
SOLENOID HARNESS (4923243).
30
87
86
85
30
87
86
85
30
87
86
85
30
87
86
85
30
87
86
85
30
87
86
85
30
87
86
85
87a
87a
87a
87a
87a
87a
87a
2. DIODES D1-D9 ARE INCLUDED IN TRANS
RELAY HARNESS ASSY (4923246).
N/C
N/C
N/C
N/C
N/C
N/C
JUMPER 1
JUMPER 2
JUMPER 1
JUMPER 2
IGN POWER
RELAY GND
RELAY GND
IGN POWER
RELAY GND
RELAY GND
RELAY GND
IGN POWER
RELAY GND
IGN POWER
RELAY GND
BOOM 21-40
BOOM 21-40
SHIFTER Y5
SHIFTER PWR
SOLENOID Y6
SOLENOID Y1
FORWARD SGN
SOLENOID Y2
REVERSE SGN
SHIFT TO 1ST
BOOM OVER 40
BOOM OVER 20
BOOM OVER 40
SHIFTER Y6 A
'A' OF CIRCUIT
BOARD &
SHIFTER HARNESS)
D1 D2 D3 D4 D5
A PLUGGED
B PLUGGED
C PLUGGED
D IGN POWER UPPER KOSTAL
TRANSMISSION
CONNECTOR
FROM CIRCUIT
('B' OF TRANS
BOARD J11
SOLENOID HARNESS)
(SEE SHT 1)
SOLENOID Y1 1
SOLENOID Y2 2
'B' OF CIRCUIT SOLENOID Y3 3
BOARD & DASH GND
SHIFTER HARNESS) 7
RELAY K18
'E' OF CIRCUIT
BOARD &
SHIFTER HARNESS)
30
87
86
85
87a
A DIRECTION INPUT
B FORWARD
C REVERSE
D NEUTRAL A UPPER KOSTAL
D10 TRANSMISSION
FROM CIRCUIT CONNECTOR
BOARD J10 ('C' OF TRANS
(SEE SHT 1) SOLENOID HARNESS)
NEUTRAL
NEUTRAL A
SOLENOID Y4 4
SOLENOID Y5 5
SOLENOID Y6 6
DASH GND 7
'C' OF CIRCUIT
BOARD & ONLY 4 OF 16
SHIFTER HARNESS) PINS SHOWN
DIRECTION INPUT (OTHERS NOT USED)
1
FORWARD
FROM SHIFTER
CONNECTOR
(SEE SHT 1)
TO DASH
GND STUD
Electrical Wiring
4.11
MANIFOLD AIR COOLANT TEMP FUEL TEMP CRANK OIL PRESSURE INJECTOR
4.12
TEMP SENSOR SENSOR SENSOR SENSOR SENSOR PUMP
MAN0280
NOTES:
A B A B A B A B A B C A B
1. ALL CONNECTOR DESIGNATOR LETTERS ON THIS SHEET REFER TO THE
R Q P N F E ENGINE ECU HARNESS (4923232).
CLT/461
INJ A/491
INJ B/493
MAN TMP/463
THR RTN/914
THR RTN/914
THR RTN/914
CRANK A/447
CRANK B/448
THR RTN/914
OVR SUP/911
OIL PRS/467
FUEL TMP/428
12 TURNS
PER FOOT
TWIST
Electrical Wiring
A
1 ECU IGN/012
2 ECU BAT/022
3 ECU GND/050
4 PLUGGED
5 CLT TMP CLT TMP CLT TEMP
6 PLUGGED SENDER Q
7 OVR SGN/918 P23222
8 FAULT LT/473
9 ALT EXC SEE SHT 1 OIL PSI OIL PRESS
10 OVR SUP/911 SENDER L
11 THR SGN/915 P23217
12 THR RTN/914
13 PLUGGED
14 HR MTR
15 OIL PSI
GAGE PWR GAGE PWR 5 PSI ENGINE OIL
16 A
TRANS TEMP HR MTR PRESSURE
HD36-24-29SE
17 B
SWITCH
18 PLUGGED
K
19 PLUGGED
20 PLUGGED
21 PLUGGED
