Front Mowers

1550, 1570, 1575, 1580,

1585 Series TerrainCut™

TECHNICAL MANUAL
Front Mower
1550, 1570, 1575, 1580, 1585 Series
TerrainCut™
TM130419 24FEB16 (ENGLISH)

John Deere Turf Care

LITHO IN U.S.A.
 Introduction
Foreword
This manual is written for an experienced technician. Information is organized in groups for the various
Essential tools required in performing certain service work components requiring service instruction. At the
are identified in this manual and are recommended for use. beginning of each group are summary listings of all
Live with safety: Read the safety messages in the applicable essential tools, service equipment and tools,
introduction of this manual and the cautions presented other materials needed to do the job, service parts kits,
throughout the text of the manual. specifications, wear tolerances, and torque values.
Technical Manuals are concise guides for specific
This is the safety-alert symbol. When you see this machines. They are on-the-job guides containing only the
symbol on the machine or in this manual, be alert to the vital information needed for diagnosis, analysis, testing,
potential for personal injury. and repair.
Technical manuals are divided in two parts: repair and Fundamental service information is available from other
operation and tests. Repair sections tell how to repair sources covering basic theory of operation, fundamentals
the components. Operation and tests sections help you of troubleshooting, general maintenance, and basic type
identify the majority of routine failures quickly. of failures and their causes.
DX,TMIFC -19-15APR14-1/1

030916
TM130419 (24FEB16)
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 Contents
Section 05—Safety Group 20—Diagnosis—3TNV80
Group 05—Safety Group 30—Diagnosis—3TNV82A, 3TNV88
Group 40—Tests and Adjustments—3TNV80F
Section 10—Specifications and Information Group 45—Tests and Adjustments—3TNV82A,
Group 10—General Information 3TNV88
Group 20—Fuels, Lubricant, and Coolants
Group 30—Machine Specifications Section 230—Electrical Operation, Tests,
and Adjustments
Section 20—Engine Repair Group 10—Theory of Operation, Non-T4
Group 10—Engine Repair—3TNV80F Group 15—Theory of Operation, Tier 4
Group 20—Engine Repair—3TNV82A, 3TNV88 Group 20—Schematics
Group 30—Engine Repair—3TNV88C Group 30—Diagnosis
Group 40—Tests and Adjustments
Group 50—Connectors
Section 30—Electrical Repair
Group 10—Electrical System Components
Group 20—Wiring Harnesses Section 235—Controllers Operation, Tests,
Group 30—Repair and Adjustments
Group 10—Adjustments
Group 15—DPF Functions and DTCs
Section 40—Power Train Repair Group 20—Set Up, PDU
Group 10—Power Train Components—Single Speed
Group 30—Theory of Operation
Group 20—Power Train Components—2 Speed
Group 35—Checks, Tests, and Procedures
Group 30—Power Train Repair—Single Speed
Group 40—Diagnose—DTCs, PDU
Group 40—Power Train Repair—2 Speed
Group 45—Diagnose—DTCs, VCU
Group 50—Diagnose—DTCs, ECU 000001—000199
Section 50—Hydraulics Repair Group 51—Diagnose—DTCs, ECU 000200—000699
Group 10—Component Location Group 52—Diagnose—DTCs, ECU 000700—001999
Group 20—Repair Group 53—Diagnose—DTCs, ECU 002000—002999
Group 54—Diagnose—DTCs, ECU 003000—003999
Section 60—Steering and Brakes Repair Group 55—Diagnose—DTCs, ECU 004000—529999
Group 10—Component Location
Group 20—Steering Repair Section 240—Power Train Operation, Tests,
Group 30—Brakes Repair and Adjustments
Group 10—Diagnosis—Single Speed
Section 70—Attachments Repair Group 20—Diagnosis—2 Speed
Group 10—Repair, Cutting Units Group 30—Tests and Adjustments—Single Speed
Group 20—Repair, Snowblowers Group 40—Tests and Adjustments—2 Speed
Group 30—Repair, GLC System
Section 250—Hydraulics Operation, Tests,
Section 80—Cab Repair and Adjustments
Group 10—Repair Group 10—Theory of Operation
Group 20—Schematics
Section 90—Miscellaneous Repair Group 30—Diagnosis
Group 10—Repair Group 40—Tests and Adjustments

Section 220—Engine Operation, Tests, Section 260—Steering and Brakes Operation,

and Adjustments Tests, and Adjustments
Group 10—Theory of Operation Group 10—Theory of Operation

Continued on next page

Original Instructions. 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 © 2016
DEERE & COMPANY
Moline, Illinois
All rights reserved.
A John Deere ILLUSTRUCTION ™ Manual
Previous Editions
Copyright © 2014, 2015

TM130419 (24FEB16) i 030916

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 Contents

Group 20—Steering Diagnosis

Group 30—Brakes Diagnosis
Group 50—Tests and Adjustments

Section 270—Attachments Operation, Tests,

and Adjustments
Group 10—Diagnosis
Group 20—Tests and Adjustments

Section 280—Cab Operation, Tests, and

Adjustments
Group 20—Operation

Section 290—HVAC Operation, Tests,

and Adjustments
Group 10—Tools and Materials
Group 20—General Information
Group 30—Tests and Adjustments

Section 299—Tools and Kits

Group 10—Tools

TM130419 (24FEB16) ii 030916

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 Section 05
Safety
Contents

Page

Group 05—Safety
Recognize Safety Information ....................... 05-05-1
Understand Signal Words.............................. 05-05-1
Replace Safety Signs .................................... 05-05-1
Handle Fluids Safely—Avoid
Fires........................................................... 05-05-2
Prepare for Emergencies............................... 05-05-2
Prevent Battery Explosions ........................... 05-05-2
Prevent Acid Burns........................................ 05-05-3
Wear Protective Clothing............................... 05-05-3
Avoid High-Pressure Fluids ........................... 05-05-4
Avoid Heating Near Pressurized
Fluid Lines ................................................. 05-05-4
Service Machines Safely ............................... 05-05-4
Use Proper Tools ........................................... 05-05-5
Park Machine Safely...................................... 05-05-5
Support Machine Properly ............................. 05-05-5
Use Proper Lifting Equipment........................ 05-05-6
Work in Clean Area ....................................... 05-05-6
Using High-Pressure Washers ...................... 05-05-6
Protect Against High Pressure
Spray ......................................................... 05-05-6
Illuminate Work Area Safely .......................... 05-05-7
Work In Ventilated Area................................. 05-05-7
WARNING: California Proposition
65 Warning ................................................ 05-05-7
Remove Paint Before Welding or
Heating ...................................................... 05-05-8
Avoid Harmful Asbestos Dust........................ 05-05-8
Follow Tire Recommendations ...................... 05-05-8
Stay Clear of Rotating Drivelines................... 05-05-9
Service Cooling System Safely ..................... 05-05-9
Dispose of Waste Properly .......................... 05-05-10
Handle Chemical Products Safely................ 05-05-10
Live With Safety........................................... 05-05-10

TM130419 (24FEB16) 05-1 030916

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 Contents

TM130419 (24FEB16) 05-2 030916

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 Group 05
Safety
Recognize Safety Information
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.
Follow recommended precautions and safe operating

T81389 —UN—28JUN13
practices.

OUO1086,1000417 -19-15JUN12-1/1

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
specific hazards. General precautions are listed on

TS187 —19—30SEP88
CAUTION safety signs. CAUTION also calls attention to
safety messages in this manual.

OUO1086,1000418 -19-15JUN12-1/1

Replace Safety Signs

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

TS201 —UN—15APR13

OUO1086,1000419 -19-15JUN12-1/1

TM130419 (24FEB16) 05-05-1 030916

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 Safety

Handle Fluids Safely—Avoid Fires

When you work around fuel, do not smoke or work near
heaters or other fire hazards.
Store flammable fluids away from fire hazards. Do not
incinerate or puncture pressurized containers.

TS227 —UN—15APR13
Make sure machine is clean of trash, grease, and debris.
Do not store oily rags; they can ignite and burn
spontaneously.

OUO1086,100041A -19-15JUN12-1/1

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,
hospital, and fire department near your telephone.

TS291 —UN—15APR13
OUO1086,100041B -19-15JUN12-1/1

Prevent Battery Explosions

Keep sparks, lighted matches, and open flame away from
the top of battery. Battery gas can explode.
Never check battery charge by placing a metal object
across the posts. Use a volt-meter or hydrometer.

TS204 —UN—15APR13
Do not charge a frozen battery; it may explode. Warm
battery to 16°C (60°F).

OUO1086,100041C -19-15JUN12-1/1

TM130419 (24FEB16) 05-05-2 030916

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 Safety

Prevent Acid Burns

Sulfuric acid in battery electrolyte is poisonous. It is strong
enough to burn skin, eat holes in clothing, and cause
blindness if splashed into eyes.
Avoid the hazard by:
1. Filling batteries in a well-ventilated area.
2. Wearing eye protection and rubber gloves.
3. Avoiding breathing fumes when electrolyte is added.
4. Avoiding spilling or dripping electrolyte.
5. Use proper jump start procedure.
If you spill acid on yourself:
1. Flush your skin with water.
2. Apply baking soda or lime to help neutralize the acid.
3. Flush your eyes with water for 15—30 minutes. Get
medical attention immediately.
If acid is swallowed:
1. Do not induce vomiting.
2. Drink large amounts of water or milk, but do not

TS203 —UN—23AUG88
exceed 2 L (2 quarts).
3. Get medical attention immediately.

OUO1086,100041D -19-15JUN12-1/1

Wear Protective Clothing

Wear close fitting clothing and safety equipment
appropriate to the job.
Prolonged exposure to loud noise can cause impairment
or loss of hearing.

TS206 —UN—15APR13
Wear a suitable hearing protective device such as
earmuffs or earplugs to protect against objectionable or
uncomfortable loud noises.
Operating equipment safely requires the full attention of
the operator. Do not wear radio or music headphones
while operating machine.
OUO1086,100041E -19-15JUN12-1/1

TM130419 (24FEB16) 05-05-3 030916

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 Safety

Avoid High-Pressure Fluids

Inspect hydraulic hoses periodically – at least once
per year – for leakage, kinking, cuts, cracks, abrasion,
blisters, corrosion, exposed wire braid or any other signs
of wear or damage.

X9811 —UN—23AUG88
Replace worn or damaged hose assemblies immediately
with John Deere approved replacement parts.
Escaping fluid under pressure can penetrate the skin
causing serious injury.
Avoid the hazard by relieving pressure before
disconnecting hydraulic or other lines. Tighten all
connections before applying pressure.
with this type of injury should reference a knowledgeable
Search for leaks with a piece of cardboard. Protect hands medical source. Such information is available in
and body from high-pressure fluids. English from Deere & Company Medical Department in
Moline, Illinois, U.S.A., by calling 1-800-822-8262 or +1
If an accident occurs, see a doctor immediately. Any fluid 309-748-5636.
injected into the skin must be surgically removed within
a few hours or gangrene may result. Doctors unfamiliar
OUO1086,100041F -19-15JUN12-1/1

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 accidentally

TS953 —UN—15MAY90
burst when heat goes beyond the immediate flame area.

OUO1086,1000420 -19-15JUN12-1/1

Service Machines Safely

Tie long hair behind your head. Do not wear a necktie,
scarf, loose clothing, or necklace when you work near
machine tools or moving parts. If these items were to get
caught, severe injury could result.
TS228 —UN—23AUG88
Remove rings and other jewelry to prevent electrical
shorts and entanglement in moving parts.

OUO1086,1000421 -19-15JUN12-1/1

TM130419 (24FEB16) 05-05-4 030916

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 Safety

Use Proper Tools

Use tools appropriate to the work. Makeshift tools and
procedures can create safety hazards.
Use power tools only to loosen threaded parts and
fasteners.

TS779 —UN—08NOV89
For loosening and tightening hardware, use the correct
size tools. DO NOT use U.S. measurement tools on
metric fasteners. Avoid bodily injury caused by slipping
wrenches.
Use only service parts meeting John Deere specifications.

OUO1086,1000422 -19-15JUN12-1/1

Park Machine Safely

Before working on the machine:
• Lower all equipment to the ground.
• Stop the engine and remove the key.
• Disconnect the battery ground strap.
• Hang a "DO NOT OPERATE" tag in operator station.

TS230 —UN—24MAY89
OUO1086,1000423 -19-15JUN12-1/1

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.

TS229 —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.
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.
OUO1086,1000424 -19-15JUN12-1/1

TM130419 (24FEB16) 05-05-5 030916

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 Safety

Use Proper Lifting Equipment

Lifting heavy components incorrectly can cause severe
injury or machine damage.
Follow recommended procedure for removal and
installation of components in the manual.

TS226 —UN—23AUG88
OUO1086,1000425 -19-15JUN12-1/1

Work in Clean Area

Before starting a job:
• Clean work area and machine.
• Make sure you have all necessary tools to do your job.
• Have the right parts on hand.

T6642EJ —UN—18OCT88
• Read all instructions thoroughly; do not attempt
shortcuts.

OUO1086,1000426 -19-15JUN12-1/1

Using High-Pressure Washers injection pumps or other sensitive parts and components
may cause product malfunctions. Reduce pressure and
Directing pressurized water at electronic/electrical spray at a 45 to 90 degree angle.
components or connectors, bearings, hydraulic seals, fuel
OUO1086,1000427 -19-15JUN12-1/1

Protect Against High Pressure Spray

Spray from high pressure nozzles can penetrate the skin
and cause serious injury. Keep spray from contacting
hands or body.
If an accident occurs, see a doctor immediately. Any high
TS1343 —UN—18MAR92
pressure spray 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.

OUO1086,1000428 -19-15JUN12-1/1

TM130419 (24FEB16) 05-05-6 030916

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 Safety

Illuminate Work Area Safely

Illuminate your work area adequately but safely. Use
a portable safety light for working inside or under the
machine. Make sure the bulb is enclosed by a wire cage.
The hot filament of an accidentally broken bulb can ignite
spilled fuel or oil.

TS223 —UN—23AUG88
OUO1086,1000429 -19-15JUN12-1/1

Work In Ventilated Area

Engine exhaust fumes can cause sickness or death. If
it is necessary to run an engine in an enclosed area,
remove the exhaust fumes from the area with an exhaust
pipe extension.
If you do not have an exhaust pipe extension, open the

TS220 —UN—15APR13
doors and get outside air into the area.

OUO1086,100042A -19-15JUN12-1/1

WARNING: California Proposition 65 Warning Gasoline engine exhaust from this product contains
Diesel engine exhaust and some of its constituents are chemicals known to the State of California to cause
known to the State of California to cause cancer, birth cancer, birth defects, or other reproductive harm.
defects, and other reproductive harm.
OUO1086,100042B -19-15JUN12-1/1

TM130419 (24FEB16) 05-05-7 030916

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 Safety

Remove Paint Before Welding or Heating

Avoid potentially toxic fumes and dust.
Hazardous fumes can be generated when paint is heated
by welding, soldering, or using a torch.
Remove paint before heating:

TS220 —UN—15APR13
• Remove paint a minimum of 100 mm (4 in.) from area
to be affected by heating. If paint cannot be removed,
wear an approved respirator before heating or welding.
• If you sand or grind paint, avoid breathing the dust.
Wear an approved respirator.
• If you use solvent or paint stripper, remove stripper with
soap and water before welding. Remove solvent or
paint stripper containers and other flammable material
from area. Allow fumes to disperse at least 15 minutes Do all work in an area that is well ventilated to carry toxic
fumes and dust away.
before welding or heating.
Do not use a chlorinated solvent in areas where welding Dispose of paint and solvent properly.
will take place.
OUO1086,100042C -19-15JUN12-1/1

Avoid Harmful Asbestos Dust

Avoid breathing dust that may be generated when
handling components containing asbestos fibers. Inhaled
asbestos fibers may cause lung cancer.
Components in products that may contain asbestos
fibers are brake pads, brake band and lining assemblies,

TS220 —UN—15APR13
clutch plates, and some gaskets. The asbestos used in
these components is usually found in a resin or sealed in
some way. Normal handling is not hazardous as long as
airborne dust containing asbestos is not generated.
Avoid creating dust. Never use compressed air for
cleaning. Avoid brushing or grinding material containing
asbestos. When servicing, wear an approved respirator.
A special vacuum cleaner is recommended to clean Keep bystanders away from the area.
asbestos. If not available, apply a mist of oil or water on
the material containing asbestos.
OUO1086,100042D -19-15JUN12-1/1

Follow Tire Recommendations

Keep your machine in proper working order.
Use only prescribed tire sizes with correct ratings and
inflate to the pressure specified in this manual.
H111235 —UN—13MAY14

Use of other than prescribed tires may decrease stability,

affect steering, result in premature tire failure, or cause
other durability or safety issues.

DX,TIRE,INFO -19-19MAY14-1/1

TM130419 (24FEB16) 05-05-8 030916

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 Safety

Stay Clear of Rotating Drivelines

Entanglement in rotating driveline can cause serious
injury or death.
Keep tractor master shield and driveline shields in place
at all times. Make sure rotating shields turn freely.

TS1644 —UN—22AUG95
Wear close fitting clothing. Stop the engine and be sure
that PTO driveline is stopped before making adjustments,
connections, or cleaning out PTO driven equipment.
Do not install any adapter device between the tractor and
the primary implement PTO drive shaft that will allow a
1000 rpm tractor shaft to power a 540 rpm implement at
speeds higher than 540 rpm.
Do not install any adapter device that results in a portion of
the rotating implement shaft, tractor shaft, or the adapter
to be unguarded. The tractor master shield shall overlap
the end of the splined shaft and the added adaptor device
as outlined in the table.
PTO Type Diameter Splines n ± 5 mm (0.20 in.)
1 35 mm (1.378 in.) 6 85 mm (3.35 in.)
2 35 mm (1.378 in.) 21 85 mm (3.35 in.)
3 45 mm (1.772 in.) 20 100 mm (4.00 in.)

H96219 —UN—29APR10
OUO1086,100042F -19-15JUN12-1/1

Service Cooling System Safely

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
to relieve pressure before removing completely.
TS281 —UN—15APR13

OUO1086,1000430 -19-15JUN12-1/1

TM130419 (24FEB16) 05-05-9 030916

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 Safety

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.

TS1133 —UN—15APR13
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
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.
OUO1086,1000431 -19-15JUN12-1/1

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.

TS1132 —UN—15APR13
A Material Safety Data Sheet (MSDS) provides specific
details on chemical products: physical and health hazards,
safety procedures, and emergency response techniques.
Check the MSDS before you start any job using a
hazardous chemical. That way you will know exactly what
the risks are and how to do the job safely. Then follow
procedures and recommended equipment.
(See your John Deere dealer for MSDS’s on chemical
products used with John Deere equipment.)
OUO1086,1000432 -19-15JUN12-1/1

Live With Safety

Before returning machine to customer, make sure
machine is functioning properly, especially the safety
systems. Install all guards and shields.
TS231 —19—07OCT88

OUO1086,1000433 -19-15JUN12-1/1

TM130419 (24FEB16) 05-05-10 030916

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 Section 10
Specifications and Information
Contents

Page

Group 10—General Information

Metric Bolt and Screw Torque
Values ........................................................ 10-10-1
Metric Cap Screw Torque
Values—Grade 7 ....................................... 10-10-1
Unified Inch Bolt and Screw Torque
Values ........................................................ 10-10-2
Service Recommendations for
O-Ring Boss Fittings.................................. 10-10-2
Service Recommendations For
Flat Face O-Ring Seal Fittings .................. 10-10-4
Service Recommendations for STC
Fittings ....................................................... 10-10-5
Using Proper Fuel.......................................... 10-10-6
Engine Oil ...................................................... 10-10-6
Hydrostatic Transaxle Oil .............................. 10-10-7
4WD Rear Axle Oil ........................................ 10-10-7
Grease........................................................... 10-10-7
Recommended Engine Coolant..................... 10-10-8

Group 20—Fuels, Lubricant, and Coolants

Diesel Fuel..................................................... 10-20-1
Handling and Storing Diesel Fuel .................. 10-20-2
Do Not Use Galvanized
Containers ................................................. 10-20-2
Lubricity of Diesel Fuel .................................. 10-20-2
Testing Diesel Fuel ........................................ 10-20-2
BioDiesel Fuel ............................................... 10-20-3
Filling Fuel Tank............................................. 10-20-4
Engine Oil ...................................................... 10-20-4
Oil Filters ....................................................... 10-20-5
Transmission and Hydraulic Oil ..................... 10-20-5
Use Correct Transmission/Hy-
draulic Filter Element................................. 10-20-5
MFWD Axle Housing and Wheel
Hub Oil....................................................... 10-20-6
Grease........................................................... 10-20-7
Grease (Specific Application) ........................ 10-20-7
Mixing of Lubricants....................................... 10-20-7
Alternative and Synthetic
Lubricants .................................................. 10-20-7
Lubricant Storage .......................................... 10-20-8
Operating in Warm Temperature
Climates..................................................... 10-20-8
Diesel Engine Coolant ................................... 10-20-9
John Deere COOL-GARD™ II
Coolant Extender..................................... 10-20-10
Testing Diesel Engine Coolant..................... 10-20-10

Group 30—Machine Specifications

Machine Specifications.................................. 10-30-1
Machine Product Identification
Number...................................................... 10-30-1
Engine Serial Number ................................... 10-30-2

TM130419 (24FEB16) 10-1 030916

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 Contents

TM130419 (24FEB16) 10-2 030916

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 Group 10
General Information
Metric Bolt and Screw Torque Values
TS1670 —UN—01MAY03

4.8 8.8 9.8 10.9 12.9 12.9

4.8 8.8 9.8 10.9 12.9 12.9

Bolt or Screw Class 4.8 Class 8.8 or 9.8 Class 10.9 Class 12.9
Size Lubricateda Dryb Lubricateda Dryb Lubricateda Dryb Lubricateda Dryb
N·m lb.-in. N·m lb.-in. N·m lb.-in. N·m lb.-in. N·m lb.-in. N·m lb.-in. N·m lb.-in. N·m lb.-in.
M6 4.7 42 6 53 8.9 79 11.3 100 13 115 16.5 146 15.5 137 19.5 172
N·m lb.-ft. N·m lb.-ft. N·m lb.-ft. N·m lb.-ft.
M8 11.5 102 14.5 128 22 194 27.5 243 32 23.5 40 29.5 37 27.5 47 35
N·m lb.-ft. N·m lb.-ft. N·m lb.-ft.
M10 23 204 29 21 43 32 55 40 63 46 80 59 75 55 95 70
N·m lb.-ft.
M12 40 29.5 50 37 75 55 95 70 110 80 140 105 130 95 165 120
M14 63 46 80 59 120 88 150 110 175 130 220 165 205 150 260 190
M16 100 74 125 92 190 140 240 175 275 200 350 255 320 235 400 300
M18 135 100 170 125 265 195 330 245 375 275 475 350 440 325 560 410
M20 190 140 245 180 375 275 475 350 530 390 675 500 625 460 790 580
M22 265 195 330 245 510 375 650 480 725 535 920 680 850 625 1080 800
M24 330 245 425 315 650 480 820 600 920 680 1150 850 1080 800 1350 1000
M27 490 360 625 460 950 700 1200 885 1350 1000 1700 1250 1580 1160 2000 1475
M30 660 490 850 625 1290 950 1630 1200 1850 1350 2300 1700 2140 1580 2700 2000
M33 900 665 1150 850 1750 1300 2200 1625 2500 1850 3150 2325 2900 2150 3700 2730
M36 1150 850 1450 1075 2250 1650 2850 2100 3200 2350 4050 3000 3750 2770 4750 3500
Torque values listed are for general use only, based on the strength of Shear bolts are designed to fail under predetermined loads. Always
the bolt or screw. DO NOT use these values if a different torque value or replace shear bolts with identical property class. Replace fasteners with
tightening procedure is given for a specific application. For stainless steel the same or higher property class. If higher property class fasteners are
fasteners or for nuts on U-bolts, see the tightening instructions for the used, tighten these to the strength of the original. Make sure fastener
specific application. Tighten plastic insert or crimped steel type lock nuts threads are clean and that you properly start thread engagement. When
by turning the nut to the dry torque shown in the chart, unless different possible, lubricate plain or zinc plated fasteners other than lock nuts,
instructions are given for the specific application. wheel bolts or wheel nuts, unless different instructions are given for the
specific application.
a
“Lubricated” means coated with a lubricant such as engine oil, fasteners with phosphate and oil coatings, or M20
and larger fasteners with JDM F13C, F13F or F13J zinc flake coating.
b
“Dry” means plain or zinc plated without any lubrication, or M6 to M18 fasteners with JDM F13B, F13E or F13H zinc flake coating.
OUO1086,100076F -19-18JUN12-1/1