22 PLUGGED TRANS TEMP TRANS TEMP
23 PLUGGED SENDER V
390 OHM, 1W
SHTDN/941
SHIELDED
CAN TERMINATOR CABLE
SHIELDED
CAN TERMINATOR CABLE
12 TURNS
PER FOOT SHIELDED
TWIST CABLE
CLT/461
PLUGGED
PLUGGED
PLUGGED
PLUGGED
PLUGGED
PLUGGED
PLUGGED
PLUGGED
PLUGGED
PLUGGED
SHTDN/941
INJ B/493
HI LO/947
CAN L/905
CAN H/904
INJ A/491
ECU IGN/012
CRANK A/447
OVR SGN/918
MAN TMP/463
CRANK B/448
THR RTN/914
THR SGN/915
OVR SUP/911
OIL PRS/467
ECU GND/050
ECU BAT/022
FUEL TMP/428
FAULT LT/473
ECU GND/050
ECU IGN/012
(SHIELD/020)
PLUGGED
PLUGGED
PLUGGED
PLUGGED
J
A1
A2
A3
B1
B2
B3
C1
C2
C3
D1
D2
D3
E1
E2
E3
F1
F2
F3
G1
G2
G3
H1
H2
H3
J1
J2
J3
K1
K2
K3
G
A B C D E F G H J
Before S/N 0160016632
F (SHT 1)
A (SHT 1)
E (SHT 1)
B (SHT 1)
CUT-OFF)
D (SHT 1)
C (SHT 1)
MAN0290
S1
2 3
2 AD4 (FORWARD)
RED-16
RED-12
RED-12
RED-12
RED-12
RED-12
PIN
POWER (SHT 1) 30 4 AD6 (NEUTRAL)
SOLENOID
1 2 3 4 1 2 3 4 1 2 3 4
BEACON FUSE 87
LIGHT
AD1 Y3 S3
BEACON
RELAY GND 5 AD3 (SHIFTER Y5)
RELAY K18
86
AD2 Y4
J7 SWITCHED PWR 85 D1
S5
AD3 Y5
6 AD2 (SHIFTER Y4)
AD4 Y1
10 AMP
S4 D2
BEACON
LIGHT FUSE
AD5 Y2 7 AD1 (SHIFTER Y3)
AD6 S6
TO 8 AD7 (SHIFTER Y6)
BEACON N/C AD7 Y6
LIGHT 87a
POWER (SHT 1) 30 9 ED2 (VP/FUSED POWER)
WIPER
RELAY GND
RELAY K19
86 11 PLUGGED
CONTROLS
NOTE: SWITCHES S1-S6 ARE RATED FOR
J7 SWITCHED PWR 0.6 AMPS WITH DAMPING DIODE.
85
12 PLUGGED
FUSE
WIPER
25 AMP
TRANSMISSION CONTROL VALVE OPERATION
SHIFTER SELECTION ACTIVATED SOLENOIDS
TO BOOM NOT OVER 20 DEGREES
WIPER N/C 87a FORWARD-4TH Y1, Y4, Y6
POWER (SHT 1) 30 FORWARD-3RD Y1, Y3, Y4, Y6
WK LIGHTS FUSE 87 FORWARD-2ND Y1, Y3, Y4, Y5
FORWARD-1ST Y1, Y3, Y5, Y6
LIGHTS
WORK
RELAY GND
RELAY K20
86 REVERSE-4TH Y2, Y3, Y4, Y6
J7 SWITCHED PWR 85 REVERSE-3RD Y2, Y3, Y4, Y6
REVERSE-2ND Y2, Y3, Y4, Y5
REVERSE-1ST Y2, Y3, Y5, Y6
FUSE
20 AMP
BOOM OVER 20 DEGREES AND NOT OVER 40 DEGREES
WORK LIGHTS
FORWARD-4TH Y1, Y3, Y4, Y5 (2ND GEAR)
TO FORWARD-3RD Y1, Y3, Y4, Y5 (2ND GEAR)
WORK N/C FORWARD-2ND Y1, Y3, Y4, Y5
LIGHTS 87a
POWER (SHT 1) 30 FORWARD-1ST Y1, Y3, Y5, Y6
REVERSE-4TH Y2, Y3, Y4, Y5 (2ND GEAR)
RD LIGHTS FUSE 87 REVERSE-3RD Y2, Y3, Y4, Y5 (2ND GEAR)
ROAD
LIGHTS
RELAY GND REVERSE-2ND Y2, Y3, Y4, Y5
RELAY K21
86
REVERSE-1ST Y2, Y3, Y5, Y6
J7 SWITCHED PWR 85
BOOM OVER 40 DEGREES
(TRANS DISABLED UNLESS FOOTSWITCH PRESSED)
FUSE
25 AMP
FORWARD-4TH Y1, Y3, Y5, Y6 (1ST GEAR)
ROAD LIGHTS
FORWARD-3RD Y1, Y3, Y5, Y6 (1ST GEAR)
FORWARD-2ND Y1, Y3, Y5, Y6 (1ST GEAR)
TO
ROAD N/C FORWARD-1ST Y1, Y3, Y5, Y6
LIGHTS 87a
REVERSE-4TH Y2, Y3, Y5, Y6 (1ST GEAR)
POWER (SHT 1) 30
REVERSE-3RD Y2, Y3, Y5, Y6 (1ST GEAR)
HEATER-A/C FUSE 87
AND A/C REVERSE-2ND Y2, Y3, Y5, Y6 (1ST GEAR)
REVERSE-1ST Y2, Y3, Y5, Y6
HEATER
RELAY GND 86
RELAY K22
J7 SWITCHED PWR 85
25 AMP
HEATER
& A/C FUSE
Electrical Wiring
TO
HEATER
AND A/C
Before S/N 0160016632
4.13
4.14
ORANGE-16 A A ORANGE-16 PIN 86 IS GROUND
38200C-4
36830B BLACK-16 B B BLACK-16 ON ALL RELAYS
GROUND
H CLUSTER GAUGE ENGINE TO
FUEL 9 8 5 6 MAINFRAME
CHECK P
6 7 BOOM ENGINE ENGINE FUEL INCLUDED IN UPPER INCLUDED IN INTERMEDIATE FUEL LEVEL 30
TRANS
WATER FAULT EXTEND PARK WATER I G HARNESS 66944D HARNESS 66961D GA SEND CONNECT BATT GRD
LOCK BRAKE TEMP CONNECTS UNDER SEAT BOX CONNECTS UNDER SEAT BOX TO LOWER STARTER
5 8 P29317
7 TRANS OIL MOUNTING BOLT
36804X POWER
HOURMETER TEMP
4 9 12 1 4 S STARTER 65724A
LAMPS BRAKE MOTOR
REAR PRESS
ENGINE BATTERY NEG. CABLE 2/0 BLACK 86 85
3 10 OSC OIL VOLTAGE 66982A 87A
LOCK TRANS
GRD DISC PRESSURE D TRANSMISSION TEMP 4923233 DASH HARNESS 'O' 4923232 ENGINE HARNESS 'A'
10 CONNECTS TO ENGINE HARNESS CONNECTS UNDER SEAT BOX 38200C-3
2 11 11 SOLENOID GROUND
87
OIL UNDER THE SEAT BOX PINS 18 - 29 PLUGGED 35646A
HOUR + BATTERY - OPER COMP TO
METER 1 12 POS. CABLE 12V MAINFRAME
G R B G Y V W T P O
+ - R E L R E I H A I R BLACK-10 2/0 RED
1 SEE SHEET 3
E D A A L O I N N A RELAY SOCKE
E 1 C Y L L T 1 K N 2 SEE SHEET 3
F N 6 K 1 O E E 6 1 G 3 SEE SHEET 3 TOP VIEW
1 1 6 W T 1 6 E 4 PLUGGED WHITE-10
6 6 1 1 6 1
5 SEE SHEET 3 38200C-5
6 6 6
6 PLUGGED R
SEE SHEET 3 E
7
STARTER D RED-12
8 SEE SHEET 3 YELLOW-14
RELAY 6 >> A (SHEET 4)
9 67789A
10 SEE SHEET 3
RED-12
>> B (SHEET 4)
11 SEE SHEET 3 RED-14 S B+
12 SEE SHEET 3 RED-12
13 PLUGGED ALTERNATOR >> C (SHEET 4)
BOSCH
14 SEE SHEET 3 95 AMP RED-12
15 SEE SHEET 3 D+ >> D (SHEET 4)
16 SEE SHEET 3
4923247
RED-12
Electrical Wiring
17 SEE SHEET 3
WIRE W/DIODE >> E (SHEET 4)
PINS 4,
ENGINE 38094A THROTTLE