Metric Cap Screw Torque Values—Grade 7

Size Steel or Gray Iron Aluminum
Torque
N•m (lb-ft) N•m (lb-ft)
M6 11 (8) 8 (6)
M8 24 (18) 19 (14)
M10 52 (38) 41 (30)
M12 88 (65) 70 (52)
M14 138 (102) 111 (82)
M16 224 (165) 179 (132)

OUO1086,1000770 -19-18JUN12-1/1

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030916
 General Information

Unified Inch Bolt and Screw Torque Values

TS1671 —UN—01MAY03

Bolt or Screw SAE Grade 1 SAE Grade 2a SAE Grade 5, 5.1 or 5.2 SAE Grade 8 or 8.2
Size Lubricatedb Dryc Lubricatedb Dryc Lubricatedb Dryc Lubricatedb Dryc
N·m lb.-in. N·m lb.-in. N·m lb.-in. N·m lb.-in. N·m lb.-in. N·m lb.-in. N·m lb.-in. N·m lb.-in.
1/4 3.7 33 4.7 42 6 53 7.5 66 9.5 84 12 106 13.5 120 17 150
N·m lb.-ft. N·m lb.-ft.
5/16 7.7 68 9.8 86 12 106 15.5 137 19.5 172 25 221 28 20.5 35 26
N·m lb.-ft. N·m lb.-ft.
3/8 13.5 120 17.5 155 22 194 27 240 35 26 44 32.5 49 36 63 46
N·m lb.-ft. N·m lb.-ft. N·m lb.-ft.
7/16 22 194 28 20.5 35 26 44 32.5 56 41 70 52 80 59 100 74
N·m lb.-ft.
1/2 34 25 42 31 53 39 67 49 85 63 110 80 120 88 155 115
9/16 48 35.5 60 45 76 56 95 70 125 92 155 115 175 130 220 165
5/8 67 49 85 63 105 77 135 100 170 125 215 160 240 175 305 225
3/4 120 88 150 110 190 140 240 175 300 220 380 280 425 315 540 400
7/8 190 140 240 175 190 140 240 175 490 360 615 455 690 510 870 640
1 285 210 360 265 285 210 360 265 730 540 920 680 1030 760 1300 960
1-1/8 400 300 510 375 400 300 510 375 910 670 1150 850 1450 1075 1850 1350
1-1/4 570 420 725 535 570 420 725 535 1280 945 1630 1200 2050 1500 2600 1920
1-3/8 750 550 950 700 750 550 950 700 1700 1250 2140 1580 2700 2000 3400 2500
1-1/2 990 730 1250 930 990 730 1250 930 2250 1650 2850 2100 3600 2650 4550 3350
Torque values listed are for general use only, based on the strength of the bolt Replace fasteners with the same or higher grade. If higher
or screw. DO NOT use these values if a different torque value or tightening grade fasteners are used, tighten these to the strength of the
procedure is given for a specific application. For plastic insert or crimped steel original. Make sure fastener threads are clean and that you
type lock nuts, for stainless steel fasteners, or for nuts on U-bolts, see the properly start thread engagement. When possible, lubricate
tightening instructions for the specific application. Shear bolts are designed to fail plain or zinc plated fasteners other than lock nuts, wheel bolts
under predetermined loads. Always replace shear bolts with identical grade. or wheel nuts, unless different instructions are given for the
specific application.
a
Grade 2 applies for hex cap screws (not hex bolts) up to 6 in. (152 mm) long. Grade 1 applies for hex cap screws over 6
in. (152 mm) long, and for all other types of bolts and screws of any length.
b
“Lubricated” means coated with a lubricant such as engine oil, fasteners with phosphate and oil coatings, or 7/8 in.
and larger fasteners with JDM F13C, F13F or F13J zinc flake coating.
c
“Dry” means plain or zinc plated without any lubrication, or 1/4 to 3/4 in. fasteners with JDM F13B, F13E or F13H zinc flake coating.
OUO1086,1000771 -19-18JUN12-1/1

Service Recommendations for O-Ring Boss

Fittings
A
Straight Fitting
TCT008637 —UN—11OCT13

1. Inspect O-ring boss seat for dirt or defects.

2. Lubricate O-ring with petroleum jelly. Place electrical B
tape over threads to protect O-ring. Slide O-ring over
tape and into O-ring groove of fitting. Remove tape.
3. Tighten fitting to torque value shown on chart.

A—Straight Boss Fitting B—Straight Stud and Tube Nut

Continued on next page OUMX258,00000F8 -19-20JAN16-1/2

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030916
 General Information

Angle Fitting
1. Inspect O-ring boss seat for dirt or defects.

TCT008638 —UN—11OCT13
A
2. Lubricate O-ring with petroleum jelly. Place electrical
tape over threads to protect O-ring. Slide O-ring over
tape and into O-ring groove of fitting. Remove tape. B C
3. Back-off locknut (A) and back-up washer (B)
completely to head-end (C) of fitting.
4. Turn fitting into threaded boss until back-up washer
contacts face of boss.
5. Turn fitting head-end counterclockwise to proper index A—Locknut C—Head-End of Fitting
(maximum of one turn). B—Washer

NOTE: Do not allow hoses to twist when tightening fittings.

6. Hold fitting head-end with a wrench and tighten locknut

and back-up washer to proper torque value.
STUD END O-RING SEAL TORQUE FOR STRAIGHT AND ADJUSTABLE FITTINGS*
Thread Size Straight Hex Size Locknut Hex Size Straight Fitting or Locknut Toque
Inch Inch Inch N·m lb-ft
3/8-24 5/8 9/16 18 13
7/16-20 5/8 5/8 24 18
1/2-20 3/4 11/16 30 22
9/16-18 3/4 3/4 37 27
3/4-16 7/8 15/16 75 55
7/8-14 1 1/16 1 1/16 104 76
1 1/16-12 1 1/4 1 3/8 176 130
1 3/16-12 1 3/8 1 1/2 230 170
1 5/16-12 1 1/2 1 5/8 270 199
*Torque tolerance is +15 -20% unless otherwise specified.
OUMX258,00000F8 -19-20JAN16-2/2

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PN=21
 General Information

Service Recommendations For Flat Face

O-Ring Seal Fittings
1. Inspect the fitting sealing surfaces and O-ring. They
must be free of dirt or defects.

TCT008639 —UN—11OCT13
2. Lubricate O-ring (A) and install into groove using A
petroleum jelly to hold in place. A
3. Index angle fittings and tighten by hand pressing joint A
together to insure O-ring remains in place. B
B
4. Unless specified otherwise, tighten fitting or nut (B) to
torque value shown on the chart. Do not allow hoses
to twist when tightening fittings, use backup wrench on
straight hose couplings. A—O-ring B—Nut

FLAT FACE O-RING SEAL FITTING TORQUE*

Nominal Tube O.D. Thread Size Swivel Nut Bulkhead Nut
mm in in N·m lb-ft N·m lb-ft
6.35 0.250 9/16-18 24 18 32 24
9.52 0.375 11/16-16 37 27 42 31
12.70 0.500 13/16-16 63 46 93 69
15.88 0.625 1-14 103 76 118 87
19.05 0.750 1 3/16-12 152 112 175 129
22.22 0.875 1 3/16-12 152 112 175 129
25.40 1.000 1 7/16-12 214 158 247 182
31.75 1.250 1 11/16-12 286 211 328 242
38.10 1.500 2-12 326 240 374 276
*Torque tolerance is +15 -20% unless otherwise specified.
OUMX258,00000F9 -19-12AUG14-1/1

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PN=22
 General Information

Service Recommendations for STC Fittings

Seal Tight Connector (STC)® Fittings:
STC fittings are used on this machine. The fittings are
designed for quick leak-proof connections.

TCAL32233 —UN—20JUN12
Compact swivel-type connections can be made easily.
Fittings are available in -06, -08, -10, -12, and -16 sizes.
Fittings are easily disconnected using hose removal tool
JDG1518. To connect fittings, simply push each half of
fitting together.
IMPORTANT: Avoid Damage! Do not pry against
release sleeve (A) or damage to fitting may result.
Do not force release sleeve beyond normal range
of travel, or release sleeve may fall off when hose
is disconnected. If this happens and fitting is
connected without the release sleeve installed,
fitting will not be able to be disconnected again.

TCAL32234 —UN—20JUN12
1. Disconnect STC-type fittings:
a. Clean area around fitting, especially around the
release sleeve (A).
b. While keeping hose removal tool JDG1518 (B)
perpendicular to the fitting, insert tool under release
sleeve until tool stops.
c. Pull hose away from fitting to disconnect. A—Release Sleeve E—O-Ring
B—Hose Removal Tool F— Backup Ring
2. Inspect STC fittings: C—Retaining Ring G—Male Half of STC Fitting
D—Female Half of STC Fitting
a. Check seal mating surfaces for nicks, scratches,
or flat spots.
b. Make sure release sleeve (A) is on male half of
b. Check O-ring (E), backup ring (F), and retaining ring
fitting before connecting fitting halves together.
(C) for wear or damage. Replace if damaged or if
fittings look good but connection leaks. c. Push fitting halves together until definite, solid stop
is felt.
c. O-ring, backup ring, and retaining ring must be in
position before connecting fitting halves. Install d. Pull back on hose to make sure fitting halves are
backup ring first, then the O-ring behind the backup locked together.
ring.
e. To prevent hoses from binding, move component
3. Connect STC fittings: into position before pressurizing hydraulic system.
a. Make sure fitting halves are clean and free of
contaminants.
IMPORTANT: Avoid Damage! If release sleeve is
not on fitting when connection is made, fitting
will not be able to be disconnected.
OUO1086,1000776 -19-16SEP14-1/1

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PN=23
 General Information

Using Proper Fuel • Sulfur content less that 0.05% (500 ppm) is
recommended for best performance.
Using Proper Fuel (Diesel)
• Diesel fuel sulfur content greater than 0.5% (5000 ppm)
Use the proper diesel fuel to help prevent decreased should not be used.
engine performance and increased exhaust emissions. IMPORTANT: Avoid Damage! Do not mix diesel
Failure to follow the fuel requirements listed below can engine oil or any other type of lubricating
void your engine warranty. oil with diesel fuel.
Contact your local fuel distributor for properties of the
diesel fuel in your area. Handling and Storing Diesel Fuel

In general, diesel fuels are blended to satisfy the low CAUTION: Avoid Injury! Handle fuel carefully. Do
temperature requirements of the geographical area in not fill the fuel tank when engine is running.
which they are marketed.
Do not smoke while you fill the fuel tank
Diesel fuels specified to EN 590 or ASTM D975 are or service the fuel system.
recommended.
Required fuel properties IMPORTANT: Avoid Damage! Do not use galvanized
containers. Diesel fuel stored in galvanized
In all cases, the fuel shall meet the following properties: containers reacts with zinc coating in the
container to form zinc flakes. If fuel contains
Cetane number of 45 minimum. Cetane number greater
water, a zinc gel will also form. The gel and
than 50 is preferred, especially when temperatures are
flakes will quickly plug fuel filters and damage
below -20°C (-4°F) or elevations above 1500 m (5000 ft).
fuel injectors and fuel pumps.
Cold Filter Plugging Point (CFPP) below the expected
low temperature OR Cloud Point at least 5°C (9°F) below • Fill the fuel tank at the end of each day’s operation to
the expected low temperature. prevent water condensation and freezing during cold
weather.
Fuel lubricity should pass a minimum load level of 3100
grams as measured by ASTM D6078 or maximum scar IMPORTANT: Avoid Damage! The fuel tank is vented
diameter of 0.45 mm as measured by ASTM D6079 or through the filler cap. If a new cap is required,
ISO 12156-1. always replace it with an original vented cap.
If a fuel of low or unknown lubricity is used, addition of • When fuel is stored for an extended period or if there is
John Deere PREMIUM DIESEL FUEL CONDITIONER at a slow turnover of fuel, add a fuel conditioner to stabilize
the specified concentration is recommended. the fuel and to prevent water condensation. Contact
Sulfur content your fuel supplier for recommendations.

• Diesel fuel quality and fuel sulfur content must comply

with all existing emissions regulations for the area in
which the engine operates.
OUMX258,0000A69 -19-19MAR13-1/1

Engine Oil • PLUS-4™

Use the appropriate oil viscosity based on the expected
• PLUS-50™
air temperature range during the period between Other oils may be used if above John Deere oils are
recommended oil changes. not available, provided they meet one of the following
specifications:
The following John Deere oils are PREFERRED:
Diesel Engines
• API Service Classifications CF or higher.
The following John Deere oils are PREFERRED:
• TORQ-GARD™ SUPREME
OUMX258,0000A6A -19-19MAR13-1/1

TM130419 (24FEB16) 10-10-6 030916

PN=24
 General Information

Hydrostatic Transaxle Oil

IMPORTANT: Avoid Damage! Transaxle is filled with HY-GARD

TCAL32236 —UN—20JUN12
John Deere HY-GARD (J20C) transmission
oil at the factory. Do not mix oils -40 -22 -4 14 50 68 86 104 122
32 F

-40 -30 -20 -10 0C 10 20 30 40 50

Use only HY-GARD (J20C) transmission fluid.
Do not use type “F” automatic transmission fluid. Low Viscosity HY-GARD

John Deere HY-GARD (J20C) transmission oil is specially

formulated to provide maximum protection against
mechanical wear, corrosion, and foaming.
must use Low Viscosity HY-GARD (J20D) or
IMPORTANT: Avoid Damage! If operating
transmission damage will occur.
temperatures are below -18°C (0°F), you
OUO1086,1000779 -19-18JUN12-1/1

4WD Rear Axle Oil • API Service Classification GL-5.

John Deere GL-5 Gear Lubricant is recommended.
Other gear case oils may be used if above recommended
John Deere gear case oils are not available, provided they
meet the following specification:
OUO1086,100077A -19-18JUN12-1/1

Grease • Engine drive shaft (1 place).

IMPORTANT: Avoid Damage! Use recommended • PTO shaft (3 places).
John Deere greases to avoid component Other Applications
failure and premature wear.
Use John Deere Multi-Purpose HD Lithium Complex
The recommended John Deere greases are Grease or John Deere Moly High Temperature EP Grease
effective within an average air temperature range for all other applications.
of -29 to 135 degrees C (-20 to 275 degrees F).
If not using any of the preferred greases, be sure to
If operating outside that temperature use a general purpose grease with a NLGI grade No. 2
range, contact your Servicing dealer for rating. Avoid use of John Deere Moly High Temperature
special-use grease. EP Grease on high speed applications such as mower
spindles and the rear axle.
The following greases are preferred:
Operating in extremely wet conditions may require use of
High Speed Applications special purpose greases. See your John Deere dealer.
Use John Deere Multi-Purpose SD Polyurea Grease or Wipe off all grease fittings before and after lubrication to
John Deere Multi-Purpose HD Lithium Complex Grease prevent contamination.
for the following high speed applications:
OUO1086,100077B -19-18JUN12-1/1

TM130419 (24FEB16) 10-10-7 030916

PN=25
 General Information

Recommended Engine Coolant If neither of recommended engine coolants is

IMPORTANT: Avoid Damage! Using incorrect coolant available, use a glycol base coolant that meets
mixture can cause overheating and damage the following specification:
to the radiator and engine:
• ASTM D4985 (JDM H24A2).
• Do not operate engine with plain water. Check container label before using to be sure it has the
• Use ethylene-glycol based antifreeze appropriate specifications for your machine. Use coolant
approved for use in aluminum radiators
or aluminum engines. with conditioner or add conditioner to coolant before using.
• Do not exceed a 50% mixture of If using concentrate, mix approximately 50 percent
coolant and water. antifreeze with 50 percent distilled or deionized water
• Do not pour coolant or water into the before adding to cooling system. This mixture will provide
radiator when the engine is hot. freeze protection to -37 degrees C (-34 degrees F).
The following John Deere coolants are preferred: Certain geographical areas may require lower temperature
protection. See the label on your antifreeze container
• COOL-GARD™ PRE-DILUTED SUMMER COOLANT or consult your John Deere dealer to obtain the latest
(TY16036). information and recommendations. Never exceed the
• COOL-GARD™ CONCENTRATED SUMMER maximum dilution rate for the coolant you are using.
COOLANT (TY16034). Exceeding the maximum rate will greatly reduce the
coolant effectiveness.
OUO1086,100077C -19-18JUN12-1/1

TM130419 (24FEB16) 10-10-8 030916

PN=26
 Group 20
Fuels, Lubricant, and Coolants
Diesel Fuel IMPORTANT: Avoid damage! Do not mix diesel
Use the proper diesel fuel to help prevent decreased engine oil or any other type of lubricating
engine performance and increased exhaust emissions. oil with diesel fuel.
Failure to follow the fuel requirements listed below can
void your engine warranty. Using BioDiesel Fuel

Consult your local fuel distributor for properties of the BioDiesel fuels may be used only if the BioDiesel fuel
diesel fuel in your area. properties meet the latest edition of ASTM D6751, ASTM
D7467, EN14214, or equivalent specification.
In general, diesel fuels are blended to satisfy the low
temperature requirements of the geographical area in The current maximum allowable BioDiesel concentration is
which they are marketed. a 20% blend (also known as B20) in petroleum diesel fuel.
Diesel fuels specified to ISO EN 590 or ASTM D975 are Use of B6-B20 fuel will require special procedures for fuel
recommended. handling and machine storage.
Required fuel properties To learn of any changes to the recommendations for
BioDiesel usage with your diesel engine, ask your John
In all cases, the fuel shall meet the following properties: Deere dealer.
Cetane number of 45 minimum. Cetane number greater Handling and Storing Diesel Fuel
than 50 is preferred, especially when temperatures are
below -20°C (-4°F) or elevations above 1500 m (5000 ft).
CAUTION: Avoid injury! Handle fuel carefully. Do
Cold Filter Plugging Point (CFPP) should be at least not fill the fuel tank when engine is running.
5°C (9°F) below the expected lowest temperature or
Cloud Point below the lowest ambient temperature. Do not smoke while you fill the fuel tank
or service the fuel system.
Fuel lubricity should comply with ISO EN 590 or ASTM
D975. IMPORTANT: Avoid damage! Do not use galvanized
containers—diesel fuel stored in galvanized
IMPORTANT: Avoid damage! Improper fuel additive
containers reacts with zinc coating in the
usage may cause damage on fuel injection
container to form zinc flakes. If fuel contains
equipment of diesel engines.
water, a zinc gel will also form. The gel and
flakes will quickly plug fuel filters and damage
If a fuel of low or unknown lubricity is used, addition of
fuel injectors and fuel pumps.
John Deere PREMIUM DIESEL FUEL CONDITIONER at
the specified concentration is recommended.
• Fill the fuel tank at the end of each day’s operation to
Sulfur content prevent water condensation and freezing during cold
weather.
• Diesel fuel quality and fuel sulfur content must comply • When fuel is stored for an extended period or if there is
with all existing emissions regulations for the area in a slow turnover of fuel, add a fuel conditioner to stabilize
which the engine operates. the fuel and to prevent water condensation. Contact
• Use only ultra low sulfur diesel (ULSD) fuel with a your fuel supplier for recommendations.
maximum of 0.0015% (15mg/kg) sulfur content.
UP00731,0000023 -19-26MAY15-1/1

TM130419 (24FEB16) 10-20-1 030916

PN=27
 Fuels, Lubricant, and Coolants

Handling and Storing Diesel Fuel

CAUTION: Reduce the risk of fire. Handle fuel When using BioDiesel fuel, the fuel filter may require more
carefully. DO NOT fill the fuel tank when engine frequent replacement due to premature plugging.
is running. DO NOT smoke while you fill the
Check engine oil level daily prior to starting engine. A
fuel tank or service the fuel system.
rising oil level may indicate fuel dilution of the engine oil.
Fill the fuel tank at the end of each day's operation to IMPORTANT: The fuel tank is vented through the
prevent water condensation and freezing during cold filler cap. If a new filler cap is required, always
weather. replace it with an original vented cap.
Keep all storage tanks as full as practicable to minimize
When fuel is stored for an extended period or if there is a
condensation.
slow turnover of fuel, add a fuel conditioner to stabilize the
Ensure that all fuel tank caps and covers are installed fuel and prevent water condensation. Contact your fuel
properly to prevent moisture from entering. Monitor water supplier or John Deere dealer for recommendations.
content of the fuel regularly.
DX,FUEL4 -19-15FEB13-1/1

Do Not Use Galvanized Containers

IMPORTANT: Diesel fuel stored in galvanized Store fuel in:
containers reacts with zinc coating on the
container to form zinc flakes. If fuel contains • plastic containers.
water, a zinc gel will also form. The gel and • aluminum containers.
flakes will quickly plug fuel filters and damage • specially coated steel containers made for diesel fuel.
fuel injectors and fuel pumps.
DO NOT use brass-coated containers: brass is an alloy of
DO NOT use a galvanized container to store diesel fuel. copper and zinc.
JG31785,0000175 -19-11NOV04-1/1

Lubricity of Diesel Fuel

Most diesel fuels manufactured in the United States, Fuel lubricity should pass a maximum scar diameter of
Canada, and the European Union have adequate lubricity 0.52 mm as measured by ASTM D6079 or ISO 12156-1.
to ensure proper operation and durability of fuel injection A maximum scar diameter of 0.45 mm is preferred.
system components. However, diesel fuels manufactured
in some areas of the world may lack the necessary lubricity. If fuel of low or unknown lubricity is used, add John Deere
Fuel-Protect Diesel Fuel Conditioner (or equivalent) at
IMPORTANT: Make sure the diesel fuel used the specified concentration.
in your machine demonstrates good
lubricity characteristics. Lubricity of BioDiesel Fuel
Fuel lubricity can improve significantly with BioDiesel
blends up to B20 (20% BioDiesel). Further increase in
lubricity is limited for BioDiesel blends greater than B20.
DX,FUEL5 -19-07FEB14-1/1

Testing Diesel Fuel operations, bacteria, cloud point, acid number, particulate
contamination, and whether the fuel meets specification.
A fuel analysis program can help to monitor the quality
of diesel fuel. The fuel analysis can provide critical Contact your John Deere dealer for more information on
data such as cetane number, fuel type, sulfur content, diesel fuel analysis.
water content, appearance, suitability for cold weather
DX,FUEL6 -19-14APR11-1/1

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PN=28
 Fuels, Lubricant, and Coolants