WILLIAMS 6, 13 &
3 3
FAULT O/R TRANSMISSION (SUSPENDED) 18 - 29
2 (RESET) 2 DISCONNECT
R PLUGGED
A WHITE-12
SWITCH 7 SWITCH B
C - + 66679A SPST-N.O., 250 PSI 67062A SPST-N.O., 250 PSI RED-12
Q B D PLUGGED BRAKE PRESSURE SWITCH ON MACHINES W/ROADWAY LIGHTS
E PLUGGED
F PLUGGED N ON DIAGNOSTIC PANEL
OPTION
67063A SPST-N.O., 1000 PSI 67064A SPST-N.O., 1000 PSI BACK-UP
TAN-16 B BLACK-16 CIRCUIT LIGHT
ON MACHINES W/DRY DISC BRAKES ON MACHINES W/DRY DISC BRAKES BREAKERS
RED-16 A RED-16
& ROADWAY LIGHTS 40 AMP
P29694
T
WHITE-16 D BLUE-16 BACK-UP
66680A DPST-N.C. SWITCH, 850 PSI ALARM
RED-16 C BLACK-16 P13774
LOW BRAKE PRESSURE SWITCH
BLACK-16 B YELLOW-16
- ON DIAGNOSTIC PANEL + -
YELLOW-16 A BROWN-16 +
USE 67065A SPST-N.C. SWITCH, 1800 PSI A
+ -
ON MACHINES WITH DRY DISC BRAKES B
M 66891C (10366981)
CIRCUIT BOARD 38329A COIL
10 AMP
2-WAY SOLENOID VALVE ON
A BOOM ANGLE GREATER THAN 40° NO
VIOLET-14 SV3 REAR AXLE STABILIZER VALVE
BLACK-14 ON REAR STABILIZER CYLINDER BOOM ANGLE LESS THAN 40° NC
A IGN. P11092 B
ENERGIZED W/BOOM BELOW 40° 37115X PROXIMITY SENSOR IS N. O.
ACC. IGNITION ON TRANSFER CARRIAGE
ST. SWITCH
10 AMP BAT.
VIOLET-16 1 STAB. SOL. SV3 (1.2 AMP INRUSH) VIOLET-16
38329A COIL
PINK-16 2 BACK-UP ALARM (.6 AMPS) PINK-16 SOLENOID VALVE ON BROWN BLACK
TO PARKING BRAKE J14 A REAR AXLE STABILIZER
BLACK-16 3 GROUND (9.6 AMPS AT INRUSH) BLACK-16 POWER
RELAY TERM 85 SV1 POWER
CONTROL VALVE(ENERGIZED IN
(SEE SHEET 2). B OUT
YELLOW-14 4 START RELAY(.41-.48 AMPS) YELLOW-14 W/BOOM BELOW 20°)
E2 BLACK-14
ORANGE-16 5 STAB. SOL. SV1 (1.2 AMP INRUSH) ORANGE-16 GROUND
RED-16 A 38329A COIL BLUE
BLACK-16 6 GROUND (2.4 AMPS) BLACK-16
BLUE-16 B J15 A 3-WAY SOLENOID VALVE ON
BLUE-16 7 STAB. SOL. SV2 (1.2 AMP INRUSH) BLUE-16 REAR AXLE STABILIZER CONTROL
66941A DPST-N.C. SWITCH,100 PSI - + SV2
VALVE ON VALVE PLATE
GRAY-14 8 HORN (6 AMPS MAX.) GRAY-14 B
PARKING BRAKE PRESSURE SWITCH ENERGIZED W/BOOM BELOW 40° OR
UNDER DASH PANEL GREEN-16 9 40° SWITCH POWER OUT BLACK-14 BOOM ABOVE 40° & FOOT BOOM ANGLE GREATER THAN 20° NO
+ - BOOM ANGLE LESS THAN 20° NC
SWITCH DEPRESSED
PINK-16 A TRANSMISSION BOOM/ TRANSFER RED-16 10 12 VOLTS 37115X PROXIMITY SENSOR IS N. O.
REAR OSC.
EXTEND LOCKOUT J2 ON TRANSFER CARRIAGE
BLACK-16 B LOCK DISCONNECT BLACK-16 11 PROXIMITY SWITCH GROUND
TO PARKING BRAKE 4 SECTION BOOM ONLY HORN
WHITE-16 12 20° SWITCH POWER OUT P13707
E1 RELAY TERM 86
(SEE SHEET 2). 13 BROWN BLACK
LAMP #10 LAMP #11 LAMP #9 14 POWER
POWER
IN
OUT
WHITE-16 A LAMP #10 A WHITE-16 GREEN-16 D GREEN-16 D
RED-16 C RED-16 C GROUND
VIOLET-16 B LAMP #11 B VIOLET-16 INTERMEDIATE HARNESS, 66961D
BLACK-16 B BLACK-16 B BLUE
TAN-16 C LAMP #9 C TAN-16 CONNECTS UNDER SEAT BOX
WHITE-16 A WHITE-16 A
BLUE-16 D DECLUTCH D BLUE-16
J16
WHITE-12 FROM ENGINE HARNESS, UNSWITCHED POWER
WHITE-14
L STUD ON BOARD
HORN 6K MACHINES)
TRANS. & PROXIMITY SWITCHES.
RELAY
F 85 87A 87
10 AMP
F4 RED-16
R BACK-UP ALARM
J7 STUD ON BOARD BLUE-16
15 AMP SWITCHED POWER FOR OPTIONS A B A B
F5 39510B HARNESS
R
BOOM PROX. SWITCH RELAYS
J J4 38329A COIL
MAN0220
RED-16
MAN0230
RELAY HARNESS ASSY (4923246).
30
87
86
85
30
87
86
85
30
87
86
85
30
87
86
85
30
87
86
85
30
87
86
85
30
87
86
85
87a
87a
87a
87a
87a
87a
87a
N/C
N/C
N/C
N/C
N/C
N/C
JUMPER 1
JUMPER 2
JUMPER 1
JUMPER 2
IGN POWER
RELAY GND
RELAY GND
IGN POWER
RELAY GND
RELAY GND
RELAY GND
IGN POWER
RELAY GND
IGN POWER
RELAY GND
BOOM 21-40
BOOM 21-40
SHIFTER Y5
SHIFTER PWR
SOLENOID Y6
SOLENOID Y1
FORWARD SGN
SOLENOID Y2
REVERSE SGN
SHIFT TO 1ST
BOOM OVER 40
BOOM OVER 20
BOOM OVER 40
SHIFTER Y6 A
'A' OF CIRCUIT
BOARD &
SHIFTER HARNESS)
D1 D2 D3 D4 D5
A PLUGGED
B PLUGGED
C PLUGGED
D IGN POWER UPPER KOSTAL
TRANSMISSION
CONNECTOR
FROM CIRCUIT
('B' OF TRANS
BOARD J11
SOLENOID HARNESS)
(SEE SHT 1)
SOLENOID Y1 1
SOLENOID Y2 2
'B' OF CIRCUIT SOLENOID Y3 3
BOARD & DASH GND
SHIFTER HARNESS) 7
RELAY K18
'E' OF CIRCUIT
BOARD &
SHIFTER HARNESS)
30
87
86
85
87a
A DIRECTION INPUT
B FORWARD
C REVERSE
D NEUTRAL A UPPER KOSTAL
D10 TRANSMISSION
FROM CIRCUIT CONNECTOR
BOARD J10 ('C' OF TRANS
(SEE SHT 1) SOLENOID HARNESS)
NEUTRAL
NEUTRAL A
SOLENOID Y4 4
SOLENOID Y5 5
SOLENOID Y6 6
DASH GND 7
'C' OF CIRCUIT
BOARD & ONLY 4 OF 16
SHIFTER HARNESS) PINS SHOWN
DIRECTION INPUT (OTHERS NOT USED)
1
FORWARD
FROM SHIFTER
CONNECTOR
(SEE SHT 1)
TO DASH
GND STUD
Electrical Wiring
4.15
4.16
MANIFOLD AIR COOLANT TEMP FUEL TEMP CRANK OIL PRESSURE INJECTOR
TEMP SENSOR SENSOR SENSOR SENSOR SENSOR PUMP
NOTES:
MAN0240
1. ALL CONNECTOR DESIGNATOR LETTERS ON THIS SHEET REFER TO THE
ENGINE ECU HARNESS (4923232).