BioDiesel Fuel
BioDiesel fuel is comprised of mono-alkyl esters of long
BioDiesel Use Requirements and Recommendations
chain fatty acids derived from vegetable oils or animal
fats. BioDiesel blends are BioDiesel mixed with petroleum The petroleum diesel portion of all BioDiesel blends must
diesel fuel on a volume basis. meet the requirements of ASTM D975 (US) or EN 590
Before using fuel containing BioDiesel, review the (EU) commercial standard.
BioDiesel Use Requirements and Recommendations in BioDiesel users in the U.S. are strongly encouraged to
this Operator’s Manual. purchase BioDiesel blends from a BQ-9000 Certified
Environmental laws and regulations can encourage or Marketer and sourced from a BQ-9000 Accredited
prohibit the use of biofuels. Operators should consult Producer (as certified by the National BioDiesel Board).
with appropriate governmental authorities prior to using Certified Marketers and Accredited Producers can be
biofuels. found at the following website: http://www.bq9000.org.
BioDiesel contains residual ash. Ash levels exceeding the
All John Deere Engines with Exhaust Filter
maximums allowed in either ASTM D6751 or EN14214
(Released 2011 and After)
can result in more rapid ash loading and require more
While 5% blends (B5) are preferred, BioDiesel frequent cleaning of the Exhaust Filter (if present).
concentrations up to a 20% blend (B20) in petroleum The fuel filter can require more frequent replacement,
diesel fuel can be used. BioDiesel blends up to B20 when using BioDiesel fuel, particularly if switching from
can be used ONLY if the BioDiesel (100% BioDiesel or diesel. Check engine oil level daily prior to starting engine.
B100) meets ASTM D6751, EN 14214, or equivalent A rising oil level can indicate fuel dilution of the engine oil.
specification. Expect a 2% reduction in power and a 3% BioDiesel blends up to B20 must be used within 90 days
reduction in fuel economy when using B20. of the date of BioDiesel manufacture. BioDiesel blends
BioDiesel concentrations above B20 can harm the above B20 must be used within 45 days from the date
engine’s emission control systems and should not be of BioDiesel manufacture.
used. Risks include, but are not limited to, more frequent When using BioDiesel blends up to B20, the following
stationary regeneration, soot accumulation, and increased must be considered:
intervals for ash removal.
John Deere approved fuel conditioners, which contain
• Cold-weather flow degradation
detergent and dispersant additives, are required when
• Stability and storage issues (moisture absorption,
microbial growth)
using BioDiesel blends from B10—B20, and are
recommended when using lower BioDiesel blends.
• Possible filter restriction and plugging (usually a problem
when first switching to BioDiesel on used engines)
All John Deere Engines Excluding Exhaust Filter • Possible fuel leakage through seals and hoses
(Primarily Released Prior to 2012) (primarily an issue with older engines)
• Possible reduction of service life of engine components
While 5% blends (B5) are preferred, BioDiesel
concentrations up to a 20% blend (B20) in petroleum Request a certificate of analysis from your fuel distributor
diesel fuel can be used. BioDiesel blends up to B20 to ensure that the fuel is compliant with the specifications
can be used ONLY if the BioDiesel (100% BioDiesel or provided in this Operator’s Manual.
B100) meets ASTM D6751, EN 14214, or equivalent Consult your John Deere dealer for approved fuel
specification. Expect a 2% reduction in power and a 3% conditioners to improve storage and performance with
reduction in fuel economy when using B20. BioDiesel fuels.
These John Deere engines can operate on BioDiesel The following must also be considered if using BioDiesel
blends above B20 (up to 100% BioDiesel). Operate at blends above B20:
levels above B20 ONLY if the BioDiesel is permitted
by law and meets the EN 14214 specification (primarily • Possible coking or blocked injector nozzles, resulting in
available in Europe). Engines operating on BioDiesel power loss and engine misfire if John Deere approved
blends above B20 might not fully comply with or be fuel conditioners are not used
permitted by all applicable emissions regulations. Expect • Possible crankcase oil dilution (requiring more frequent
up to a 12% reduction in power and an 18% reduction in oil changes)
fuel economy when using 100% BioDiesel. • Possible lacquering or seizure of internal components
• Possible formation of sludge and sediments
John Deere approved fuel conditioners, which contain • Possible thermal oxidation of fuel at elevated
detergent and dispersant additives, are required when temperatures
using BioDiesel blends from B10—B20, and are • Possible compatibility issues with other materials
recommended when using lower BioDiesel blends. (including copper, lead, zinc, tin, brass, and bronze)
used in fuel handling equipment
Continued on next page DX,FUEL7 -19-15MAY13-1/2

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 Fuels, Lubricant, and Coolants

• Possible reduction in water separator efficiency ash loading and require more frequent cleaning of the
• Possible damage to paint if exposed to BioDiesel Exhaust Filter (if present)
• Possible corrosion of fuel injection equipment IMPORTANT: Raw pressed vegetable oils are
• Possible elastomeric seal and gasket material NOT acceptable for use as fuel in any
degradation (primarily an issue with older engines)
• Possible high acid levels within fuel system concentration in John Deere engines. Their
• Because BioDiesel blends above B20 contain more use could cause engine failure.
ash, using blends above B20 can result in more rapid
DX,FUEL7 -19-15MAY13-2/2

Filling Fuel Tank

CAUTION: 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.

TS202 —UN—23AUG88
Fill fuel tank outdoors.
Prevent fires by keeping machine clean
of accumulated trash, grease, and debris.
Always clean up spilled fuel.

Fill fuel tank at the end of each day of operation. This

action prevents condensation in tank as moist air cools.
IMPORTANT: The fuel tank use a vented filler NOTE: John Deere Fuel Flow Improver, or equivalent,
cap. If a new filler cap is required, always can be added to fuel or bulk storage tank
replace it with a vented cap. during cold weather to reduce gelling and
control wax separation.

JY20514,00006EB -19-03NOV10-1/1

Engine Oil 50 o C 122o F

Use oil viscosity based on the expected air temperature
range during the period between oil changes. 40 o C 104o F

The following John Deere oils are preferred: 30 o C 86 o F

SAE 15W-40

• John DeerePlus-50™ II
SAE 10W-40

• John DeereTorq-Gard™ Supreme 20 o C 68 o F

SAE 10W-30

SAE 0W-40
SAE 5W-30

Other oils may be used if above John Deere oils 10 o C 50 o F

are not available, provided they meet the following
specification: 0o C 32 o F
• API Service Classification CJ-4
• ACEA Specification E6 or E9 -10 o C 14 o F
• JASO Specification DH-2
-20 o C -4 o F
TS1691 —UN—18JUL07

Diesel fuel quality and fuel sulfur content must comply

with all existing emissions regulations for the area in -30 o C -22 o F
which the engine operates.
-40 o C -40 o F

Oil Viscosities for Air Temperature Ranges

Plus-50 is a trademark of Deere & Company

Torq-Gard is a trademark of Deere & Company
UP00731,1004800 -19-24APR15-1/1

TM130419 (24FEB16) 10-20-4 030916

PN=30
 Fuels, Lubricant, and Coolants

Oil Filters Use filters meeting John Deere performance

Filtration of oils is critical to proper operation and specifications.
lubrication.
Always change filters regularly as specified in this manual.
DX,FILT -19-18MAR96-1/1

Transmission and Hydraulic Oil

Use oil viscosity based on the expected air temperature
range during the period between oil changes.
The following oils are preferred:
• John Deere HY-GARD™
• John Deere Low Viscosity HY-GARD™
Other oils may be used if they meet one of the following:
• John Deere Standard JDM J20C
• John Deere Standard JDM J20D
Use John Deere BIO-HY-GARD™ oil when a
biodegradable fluid is required.1

TS1660 —UN—10OCT97
HY-GARD is a trademark of Deere & Company
BIO-HY-GARD is a trademark of Deere & Company
1
BIO-HY-GARD meets or exceeds the minimum biodegradability of 80%
within 21 days according to CEC-L-33-T-82 test method. BIO-HY-GARD
should not be mixed with mineral oils, because this reduces the
biodegradability and makes proper oil recycling impossible.
DX,ANTI -19-07NOV03-1/1

Use Correct Transmission/Hydraulic Filter

See Maintenance and Service Intervals section for
Element recommended filter change intervals.
To protect systems, replace transmission-hydraulic oil
filter with a John Deere service filter element.
OUMX005,00019A8 -19-19AUG04-1/1

TM130419 (24FEB16) 10-20-5 030916

PN=31
 Fuels, Lubricant, and Coolants

MFWD Axle Housing and Wheel Hub Oil

Use oil viscosity based on the expected air temperature
range during the period between oil changes.
The following oils are preferred:
• John Deere Hy-Gard™
• John Deere Low Viscosity Hy-Gard™
Other oils may be used if they meet one of the following:
• John Deere Standard JDM J20C
• John Deere Standard JDM J20D
Use John Deere Bio Hy-Gard™ oil when a biodegradable
fluid is required.1

TS1651 —UN—14MAR96
Hy-Gard is a trademark of Deere & Company
Bio Hy-Gard is a trademark of Deere & Company
1
Bio Hy-Gard meets or exceeds the minimum biodegradability of
80% within 21 days according to CEC-L-33-T-82 test method. Bio
Hy-Gard should not be mixed with mineral oils, because this reduces
the biodegradability and makes proper oil recycling impossible.
RF30435,000002E -19-15JUL04-1/1

TM130419 (24FEB16) 10-20-6 030916

PN=32
 Fuels, Lubricant, and Coolants

Grease
Use grease based on NLGI consistency numbers and the
expected air temperature range during the service interval.
John Deere SD Polyurea Grease is preferred.
The following greases are also recommended:
• John Deere HD Lithium Complex Grease
• John Deere HD Water Resistant Grease
• John Deere GREASE-GARD™
Other greases may be used if they meet the following:
• NLGI Performance Classification GC-LB
IMPORTANT: Some types of grease thickeners are not

TS1673 —UN—31OCT03
compatible with others. Consult your grease
supplier before mixing different types of grease.

Greases for Air Temperature Ranges

GREASE-GARD is a trademark of Deere & Company

DX,GREA1 -19-14APR11-1/1

Grease (Specific Application)

TY6333 John Deere Moly High Temperature EP Grease
Lithium Grease with Molybdenum Disulphide is is recommended for use on the traction clutch and PTO
recommended for use on internal components of clutch splines.
transmission.
JG31785,0000179 -19-11NOV04-1/1

Mixing of Lubricants

In general, avoid mixing different brands or types of oil. Mixing different oils can interfere with the proper
Oil manufacturers blend additives in their oils to meet functioning of these additives and degrade lubricant
certain specifications and performance requirements. performance.
Consult your John Deere dealer to obtain specific
information and recommendations.
DX,LUBMIX -19-18MAR96-1/1

Alternative and Synthetic Lubricants

Conditions in certain geographical areas may require
lubricant recommendations different from those printed in Synthetic lubricants may be used if they meet the
this manual. performance requirements as shown in this manual.

Some John Deere brand coolants and lubricants may not The temperature limits and service intervals shown in
be available in your location. this manual apply to both conventional and synthetic
lubricants.
Consult your John Deere dealer to obtain information and
recommendations. Re-refined base stock products may be used if the
finished lubricant meets the performance requirements.
DX,ALTER -19-11APR11-1/1

TM130419 (24FEB16) 10-20-7 030916

PN=33
 Fuels, Lubricant, and Coolants

Lubricant Storage
Your equipment can operate at top efficiency only when
clean lubricants are used. Make certain that all containers are properly marked to
identify their contents.
Use clean containers to handle all lubricants.
Properly dispose of all old containers and any residual
Store lubricants and containers in an area protected from lubricant they may contain.
dust, moisture, and other contamination. Store containers
on their side to avoid water and dirt accumulation.
DX,LUBST -19-11APR11-1/1

Operating in Warm Temperature Climates

John Deere engines are designed to operate using Foaming, hot surface aluminum and iron
recommended engine coolants. corrosion, scaling, and cavitation occur when
Always use a recommended engine coolant, even when water is used as the coolant, even when
operating in geographical areas where freeze protection coolant conditioners are added.
is not required. Drain cooling system and refill with
IMPORTANT: Water may be used as coolant in recommended engine coolant as soon
emergency situations only. as possible.
DX,COOL6 -19-15MAY13-1/1

TM130419 (24FEB16) 10-20-8 030916

PN=34
 Fuels, Lubricant, and Coolants

Diesel Engine Coolant

Preferred coolants: If coolant meeting one of these specifications is
The following pre-mix engine coolants are preferred: unavailable, use a coolant concentrate or pre-mix coolant
that has a minimum of the following chemical and physical
• John Deere Cool-Gard™ II properties:
• John Deere Cool-Gard™ II PG
• Is formulated with a quality nitrite-free additive package.
Not all Cool-Gard™ II pre-mix products are available in • Protects the cooling system metals (cast iron, aluminum
all countries. alloys, and copper alloys such as brass) from corrosion.
Use COOL-GARD™ II PG when a non-toxic coolant Water Quality
formulation is required.
Water quality is important to the performance of the
Additional Recommended Coolants cooling system. Distilled, deionized, or demineralized
water is recommended for mixing with ethylene glycol
The following engine coolant is also recommended:
base engine coolant concentrate.
• John Deere COOL-GARD™ II Concentrate in a Coolant Drain Intervals
40—60% mixture of concentrate with quality water.
IMPORTANT: Avoid damage! When mixing coolant Drain and flush the cooling system and refill with fresh
concentrate with water, do not use less than coolant at the indicated interval, which varies with the
40% or greater than 60% concentration of coolant used.
coolant. Less than 40% gives inadequate When Cool-Gard™ II or Cool-Gard™ II PG is used, the
additives for corrosion protection. Greater drain interval is 6 yr. or 6000 operating hours.
than 60% can result in coolant gelation and
cooling system problems. If a coolant other than Cool-Gard™ II or Cool-Gard™ II
PG is used, reduce the drain interval to 2 yr. or 2000
Other Coolants operating hours.
Other ethylene glycol or propylene glycol base IMPORTANT: Avoid damage! Do not use cooling
coolants may be used if they meet one of the following system sealing additives or antifreeze that
specifications: contains sealing additives.

• Pre-mix coolant meeting ASTM D6210 requirements IMPORTANT: Avoid damage! Do not mix ethylene
• Coolant concentrates meeting ASTM D6210 glycol and propylene glycol base coolants.
requirements in a 40% to 60% mixture of concentrate
with quality water IMPORTANT: Avoid damage! Do not use coolants
• Pre-mix coolant meeting ASTM D3306 requirements that contain nitrites.
• Coolant concentrates meeting ASTM D3306
requirements in a 40% to 60% mixture of concentrate
with quality water

Cool-Gard is a trademark of Deere & Company

UP00731,0000022 -19-29JUN15-1/1

TM130419 (24FEB16) 10-20-9 030916

PN=35
 Fuels, Lubricant, and Coolants

John Deere COOL-GARD™ II Coolant Extender

Some coolant additives gradually deplete during COOL-GARD II Coolant Extender is not intended for use
engine operation. For COOL-GARD™ II pre-mix and with nitrite-containing coolants.
COOL-GARD II Concentrate, replenish coolant additives
between drain intervals by adding COOL-GARD II Coolant IMPORTANT: Do not add a supplemental coolant
Extender. additive when the cooling system is drained
and refilled with any of the following:
COOL-GARD II Coolant Extender should not be added
unless indicated by COOL-GARD II Test Strips. These • John Deere COOL-GARD II
test strips provide a simple, effective method to check the • John Deere COOL-GARD II PG
freeze point, additive levels, and pH of your engine coolant.
The use of non-recommended supplemental coolant
Test the coolant solution at intervals of 12 months and additives can result in additive drop-out, gelation of the
whenever excessive coolant is lost through leaks or coolant, or corrosion of cooling system components.
overheating.
Add the recommended concentration of COOL-GARD
IMPORTANT: Do not use COOL-GARD II Test II Coolant Extender. DO NOT add more than the
Strips with COOL-GARD II PG. recommended amount.

COOL-GARD II Coolant Extender is a chemically matched

additive system for use with all COOL-GARD II coolants.
COOL-GARD is a trademark of Deere & Company
DX,COOL16 -19-15MAY13-1/1

Testing Diesel Engine Coolant

Maintaining adequate concentrations of glycol and
inhibiting additives in the coolant is critical to protect the Add only the recommended concentration of John Deere
engine and cooling system against freezing, corrosion, COOL-GARD II Coolant Extender. DO NOT add more
and cylinder liner erosion and pitting. than the recommended amount.

Test the coolant solution at intervals of 12 months or less When Using Nitrite-Containing Coolants
and whenever excessive coolant is lost through leaks or Compare the test strip results to the supplemental coolant
overheating. additive (SCA) chart to determine the amount of inhibiting
Coolant Test Strips additives in your coolant and whether more John Deere
Liquid Coolant Conditioner should be added.
Coolant test strips are available from your John Deere
dealer. These test strips provide a simple, effective Add only the recommended concentration of John Deere
method to check the freeze point and additive levels of Liquid Coolant Conditioner. DO NOT add more than the
your engine coolant. recommended amount.

When Using John Deere COOL-GARD II Coolant Analysis

John Deere COOL-GARD II Premix™ , COOL-GARD For a more thorough evaluation of your coolant, perform a
II PG Premix and COOL-GARD II Concentrate are coolant analysis. The coolant analysis can provide critical
maintenance free coolants for up to six years or 6000 data such as freezing point, antifreeze level, pH, alkalinity,
hours of operation, provided that the cooling system is nitrite content (cavitation control additive), molybdate
topped off using only John Deere COOL-GARD II Premix content (rust inhibitor additive), silicate content, corrosion
or COOL-GARD II PG premix. Test the coolant condition metals, and visual assessment.
annually with coolant test strips designed for use with Contact your John Deere dealer for more information on
John Deere COOL-GARD II coolants. If the test strip coolant analysis.
chart indicates that additive is required, add John Deere
COOL-GARD II Coolant Extender as directed.
COOL-GARD is a trademark of Deere & Company
DX,COOL9 -19-11APR11-1/1

TM130419 (24FEB16) 10-20-10 030916

PN=36
 Group 30
Machine Specifications
Machine Specifications
NOTE: Specifications and design subject to
change without notice.
1550 1570/1575 WW 1570/1575 N.A. 1580/1585 N.A. 1580/1585 EX
Ground Speed:
Hi Forward 0—19.3 ±3.2 km/h (0—12 ±2 mph) 0—24.1 km/h (0—15 mph)
Lo Forward 0—24.1 ±3.2 km/h (0—15 ±2 mph) 0—13.7 km/h (0—8.5 mph)
Hi Reverse 0—8 ±1.6 km/h (0—5 ±1 mph) 0—12.9 km/h (0—8 mph)
Lo Reverse 0—8 ±1.6 km/h (0—5 ±1 mph) 0—6.8 km/h (0—4.2 mph)

Engine:
Make Yanmar
Engine Model 3TNV80 3TNV82A 3TNV88C 3TNV88
Oil Capacity (with Filter) 3.1 L (3.3 qt.) 3.1 L (3.3 qt.) 4.1 L (4.3 qt.) 4.8 L (5.1 qt.)
Coolant Capacity 7.1 L (7.5 qt) 7.6 L (2 gal.)

Fuel System:
Type Diesel
Tank Capacity 60.5 L (16.0 US gal.)

Electrical System:
Type 12 Volt Negative Ground
Battery 12-volt

Power Train:
Type Hydrostatic Pump
Drive Hydraulic Wheel Drive
Hi / Lo Range Single Speed Transmission Duel Speed Transmission
4 Wheel Drive Optional Standard
Transmission Oil John Deere High Viscosity HY-GARD™ J20C
Transmission Capacity (2WD) 8.5 L (9 qt.)
Transmission Capacity 1550, 8.7 L (9.2 qt.)
1575(4WD)
Transmission Capacity (1575, 1580, 10.0 L (10.5 qt.)
1585)

OUMX258,0000A6B -19-11SEP14-1/1

Machine Product Identification Number

When ordering parts or submitting a warranty claim, it
is IMPORTANT that the machine product identification
number (PIN) and component serial numbers are included.
The machine identification number (A) is located on the
rear frame plate.
TCAL32231 —UN—20JUN12

A—Machine Identification
Number

OUMX258,0000A67 -19-19MAR13-1/1

TM130419 (24FEB16) 10-30-1 030916

PN=37
 Machine Specifications

Engine Serial Number

The engine serial number plate (A) is located on top of the
valve cover for both diesel and gasoline engines.

A—Engine Serial Number Plate

TCAL32232 —UN—20JUN12
OUMX258,0000A68 -19-19MAR13-1/1

TM130419 (24FEB16) 10-30-2 030916

PN=38
 Section 20
Engine Repair
Contents

Page
Page
Group 10—Engine Repair—3TNV80F
Summary of References................................ 20-10-1 Check Crankshaft Main Bearing
Remove and Install Rocker Arm Clearance—3TNV80F ............................. 20-10-41
Cover—3TNV80F ...................................... 20-10-2 Check Crankshaft End
Remove and Install Rocker Arm Play—3TNV80F....................................... 20-10-42
Assembly—3TNV80F ................................ 20-10-3 Remove and Install
Inspect Rocker Arm Assembly and Flywheel—3TNV80F ............................... 20-10-43
Push Rods—3TNV80F .............................. 20-10-4 Remove and Install
Remove and Install Cylinder Head Camshaft—3TNV80F .............................. 20-10-44
and Valves—3TNV80F .............................. 20-10-5 Inspect Camshaft—3TNV80F...................... 20-10-45
Disassemble and Assemble Check Camshaft End
Cylinder Head and Play—3TNV80F....................................... 20-10-48
Valves—3TNV80F ..................................... 20-10-7 Check Timing Gear
Inspect Cylinder Head and Backlash—3TNV80F ............................... 20-10-49
Valves—3TNV80F ..................................... 20-10-8 Remove and Install Camshaft
Remove and Install Exhaust Gear—3TNV80F...................................... 20-10-49
Manifold—3TNV80F ................................ 20-10-12 Remove and Install Camshaft
Remove and Install Intake Follower—3TNV80F ................................ 20-10-50
Manifold—3TNV80F ................................ 20-10-13 Inspect Camshaft Fol-
Grind Valve Seats—3TNV80F..................... 20-10-13 lower—3TNV80F ..................................... 20-10-50
Lap Valves—3TNV80F ................................ 20-10-15 Remove and Install Timing Gear
Remove and Install Fuel Injection Cover—3TNV80F .................................... 20-10-51
Pump—3TNV80F .................................... 20-10-15 Remove and Install Idler
Remove, Inspect, and Install Fuel Gear—3TNV80F...................................... 20-10-52
Injection Nozzle—3TNV80F .................... 20-10-18 Inspect Idler Gear—3TNV80F ..................... 20-10-52
Remove and Install Fuel Shutoff Remove and Install Timing Gear
Solenoid—3TNV80F................................ 20-10-22 Housing—3TNV80F ................................ 20-10-54
Remove and Install Electric Fuel Remove and Install Oil Pan and
Pump—3TNV80F .................................... 20-10-22 Strainer—3TNV80F ................................. 20-10-54
Remove and Install Piston and Remove and Install Oil
Connecting Rod—3TNV80F.................... 20-10-23 Pump—3TNV80F .................................... 20-10-55
Disassemble and Assemble Inspect Oil Pump—3TNV80F ...................... 20-10-55
Piston and Connecting Remove and Install
Rod—3TNV80F ....................................... 20-10-25 Thermostat—3TNV80F ........................... 20-10-57
Inspect Piston and Connecting Remove and Install
Rod—3TNV80F ....................................... 20-10-28 Coolant Temperature
Check Connecting Rod Side Switch—3TNV80F ................................... 20-10-58
Play—3TNV80F....................................... 20-10-31 Inspect Water Pump—3TNV80F ................. 20-10-59
Check Connecting Rod Bearing Remove and Install Water
Clearance—3TNV80F ............................. 20-10-32 Pump—3TNV80F .................................... 20-10-59
Inspect Cylinder Bore—3TNV80F................ 20-10-33
Inspect Cylinder Bore Taper and Group 20—Engine Repair—3TNV82A, 3TNV88
Out-of-Round—3TNV80F........................ 20-10-35 Summary of References................................ 20-20-1
Replace Crankshaft Rear Oil Remove and Install Rocker Arm
Seal—3TNV80F ...................................... 20-10-35 Cover—3TNV82A, 3TNV88....................... 20-20-2
Replace Crankshaft Front Oil Check Valve Lift—3TNV82A,
Seal—3TNV80F ...................................... 20-10-36 3TNV88 ..................................................... 20-20-3
Remove and Install Crankshaft and Service Rocker Arm
Main Bearings—3TNV80F....................... 20-10-38 Assembly—3TNV82A,
Inspect Crankshaft and Main 3TNV88 ..................................................... 20-20-4
Bearings—3TNV80F ............................... 20-10-39

Continued on next page

TM130419 (24FEB16) 20-1 030916

PN=1
 Contents

Page Page

Remove and Install Cylinder Remove and Install Camshaft

Head and Valves—3TNV82A, Followers—3TNV82A,
3TNV88 ..................................................... 20-20-6 3TNV88 ................................................... 20-20-40
Disassemble and Assemble Remove and Install Timing Gear
Cylinder Head and Cover—3TNV82A, 3TNV88..................... 20-20-41
Valves—3TNV82A, 3TNV88...................... 20-20-8 Check Timing Gear
Valve Seats—3TNV82A, 3TNV88.................. 20-20-9 Backlash—3TNV82A, 3TNV88................ 20-20-42
Intake and Exhaust Remove and Install Idler
Valves—3TNV82A, 3TNV88.................... 20-20-10 Gear—3TNV82A, 3TNV88 ...................... 20-20-43
Valve Recession—3TNV82A, Remove and Install Timing
3TNV88 ................................................... 20-20-11 Gear Cover Mounting
Valve Guides—3TNV82A, Plate—3TNV82A, 3TNV88 ...................... 20-20-44
3TNV88 ................................................... 20-20-12 Remove and Install Oil Pan,
Valve Springs—3TNV82A, Crankcase Extension, and
3TNV88 ................................................... 20-20-13 Strainer—3TNV82A, 3TNV88.................. 20-20-44
Remove and Install Exhaust Remove, Inspect, and Install Oil
Manifold—3TNV82A, 3TNV88................. 20-20-14 Pump—3TNV82A, 3TNV88..................... 20-20-45
Remove and Install Intake Remove and Install
Manifold—3TNV82A, 3TNV88................. 20-20-14 Thermostat—3TNV82A,
Grind Valve Seats—3TNV82A, 3TNV88 ................................................... 20-20-47
3TNV88 ................................................... 20-20-14 Inspect, Remove, and Install Water
Lap Valves—3TNV82A, 3TNV88................. 20-20-15 Pump—3TNV82A, 3TNV88..................... 20-20-48
Check Piston-to-Cylinder Head Remove, Install and Inspect
Clearance—3TNV82A, Radiator—3TNV82A, 3TNV88................. 20-20-49
3TNV88 ................................................... 20-20-16 Disassemble and Assemble
Remove and Install Piston and Water Separator—3TNV82A,
Connecting Rod—3TNV82A, 3TNV88 ................................................... 20-20-51
3TNV88 ................................................... 20-20-17 Remove Fuel Injection
Inspect Piston—3TNV82A, Pump—3TNV82A, 3TNV88..................... 20-20-52
3TNV88 ................................................... 20-20-22 Install Fuel Injection
Cylinder Bore—3TNV82A, Pump—3TNV82A, 3TNV88..................... 20-20-56
3TNV88 ................................................... 20-20-26 Remove and Install Fuel Injection
Crankshaft Rear Oil Nozzles—3TNV82A, 3TNV88 ................. 20-20-57
Seal—3TNV82A, 3TNV88 ....................... 20-20-28
Crankshaft Front Oil Group 30—Engine Repair—3TNV88C
Seal—3TNV82A, 3TNV88 ....................... 20-20-28 Summary of References................................ 20-30-1
Check Crankshaft End Engine Remove ............................................. 20-30-1
Play—3TNV82A, 3TNV88 ....................... 20-20-29 Engine Install ................................................. 20-30-8
Remove and Install Crankshaft
and Main Bearings—3TNV82A,
3TNV88 ................................................... 20-20-30
Check Connecting Rod Side
Play—3TNV82A, 3TNV88 ....................... 20-20-33
Check Crankshaft Main Bearing
Clearance—3TNV82A,
3TNV88 ................................................... 20-20-33
Remove and Install Flywheel
and Flex Plate—3TNV82A,
3TNV88 ................................................... 20-20-34
Check Camshaft End
Play—3TNV82A, 3TNV88 ....................... 20-20-35
Remove and Install
Camshaft—3TNV82A,
3TNV88 ................................................... 20-20-36
Inspect Camshaft—3TNV82A,
3TNV88 ................................................... 20-20-37
Remove and Install Camshaft
Gear—3TNV82A, 3TNV88 ...................... 20-20-40

TM130419 (24FEB16) 20-2 030916

PN=2
 Group 10
Engine Repair—3TNV80F
Summary of References • Replace Crankshaft Rear Oil Seal—3TNV80F
• Remove and Install Rocker Arm Cover—3TNV80F • Replace Crankshaft Front Oil Seal—3TNV80F
• Remove and Install Crankshaft and Main
• Remove and Install Rocker Arm Assembly—3TNV80F Bearings—3TNV80F
• Inspect Rocker Arm Assembly and Push • Inspect Crankshaft and Main Bearings—3TNV80F
Rods—3TNV80F
• Check Crankshaft Main Bearing Clearance—3TNV80F
• Remove and Install Cylinder Head and
• Check Crankshaft End Play—3TNV80F
Valves—3TNV80F • Remove and Install Flywheel—3TNV80F
• Disassemble and Assemble Cylinder Head and
• Remove and Install Camshaft—3TNV80F
Valves—3TNV80F
• Inspect Camshaft—3TNV80F
• Inspect Cylinder Head and Valves—3TNV80F
• Check Camshaft End Play—3TNV80F
• Remove and Install Exhaust Manifold—3TNV80F
• Check Timing Gear Backlash—3TNV80F
• Remove and Install Intake Manifold—3TNV80F
• Remove and Install Camshaft Gear—3TNV80F
• Grind Valve Seats—3TNV80F
• Remove and Install Camshaft Follower—3TNV80F
• Lap Valves—3TNV80F
• Inspect Camshaft Follower—3TNV80F
• Remove and Install Fuel Injection Pump—3TNV80F
• Remove and Install Timing Gear Cover—3TNV80F
• Remove, Inspect, and Install Fuel Injection
• Remove and Install Idler Gear—3TNV80F
Nozzle—3TNV80F • Inspect Idler Gear—3TNV80F
• Remove and Install Fuel Shutoff Solenoid—3TNV80F
• Remove and Install Timing Gear Housing—3TNV80F
• Remove and Install Electric Fuel Pump—3TNV80F
• Remove and Install Oil Pan and Strainer—3TNV80F
• Remove and Install Piston and Connecting
• Remove and Install Oil Pump—3TNV80F
Rod—3TNV80F • Inspect Oil Pump—3TNV80F
• Disassemble and Assemble Piston and Connecting
• Remove and Install Thermostat—3TNV80F
Rod—3TNV80F
• Inspect Piston and Connecting Rod—3TNV80F
• Remove and Install Coolant Temperature
Switch—3TNV80F
• Check Connecting Rod Side Play—3TNV80F
• Inspect Water Pump—3TNV80F
• Check Connecting Rod Bearing Clearance—3TNV80F
• Remove and Install Water Pump—3TNV80F
• Inspect Cylinder Bore—3TNV80F
• Inspect Cylinder Bore Taper and Out-of-
Round—3TNV80F
OUMX258,0000A6C -19-27MAR13-1/1

TM130419 (24FEB16) 20-10-1 030916

PN=41
 Engine Repair—3TNV80F

Remove and Install Rocker Arm

Cover—3TNV80F
1. Park machine safely.
2. Loosen hose clamps from air cleaner hose and
remove air cleaner.
3. Remove cap screws (A and B).
4. Remove rocker cover.
5. Remove intake cover (C) and clean off mating
surfaces and replace gasket (D).
6. Remove and disassemble breather baffle (F) and
clean or replace mesh media.

TCT005860 —UN—16NOV12
7. Remove diaphragm cover (G), spring (H), center plate
(I), and diaphragm (J).
8. Inspect diaphragm, spring, and center plate for wear or
damage. Diaphragm must not have any cracks or tears
and must not leak. Replace parts showing any wear.
Installation

• Clean all parts.

• Reassemble rocker arm cover using new gaskets. A—Cap Screw, Long (6 used) F— Breather Baffle
• Use John Deere Form in Place Gasket between B—Cap Screw, Short (3 used) G—Diaphragm Cover
breather baffle and rocker cover. C—Intake Cover H—Spring
• Tighten rocker cover cap screws to specification. D—Gasket
E—Gasket
I— Center Plate
J— Diaphragm
Specification
Rocker Arm
Cover-to-Cylinder Head
Cap Screws—Torque.................................................................... 11 N·m
(97 lb.-in.)

OUMX068,00003B8 -19-15SEP14-1/1

TM130419 (24FEB16) 20-10-2 030916

PN=42
 Engine Repair—3TNV80F

Remove and Install Rocker Arm

Assembly—3TNV80F
Removal
1. Remove the rocker arm cover. (See Remove and
Install Rocker Arm Cover—3TNV80F.)

TCT006372 —UN—18JAN13
A—Bolt (3 Used) D—Spring (3 Used) H—Ball (2 Used) L— Rocker Arm (6 Used)
B—Retaining Ring (2 Used) E—Nut (6 Used) I— Rocker Arm Shaft
C—Shaft Support (3 Used) F— Set Screw J— Valve Cap (6 Used)
G—Adjuster Screw (6 Used) K—Push Rod (6 Used)

2. Remove the rocker arm support bolts (A). 7. Inspect the rocker arm components and push rods.
3. Lift the rocker arm assembly from the cylinder head (See Inspect Rocker Arm Assembly and Push
and set the assembly on a bench. Rods—3TNV80F.)

NOTE: If the rocker arm shaft assembly is disassembled, Installation

replace components in same location on the rocker
arm shaft they were removed from. 1. Install the push rods in their original locations in the
cylinder head, with the ball shaped end down in head.
4. Note the positions of the rocker arm assembly 2. Lubricate all parts with clean oil during assembly.
components. Slide the components off the rocker arm
shaft. 3. Assemble the rocker arm assembly components in the
reverse order of removal.
5. Remove set screw from center support. Remove
rocker shaft from center support. 4. Place the rocker arm assembly on the cylinder head.
6. Lift the push rods from the cylinder head and note the a. Align the rocker arms with the valves and push rods.
order of removal for reassembly.
Continued on next page OUMX258,0000A6D -19-15SEP14-1/2

TM130419 (24FEB16) 20-10-3 030916

PN=43
 Engine Repair—3TNV80F

b. Align the rocker arm supports with the corresponding 6. Adjust the valve clearance. (See Adjust Valve
holes in the head. Clearance—3TNV80F.)
5. Install the rocker arm support bolts. Tighten the bolts 7. Install rocker arm cover. (See Remove and Install
to specification. Rocker Arm Cover—3TNV80F.)
Specification
Rocker Arm Support
Bolts—Torque................................................................................26 N·m
(230 lb.-in.)
OUMX258,0000A6D -19-15SEP14-2/2

Inspect Rocker Arm Assembly and Push

Rods—3TNV80F
Rocker Arm Inspection

TCAL28379 —UN—28JUN12
1. Measure outer diameter of rocker arm shaft. Replace
rocker arm shaft if measurement is less than wear limit.
Specification
Rocker Arm Shaft—OD............................................ 11.966—11.984 mm
(0.471—0.472 in.)
Rocker Arm Shaft (Wear
Limit)—OD.................................................................................11.95 mm
(0.47 in.)

OUMX068,00003EB -19-04FEB14-1/2

2. Measure inside diameter of rocker arms and rocker

shaft supports. Replace rocker arms or supports if
inner diameter is more than wear limit.
Specification
Rocker Arm and Shaft
Support—ID..................................................................12.00—12.02 mm
(0.472—0.473 in.)
Rocker Arm and Shaft

TCAL28380 —UN—28JUN12
Support—ID (Wear
Limit)......................................................................................... 12.07 mm
(0.475 in.)

3. If shaft and support/arm clearance (support/arm ID

minus shaft OD) exceeds wear limit, replace all parts.
Specification
Rocker Arm/Support-to-
Shaft—Clearance.........................................................0.016—0.054 mm
(0.006—0.002 in.)
Rocker Arm/Support-to- Specification
Shaft—Clearance (Wear Push Rod—Bend (limit).............................................................. 0.03 mm
Limit)........................................................................................... 0.13 mm (0.001 in.)
(0.005 in.)
2. Check the surface of the adjusting screw that contacts
Push Rod Inspection the push rod for wear. Replace push rod or adjusting
screw if worn.
1. Lay push rod on flat surface and roll while checking for
a gap under center of rod. Use feeler gage to check 3. Check the rocker arm-to-valve stem cap contact
dimension. surface for wear. Replace rocker arm if worn.
OUMX068,00003EB -19-04FEB14-2/2

TM130419 (24FEB16) 20-10-4 PN=44

030916
 Engine Repair—3TNV80F

Remove and Install Cylinder Head and

TCAL28382 —UN—28JUN12
Valves—3TNV80F
Special or Required Tools

• Hoist
• JT01748 Lifting Bracket (2 used)
Removal
1. Park machine on level surface with park brake locked Top of Drawing Is Exhaust Manifold Side, Bottom Is Intake Manifold Side
and engine off.
2. Disconnect negative (—) battery cable from battery.
3. Shut off fuel valve on fuel filter.
4. Allow engine to cool, and cooling system pressure to
return to zero. Drain coolant from drain valves located
on left side of engine and radiator.
5. Remove pipe from exhaust manifold. (See Remove
and Install Exhaust Manifold—3TNV80F.)
6. Remove upper and lower radiator hoses from water
pump.
7. Disconnect wiring from coolant temperature sensor.
8. Remove upper alternator bracket and belt from water
pump.
9. Remove water pump. (See Remove and Install Water
Pump—3TNV80F.)
10. Remove high-pressure fuel lines and fuel leak-off line
running from fuel injection pump to nozzles.
11. Disconnect glow plug wiring harness from engine
harness.
12. Remove rocker arm cover. (See Remove and Install
Rocker Arm Cover—3TNV80F.)
13. Remove rocker arm assembly, push rods, and valve
caps from cylinder head. (See Remove and Install
Rocker Arm Assembly—3TNV80F.)
14. Remove cylinder head cap screws in the order shown.
15. Using lift brackets and hoist, pull head straight up from
block.
16. Remove exhaust and intake manifolds. (See Remove
and Install Exhaust Manifold—3TNV80F and Remove
and Install Intake Manifold—3TNV80F.)
17. Disassemble and inspect cylinder head and valves.
(See Disassemble and Assemble Cylinder Head and
Valves—3TNV80F and Inspect Cylinder Head and
Valves—3TNV80F.)
Continued on next page OUMX258,0000A6E -19-15SEP14-1/3

TM130419 (24FEB16) 20-10-5 030916

PN=45
 Engine Repair—3TNV80F

Installation
1. Clean all threads in top of cylinder block with a flat
bottom tap, and blow debris from hole.
2. Clean top of cylinder block and check for flatness.
IMPORTANT: Oil passage in gasket must be located
over oil passage (A) in cylinder block.
If cylinder head was resurfaced, check
piston-to-cylinder head clearance.

3. Place a new cylinder head gasket on cylinder block

with locating pins on front and rear of block inside
holes in gasket. Line up oil passage (A) on left rear of
block with oil passage in gasket. If cylinder head was
resurfaced, check piston-to-cylinder head clearance.
4. Clean threads of cylinder head cap screws and dip in
clean oil before installing. Install all cap screws finger
tight before tightening with wrench.

TCAL28383 —UN—28JUN12
A—Oil Passage

OUMX258,0000A6E -19-15SEP14-2/3

5. Tighten cylinder head cap screws to specification in

TCAL28384 —UN—28JUN12
sequence shown, in three steps.
Cylinder Head Cap Screws—Specification
First Pass—Torque........................................................................27 N·m
(20 lb.-ft.)
Second Pass—Torque...................................................................41 N·m
(30 lb.-ft.)
Final Pass—Torque............................................................... 59—64 N·m
(43—47 lb.-ft.) Top of Drawing Is Exhaust Manifold Side, Bottom Is Intake Manifold Side

6. Install rocker arm assembly, push rods, and valve

caps. (See Remove and Install Rocker Arm 10. Install exhaust pipe to manifold. (See Remove and
Assembly—3TNV80F.) Install Exhaust Manifold—3TNV80F.)
7. Install rocker arm cover. (See Remove and Install 11. Install upper alternator bracket and belt.
Rocker Arm Cover—3TNV80F.)
IMPORTANT: Cylinder head mounting cap screws
8. Connect fuel lines, radiator hoses, and wires. must be checked for proper torque after 50
hours of engine operation.
9. Install water pump. (See Remove and Install Water
Pump—3TNV80F.)
OUMX258,0000A6E -19-15SEP14-3/3

TM130419 (24FEB16) 20-10-6 030916

PN=46
 Engine Repair—3TNV80F

Disassemble and Assemble Cylinder Head

and Valves—3TNV80F
Special or Required Tools

• JDE138 Valve Spring Compressor

NOTE: Order tools according to information given in
the U.S. SERVICEGARD™ Catalog or in the
European Microfiche Tool Catalog (MTC).

Disassembly
1. Check valve recession before disassembly. (See
Inspect Cylinder Head and Valves—3TNV80F.)

TCAL28385 —UN—28JUN12
2. Compress valve springs (A) using JDE138 Valve
Spring Compressor.
NOTE: It can be necessary to tap on valve spring
retainer (C) while initially operating compressor
to break retainer free from valve stem.

3. Remove valve collets (B) from retainer.

4. Slowly release compressor and valve spring.
A—Valve Springs E—Intake and Exhaust Valve
IMPORTANT: Do not reuse stem seals (D) if B—Valve Collets Guides
C—Valve Spring Retainer F— Head
removed. Used seals will leak. D—Stem Seal G—Valve
H—Valve
5. Remove valve spring, stem seal (D), and valve (G or
H) from Intake and exhaust valve guides (F).
NOTE: Valve seats are not replaceable. 3. Use valve spring compressor to compress spring and
retainer, and install collet as removed.
6. Intake and exhaust valve guides (E) are press fit.
Remove guides only if replacement is necessary. 4. After valve has been assembled, tap on top of valve
stem with a plastic hammer to seat retainer.
7. Inspect all parts for wear or damage. Clean all carbon
deposits and measure all parts for proper clearances. 5. Repeat for remaining valves.
6. Measure valve recession if new valves were installed.
Assembly
(See Inspect Cylinder Head and Valves—3TNV80F.)
1. Apply clean engine oil on intake and exhaust valve
stems during assembly.
2. Install springs with smaller pitch end or paint mark
toward cylinder head.
SERVICEGARD is a trademark of Deere & Company
OUMX258,0000A6F -19-15SEP14-1/1

TM130419 (24FEB16) 20-10-7 030916

PN=47
 Engine Repair—3TNV80F

Inspect Cylinder Head and Valves—3TNV80F

Special or Required Tools

• JDG504 Valve Guide Driver

TCAL28386 —UN—28JUN12
• 6 mm Valve Guide Reamer
NOTE: Order tools according to information given in
the U.S. SERVICEGARD™ Catalog or in the
European Microfiche Tool Catalog (MTC).

IMPORTANT: Avoid Damage! Before inspection,

thoroughly clean all components of
carbon or dirt.
I— Straightedge J— Feeler Gauge
Cylinder Head
1. Measure cylinder head flatness. Place a straightedge Cylinder Head—Maxi-
(I) along each of the four sides and each diagonal. mum Allowable Removed
Measure clearance between straightedge and gasket Material....................................................................................... 0.20 mm
surface with a feeler gauge (J). (0.008 in.)
Specification
3. Inspect for cracks or other damage.
Cylinder Head—Out-of-
Flat............................................................................................. 0.05 mm 4. Inspect condition of valve seats and measure valve
(0.002 in.) seat width. (See Valve Seat Width procedure.)
2. If distortion exceeds the wear limit, resurface or 5. If cylinder head was resurfaced, measure valve
replace cylinder head. Remove only enough metal to recession. (See Valve Recession Measurement
make cylinder head flat, but do not remove more than procedure.)
maximum amount specified.
Specification
Cylinder Head—Out-of-
Flat (Wear Limit)......................................................................... 0.15 mm
(0.006 in.)

SERVICEGARD is a trademark of Deere & Company

OUMX068,00003BE -19-16SEP14-1/9

Valve Seat Width

1. Measure valve seat width (K) for intake and exhaust
valves and compare to specification.
Specification
Intake Valve
Seat—Width............................................................................... 1.44 mm
(0.057 in.)
TCAL28387 —UN—28JUN12
Intake Valve Seat (Wear
Limit)—Width.............................................................................. 1.98 mm
(0.078 in.)
Exhaust Valve
Seat—Width............................................................................... 1.77 mm
(0.07 in.)
Exhaust Valve Seat
(Wear Limit)—Width................................................................... 2.27 mm
(0.089 in.)
K—Valve Seat Width
2. If necessary, grind valve seats to meet specification.
Continued on next page OUMX068,00003BE -19-16SEP14-2/9

TM130419 (24FEB16) 20-10-8 PN=48

030916
 Engine Repair—3TNV80F

Intake and Exhaust Valves

1. Check valve for out-of-round, bent, or warped
condition using a valve inspection center and dial
indicator. Replace valve if necessary.

TCAL28388 —UN—28JUN12
OUMX068,00003BE -19-16SEP14-3/9

2.
Specification

TCAL28389 —UN—28JUN12
Valve Face
Angle—Angle.......................... 30° for Intake Seat, 45° for Exhaust Seat

Specification
Valve Margin (Wear
Limit)—Width.............................................................................. 0.50 mm
(0.020 in.)

If valve faces are worn, burned, or pitted, grind valves

to proper face angle (M). If valve face margin (L) is
less than specification after grinding, replace valve. L— Valve Margin M—Proper Face Angle

OUMX068,00003BE -19-16SEP14-4/9

3. Measure valve stem diameter at the two locations (N

and O) shown above. Replace valve if measurement
exceeds wear limit specification.
Specification
Intake Valve Stem
Standard—OD..............................................................5.960—5.975 mm
(0.234—0.235 in.)
Exhaust Valve Stem
Standard—OD..............................................................5.945—5.960 mm
(0.234—0.2346 in.)
Intake and Exhaust Valve
Stem (Wear Limit)—OD............................................................. 5.90 mm
(0.232 in.)
TCAL28390 —UN—28JUN12

N—20 mm (0.787 in.) O—40 mm (1.575 in.)

Continued on next page OUMX068,00003BE -19-16SEP14-5/9

TM130419 (24FEB16) 20-10-9 030916

PN=49
 Engine Repair—3TNV80F

Valve Recession Measurement

Measure valve recession (P) using a depth gauge (Q).
Replace valve or cylinder head if measurement exceeds
wear limit specification.
Specification
Intake Valve
Standard—Recess...........................................................0.40—0.60 mm
(0.016—0.024 in.)
Intake Valve (Wear
Limit)—Recess........................................................................... 0.90 mm
(0.035 in.)
Exhaust Valve
Standard—Recess...........................................................0.40—0.60 mm
(0.016—0.024 in.)
Exhaust Valve (Wear
Limit)—Recess............................................................................. 0.8 mm
(0.032 in.)

TCAL28391 —UN—28JUN12
P—Valve Recession Q—Depth Gauge

Continued on next page OUMX068,00003BE -19-16SEP14-6/9

TM130419 (24FEB16) 20-10-10 030916

PN=50
 Engine Repair—3TNV80F

Valve Guide Measurement

1. Clean valve guides using a valve guide brush.
2. Measure valve guide inside diameter using a ball or
telescoping snap gage.

TCAL28392 —UN—28JUN12
• If valve guide inside diameter exceeds wear limit
specification, replace guide.
Specification
Valve Guide
Standard—ID......................................................................6.0—6.01 mm
(0.236—0.237 in.)
Valve Guide (Wear
Limit)—ID................................................................................... 6.08 mm
(0.239 in.) R—Installation Height S—Tapered End

• If valve guide inside diameter is less than wear limit

specification, determine guide-to-stem oil clearance
(valve guide diameter minus valve stem diameter).
• If clearance exceeds wear limit specification, replace
valve guides.
Specification
Intake Valve Guide-
3. Install valve guides with tapered end (S) down using
to-Valve Stem—Oil
JDG504 Valve Guide Driver. Push valve guides down
Clearance.....................................................................0.025—0.052 mm
until tops of valve guides are projecting at the specified
(0.001—0.002 in.)
height (R) from the valve spring seat in the cylinder
Exhaust Valve
head.
Guide-to-Valve Specification
Stem—Oil Clearance....................................................0.040—0.067 mm Valve Guide—Installation
(0.0016—0.0026 in.) height above valve seat......................................................9.8—10.0 mm
Intake Valve (0.386—0.394 in.)
Guide-to-Valve Stem
(Wear Limit)—Oil 4. Ream inside diameter of valve guides using a 6 mm
Clearance................................................................................... 0.15 mm valve guide reamer.
(0.006 in.)
Exhaust Valve
Guide-to-Valve Stem
(Wear Limit)—Oil
Clearance................................................................................... 0.17 mm
(0.007 in.)
OUMX068,00003BE -19-16SEP14-7/9

Valve Springs
1. Measure spring free length. Replace spring if
measurement exceeds specification.
Specification TCAL28393 —UN—28JUN12
Valve Spring—Free
Length........................................................................................ 37.8 mm
(1.488 in.)