A B A B A B A B A B C A B
R Q P N F E
CLT/461
INJ A/491
INJ B/493
MAN TMP/463
THR RTN/914
THR RTN/914
THR RTN/914
CRANK A/447
CRANK B/448
THR RTN/914
OVR SUP/911
OIL PRS/467
FUEL TMP/428
12 TURNS
PER FOOT
Electrical Wiring
TWIST
A
1 ECU IGN/012
2 ECU BAT/022
3 ECU GND/050
4 PLUGGED
5 CLT TMP CLT TMP CLT TEMP
6 PLUGGED SENDER Q
7 OVR SGN/918 P23222
8 FAULT LT/473
9 ALT EXC SEE SHT 1 OIL PSI OIL PRESS
10 OVR SUP/911 SENDER L
11 THR SGN/915 P23217
12 THR RTN/914
13 PLUGGED
14 HR MTR
15 OIL PSI
GAGE PWR GAGE PWR 5 PSI ENGINE OIL
16 A
TRANS TEMP HR MTR PRESSURE
HD36-24-29SE
17 B
SWITCH
18 PLUGGED
K
19 PLUGGED
20 PLUGGED
21 PLUGGED
22 PLUGGED TRANS TEMP TRANS TEMP
23 PLUGGED SENDER V
390 OHM, 1W
SHTDN/941
SHIELDED
CAN TERMINATOR CABLE
SHIELDED
CAN TERMINATOR CABLE
12 TURNS
PER FOOT SHIELDED
TWIST CABLE
CLT/461
PLUGGED
PLUGGED
PLUGGED
PLUGGED
PLUGGED
PLUGGED
PLUGGED
PLUGGED
PLUGGED
PLUGGED
SHTDN/941
INJ B/493
HI LO/947
CAN L/905
CAN H/904
INJ A/491
ECU IGN/012
CRANK A/447
OVR SGN/918
MAN TMP/463
CRANK B/448
THR RTN/914
THR SGN/915
OVR SUP/911
OIL PRS/467
ECU GND/050
ECU BAT/022
FUEL TMP/428
FAULT LT/473
ECU GND/050
ECU IGN/012
(SHIELD/020)
PLUGGED
PLUGGED
PLUGGED
PLUGGED
A1
A2
A3
B1
B2
B3
C1
C2
C3
D1
D2
D3
E1
E2
E3
F1
F2
F3
G1
G2
G3
H1
H2
H3
J1
J2
J3
K1
K2
K3
G
A B C D E F G H J
S/N 0160016632 & After
F (SHT 1)
A (SHT 1)
E (SHT 1)
B (SHT 1)
CUT-OFF)
D (SHT 1)
C (SHT 1)
MAN0250
S1
2 AD4 (FORWARD)
S2
3 AD5 (REVERSE)
N/C FORWARD REVERSE NEUTRAL
87a
RED-16
RED-12
RED-12
RED-12
RED-12
RED-12
PIN
POWER (SHT 1) 30 4 AD6 (NEUTRAL)
SOLENOID
1 2 3 4 1 2 3 4 1 2 3 4
BEACON FUSE 87
LIGHT
AD1 Y3 S3
BEACON
RELAY GND 5 AD3 (SHIFTER Y5)
RELAY K18
86
AD2 Y4
J7 SWITCHED PWR 85 D1
S5
AD3 Y5
6 AD2 (SHIFTER Y4)
AD4 Y1
10 AMP
S4 D2
BEACON
LIGHT FUSE
AD5 Y2 7 AD1 (SHIFTER Y3)
AD6 S6
TO 8 AD7 (SHIFTER Y6)
BEACON N/C AD7 Y6
LIGHT 87a
POWER (SHT 1) 30 9 ED2 (VP/FUSED POWER)
WIPER
RELAY GND
RELAY K19
86 11 PLUGGED
CONTROLS
NOTE: SWITCHES S1-S6 ARE RATED FOR
J7 SWITCHED PWR 0.6 AMPS WITH DAMPING DIODE.