Continued on next page OUMX068,00003BE -19-16SEP14-8/9

TM130419 (24FEB16) 20-10-11 PN=51

030916
 Engine Repair—3TNV80F

2. Measure spring inclination (T). Replace spring if

measurement exceeds specification.
Specification
Valve Spring—Inclination
(Maximum)................................................................................... 1.3 mm
(0.051 in.)

T— Valve Spring Inclination

TCAL28394 —UN—28JUN12
OUMX068,00003BE -19-16SEP14-9/9

Remove and Install Exhaust

Manifold—3TNV80F
Removal
1. Remove four nuts (A). Slide exhaust pipe off studs.
Remove gasket.

A— Nuts (4 used)

TCAL28359 —UN—28JUN12
Continued on next page OUMX258,0000A70 -19-15SEP14-1/2

TM130419 (24FEB16) 20-10-12 030916

PN=52
 Engine Repair—3TNV80F

2. Remove two nuts (B) and four cap screws (C).

3. Remove manifold and gasket.
4. Clean all mating surfaces thoroughly.
Installation

TCAL28360 —UN—28JUN12
NOTE: Installation is done in the reverse order of removal.

1. Install new gasket between exhaust manifold, cylinder

head, and exhaust pipe.
2. Tighten mounting cap screws to specification.
Specification
Exhaust Manifold
Mounting Cap B— Nuts (2 used) C— Cap Screws (4 used)
Screw—Torque..............................................................................28 N·m
(240 lb.-in.)
OUMX258,0000A70 -19-15SEP14-2/2

Remove and Install Intake

Manifold—3TNV80F
NOTE: The intake manifold is integral with the rocker
arm cover. (See Remove and Install Rocker
Arm Cover—3TNV80F.)
OUMX258,0000A71 -19-25MAR13-1/1

Grind Valve Seats—3TNV80F

NOTE: Lightly grind valve seats for only a few seconds to
avoid excessive valve seat width. If valve guide is to
be replaced, always replace guide before grinding
valve seat, as seat grinder pilot is centered by guide.

1. Grind intake valve seat using a 30°-seat grinder, and

exhaust valve seat using a 45° seat grinder. Follow

TCAL28395 —UN—28JUN12
tool manufacturer’s instructions.

Continued on next page OUMX258,0000A72 -19-15SEP14-1/3

TM130419 (24FEB16) 20-10-13 030916

PN=53
 Engine Repair—3TNV80F

2. Measure valve seat width (A) after grinding.

A—Valve Seat Width

TCT006902 —UN—08APR13
OUMX258,0000A72 -19-15SEP14-2/3

3. If seat (A) is too wide after grinding, grind lower seat

surface (B) using a 70° seat grinder until seat width
is close to specifications.
Valve Grinding—Specification
Intake Valve Face
Margin—Width..................................................................0.99—1.29 mm
(0.039—0.051 in.)
Exhaust Valve Face
Margin—Width..................................................................0.95—1.25 mm
(0.037—0.049 in.)

TCT006903 —UN—08APR13
Valve Face
Margin—Width (Wear
Limit)........................................................................................... 0.50 mm
(0.020 in.)
Intake Valve Face
Angle—Angle......................................................................................30°
Exhaust Valve Face
Angle—Angle......................................................................................45°

4. Grind upper seat surface (C) using a 15°-seat grinder

A—Valve Seat Surface C—Upper Seat Angle
until seat width is narrowed to specification. B—Lower Seat Angle D—30° for Intake Seat, 45° for
Exhaust Seat
5. Dimension (D) is 30° for intake and 45° for exhaust
seat.
NOTE: If valve recession exceeds maximum specification, 7. Lap valves. (See Lap Valves—3TNV80F.)
replace cylinder head.

6. If valve seats are ground, measure valve recession

and check contact pattern between the seat and valve
with bluing dye.
OUMX258,0000A72 -19-15SEP14-3/3

TM130419 (24FEB16) 20-10-14 030916

PN=54
 Engine Repair—3TNV80F

Lap Valves—3TNV80F
NOTE: Use a rubber-type lapping tool for valves
without a lapping tool groove slit.
If seat does not make proper contact, lap

TCAL28398 —UN—28JUN12
the valve into the seat.

1. Apply small amount of fine lapping compound to face

of valve.
2. Turn valve to lap valve to seat.

OUMX068,00003F0 -19-25MAR13-1/2

TCAL28399 —UN—28JUN12
3. Lift valve from seat every 8 to 10 strokes. Lap until
a uniform ring appears around the surface (Y) of the
valve face.
4. Wash all parts in solvent to remove lapping compound.
Dry parts.
5. Check position of lap mark on valve face. Lap mark
must be on or near center of valve face.

Y—Valve Face Surface

OUMX068,00003F0 -19-25MAR13-2/2

Remove and Install Fuel Injection

Pump—3TNV80F
1. Park machine safely. See “Parking Safely” in the
Safety section.
2. Turn the fuel shutoff valve on the fuel filter and water
separator to the CLOSED (“C”) position.
3. Clean the injection pump lines and area around the

TCT005871 —UN—16NOV12
pump using a parts cleaning solvent or steam cleaner.
4. Remove the air cleaner assembly.
5. Slowly loosen fuel line connectors (A) at injection
pump to release pressure in the fuel system. When
loosening connectors, use a backup wrench to prevent
delivery valves (B) from turning.
6. Remove fuel line connector nuts at the injection pump
and the injectors. Remove injector lines. A—Injector Line Nuts (Pump E—Inlet Fuel Hose
End) F— Lubrication Line
7. Cover ends of injectors, delivery valves, and fuel lines B—Delivery Valves G—Banjo Bolt
with plastic caps to prevent dirt from entering system. C—Injector Line Nuts (Injector
End)
8. Disconnect the fuel inlet hose (E) and the return hose D—Return Fuel Hose
(D).
9. Remove the lubrication line (F) by removing the upper
(G) and lower banjo bolts.
Continued on next page OUMX068,00003D9 -19-16JUN14-1/3

TM130419 (24FEB16) 20-10-15 030916

PN=55
 Engine Repair—3TNV80F

10. Remove injection pump gear cover on front of timing

gear cover.
IMPORTANT: DO NOT loosen four cap screws
attaching gear to hub. This assembly times
the injection pump camshaft in relation to
the crankshaft for precise timing of EPA
engines. This procedure is done at the
pump manufacturing plant and CAN NOT
be duplicated in the field.

TCT005872 —UN—16NOV12
11. Rotate crankshaft and align timing marks (H).
12. Remove the nut (I) and using a puller, remove the
injection pump gear.
13. Do NOT loosen gear to hub bolts (J).

H—Timing Marks J— Gear to Hub Bolts (DO NOT

I— Injector Pump Camshaft LOOSEN)
Nut

Continued on next page OUMX068,00003D9 -19-16JUN14-2/3

TM130419 (24FEB16) 20-10-16 030916

PN=56
 Engine Repair—3TNV80F

14. Note the location of the injection pump timing mark (K)
as related to the timing gear housing timing marks (L).
The replacement pump must be installed in the exact
same location.
15. Remove the three mounting nuts (M) securing the
injection pump to the crankcase and remove the
injection pump.
Installation

CAUTION: DO NOT attempt to remove or

TCT005873 —UN—16NOV12
install the fuel injection pump unless you
are an EPA Authorized Diesel Service (ADS)
Center technician with authorization to service
fuel injection engines.

1. Install injection pump, aligning the timing mark to the

same mark on the timing gear housing as noted during
removal. Tighten nuts to specification. Injector Pump Timing Marks
Specification
Injector Pump Mounting K—Injector Pump Mark M—Nut
Nuts—Torque.................................................................. 22.5—28.4 N·m L— Timing Gear Housing
(17—21 lb.-ft.) Timing Marks

2. Align the timing gear marks and install injection pump

gear and lock nut and tighten to specification. 6. Install fuel lines at the injection pump and the injector
Specification nozzles and tighten the connector nuts to specification.
Fuel Injection Pump Drive When tightening connectors, use a backup wrench to
Gear Nut—Torque................................................................. 58—68 N·m prevent delivery valves from turning.
(43—50 lb.-ft.)
Specification
3. Install injection pump gear cover and tighten to Fuel Injection Line
specification. Nuts—Torque.................................................................. 29.4—34.4 N·m
(22—25 lb.-ft.)
Specification
Fuel Injection Gear Cover 7. Connect the fuel shutoff solenoid wire.
Cap Screws—Torque.................................................................... 11 N·m
(97 lb.-in.)
8. Install the air cleaner assembly.

4. Install the lubrication line and secure with banjo bolts. 9. Turn the fuel shutoff valve on the fuel filter and water
separator to the OPEN (“O”) position.
5. Install the fuel input hose and injector nozzle return
hose to the injection pump. 10. Bleed the fuel system.
OUMX068,00003D9 -19-16JUN14-3/3

TM130419 (24FEB16) 20-10-17 PN=57

030916
 Engine Repair—3TNV80F

Remove, Inspect, and Install Fuel Injection

Nozzle—3TNV80F
Special or Required Tools

TCAL28489 —UN—28JUN12
• JDF13 Nozzle Cleaning Kit
• Inspection Magnifier
Removal

CAUTION: Escaping fluid under pressure can

penetrate the skin causing serious injury.
Avoid the hazard by relieving pressure before
disconnecting hydraulic or other lines. Tighten
all connections before applying pressure. Search A—Fuel Line Connectors B—Backup Wrench
for leaks with a piece of cardboard. Protect hands
and body from high-pressure fluids.
may damage pump internally. Always use a
If an accident occurs, see a doctor immediately. backup wrench when removing lines.
Any fluid injected into the skin must be surgically
removed within a few hours or gangrene may 1. Clean the injection pump lines and area around the
result. Doctors unfamiliar with this type of pump using a parts cleaning solvent or steam cleaner
injury should reference a knowledgeable medical (cold engine).
source. Such information is available from Deere
& Company Medical Department in Moline, Illinois, NOTE: Nozzles are matched to the cylinders. If removing
U.S.A. Information may be obtained in the United more than one nozzle, tag each nozzle according
States and Canada only by calling 1-800-822-8262. to the cylinder from which it was removed.

IMPORTANT: Never steam clean or pour cold water 2. Loosen fuel line connectors (A) at injection pump to
on injection pump while the pump is running or release pressure in the fuel system. When loosening
engine is warm. Doing so can damage the pump. connectors, use a backup wrench (B) to prevent
delivery valves from turning.
When removing injection lines, Do not turn
pump delivery valve fittings. Turning fittings
OUMX258,0000BA8 -19-15SEP14-1/6

3. Remove fuel line nuts at injection nozzles (C) and

remove injection lines.

C—Fuel Line Nuts

TCAL28490 —UN—28JUN12

Continued on next page OUMX258,0000BA8 -19-15SEP14-2/6

TM130419 (24FEB16) 20-10-18 030916

PN=58
 Engine Repair—3TNV80F

4. Remove three nuts (D) and leak-off hoses (H) and

fittings (I).
5. Remove bronze washers (E) and O-rings (F).
6. Remove injection nozzle (G), washers (J), and heat
protector (K).
7. Test injection nozzles. (See Test Fuel Injection
Nozzle—3TNV80F.)
Installation
NOTE: Installation is done in the reverse order of removal.

TCAL28491 —UN—28JUN12
1. Replace heat protectors, washers, and O-rings.
2. Tighten injection nozzle body to specification.
Specification
Injection Nozzle
Body—Torque................................................................................50 N·m
(37 lb.-ft.)

3. Tighten leak-off fitting nut to specification.

Specification D—Nuts (3) H—Leak-Off Hoses
Leak-Off E—Bronze Washers I— Fittings
F— O-Rings J— Washers
Fitting—Torque..............................................................................40 N·m
G—Injection Nozzle K—Heat Protector
(30 lb.-ft.)

Repair
IMPORTANT: If injection nozzles are disassembled
to be cleaned, the same number and thickness
of shims must be installed.

NOTE: If servicing more than one nozzle, keep parts for

each nozzle separate from one another.

• Clean and inspect nozzle assembly. (See Cleaning and

Inspection procedure.)
• After assembly is complete, test injection nozzle. (See
Test Fuel Injection Nozzle—3TNV80F.)

TCAL28492 —UN—28JUN12
A—Injector Body E—Nozzle Fitting
B—Shims (as required) F— Nozzle Body
C—Spring G—Nozzle Valve
D—Spring Seat H—Separator Plate

Continued on next page OUMX258,0000BA8 -19-15SEP14-3/6

TM130419 (24FEB16) 20-10-19 030916

PN=59
 Engine Repair—3TNV80F

Injection Nozzle Cross Section

Cleaning and Inspection
NOTE: To clean nozzles properly, JDF13 Nozzle
Cleaning Kit is recommended. The cleaning
kit is available through the John Deere™
SERVICEGARD™ Catalog.

1. Remove anti-corrosive grease from new or

reconditioned nozzles by washing them thoroughly in
diesel fuel.
IMPORTANT: Never use a steel brush to clean nozzles,
as this will distort the spray hole.

2. Remove carbon from used nozzles, and clean by

washing in diesel fuel. If parts are coated with
hardened carbon or lacquer, it may be necessary to
use a brass wire brush (supplied in JDF13 Nozzle
Cleaning Kit).
3. After removing carbon or lacquer from the exterior of
nozzle, inspect sealing surfaces between separator
plate and nozzle body for nicks or scratches.
Specification
Separator
Plate—Contact Surface.............................................................. 0.10 mm
(0.0039 in.)

A—Injector Body E—Nozzle Fitting

B—Shims (as required) F— Nozzle Body
C—Spring G—Nozzle Valve
D—Spring Seat H—Separator Plate

TCAL28493 —UN—28JUN12
John Deere is a trademark of Deere & Company
SERVICEGARD is a trademark of Deere & Company
Continued on next page OUMX258,0000BA8 -19-15SEP14-4/6

TM130419 (24FEB16) 20-10-20 030916

PN=60
 Engine Repair—3TNV80F

4. Inspect condition of separator plate and nozzle body.

Contact area of separator plate (A) (both parts) must
not be scored or pitted. Use an inspection magnifier
(No. 16487 or equivalent) to aid in making the
inspection.
5. Check nozzle contact surface (B) on separator plate
for wear. If contact surface is more than the specified

TCAL28494 —UN—28JUN12
measurement, replace nozzle assembly.

A—Separator Plate B—Nozzle Body

OUMX258,0000BA8 -19-15SEP14-5/6

6. Inspect the piston (D) (large) part of nozzle valve

to see that it is not scratched or scored and that
lower (tip) end of valve is not broken. If any of these

TCAL28495 —UN—28JUN12
conditions are present, replace the nozzle assembly.
7. Further inspect the nozzle assembly by performing
a slide test.
• Dip the nozzle valve (C) in clean diesel fuel. Insert
valve in nozzle body (E).
• Hold nozzle vertical, and pull valve out about 1/3 of
its engaged length.
• Release valve. Valve should slide down to its seat
by its own weight. C—Nozzle Valve E—Nozzle Body
D—Piston
8. Replace nozzle assembly if the valve does not slide
freely to its seat.
OUMX258,0000BA8 -19-15SEP14-6/6

TM130419 (24FEB16) 20-10-21 030916

PN=61
 Engine Repair—3TNV80F

Remove and Install Fuel Shutoff

Solenoid—3TNV80F
Removal

TCAL28496 —UN—28JUN12
1. Park machine on level surface, park brake locked, key
switch in OFF position.
2. Clean around the fuel shutoff solenoid using a parts
cleaning solvent or steam cleaner.
3. Disconnect the electrical lead to the fuel shutoff
solenoid.
4. Disconnect electrical lead and remove fuel shutoff
solenoid. A—Solenoid Mounting Cap B—Solenoid
Screws
5. Remove the two solenoid mounting cap screws (A)
and remove solenoid (B) from governor housing.
6. Test fuel solenoid. (See Fuel Shutoff Solenoid Test, Install fuel shutoff solenoid. Installation is done in the
Non-T4.) reverse order of removal.
Installation
NOTE: Check condition of O-ring on solenoid
before installing.
OUMX258,0000BA9 -19-15SEP14-1/1

Remove and Install Electric Fuel

Pump—3TNV80F
NOTE: Mark hoses and note direction of “OUT” marking
on pump so replacement pump is installed correctly.

1. Disconnect wiring connector (A).

TCT006382 —UN—20FEB13
2. Use pliers to squeeze tabs on clamps (B) together and
slide clamps away from pump. Disconnect hoses
3. Remove bolts (C) and remove fuel pump.
Installation
1. Install fuel pump and secure with bolts.
2. Connect fuel hoses and secure with clamps.
A—Wiring Connector C—Bolts
3. Connect wiring. B—Hose Clamps

OUMX068,00003DF -19-25MAR13-1/1

TM130419 (24FEB16) 20-10-22 030916

PN=62
 Engine Repair—3TNV80F

Remove and Install Piston and Connecting

Rod—3TNV80F
Special or Required Tools

• Ridge Reamer
Removal
NOTE: The engine must be removed from the machine
to perform this procedure.

1. Remove the oil pan and oil pickup tube. (See Remove
and Install Oil Pan and Strainer—3TNV80F.)
2. Remove the cylinder head. (See Remove and Install
Cylinder Head and Valves—3TNV80F.)
3. Check the cylinder bore for ridges. These ridges can
cause damage to piston if ridge is not removed. If
necessary, remove any ridge from top of cylinder bore
using a ridge reamer.
4. Measure the connecting rod side play. (See Check
Connecting Rod Side Play—3TNV80F.)
5. Measure the crankshaft end play. (See Check
Crankshaft End Play—3TNV80F.)

TCT004701 —UN—25SEP12
6. Measure the connecting rod bearing clearance.
(See Check Connecting Rod Bearing
Clearance—3TNV80F.)
IMPORTANT: Keep the connecting rods and rod caps
together. Rods and caps are a matched set.
Note the alignment marks on each part.

7. Remove the rod cap screws (E), connecting rod cap

(C), and bearing inserts (B). A—Piston and Connecting Rod D—Connecting Rod Alignment
B—Bearing Inserts Mark
IMPORTANT: The pistons and cylinders are matched. C—Connecting Rod Cap E—Rod Cap Screws
Pistons must be installed in the cylinders
from which they were removed.

8. Note the connecting rod alignment mark (D) in relation 10. Disassemble and inspect all parts for wear or
to the cylinders. Start at the flywheel end with cylinder damage. (See Disassemble and Assemble Piston and
number one, then two, etc. Connecting Rod—3TNV80F.)

9. Push the piston and connecting rod (A) out of the 11. Inspect cylinder bore. (See Inspect Cylinder
cylinder bore using a wooden dowel. Bore—3TNV80F.)
Continued on next page OUMX258,0000A74 -19-15SEP14-1/2

TM130419 (24FEB16) 20-10-23 030916

PN=63
 Engine Repair—3TNV80F

Installation
1. Apply clean engine oil to all parts during installation.
2. Always replace the connecting rod cap screws. Do
not reuse the bolts.
3. Assemble the piston and connecting rod. (See
Disassemble and Assemble Piston and Connecting
Rod—3TNV80F.)
IMPORTANT: Pistons must be installed in the
cylinders from which they were removed and in
the same direction. Be careful not to damage the
crankshaft rod journals while installing pistons.

4. Install the piston and connecting rod into the cylinder

from which it was removed. The alignment mark (D)
on the connecting rod or the piston recess (A) on top
of piston should point toward the fuel injection pump.
IMPORTANT: Do not touch bearing insert surfaces.
Oil and acid from your finger will corrode
the bearing surface.

5. Install the bearing inserts to the connecting rod and

rod cap, aligning tangs (F) with grooves (E).
IMPORTANT: Connecting rod caps must be

TCT004702 —UN—25SEP12
installed on the same connecting rods
they were removed from.

6. Match the connecting rods to caps using alignment

marks (D). Install the rod caps.
7. Dip the entire connecting rod cap screws (G) in clean
engine oil. Install new cap screws and tighten to
specification.
A—Piston Recess E—Groove
Specification B—Fuel Injection Pump Side F— Tang
Connecting Rod Cap C—Flywheel Side G—Cap Screws
Screw—Torque...................................................................... 23—28 N·m D—Alignment Mark
(17—20 lb.-ft.)

8. If a new piston and connecting rod were installed,

stamp a number corresponding to the cylinder number 10. Install the oil pan and oil pickup tube. (See Remove
on the connecting rod and rod cap. and Install Oil Pan and Strainer—3TNV80F.)

9. Install the cylinder head. (See Remove and Install

Cylinder Head and Valves—3TNV80F.)
OUMX258,0000A74 -19-15SEP14-2/2

TM130419 (24FEB16) 20-10-24 030916

PN=64
 Engine Repair—3TNV80F

Disassemble and Assemble Piston and

Connecting Rod—3TNV80F
Disassembly
IMPORTANT: Pistons must be installed on the same
connecting rod they were removed from.

1. Put a mark on each piston and connecting rod to aid

in assembly.
2. Inspect all parts for wear or damage. Replace as
necessary.

A—Top Piston Ring E—Piston Pin

B—Middle Piston Ring F— Snap Ring
C—Oil Control Ring with G—Connecting Rod
Expander
D—Piston

TCT004703 —UN—25SEP12
Continued on next page OUMX068,00003F1 -19-19MAY14-1/4

TM130419 (24FEB16) 20-10-25 030916

PN=65
 Engine Repair—3TNV80F

Assembly
1. Apply clean engine oil to all parts during assembly.
IMPORTANT: The pistons must be installed on the
same connecting rod they were removed from.

2. Install piston pin bushing in connecting rod with oil

holes aligned.
3. Assemble the piston (A) to the connecting rod (G) with
piston recess (B) on the same side as the connecting
rod stamped mark (E). If a new connecting rod is
used, assemble the piston to the connecting rod with
piston recess opposite the connecting rod bearing
insert groove (F).
4. Install piston pin (C) and snap rings (D).

TCT004704 —UN—25SEP12
A—Piston E—Connecting Rod Stamped
B—Piston Recess Mark
C—Piston Pin F— Connecting Rod Bearing
D—Snap Rings Insert Groove
G—Connecting Rod

OUMX068,00003F1 -19-19MAY14-2/4

5. Install an oil ring expander (H) in the bottom ring

groove of the piston, with the ends (I) above either
end of the piston pin.
6. Install oil ring (J) over the expander with the ring gap
(K) opposite (180°) the expander ends.

TCAL28406 —UN—28JUN12
H—Oil Ring Expander J— Oil Ring
I— Ends K—Ring Gap

Continued on next page OUMX068,00003F1 -19-19MAY14-3/4

TM130419 (24FEB16) 20-10-26 030916

PN=66
 Engine Repair—3TNV80F

7. Install the middle piston ring (L), with the small

diameter of taper toward top of piston, in the middle
groove. Turn the ring until the middle piston ring gap
(P) is 120° away from the oil ring gap (O).
8. Install the top piston ring (chrome plated) (M), with the
manufacturer’s mark “R,” “T,” or “RN” (near the ring
gap) toward the top of the piston, in the top groove.
Turn the ring until the top piston ring gap (N) is 120°
away from the second ring gap (P).