85
12 PLUGGED
FUSE
WIPER
25 AMP
TRANSMISSION CONTROL VALVE OPERATION
SHIFTER SELECTION ACTIVATED SOLENOIDS
TO BOOM NOT OVER 20 DEGREES
WIPER N/C 87a FORWARD-4TH Y1, Y4, Y6
POWER (SHT 1) 30 FORWARD-3RD Y1, Y3, Y4, Y6
WK LIGHTS FUSE 87 FORWARD-2ND Y1, Y3, Y4, Y5
FORWARD-1ST Y1, Y3, Y5, Y6
LIGHTS
WORK
RELAY GND
RELAY K20
86 REVERSE-4TH Y2, Y3, Y4, Y6
J7 SWITCHED PWR 85 REVERSE-3RD Y2, Y3, Y4, Y6
REVERSE-2ND Y2, Y3, Y4, Y5
REVERSE-1ST Y2, Y3, Y5, Y6
FUSE
20 AMP
BOOM OVER 20 DEGREES AND NOT OVER 40 DEGREES
WORK LIGHTS
FORWARD-4TH Y1, Y3, Y4, Y5 (2ND GEAR)
TO FORWARD-3RD Y1, Y3, Y4, Y5 (2ND GEAR)
WORK N/C FORWARD-2ND Y1, Y3, Y4, Y5
LIGHTS 87a
POWER (SHT 1) 30 FORWARD-1ST Y1, Y3, Y5, Y6
REVERSE-4TH Y2, Y3, Y4, Y5 (2ND GEAR)
RD LIGHTS FUSE 87 REVERSE-3RD Y2, Y3, Y4, Y5 (2ND GEAR)
ROAD
LIGHTS
RELAY GND REVERSE-2ND Y2, Y3, Y4, Y5
RELAY K21
86
REVERSE-1ST Y2, Y3, Y5, Y6
J7 SWITCHED PWR 85
BOOM OVER 40 DEGREES
(TRANS DISABLED UNLESS FOOTSWITCH PRESSED)
FUSE
25 AMP
FORWARD-4TH Y1, Y3, Y5, Y6 (1ST GEAR)
ROAD LIGHTS
FORWARD-3RD Y1, Y3, Y5, Y6 (1ST GEAR)
FORWARD-2ND Y1, Y3, Y5, Y6 (1ST GEAR)
TO
ROAD N/C FORWARD-1ST Y1, Y3, Y5, Y6
LIGHTS 87a
REVERSE-4TH Y2, Y3, Y5, Y6 (1ST GEAR)
POWER (SHT 1) 30
REVERSE-3RD Y2, Y3, Y5, Y6 (1ST GEAR)
HEATER-A/C FUSE 87 REVERSE-2ND Y2, Y3, Y5, Y6 (1ST GEAR)
AND A/C
HEATER REVERSE-1ST Y2, Y3, Y5, Y6
RELAY GND
RELAY K22
86
J7 SWITCHED PWR 85
25 AMP
HEATER
& A/C FUSE
Electrical Wiring
TO
HEATER
AND A/C
S/N 0160016632 & After
4.17
Electrical Wiring
JLG Deutschland GmbH JLG Equipment Services Ltd. JLG Industries (Italia) JLG Europe B.V.
Max Planckstrasse 21 Rm 1107 Landmark North Via Po. 22 Polaris Avenue 63
D-27721 Ritterhude/lhlpohl 39 Lung Sum Avenue 20010 Pregnana Milanese - MI 2132 JH Hoofddorp
Bei Bremen Sheung Shui N.T. Italy The Netherlands
Germany Hong Kong Phone: (39) 029 359 5210 Phone: (31) 235 655 665
Phone: (49) 421 693 500 Phone: (852) 2639 5783 Fax: (39) 029 359 5845 Fax: (31) 235 572 493
Fax: (49) 421 693 5035 Fax: (852) 2639 5797
JLG Polska JLG Industries (Scotland) Plataformas Elevadoras JLG Industries (Sweden)
UI. Krolewska Wright Business Centre JLG Iberica, S.L. Enkopingsvagen 150
00-060 Warsawa 1 Lonmay Road Trapadella, 2 Box 704
Poland Queenslie, Glasgow G33 4EL P.I. Castellbisbal Sur SE - 17527 Jarfalla
Phone: (48) 914 320 245 Scotland 08755Castellbisbal, Barcelona Sweden
Fax: (48) 914 358 200 Phone: (44) 141 781 6700 Spain Phone: (46) 850 659 500
Fax: (44) 141 773 1907 Phone: (34) 937 724 700 Fax: (46) 850 659 534
Fax: (34) 937 711 762