L— Middle Piston Ring O—Oil Ring Gap

M—Top Piston Ring P—Middle Piston Ring Gap
N—Top Piston Ring Gap

TCT004705 —UN—25SEP12
OUMX068,00003F1 -19-19MAY14-4/4

TM130419 (24FEB16) 20-10-27 030916

PN=67
 Engine Repair—3TNV80F

Inspect Piston and Connecting

Rod—3TNV80F
Special or Required Tools

• Bushing, Bearing, and Seal Driver Set

Connecting Rod Bearing
1. Install the connecting rod cap and bearing inserts on
the connecting rod. Install the old connecting rod cap
screws and tighten to specification.
Specification

TCAL28408 —UN—28JUN12
Connecting Rod Cap
Screw—Torque...................................................................... 23—28 N·m
(17—20 lb.-ft.)

2. Measure the connecting rod bearing diameter.

Replace the bearing inserts if bearing diameter is not
within specification.
Specification
Connecting Rod
Bearings—ID............................................................41.982—42.002 mm
(1.653—1.654 in.) Specification
Connecting Rod
3. Measure the oil clearance between the bearing inserts Bearings—Oil
and the crankshaft, and verify that the clearance Clearance.....................................................................0.020—0.050 mm
is within specification. If the bearing oil clearance (0.0008—0.0020 in.)
exceeds the wear limit, grind the crankshaft connecting Connecting Rod Bearings
rod journals and install undersized bearing inserts, or (Wear Limit)—Oil
replace the bearing inserts and the crankshaft. Clearance..................................................................................0.110 mm
(0.0043 in.)

OUMX068,00003F2 -19-04FEB14-1/7

Piston Ring Groove

1. With the rings installed on the piston, measure the
piston ring groove side clearance. Measure at several
places around each piston.
2. Replace the rings or the piston if the clearances
exceed specification.

TCAL28409 —UN—28JUN12
Piston Ring Groove—Specification
Top Piston Ring
Groove—Side
Clearance.....................................................................0.080—0.120 mm
(0.0031—0.0047 in.)
Middle Piston Ring
Groove—Side
Clearance.....................................................................0.050—0.090 mm
(0.0020—0.0035 in.)
Middle Piston Ring Oil Control Ring Groove
Groove (Wear (Wear Limit)—Side
Limit)—Side Clearance............................................................ 0.285 mm Clearance................................................................................. 0.180 mm
(0.0112 in.) (0.0071 in.)
Oil Control Ring
Groove—Side
Clearance.....................................................................0.020—0.055 mm
(0.0008—0.0022 in.)
Continued on next page OUMX068,00003F2 -19-04FEB14-2/7

TM130419 (24FEB16) 20-10-28 PN=68

030916
 Engine Repair—3TNV80F

Piston Ring End Gap

1. Push ring into cylinder bore, using a piston, until ring
installed depth (B) is approximately 30 mm (1.18 in.)
from bottom of cylinder bore.
2. Measure piston ring end gap (A). If ring end gap
exceeds wear limit specifications, replace ring.
Piston Ring End Gap—Specification
Top Piston Ring—End
Gap...................................................................................0.15—0.30 mm
(0.0059—0.0118 in.)
Top Piston Ring (Wear
Limit)—End Gap......................................................................... 0.39 mm
(0.015 in.)
Middle Piston Ring—End
Gap...................................................................................0.18—0.33 mm
(0.0071—0.0130 in.)
Middle Piston Ring (Wear
Limit)—End Gap......................................................................... 0.42 mm

TCAL28410 —UN—28JUN12
(0.0165 in.)
Oil Control Ring—End
Gap...................................................................................0.20—0.45 mm
(0.0079—0.0177 in.)
Oil Control Ring (Wear
Limit)—End Gap......................................................................... 0.54 mm
(0.0213 in.)

A—Piston Ring End Gap B—30 mm (1.18 in.)

OUMX068,00003F2 -19-04FEB14-3/7

Piston Pin
Measure the piston pin diameter at six places. Replace
any pin that is not within specification.
Piston Pins—Specification
Piston Pin—OD..........................................................21.995—22.00 mm
(0.8659—0.866 in.)
Piston Pin (Wear
Limit)—OD.............................................................................. 21.965 mm
(0.8648 in.)

TCAL28411 —UN—28JUN12

Continued on next page OUMX068,00003F2 -19-04FEB14-4/7

TM130419 (24FEB16) 20-10-29 030916

PN=69
 Engine Repair—3TNV80F

Piston Pin Bore

1. Measure the pin bore diameter in the piston. If the
piston pin bore exceeds the wear limit, replace the
piston.

TCAL28412 —UN—28JUN12
2. If the piston pin-to-piston oil clearance (bore ID minus
pin OD) exceeds the wear limit specifications, replace
the piston, piston pin, or both.
Piston Pin Bores—Specification
Piston Pin Bore—ID.....................................................22.0—22.009 mm
(0.8661—0.8665 in.)
Piston Pin Bore (Wear
Limit)—ID............................................................................. 22.0039 mm
(0.8677 in.)
OUMX068,00003F2 -19-04FEB14-5/7

Piston Pin Bushing

NOTE: The piston pin bushing is a press fit. Replace
the bushing using a driver set. When installing
the bushing, make sure to align the oil hole in the
bushing with the hole in the connecting rod.

1. Measure the piston pin bushing diameter in the

connecting rod. If the bushing diameter exceeds the
wear limit specifications, replace bushing.
Piston Pin Bushings—Specification

TCAL28413 —UN—28JUN12
Piston Pin Bushing—ID............................................22.025—22.038 mm
(0.8671—0.8676 in.)
Piston Pin Bushing (Wear
Limit)—ID............................................................................... 22.068 mm
(0.8688 in.)

2. If piston pin-to-rod bore oil clearance (bushing ID

minus pin OD) exceeds specification, replace the
bushing or the piston pin.
Piston Pin-to-Rod
Piston Pin Bushings—Specification
Bore (Wear Limit)—Oil
Piston Pin Bushing—Oil
Clearance................................................................................. 0.105 mm
Clearance.....................................................................0.025—0.043 mm
(0.0041 in.)
(0.001—0.0017 in.)
Continued on next page OUMX068,00003F2 -19-04FEB14-6/7

TM130419 (24FEB16) 20-10-30 PN=70

030916
 Engine Repair—3TNV80F

Piston Diameter
NOTE: If the engine has had a previous major overhaul,
oversize pistons and rings may have been
installed. Pistons and rings are available in
0.25 mm (0.010 in.) oversize.

TCAL28414 —UN—28JUN12
Measure the piston diameter perpendicular to the piston
pin bore at distance (A). If the piston diameter is less than
the wear limit specifications, install a new piston.
Pistons—Specification
Standard Size
Piston—OD..............................................................79.962—79.972 mm
(3.148—3.1485 in.)
Standard Size Piston
(Wear Limit)—OD..................................................................... 79.91 mm
(3.146 in.)

A—5 mm (0.197 in.)

TCAL28415 —UN—28JUN12
OUMX068,00003F2 -19-04FEB14-7/7

Check Connecting Rod Side Play—3TNV80F

Procedure
1. Remove crankshaft from cylinder block. (See Remove
and Install Crankshaft and Main Bearings—3TNV80F.)
2. Install connecting rod on crankshaft. Tighten
connecting rod cap screws to specification.

TCAL28416 —UN—28JUN12
Specification
Connecting Rod Cap
Screw—Torque...................................................................... 23—28 N·m
(17—20 lb.-ft.)

3. Measure connecting rod side play using a feeler

gage (A). Replace connecting rod and crankshaft, as
necessary, if side play exceeds specification.
Specification
Connecting Rod—Side A—Feeler Gage
Play..................................................................................0.20—0.40 mm
(0.008—0.016 in.)

OUMX258,0000A75 -19-15SEP14-1/1

TM130419 (24FEB16) 20-10-31 030916

PN=71
 Engine Repair—3TNV80F

Check Connecting Rod Bearing

Clearance—3TNV80F
Reason
To measure oil clearance between connecting rod bearing

TCAL28417 —UN—28JUN12
and crankshaft journal.
Special or Required Tools

• Plastigage® Bearing Clearance Measurement Tool (or

equivalent)
Procedure
IMPORTANT: Connecting rod caps must be installed
on the same connecting rod and in the A—Plastigage®
same direction to prevent crankshaft and
connecting rod damage.
NOTE: Lightly lubricate bolts with engine oil
1. Remove connecting rod cap. before installing.
2. Wipe oil from bearing insert and crankshaft journal.
5. Install connecting rod end cap and original cap screws.
3. Put a piece of Plastigage® (A), or an equivalent, along Tighten cap screws to specification.
the full width of the bearing insert, approximately 6
Specification
mm (0.250 in.) off center.
Connecting Rod Cap
4. Turn crankshaft approximately 30° from bottom dead Screw—Torque...................................................................... 23—28 N·m
center. (17—20 lb.-ft.)

IMPORTANT: Rotating the crankshaft will cause 6. Remove cap screws and connecting rod cap.
Plastigage® to smear, resulting in a false
reading. Do not allow crankshaft to rotate
after installing bearing cap.
Plastigage is a trademark of Perfect Circle Corporation
OUMX068,00003C4 -19-04FEB14-1/2

NOTE: The flattened Plastigage® is found on either the

bearing insert or the crankshaft journal.

7. Use the graduation marks on the envelope to compare

the width of the flattened Plastigage® (B) at its widest

TCAL28418 —UN—28JUN12
point.
8. Determine bearing clearance. The number within the
graduation marks indicates the bearing clearance in
inches or millimeters, depending on which side of the
envelope is used.
Specification
Connecting Rod-to-
Crankshaft Journal—Oil
Clearance.....................................................................0.020—0.050 mm B—Flattened Plastigage®
(0.0008—0.0020 in.)
Connecting Rod-to-
Crankshaft Journal (Wear
Results
Limit)—Oil Clearance................................................................0.110 mm
(0.0043 in.) If clearance exceeds specification, replace bearing inserts.
®
9. Remove Plastigage .
OUMX068,00003C4 -19-04FEB14-2/2

TM130419 (24FEB16) 20-10-32 PN=72

030916
 Engine Repair—3TNV80F

Inspect Cylinder Bore—3TNV80F

Special or Required Tools

• Flex Hone (with 180-Grit Stone)

• Rigid Hone (with 300-Grit Stone)
• Drill Press
Cylinder Bore Diameter
NOTE: If engine has had a previous major overhaul,
the cylinders may have been bored oversize.
Pistons and rings are available in 0.25 mm
(0.010 in.) oversize.

NOTE: Slightly uneven wear, flaws, or minor damage

can be corrected by deglazing.

1. Measure cylinder bore diameter at three positions:

top (A), middle (B), and bottom (C). At these three

TCAL28419 —UN—28JUN12
positions, measure in both directions: along crankshaft
centerline (D) and direction of crankshaft rotation (E).
2. If cylinder bore inner diameter exceeds wear limit, have
cylinder rebored. (See Reboring within this Group.)
3. If cylinder is rebored, oversize pistons and rings must
be installed.
4. If cylinder bore exceeds oversize bore inner diameter,
replace the cylinder block. A—Top D—Crankshaft Centerline
B—Middle E—Direction of Crankshaft
Cylinder Bore Diameter—Specification
C—Bottom Rotation
Standard Cylinder
Bore—ID.......................................................................80.00—80.03 mm
(3.150—3.151 in.)
Standard Cylinder Bore 5. If clearance (cylinder bore ID minus piston OD)
—ID (Wear Limit)...................................................................... 80.20 mm exceeds specification, replace cylinder block, piston,
(3.157 in.) or both, or rebore cylinder and install oversize pistons
Oversize Cylinder and rings.
Bore—ID.......................................................................80.25—80.28 mm
(3.159—3.161 in.)
Oversize Cylinder
Bore—ID (Wear Limit).............................................................. 80.45 mm
(3.167 in.)
Continued on next page OUMX258,0000A76 -19-15SEP14-1/3

TM130419 (24FEB16) 20-10-33 030916

PN=73
 Engine Repair—3TNV80F

Deglazing
IMPORTANT: If cylinder bores are to be deglazed with
crankshaft installed in engine, put clean shop
towels over crankshaft to protect journal and
bearing surfaces from any abrasives.

TCAL28420 —UN—28JUN12
1. Deglaze cylinder bores using a flex hone with 180-grit
stone.
2. Use flex hone as instructed by manufacturer to obtain
a 30-40° crosshatch pattern as shown.
IMPORTANT: Do not use gasoline, kerosene,
or commercial solvents to clean cylinder
bores. Solvents will not remove all abrasives
from cylinder walls. white rags and warm soapy water. Continue to clean
cylinder until white rags show no discoloration.
3. Remove excess abrasive residue from cylinder walls
using a clean dry rag. Clean cylinder walls using clean
OUMX258,0000A76 -19-15SEP14-2/3

Reboring
NOTE: The cylinder block can be rebored to use oversize
pistons and rings. Pistons and rings are available
in 0.25 mm (0.010 in.) oversize.

1. Align center of bore to drill press center.

IMPORTANT: Check stone for wear or damage. Use
a rigid hone with 300-grit stone.

2. Adjust rigid hone so lower end is even with lower end

of cylinder bore.
3. Adjust rigid hone stones until they contact narrowest

TCAL28421 —UN—28JUN12
point of cylinder.
4. Coat cylinder with honing oil. Rigid hone should turn
by hand. Adjust if too tight.
5. Run drill press at about 250 rpm. Move rigid hone up
and down in order to obtain a 30—40° crosshatch
pattern.
NOTE: Measure bore when cylinder is cool.
IMPORTANT: Do not use solvents to clean cylinder
6. Stop press and check cylinder diameter. bore. Solvents will not remove all metal particles
NOTE: Finish should not be smooth. It should have and abrasives produced during honing.
a 30-40° crosshatch pattern.
10. Clean cylinder thoroughly using warm soapy water
7. Remove rigid hone when cylinder is within 0.03 mm until clean white rags show no discoloration.
(0.001 in.) of desired size. 11. Dry the cylinder and apply engine oil.
8. Use a flex hone with 180-grit stone for honing to final
size.
9. Check the bore for taper and out-of-round.
(See Inspect Cylinder Bore Taper and
Out-of-Round—3TNV80F.)
OUMX258,0000A76 -19-15SEP14-3/3

TM130419 (24FEB16) 20-10-34 030916

PN=74
 Engine Repair—3TNV80F

Inspect Cylinder Bore Taper and

8. Compare results of measurements from steps 2, 3, 4,
Out-of-Round—3TNV80F and 5 to find out whether the bore has worn tapered.
1. Use a cylinder dial gauge and inside micrometer, or a Cylinder Bore Roundness—Specification
telescope gauge and outside micrometer, to measure Piston-to-Cylinder
cylinder bore. Bore—Clearance..........................................................0.040—0.060 mm
(0.001—0.002 in.)
2. Measure the bore parallel to the crankshaft at the top
Cylinder—Roundness......................................................0.00—0.01 mm
end of the ring travel zone.
(0.0000—0.0004 in.)
3. Measure the bore in the same position at the bottom Cylinder (Wear
end of the ring travel zone. Limit)—Roundness..................................................................... 0.03 mm
(0.001 in.)
4. Measure the bore at right angles to the crankshaft at Cylinder—Taper................................................................0.00—0.01 mm
the top end of the ring travel zone. (0.0000—0.0004 in.)
5. Measure the bore in the same position at the bottom Cylinder (Wear
end of the ring travel zone. Limit)—Taper.............................................................................. 0.03 mm
(0.001 in.)
6. Compare measurements from steps 2 and 4 to find
the out-of-round wear at the top end of the bore.
7. Compare measurements from steps 3 and 5 to find
the out-of-round wear at the bottom end of the bore.
OUMX068,00003F3 -19-04FEB14-1/1

Replace Crankshaft Rear Oil Seal—3TNV80F

Special or Required Tools

• Hoist
• Lifting Bracket (2 used)
• Bushing, Bearing, and Seal Driver Set
Rear Oil Seal
IMPORTANT: Flywheel is heavy! Do not remove

TCAL28422 —UN—28JUN12
flywheel mounting cap screws unless flywheel
is secure. Use a hoist and lifting brackets
to lift flywheel from crankshaft.

NOTE: Engine removal is not necessary to

replace rear oil seal.

1. Remove flywheel. (See Remove and Install

Flywheel—3TNV80F.)
NOTE: It is not necessary to remove oil seal case A—Oil Seal B—Oil Seal Case
(B) to remove oil seal (A).

2. Carefully pry oil seal (A) from oil seal case (B). 3. Replace oil seal using a driver set. Install seal with lip
toward cylinder block. Install seal flush with surface
NOTE: Oil seal is normally installed flush with surface of oil seal case.
of oil seal case. If oil seal has worn a groove in
crankshaft at oil seal contact point, seal can be
installed 3 mm (0.120 in.) deeper into oil seal case.
Continued on next page OUMX258,0000B9F -19-15SEP14-1/2

TM130419 (24FEB16) 20-10-35 PN=75

030916
 Engine Repair—3TNV80F

Rear Oil Seal Case

NOTE: It is not necessary to remove oil seal case to
remove oil seal. It is not necessary to remove
oil seal to remove oil seal case.

1. Remove oil seal case-to-cylinder block cap screws (C).

2. Pry oil seal case (D) from engine block.
3. Clean all old gasket material from oil seal case and
engine block.

TCAL28423 —UN—28JUN12
4. Apply PM37465 Ultra-Blue RTV Form-in-Place Gasket
to seal case-to-engine block mating surfaces. Install
seal case.
5. Install new oil seal after oil seal case is installed.
6. Install flywheel onto crankshaft, aligning crankshaft
pin into flywheel mounting flange. Tighten mounting
cap screws to specification.
Specification
Flywheel Mounting Cap C—Oil Seal Case-to-Cylinder D—Oil Seal Case
Block Cap Screws
Screw—Torque...................................................................... 83—88 N·m
(62—65 lb.-ft.)

7. Install flex plate with longer center hub facing out.

8. Install drive shaft.
OUMX258,0000B9F -19-15SEP14-2/2

Replace Crankshaft Front Oil Seal—3TNV80F

Special or Required Tools

• Pulley Puller
• Bushing, Bearing, and Seal Driver Set
Procedure

TCAL28424 —UN—28JUN12
1. Park machine with engine off and park brake on.
2. Remove alternator belt.
3. Remove crankshaft sheave cap screw. Install puller to
crankshaft sheave and remove sheave.

Continued on next page OUMX258,0000BA0 -19-15SEP14-1/2

TM130419 (24FEB16) 20-10-36 030916

PN=76
 Engine Repair—3TNV80F

4. Carefully pry oil seal (B) from timing gear cover.

5. Install new oil seal using a bushing, bearing, and seal
driver set. Install seal with lip toward engine. Install
seal flush with surface of cover.
6. Coat lip of seal with clean engine oil.
7. Install crankshaft sheave on crankshaft, lining up pin
(A) on crankshaft timing gear with hole in crankshaft
sheave.

TCAL28425 —UN—28JUN12
8. Install flat washer and cap screw. Tighten cap screw
to specification.
Specification
Crankshaft Sheave Cap
Screw—Torque..............................................................................88 N·m
(65 lb.-ft.)

9. Install alternator belt and adjust belt. (See Check and

Adjust Alternator Drive Belt Tension—3TNV80F.)
A—Pin B—Oil Seal

OUMX258,0000BA0 -19-15SEP14-2/2

TM130419 (24FEB16) 20-10-37 030916

PN=77
 Engine Repair—3TNV80F

Remove and Install Crankshaft and Main

Bearings—3TNV80F
Special or Required Tools

• Knife-Edge Puller
• Press
• Dial Indicator
• V-Block (2 used)
Removal
1. Check crankshaft end play. (See Check Crankshaft
End Play—3TNV80F.)

TCAL28426 —UN—28JUN12
2. Remove flywheel. (See Remove and Install
Flywheel—3TNV80F.)
3. Remove rear oil seal case. (See Replace Crankshaft
Rear Oil Seal—3TNV80F.)
4. Remove timing gear cover, timing gears, timing gear
housing, and flywheel of engine.
Arrow Points to Front of Engine
5. Check crankshaft bearing clearance. (See Check
Crankshaft Main Bearing Clearance—3TNV80F.)
A—Crankshaft D—Main Bearing Cap Screws
IMPORTANT: Connecting rod end caps must be B—Block Thrust Bearings E—Caps
C—Main Bearing Inserts F— Cap Thrust Bearings
installed on the same connecting rods from
which they were removed. Note alignment
marks on caps and rods.
NOTE: Main bearing caps have raised arrows that
6. Remove connecting rod cap screws and end caps. are stamped with numbers. Both correspond to
Push pistons and connecting rods away from their location on the engine block. The number
crankshaft. “1” main bearing bore is at flywheel end. Install
bearing caps beginning with number 1, then 2,
IMPORTANT: Main bearing caps must be installed etc. The main bearing cap at gear train end does
on the same main bearings from which not have a number. Also install bearing caps with
they were removed. the arrow toward the flywheel end.
7. Remove main bearing cap screws (D), caps (E), and 4. Install crankshaft.
cap thrust bearings (F).
5. Install smooth bearing inserts in main bearing caps,
8. Remove crankshaft (A). aligning tangs with slots in caps.
9. Remove block thrust bearings (B) and main bearing 6. Install cap thrust bearings with oil grooves facing away
inserts (C). from cap, in the number “1” main bearing cap.
10. Inspect all parts for wear or damage. (See 7. Install main bearing caps in their original locations with
Inspection/Replacement procedures within this arrows pointing toward flywheel side of engine.
Group.)
IMPORTANT: Do not use high-speed power tools or air
Installation wrenches to tighten main bearing cap screws.
1. Apply clean engine oil on all parts during installation.
8. Dip entire main bearing cap screws in clean engine
IMPORTANT: Do not touch bearing insert surfaces. oil. Install cap screws and tighten. Do not tighten to
Oil and acid from your finger will corrode specification at this time.
the bearing surfaces.
9. Using a soft-faced hammer, tap the front end of the
2. Install bearing inserts drilled with oil passage in cylinder crankshaft and then the rear end of the crankshaft to
block bearing bores, aligning tangs with slots in bores. align the thrust bearings.

3. Install block thrust bearings with oil grooves facing

away from engine block.

Continued on next page OUMX258,0000BA5 -19-27MAR13-1/2

TM130419 (24FEB16) 20-10-38 030916

PN=78
 Engine Repair—3TNV80F

10. Tighten main bearing cap screws to specification. Specification

When tightening, start at center main bearing cap Connecting Rod Cap
and work your way out, alternating to the ends. Screw—Torque.............................................. 23—28 N·m (17—20 lb.-ft.)
Turn crankshaft by hand. If it does not turn easily,
disassemble the parts and find the cause. 13. Install the rear oil seal. (See Replace Crankshaft Rear
Oil Seal—3TNV80F.)
Specification
Main Bearing Cap 14. Install the flywheel. (See Remove and Install
Screw—Torque.............................................. 79—83 N·m (58—61 lb.-ft.) Flywheel—3TNV80F.)
IMPORTANT: The connecting rod caps must be 15. Install the timing gear cover. (See Remove and Install
installed on the same connecting rods from Timing Gear Cover—3TNV80F.)
which they were removed. Never reuse
16. Install the front oil seal. (See Replace Crankshaft
connecting rod cap screws. Replace with new.
Front Oil Seal—3TNV80F.)
11. Match the connecting rod caps to the rods using 17. Install the oil pan. (See Remove and Install Oil Pan
alignment marks. Install the caps to the rods. and Strainer—3TNV80F.)
12. Dip entire connecting rod cap screws in clean engine
oil. Install new cap screws to the rods, and tighten
to specification.
OUMX258,0000BA5 -19-27MAR13-2/2

Inspect Crankshaft and Main

Bearings—3TNV80F
1. Inspect crankshaft gear for chipped or broken teeth.
If replacement is necessary, remove gear from
crankshaft using a knife-edge puller and a press.

TCAL28427 —UN—28JUN12
CAUTION: Do not heat oil over 182°C (360°F). Oil
fumes or oil can ignite above 193°C (380°F). Use
a thermometer. Do not allow a flame or heating
element to come in direct contact with the oil.
Heat the oil in a well-ventilated area. Plan a safe
handling procedure to avoid burns.

2. Heat gear to approximately 150°C (300°F). Install gear

(F) with timing mark (G) toward press table.
3. Align slot in gear with key in shaft. Press crankshaft F— Gear G—Timing Mark
into gear until gear is tight against crankshaft shoulder.
Continued on next page OUMX068,00003C9 -19-04FEB14-1/4

TM130419 (24FEB16) 20-10-39 PN=79

030916
 Engine Repair—3TNV80F

4. Inspect crankshaft for bend using V-blocks (I) and a

dial indicator (H). Turn crankshaft slowly and read

TCAL28428 —UN—28JUN12
variation on indicator. If variation is greater than
specification, replace crankshaft.
Specification
Crankshaft—Bend
(Maximum)................................................................................. 0.02 mm
(0.0008 in.)

H—Dial Indicator I— V-blocks

TCAL28429 —UN—28JUN12
OUMX068,00003C9 -19-04FEB14-2/4

NOTE: If engine has had a previous major overhaul,

journals may have been ground and undersize
bearing inserts installed.

TCAL28430 —UN—28JUN12
5. Measure crankshaft connecting rod journals (K) and
main bearing journal (J) diameters. Measure several
places around each journal.
Crankshaft and Main Bearings—Specification
Crankshaft Connecting
Rod Journal—OD.....................................................41.952—41.962 mm
(1.8485—1.8488 in.)
Crankshaft Connecting
Rod Journal (Wear J— Main Bearing Journal K—Connecting Rod Journals
Limit)—OD.............................................................................. 41.902 mm
(1.650 in.)
Crankshaft Main Bearing
8. Install bearing inserts and main bearing cap on
Journal—OD.............................................................46.952—46.962 mm
main bearing. Tighten main bearing cap screws to
(1.848—1.8489 in.)
specification.
Crankshaft Main
Bearing Journal (Wear Specification
Limit)—OD.............................................................................. 46.902 mm Main Bearing Cap
(1.8465 in.) Screw—Torque...................................................................... 76—82 N·m
(56—60 lb.-ft.)
6. If journal diameter is less than wear limit, replace
crankshaft or have journals ground undersize by a
qualified machine shop.
7. If journals are ground, undersize bearing inserts must
be installed. Bearing inserts are available in 0.25 mm
(0.010 in.) undersize.
Continued on next page OUMX068,00003C9 -19-04FEB14-3/4

TM130419 (24FEB16) 20-10-40 PN=80

030916
 Engine Repair—3TNV80F

9. Measure main bearing diameter.

10. Subtract the crankshaft main bearing journal outer
diameter from the main bearing inner diameter to
obtain the main bearing oil clearance.

TCAL28431 —UN—28JUN12
• If crankshaft is within specification but main bearing
oil clearance exceeds the wear limit, replace the
bearing inserts.
• If crankshaft is not within specification, have
crankshaft journals ground undersize by a qualified
machine shop and install undersize bearing inserts.
• If crankshaft is worn past the wear limit, replace the
crankshaft.
Crankshaft and Main Bearings—Specification 11. Clean and inspect oil passages in main bearing
Main Bearing—Oil journals, connecting rod journals, and main bearing
Clearance.....................................................................0.020—0.050 mm bores in cylinder block.
(0.001—0.002 in.)
Main Bearing (Wear 12. Inspect crankshaft for cracks or damage. Replace if
Limit)—Oil Clearance................................................................. 0.12 mm necessary.
(0.005 in.)
OUMX068,00003C9 -19-04FEB14-4/4

Check Crankshaft Main Bearing

Clearance—3TNV80F
Reason

TCAL28432 —UN—28JUN12
To measure oil clearance between main bearing and
crankshaft journal.
Special or Required Tools

• Plastigage®
Procedure
NOTE: The engine must be removed from the
tractor to perform this test.
A—Plastigage® Placement
1. Remove the oil pan, oil pick-up, crankcase extension,
and balancer assembly.
reading. Do not allow crankshaft to rotate
IMPORTANT: Main bearing caps must be installed to after installing bearing cap.
the same location and in the same direction to
prevent crankshaft and main bearing damage. NOTE: Lightly lubricate bolts with engine oil
before installing.
2. Remove the main bearing cap.
5. Install main bearing cap and bolts. Tighten bolts to
3. Wipe oil from the bearing insert and the crankshaft specification.
journal.
Specification
4. Put a piece of Plastigage® (A), or equivalent, along the Main Bearing Cap
full width of the bearing insert approximately 6 mm Screw—Torque...................................................................... 76—82 N·m
(0.25 in.) off center. (56—60 lb.-ft.)
IMPORTANT: Rotating the crankshaft will cause 6. Remove bolts and main bearing cap.
Plastigage® to smear, resulting in a false
Plastigage is a trademark of Perfect Circle Corporation
Continued on next page OUMX068,00003CA -19-04FEB14-1/2

TM130419 (24FEB16) 20-10-41 PN=81

030916
 Engine Repair—3TNV80F

NOTE: The flattened Plastigage® will be found on either

the bearing insert or crankshaft journal.

7. Use the graduation marks on the envelope (B) to

compare the width of the flattened Plastigage® (C) at its

TCAL28433 —UN—28JUN12
widest point. The number within the graduation marks
indicates the bearing clearance in inches or millimeters
depending on which side of the envelope is used.
8. Main bearing clearance must be to specification.
Specification
Main Bearing-to-
Crankshaft Journal—Oil
Clearance.....................................................................0.020—0.050 mm
(0.001—0.002 in.) B—Graduation Marks C—Flattened Plastigage®
Main Bearing (Wear
Limit)—Oil Clearance............................................................... 0.120 mm
(0.005 in.)
Results
9. Remove Plastigage®.
If the clearance exceeds maximum specification, replace
the bearing inserts.
OUMX068,00003CA -19-04FEB14-2/2

Check Crankshaft End Play—3TNV80F

Reason
To determine proper side clearance between the
crankshaft and the engine block.
Special or Required Tools

• Dial Indicator

TCAL28434 —UN—28JUN12
Procedure
1. Fasten the dial indicator (A) to engine and position
indicator tip on end of crankshaft (B).
IMPORTANT: Do not use excessive force when
moving crankshaft to avoid damaging bearings.

2. Push the crankshaft toward rear as far as possible.

3. Zero the dial indicator. A—Dial Indicator B—Crankshaft

4. Using a bar, gently pry the crankshaft as far forward

as possible. Crankshaft (Wear
Results Limit)—End Play (Wear
Limit)........................................................................................... 0.28 mm
• If the end play exceeds specification, replace the thrust (0.0110 in.)
bearings.
Specification
Crankshaft—End Play..................................................0.133—0.228 mm
(0.0052—0.0090 in.)
OUMX068,00003CB -19-04FEB14-1/1

TM130419 (24FEB16) 20-10-42 PN=82

030916
 Engine Repair—3TNV80F

Remove and Install Flywheel—3TNV80F

Removeand Install
1. Flywheel can be removed without removing engine
from machine. If removing flywheel in machine (See
Remove and Install Engine Driveshaft.)

TCAL28435 —UN—28JUN12
2. Remove eight cap screws (A) and flex plate (B).

A—Cap Screws (8) B—Flex Plate

OUMX258,0000BCC -19-17SEP14-1/2

IMPORTANT: Always install new flywheel

mounting cap screws.

3. Remove the flywheel mounting cap screws (C) and

remove the flywheel (D) from crankshaft.

TCAL28436 —UN—28JUN12
4. Use pin (E) in crankshaft to correctly locate the
flywheel on the crankshaft.
5. Install the flywheel. Apply lubrication oil to the
mounting cap screws and tighten to specification.
Specification
Flywheel Mounting Cap
Screw—Torque...................................................................... 83—88 N·m
(62—65 lb.-ft.)
C—Mounting Cap Screws E—Pin
6. Install flex plate with raised hub facing away from D—Flywheel
flywheel.
7. Install cap screws and tighten to specification. Flywheel—Out-of-Flat
Specification (Maximum)................................................................................. 0.02 mm
Flywheel Mounting Cap (0.001 in.)
Screw—Torque...................................................................... 83—88 N·m
(62—65 lb.-ft.)
OUMX258,0000BCC -19-17SEP14-2/2

TM130419 (24FEB16) 20-10-43 PN=83

030916
 Engine Repair—3TNV80F

Remove and Install Camshaft—3TNV80F

IMPORTANT: Always replace camshaft followers
when installing a new camshaft. Always replace
camshaft when replacing camshaft followers.
The components wear as a set and replacing
only one will accelerate the wear of the other.

Special or Required Tools

TCAL28445 —UN—28JUN12
• D15001NU Magnetic Follower Holder Kit
• Knife-Edge Puller
• Arbor Press
• V-Block (2 used)
• Dial Indicator
• Micrometer
• Bushing Driver Set Arrows Indicate Direction of Rotation (Viewed from Gear Case)

Removal
A—Idler Gear D—Crankshaft Gear
1. Remove engine. B—Timing Marks E—Oil Pump Gear
C—Camshaft Gear F— Fuel Injection Drive Gear
2. Remove rocker arm assembly and push
rods. (See Remove and Install Rocker Arm
Cover—3TNV80F and Remove and Install Rocker
Arm Assembly—3TNV80F.) NOTE: Apply clean engine oil on all parts during
installation.
3. Remove timing gear cover. (See Remove and Install
Timing Gear Cover—3TNV80F.) The fuel injection drive gear, camshaft gear, and
crankshaft gear all must be correctly timed to the
4. Check camshaft end play. (See Check Camshaft End idler gear. It is not necessary to time the oil pump
Play—3TNV80F.) gear. Due to the odd number of teeth on the idler
gear, timing marks will only align periodically. (See
5. Check backlash of timing gears. (See Check Timing Check Timing Gear Backlash—3TNV80F.)
Gear Backlash—3TNV80F.)
NOTE: If camshaft is being removed with cylinder head 1. Rotate the crankshaft to align the timing marks.
installed, use a magnetic follower holder tool, 2. Install the camshaft.
or turn engine until oil pan is upward, to hold
cam followers away from camshaft. 3. Install the thrust plate and cap screws. Tighten to
specification.
6. Hold cam followers away from camshaft using a Specification
magnetic follower holder kit such as D15001NU. Camshaft Thrust Plate
7. Rotate the crankshaft and align the timing marks. Cap Screw—Torque...................................................................... 11 N·m
(96 lb.-in.)
IMPORTANT: Do not allow camshaft lobes to hit
bearing surfaces while removing camshaft. 4. Install timing gear cover. (See Remove and Install
Machined surfaces can be damaged. Timing Gear Cover—3TNV80F.)
5. If cam followers were removed, replace into same
8. Remove two thrust plate mounting cap screws, the holes as removed.
thrust plate, and the camshaft.
6. Install push rods and rocker arm assembly.
9. Inspect all parts for wear or damage. (See Inspect (See Remove and Install Rocker Arm
Camshaft—3TNV80F.) Assembly—3TNV80F and Remove and Install
Installation Rocker Arm Cover—3TNV80F.)

IMPORTANT: Do not allow camshaft lobes to hit

bearing surfaces while installing camshaft.
Machined surfaces can be damaged.
OUMX258,0000BBF -19-15SEP14-1/1

TM130419 (24FEB16) 20-10-44 PN=84

030916
 Engine Repair—3TNV80F

Inspect Camshaft—3TNV80F
Special or Required Tools
• D15001NU Magnetic Follower Holder Kit
• Knife-Edge Puller
• Arbor Press
• V-Block (2 used)
• Dial Indicator

TCAL28437 —UN—28JUN12
• Micrometer
• Bushing Driver Set
1. Inspect camshaft for bend by using a pair of V-blocks
(B) and a dial indicator (A). Turn camshaft slowly and
read variation of camshaft bearing journals (C) on
indicator. If variation is greater than wear limit, replace
camshaft.
Camshaft—Specification
Camshaft—Bend..............................................................0.00—0.02 mm
(0.00—0.0008 in.)
Camshaft (Wear
Limit)—Bend............................................................................... 0.05 mm
(0.002 in.)

TCAL28438 —UN—28JUN12
A—V-blocks C—Camshaft Bearing Journals
B—Dial Indicator

OUMX068,00003F5 -19-16JUN14-1/5

2. Measure camshaft lobe height (D) using a micrometer.

If lobe height is less than wear limit, or if there are
chips or scratches in lobes or bearing journals, replace

TCAL28439 —UN—28JUN12
camshaft.
Camshaft—Specification
Camshaft Lobe—Height...........................................34.535—34.665 mm
(1.3596—1.3647 in.)
Camshaft Lobe (Wear
Limit)—Height........................................................................... 34.29 mm
(1.35 in.)

D—Camshaft Lobe Height

Continued on next page OUMX068,00003F5 -19-16JUN14-2/5

TM130419 (24FEB16) 20-10-45 030916

PN=85
 Engine Repair—3TNV80F

3. Measure camshaft end journal (E) and intermediate

journal (F) outside diameters. If journal diameters are
less than wear limit, replace camshaft.
Camshaft Journals—Specification
Intermediate

TCAL28440 —UN—28JUN12
Journal—OD.............................................................39.910—39.935 mm
(1.571—1.572 in.)
Intermediate Journal
(Wear Limit)—OD................................................................... 39.875 mm
(1.569 in.)
Gear Housing
and Flywheel End
Journals—OD...........................................................39.940—39.960 mm
(1.572—1.573 in.)
Gear Housing and
Flywheel End Journals
(Wear Limit)—OD................................................................... 39.905 mm
(1.571 in.)

TCAL28441 —UN—28JUN12
E—Camshaft End Journal F— Intermediate Journal

OUMX068,00003F5 -19-16JUN14-3/5

4. Measure camshaft bushing diameter (G) at gear

housing end. If bushing diameter exceeds wear limit,
replace bushing using a driver set.
a. Align oil holes (H) in new bushing and cylinder block.
b. Install bushing flush with surface of idler gear.

TCAL28442 —UN—28JUN12
5. If bushing oil clearance (bushing ID minus camshaft
journal OD) exceeds specification, replace bushing,
camshaft, or both.
Camshaft Gear End—Specification
Camshaft
Bushing—Gear
End—ID...........................................................................40—40.025 mm
(1.5748—1.5758 in.)
G—Camshaft Bushing H—Oil Holes
Camshaft
Diameter
Bushing—Gear End
(Wear Limit)—ID..................................................................... 40.150 mm
(1.5807 in.) Camshaft
Camshaft Bushing—Gear End
Bushing—Gear End—Oil (Wear Limit)—Oil
Clearance.....................................................................0.040—0.085 mm Clearance................................................................................. 0.245 mm
(0.0016—0.0033 in.) (0.0096 in.)

Continued on next page OUMX068,00003F5 -19-16JUN14-4/5

TM130419 (24FEB16) 20-10-46 PN=86

030916
 Engine Repair—3TNV80F

NOTE: Engine back plate must be removed to

measure camshaft intermediate (J) and flywheel
end (K) bearing diameters.

6. Remove engine back plate.

TCAL28443 —UN—28JUN12
7. Remove plug (I).
8. Measure intermediate (J) and flywheel end (K)
camshaft bore diameters. If bore diameter exceeds
wear limit, replace cylinder block.
9. If bore clearance (bore ID minus camshaft journal OD)
exceeds oil clearance specification, replace camshaft,
cylinder block, or both.
Camshaft Intermediate Bore—Specification
Camshaft Intermediate
Bore—ID..........................................................................40—40.025 mm
(1.5748—1.5758 in.)
Camshaft Intermediate

TCAL28444 —UN—28JUN12
Bore (Wear Limit)—ID.............................................................. 40.10 mm
(1.5787 in.)
Camshaft Intermediate
Bore—Oil Clearance.................................................... 0.065—0.115 mm
(0.0026—0.0045 in.)
Camshaft Intermediate
Bore (Wear Limit)—Oil
Clearance................................................................................. 0.225 mm
(0.0089 in.)
I— Plug K—Camshaft Flywheel Bore
Camshaft Flywheel End Bore—Specification J— Camshaft Intermediate
Camshaft Flywheel-End Bore
Bore—ID..........................................................................40—40.025 mm
(1.5748—1.5758 in.)
Camshaft Flywheel-End 10. Apply PM37465 Ultra-Blue RTV Form-in-Place
Bore (Wear Limit)—ID.............................................................. 40.10 mm Gasket, or equivalent, on outer edge of plug. Install
(1.5787 in.) plug until it bottoms in bore.
Camshaft Flywheel-End
Bore—Oil Clearance....................................................0.040—0.085 mm 11. Install engine back plate.
(0.0016—0.0033 in.)
Camshaft Flywheel-End
Bore (Wear Limit)—Oil
Clearance................................................................................. 0.195 mm
(0.0077 in.)
OUMX068,00003F5 -19-16JUN14-5/5

TM130419 (24FEB16) 20-10-47 030916

PN=87
 Engine Repair—3TNV80F

Check Camshaft End Play—3TNV80F

Reason
NOTE: Follow this procedure if camshaft is installed
in cylinder block. If camshaft is removed from
cylinder block, check end play (B) using a feeler
gage between camshaft thrust plate (A) and front
side of first camshaft bearing journal.

To determine proper side clearance between camshaft

gear end journal and thrust plate.

TCAL28446 —UN—28JUN12
Special or Required Tools

• Dial Indicator
A—Camshaft Thrust Plate B—End Play

OUMX258,0000BC0 -19-16SEP14-1/2

Procedure
1. Remove the timing gear cover. (See Remove and
Install Timing Gear Cover—3TNV80F.)
2. Fasten the dial indicator (A) to the engine and position
indicator tip on end of camshaft (B).
3. Push the camshaft toward the rear as far as possible.

TCT006370 —UN—18JAN13
4. Zero the dial indicator.
5. Pull the camshaft forward as far as possible.
Results

• If camshaft end play exceeds specification, remove

camshaft and inspect thrust plate, camshaft, and
camshaft gear for wear. Replace parts as needed. (See
Inspect Camshaft—3TNV80F.)
Specification A—Dial Indicator B—Camshaft
Camshaft—End Play........................................................0.05—0.15 mm
(0.0020—0.0059 in.)
Camshaft—End Play
(Wear Limit)................................................................................ 0.25 mm
(0.0098 in.)
OUMX258,0000BC0 -19-16SEP14-2/2

TM130419 (24FEB16) 20-10-48 030916

PN=88
 Engine Repair—3TNV80F

Check Timing Gear Backlash—3TNV80F

1. Remove timing gear cover. (See Remove and Install
Timing Gear Cover—3TNV80F.)
2. Place dial indicator magnetic base on cylinder block
with tip of indicator on tooth of gear being measured.
3. Holding opposite gear stationary, move measured gear

TCAL28448 —UN—28JUN12
back and forth while measuring backlash between
meshing gears.
4. If backlash exceeds specifications, replace worn gears
as a complete set.
Specification
Timing Gear—Backlash....................................................0.06—0.12 mm
(0.0024—0.0047 in.) Arrows Indicate Direction of Rotation (Viewed from Gear Case)
Timing Gear—Backlash
(Wear Limit)................................................................................ 0.14 mm
A—Idler Gear D—Oil Pump Gear
(0.0055 in.)
B—Camshaft Gear E—Fuel Injection Drive Gear
C—Crankshaft Gear

OUMX258,0000BC1 -19-15SEP14-1/1

Remove and Install Camshaft

Gear—3TNV80F
Removal

TCAL28449 —UN—28JUN12
1. Remove gear from camshaft using a knife-edge puller
and an arbor press. Place fat side of puller against
camshaft gear.
2. Inspect gear for chipped or broken teeth. Replace if
necessary.
Installation
A—Key C—Thrust Plate
CAUTION: Do not heat oil over 182°C (360°F). Oil B—Camshaft Gear D—Stepped Shoulder
fumes or oil can ignite above 193°C (380°F). Use
a thermometer. Do not allow a flame or heating
element to come in direct contact with the oil.
Heat the oil in a well-ventilated area. Plan a safe IMPORTANT: Be sure thrust plate is not trapped
handling procedure to avoid burns. between camshaft gear and stepped shoulder
while gear is being pressed on.
1. Heat gear to approximately 150°C (300°F).
4. Install heated camshaft gear (B) with longer hub of
2. Install key (A) into slot of camshaft. camshaft gear facing camshaft. Align slot in gear with
3. Install thrust plate (C) onto camshaft, centering onto key in shaft. Press camshaft into gear until hub of gear
stepped shoulder (D). (Thrust plate has no “front” or is tight against camshaft shoulder. Thrust plate must
“rear” side.) spin freely on camshaft.
OUMX068,00003F7 -19-25MAR13-1/1

TM130419 (24FEB16) 20-10-49 030916

PN=89
 Engine Repair—3TNV80F

Remove and Install Camshaft installing new camshaft. The components

Follower—3TNV80F wear as a set and replacing only one will
accelerate the wear of the other.
Special or Required Tools
2. Remove cam followers from cylinder block with
• Magnetic Pick-Up Tool magnetic pick-up tool.
1. Remove cylinder head. (See Remove and Install
Cylinder Head and Valves—3TNV80F.) 3. Inspect all parts for wear or damage. (See Inspect
Camshaft Follower—3TNV80F.)
IMPORTANT: Cam followers must be installed in the
same bores from which they were removed. 4. Apply clean engine oil on all parts during installation.
Put a mark on each cam follower and cylinder 5. Install cam followers after camshaft is installed.
block bore to aid in installation. Installation is done in the reverse order of removal.
Always replace camshaft when replacing cam
followers. Always replace cam followers when
OUMX258,0000BC2 -19-27MAR13-1/1

Inspect Camshaft Follower—3TNV80F

1. Inspect cam follower contact surface for abnormal

TCAL28450 —UN—28JUN12
wear (A). Normal wear (B) has light circular lines and
flat surface.

A—Abnormal Wear B—Normal Wear

OUMX068,00003F8 -19-04FEB14-1/2

2. Measure cam follower diameter. If outside diameter is

less than wear limit, replace cam follower.
Specification
Camshaft

TCAL28451 —UN—28JUN12
Followers—OD.............................................................20.94—20.96 mm
(0.824—0.825 in.)
Camshaft Followers
(Wear Limit)—OD..................................................................... 20.91 mm
(0.823 in.)

3. Measure cam follower bore diameter in cylinder block.

If cam follower bore diameter exceeds wear limit,
replace cylinder block.
Specification
Camshaft Follower Specification
Bore—ID.......................................................................21.00—21.02 mm Follower to Bore—Oil
(0.827—0.828 in.) Clearance.....................................................................0.040—0.082 mm
Camshaft Follower Bore (0.0016—0.0032 in.)
(Wear Limit)—ID....................................................................... 21.04 mm Follower to Bore (Wear
(0.828 in.) Limit)—Oil Clearance............................................................... 0.134 mm
(0.0053 in.)
4. If tappet-to-bore oil clearance (bore ID minus follower
OD) exceeds specification, replace cam follower,
cylinder block, or both.
OUMX068,00003F8 -19-04FEB14-2/2

TM130419 (24FEB16) 20-10-50 PN=90

030916
 Engine Repair—3TNV80F

Remove and Install Timing Gear

Cover—3TNV80F
Procedure
1. Remove alternator and belt.

TCAL28452 —UN—28JUN12
2. Remove crankshaft sheave mounting cap screw and
washer.
3. Install puller to crankshaft sheave and remove sheave.

OUMX258,0000BC3 -19-15SEP14-1/2

4. Remove timing gear cover mounting cap screws.

5. Remove timing gear cover.
6. Clean all old gasket material from timing gear cover
and timing gear cover housing on block.
7. Apply a thin bead of PM37465 ULTRA BLUE® RTV
Form-in-Place Gasket to timing gear cover prior to

TCAL28453 —UN—28JUN12
installation.
8. Tighten all timing gear cover mounting cap screws to
specification.
Specification
Timing Gear Cover
Mounting Cap
Screw—Torque................................................................................9 N·m
(78 lb.-in.)
A—M8 x 60 Cap Screw (4 used) E—Cover
9. Install crankshaft sheave, lining up pin on crankshaft. B—M8 x 16 Cap Screw (2 used) F— Dowel Pin (2 used)
Install flat washer and cap screw and tighten to C—Seal G—M8 x 30 Cap Screw (8 used)
specification. D—M8 x 80 Cap Screw (6 used)

Specification
Crankshaft Sheave Cap
Screw—Torque..............................................................................88 N·m 11. Adjust belt tension. (See Check and Adjust Alternator
(65 lb.-ft.) Drive Belt Tension—3TNV80F.)
10. Install alternator and belt.
ULTRA BLUE is a trademark of Loctite Corp.
OUMX258,0000BC3 -19-15SEP14-2/2

TM130419 (24FEB16) 20-10-51 030916

PN=91
 Engine Repair—3TNV80F

Remove and Install Idler Gear—3TNV80F

1. Remove timing gear cover. (See Remove and Install
Timing Gear Cover—3TNV80F.)
2. Check backlash of timing gears. (See Check Timing
Gear Backlash—3TNV80F.)
NOTE: Due to the odd number of teeth on the idler
gear, timing marks will only align periodically.
When all timing marks on gears align, the piston

TCT006702 —UN—28MAR13
closest to the water pump, number three, is
at TDC on compression stroke. (Number one
cylinder is closest to the flywheel.)

3. Rotate crankshaft and align timing marks (D).

NOTE: Timing mark on crankshaft gear is on front of tooth
used for timing, but since gear is spiral cut it will
appear to not be aligned with mark on idler gear.
A—Bolts C—Gear
4. Remove bolts (A), shaft (B), and gear (C). B—Shaft D—Timing Marks

5. Inspect all parts for wear or damage. (See Inspect

Idler Gear—3TNV80F.)
6. During installation align all timing marks.
OUMX258,0000BC4 -19-28MAR13-1/1

Inspect Idler Gear—3TNV80F

Special or Required Tools
• Bushing Driver Set
1. Inspect gear for chipped or broken teeth. Replace if
necessary.
2. Measure idler gear shaft diameter. If shaft diameter is
less than wear limit, replace idler gear shaft.

TCT006703 —UN—28MAR13
Specification
Idler Gear Shaft—OD...............................................36.950—36.975 mm
(1.4547—1.4557 in.)
Idler Gear Shaft (Wear
Limit)—OD................................................................................ 36.90 mm
(1.4528 in.)

A—Shaft Diameter Idler Gear Shaft

Continued on next page OUMX068,00003F9 -19-04FEB14-1/2

TM130419 (24FEB16) 20-10-52 030916

PN=92
 Engine Repair—3TNV80F

3. Measure idler gear bushing diameter. If bushing

diameter exceeds wear limit, replace bushing using
a driver set.
Specification
Idler Gear Bushing—ID................................................37.0—37.025 mm
(1.4567—1.4577 in.)
Idler Gear Bushing (Wear
Limit)—ID............................................................................... 37.075 mm
(1.4596 in.)

a. Align oil holes in bushing and idler gear.

TCT006704 —UN—28MAR13
b. Install bushing flush with surface of idler gear.
4. If bushing oil clearance (bushing ID minus shaft OD)
exceeds specification, replace bushing, shaft, or both.
Specification
Idler Gear Bushing-to-
Shaft—Oil Clearance....................................................0.025—0.075 mm
(0.0010—0.0030 in.)
Idler Gear Bushing-to-
Shaft (Wear Limit)—Oil B—Bushing
Clearance................................................................................. 0.175 mm
(0.0069 in.)

OUMX068,00003F9 -19-04FEB14-2/2

TM130419 (24FEB16) 20-10-53 030916

PN=93
 Engine Repair—3TNV80F

Remove and Install Timing Gear

Housing—3TNV80F
Removal
1. Remove engine.
2. Remove timing gear cover. (See Remove and Install
Timing Gear Cover—3TNV80F.)

TCT005870 —UN—16NOV12
3. Remove fuel injection lines from engine. (See Remove,
Inspect, and Install Fuel Injection Nozzle—3TNV80F.)
4. Remove engine camshaft. (See Remove and Install
Camshaft—3TNV80F.)
5. Remove water pump. (See Remove and Install Water
Pump—3TNV80F.)
6. Remove oil pan. (See Remove and Install Oil Pan and A—PM37465 Ultra-Blue® RTV E—Cap Screws
Strainer—3TNV80F.) Form-in-Place Gasket F— Timing Gear Housing
B—Timing Gear Housing G—Alignment Dowels
7. Remove timing gear housing mounting cap screws C—Alignment Dowels H—O-Rings
and remove housing from cylinder block. D—O-Rings

8. If replacing timing housing, remove fuel injection pump

and governor.
4. Apply PM37465 ULTRA BLUE® RTV Form-in-Place
Installation Gasket (A) to timing gear housing when installing to
cylinder block.
NOTE: Installation is done in the reverse order of removal.
5. Tighten mounting cap screws to specification.
1. Clean all parts of old gasket sealer, gasket material,
Specification
oil, and dirt before attempting installation.
Timing Gear Housing
2. Install alignment dowels (C) in timing gear housing (B). Mounting Cap
Screw—Torque.............................................................................. 11 N·m
3. Replace O-rings (D) between timing gear housing and (96 lb.-in.)
engine block.
ULTRA BLUE is a trademark of Loctite Corp.
OUMX258,0000BC5 -19-15SEP14-1/1

Remove and Install Oil Pan and

Strainer—3TNV80F
NOTE: Engine must be removed from machine
to remove oil pan.

1. Remove flywheel and flywheel housing to access

oil pan cap screws. (See Remove and Install
Flywheel—3TNV80F.)
TCAL28458 —UN—28JUN12

2. Remove 16 cap screws (A) and six cap screws (E).

3. Remove oil pan (B).
4. Remove cap screws from strainer and remove strainer
(D) and O-ring (C).

A—Cap Screw (16 used) D—Strainer

B—Oil Pan E—Cap Screw (6 used)
C—O-Ring

OUMX258,0000BC6 -19-27MAR13-1/1

TM130419 (24FEB16) 20-10-54 PN=94

030916
 Engine Repair—3TNV80F

Remove and Install Oil Pump—3TNV80F

1. Remove timing gear cover.
2. Remove the eight screws (A) from oil pump cover (B)
and remove cover.

TCT005862 —UN—13NOV12
A—Screws B—Pump Cover

OUMX258,0000BC7 -19-27MAR13-1/2

3. Remove inner rotor (C) and outer rotor (D) and check
for wear or damage. Check inside of cover for wear or
deep scratches. Replace any worn or damaged parts.
(See Inspect Oil Pump—3TNV80F.)
Installation
• Installation is done in the reverse order of removal.

TCT005863 —UN—13NOV12
• Apply medium strength thread locking compound to oil
pump cover screws and relief valve cap when installing.

C—Inner Rotor D—Outer Rotor

OUMX258,0000BC7 -19-27MAR13-2/2

Inspect Oil Pump—3TNV80F

1. Inspect inside of oil pump cover for grooves or deep
scratches. Replace cover if worn or damaged.

TCT005864 —UN—13NOV12

Oil Pump Cover

Continued on next page OUMX068,00003FA -19-04FEB14-1/5

TM130419 (24FEB16) 20-10-55 030916

PN=95
 Engine Repair—3TNV80F

2. Remove relief valve cap (E), spring (F), and valve (G).
Inspect all parts for wear or damage. Replace any
worn or damaged parts.

TCT005865 —UN—13NOV12
OUMX068,00003FA -19-04FEB14-2/5

3. Measure clearance between outer rotor (H) and timing

cover (I) with a feeler gauge (J). If clearance exceeds
wear limit, replace timing cover and both rotors.
Specification
Oil Pump Rotor Side
Clearance—Clearance.....................................................0.12—0.21 mm
(0.0047—0.0083 in.)
Oil Pump Rotor Side
Clearance (Wear

TCT005866 —UN—13NOV12
Limit)—Clearance....................................................................... 0.30 mm
(0.0118 in.)

Outer Rotor to Timing Cover Clearance

OUMX068,00003FA -19-04FEB14-3/5

4. Measure between high spots of inner and outer

rotors (K) with a feeler gage. If clearance exceeds
specification replace rotors.
Specification
Oil Pump Rotor
Inner-to-Outer
(Limit)—Clearance..................................................................... 0.16 mm
(0.006 in.)
TCT005867 —UN—16NOV12

K—Clearance Between Rotors

Continued on next page OUMX068,00003FA -19-04FEB14-4/5

TM130419 (24FEB16) 20-10-56 030916

PN=96
 Engine Repair—3TNV80F

5. Place a straight edge (L) across timing gear cover

bosses and measure gap between edge of timing
gear cover and the rotors with a feeler gauge (M).
If clearance exceeds wear limit replace timing gear
cover and rotors.
Specification
Oil Pump Outer
Rotor-to-Timing
Cover—Clearance............................................................0.02—0.07 mm
(0.0008—0.0028 in.)
Oil Pump Outer Rotor-

TCT005868 —UN—16NOV12
to-Timing Cover (Wear
Limit)—Clearance...................................................................... 0.12 mm
(0.0047 in.)

L— Straightedge M—Feeler Gauge

OUMX068,00003FA -19-04FEB14-5/5

Remove and Install Thermostat—3TNV80F

Removal

CAUTION: Explosive release of fluids from

pressurized cooling system can cause serious
burns. Shut off engine. Remove filler cap

TCAL28361 —UN—28JUN12
only when cool enough to touch with bare
hands. Slowly loosen cap to first stop to relieve
pressure before removing cap.

1. Park machine safely.

2. Turn key switch to STOP position and allow the engine
to cool.
3. Raise hood. A—Drain Plug
4. Loosen radiator cap to first stop to relieve pressure.
5. Remove radiator cap.
6. Remove air cleaner assembly.
7. Attach a 12 in. hose to drain valve located on lower
right side of radiator.
8. Drain coolant from radiator into container large enough
to hold full capacity of cooling system.
9. Drain coolant from engine. Drain plug (A) is located
on the left side of the engine near oil pressure switch.
Continued on next page OUMX258,0000BC8 -19-15SEP14-1/2

TM130419 (24FEB16) 20-10-57 030916

PN=97
 Engine Repair—3TNV80F

10. Loosen hose clamp (B).

11. Remove radiator hose (C) from thermostat cover.
12. Remove two cap screws (D) from cover and remove
cover and gasket.

TCT006911 —UN—04MAR13
13. Remove thermostat from housing.
14. If thermostat is to be reinstalled, test thermostat. (See
Test Thermostat—3TNV80F.)
Installation
Installation is done in reverse order of removal.
• Install thermostat in housing with spring end inside
coolant pump. B—Hose Clamp D—Cap Screw
• Place gasket over thermostat and place cover over C—Radiator Hose
thermostat on coolant pump.
• Start engine and watch coolant level in radiator. Add
coolant if necessary to bring coolant level up to filler
neck.
Specification
Cooling System—Capac-
ity (Approximate).............................................................................. 6.6 L
(7 qt.)
OUMX258,0000BC8 -19-15SEP14-2/2

Remove and Install Coolant Temperature

Switch—3TNV80F
Removal

TCAL28364 —UN—28JUN12
CAUTION: Explosive release of fluids from
pressurized cooling system can cause serious
burns. Shut off engine. Remove filler cap
only when cool enough to touch with bare
hands. Slowly loosen cap to first stop to relieve
pressure before removing cap.

1. Park machine safely.

2. Turn key switch to STOP position and allow the engine
to cool. A—Drain Plug

3. Raise hood.
4. Loosen radiator cap to first stop to relieve pressure.
5. Remove radiator cap.
6. Remove air cleaner assembly.
7. Attach a 30 cm (12 in.) hose to drain valve located on
lower right side of radiator.
8. Drain coolant from radiator into container large enough
to hold full capacity of cooling system.
9. Drain coolant from engine. Drain plug (A) is located
on the left side of the engine near oil pressure switch.
Continued on next page OUMX258,0000BC9 -19-16SEP14-1/2

TM130419 (24FEB16) 20-10-58 030916

PN=98
 Engine Repair—3TNV80F

10. Disconnect electrical connector (B).

11. Remove switch (C).
12. Test switch. (See Coolant Temperature Switch Test.)
Installation

TCT006912 —UN—04MAR13
Installation is done in reverse order of removal.
1. Apply PM37397 Pipe Sealant to temperature coolant
switch threads.
2. Install switch.
3. Start engine and watch coolant level in radiator. Add
coolant if necessary to bring coolant level up to filler
neck. B—Electrical Connector C—Switch
Specification
Cooling System
—Capacity
(Approximate)................................................................................... 6.6 L
(7 qt.)
OUMX258,0000BC9 -19-16SEP14-2/2

Inspect Water Pump—3TNV80F • If coolant leaks between plate and engine block,
remove coolant pump and replace gasket.
1. Inspect coolant pump for coolant leakage. If origin of
leak cannot be determined, pressurize coolant system. 2. Inspect coolant pump for worn bearing shaft by
(See Pressure Test Cooling System—3TNV80F.) removing alternator belt and checking for excessive
movement of pulley. Replace coolant pump if
• If coolant leaks at pulley flange, shaft seal is excessive movement is noticed.
defective. Replace coolant pump.
• If coolant leaks between plate and pump housing, • If bearing shaft is making noise when operating,
gasket between plate and pump housing is defective. check pulley belt tension. (See Check and Adjust
Remove plate and replace gasket. Alternator Drive Belt Tension—3TNV80F.)
OUMX258,0000BCA -19-27MAR13-1/1

Remove and Install Water Pump—3TNV80F

Removal
1. Park machine on level surface with park brake locked.

TCAL28465 —UN—28JUN12
2. Allow engine to cool and pressure in cooling system to
drop before working on water pump.
3. Disconnect battery negative (-) cable from battery.
4. Open engine drain valve (A) to drain coolant from
cylinder block.
5. Disconnect upper and lower radiator hoses from water
pump. A—Engine Drain Valve
6. Loosen tension pulley mounting bolts and remove
water pump drive belt.
Continued on next page OUMX258,0000BCB -19-27MAR13-1/2

TM130419 (24FEB16) 20-10-59 030916

PN=99
 Engine Repair—3TNV80F

7. Disconnect coolant temperature switch connector.

Remove switch and plug.
8. Remove four cap screws and remove sheave.
9. Remove pump mounting cap screws, pump, and
gasket.
10. Inspect all parts for wear or damage.
11. Clean cylinder block mating surfaces of all old gasket
material.
Installation
1. Install water pump and thermostat. Installation is done
in the reverse order of removal.
2. Install coolant temperature switch and plug.

TCAL28466 —UN—28JUN12
3. Adjust water pump drive belt tension. (See Check and
Adjust Alternator Drive Belt Tension—3TNV80F.)
4. Start engine and watch coolant level in radiator. Add
coolant if necessary to bring coolant level up to filler
neck.

B—Thermostat Housing G—Belt

C—Gasket H—Water Pump
D—Thermostat I— O-Ring
E—Plug J— Coolant Switch
F— Sheave K—Gasket

OUMX258,0000BCB -19-27MAR13-2/2

TM130419 (24FEB16) 20-10-60 030916

PN=100
 Group 20
Engine Repair—3TNV82A, 3TNV88
Summary of References • Check Crankshaft Main Bearing Clearance—3TNV82A,
3TNV88
• Remove and Install Rocker Arm Cover—3TNV82A, • Remove and Install Flywheel and Flex Plate—3TNV82A,
3TNV88 3TNV88
• Check Valve Lift—3TNV82A, 3TNV88 • Check Camshaft End Play—3TNV82A, 3TNV88
• Service Rocker Arm Assembly—3TNV82A, 3TNV88 • Remove and Install Camshaft—3TNV82A, 3TNV88
• Remove and Install Cylinder Head and • Inspect Camshaft—3TNV82A, 3TNV88
Valves—3TNV82A, 3TNV88 • Remove and Install Camshaft Gear—3TNV82A,
• Disassemble and Assemble Cylinder Head and 3TNV88
Valves—3TNV82A, 3TNV88
• Remove and Install Camshaft Followers—3TNV82A,
• Valve Seats—3TNV82A, 3TNV88 3TNV88
• Intake and Exhaust Valves—3TNV82A, 3TNV88
• Remove and Install Timing Gear Cover—3TNV82A,
• Valve Recession—3TNV82A, 3TNV88 3TNV88
• Valve Guides—3TNV82A, 3TNV88
• Check Timing Gear Backlash—3TNV82A, 3TNV88
• Valve Springs—3TNV82A, 3TNV88
• Remove and Install Idler Gear—3TNV82A, 3TNV88
• Remove and Install Exhaust Manifold—3TNV82A,
• Remove and Install Timing Gear Cover Mounting
3TNV88 Plate—3TNV82A, 3TNV88
• Remove and Install Intake Manifold—3TNV82A,
• Remove and Install Oil Pan, Crankcase Extension, and
3TNV88 Strainer—3TNV82A, 3TNV88
• Grind Valve Seats—3TNV82A, 3TNV88
• Remove, Inspect, and Install Oil Pump—3TNV82A,
• Lap Valves—3TNV82A, 3TNV88 3TNV88
• Check Piston-to-Cylinder Head Clearance—3TNV82A,
• Remove and Install Thermostat—3TNV82A, 3TNV88
3TNV88 • Inspect, Remove, and Install Water Pump—3TNV82A,
• Remove and Install Piston and Connecting 3TNV88
Rod—3TNV82A, 3TNV88 • Remove, Install and Inspect Radiator—3TNV82A,
• Inspect Piston—3TNV82A, 3TNV88 3TNV88
• Cylinder Bore—3TNV82A, 3TNV88
• Disassemble and Assemble Water Separa-
• Crankshaft Rear Oil Seal—3TNV82A, 3TNV88 tor—3TNV82A, 3TNV88
• Crankshaft Front Oil Seal—3TNV82A, 3TNV88 • Remove Fuel Injection Pump—3TNV82A, 3TNV88
• Check Crankshaft End Play—3TNV82A, 3TNV88
• Install Fuel Injection Pump—3TNV82A, 3TNV88
• Remove and Install Crankshaft and Main • Remove and Install Fuel Injection Nozzles—3TNV82A,
Bearings—3TNV82A, 3TNV88 3TNV88
• Check Connecting Rod Side Play—3TNV82A, 3TNV88
OUMX258,0000BF6 -19-15SEP14-1/1

TM130419 (24FEB16) 20-20-1 030916

PN=101
 Engine Repair—3TNV82A, 3TNV88

Remove and Install Rocker Arm

Cover—3TNV82A, 3TNV88
Remove
1. Loosen hose clamps from air cleaner hose and
remove air cleaner.
2. Remove cap screws (A and B).
3. Remove rocker cover.
4. Remove intake cover (C) and clean off mating
surfaces and replace gasket (D).
5. Remove and disassemble breather baffle (F) and
clean or replace mesh media.

TCT005860 —UN—16NOV12
6. Remove diaphragm cover (G), spring (H), center plate
(I), and diaphragm (J).
7. Inspect diaphragm, spring, and center plate for wear or
damage. Diaphragm must not have any cracks or tears
and must not leak. Replace parts showing any wear.
Install

• Clean all parts.

• Reassemble rocker arm cover using new gaskets. A—Cap Screw, Long (6 used) F— Breather Baffle
• Use John Deere Form in Place Gasket between B—Cap Screw, Short (3 used)
C—Intake Cover
G—Diaphragm Cover
H—Spring
breather baffle and rocker cover.
D—Gasket I— Center Plate
• Tighten rocker cover cap screws to specification. E—Gasket J— Diaphragm
Specification
Rocker Arm
Cover-to-Cylinder Head
Cap Screws—Torque.................................................................... 11 N·m
(97 lb.-in.)
OUMX258,0000BCE -19-15SEP14-1/1

TM130419 (24FEB16) 20-20-2 030916

PN=102
 Engine Repair—3TNV82A, 3TNV88

Check Valve Lift—3TNV82A, 3TNV88

Reason
Check wear on cam lobes, followers, and/or push rods.

TCAL28524 —UN—29JUN12
Special or Required Tools

• Dial Indicator with Magnetic Base

Procedure
1. Remove the rocker arm cover. (See Remove and
Install Rocker Arm Cover—3TNV82A, 3TNV88.)
2. Adjust the valve clearance.
3. Fasten the dial indicator to the engine and position the
Results
indicator tip on the valve retainer. The valve must be
fully closed and the rocker arm must move freely. • The valve lift should be the same for all valves. If one or
4. Zero the dial indicator. more valves have less travel than the others, remove
and inspect the camshaft, followers and push rods. (See
5. Manually turn the crankshaft pulley clockwise (from Remove and Install Camshaft—3TNV82A, 3TNV88.)
the fan end).
6. Observe the dial indicator as the valve is moved to the
full open position. Repeat for each valve.
OUMX258,0000BFC -19-28MAR13-1/1

TM130419 (24FEB16) 20-20-3 030916

PN=103
 Engine Repair—3TNV82A, 3TNV88

Service Rocker Arm Assembly—3TNV82A, 3TNV88

Removal and Installation

TCAL28546 —UN—29JUN12
A—Shaft End Support (2 used) D—Adjuster Screw (6 used) H—Plug (2 used) M—Cap Screw, M8 x 25
B—Cap Screw, M8 x 50 (6 used) E—Spring (3 used) I— Stud
C—Jam Nut (6 used) F— Rocker Arm (6 used) J— Push Rod (6 used)
G—Rocker Arm Shaft K—Valve Caps (6 used)
L— Center Support (2 used)

1. Remove the rocker cover. (SeeRemove and Install 7. Reinstall the push rods to their original location in the
Rocker Arm Cover—3TNV82A, 3TNV88 .) cylinder head, with the ball-shaped end down in head.
2. Remove the rocker arm end support and rocker arm 8. Lubricate all parts with clean oil during assembly.
center support mounting cap screws.
9. Assemble the rocker arm assembly components in the
3. Lift the rocker arm assembly from the cylinder head reverse order of removal.
and set the assembly on a bench.
10. Place the rocker arm assembly on the cylinder head.
NOTE: If the rocker arm shaft assembly is to be
disassembled, install components in same location • Align the rocker arms with the valves and push rods.
on the rocker arm shaft they were removed from. • Align the rocker arm end supports and center
supports with the corresponding holes in the head.
4. Note the positions of the rocker arm assembly
components. Slide the components off the rocker arm 11. Install the rocker arm support cap screws. Tighten the
shaft. cap screws to specification.
Specification
5. Lift the push rods from the cylinder head and note the
Rocker Arm Assembly
order of removal for reassembly.
Mounting Nut—Torque..................................................................26 N·m
6. Inspect the rocker arm components and push rods. (230 lb.-in.)

Continued on next page OUMX258,0000BCF -19-15SEP14-1/5

TM130419 (24FEB16) 20-20-4 PN=104

030916
 Engine Repair—3TNV82A, 3TNV88

12. Adjust the valve clearance.

OUMX258,0000BCF -19-15SEP14-2/5

Rocker Arm Inspection

1. Measure the outer diameter of the rocker arm shaft.
• Replace the rocker arm shaft if the OD is less than
specification.
Specification
Rocker Arm Shaft—OD................................................15.97—15.98 mm

TCAL28547 —UN—29JUN12
(0.628—0.629 in.)
Rocker Arm Shaft—OD
(Wear Limit).............................................................................. 15.94 mm
(0.628 in.)

OUMX258,0000BCF -19-15SEP14-3/5

2. Measure the inner diameters of the rocker arms and

supports.
• Replace the rocker arms or supports if the ID is more
than specification.
Specification
Rocker Arm and Shaft
Support Bushing—ID....................................................16.00—16.02 mm
(0.630—0.631 in.)

TCAL28548 —UN—29JUN12
Rocker Arm and Shaft
Support Bushing—ID
(Wear Limit).............................................................................. 16.08 mm
(0.633 in.)

3. Measure the rocker arm shaft to rocker arm bushing

oil clearance. Oil clearance is the difference between
the OD of the rocker arm shaft and the ID of the rocker
arms.
• If the clearance exceeds specification, replace the Measure Push Rod Bend
rocker arm shaft and rocker arms.
Specification Place the push rod on a flat surface. Use a feeler gage to
Rocker Arm measure any gaps between the push rod and flat surface.
Shaft-to-Rocker Arm
Bushing—Oil Clearance...................................................0.02—0.05 mm
• Replace any push rod not within specification.
(0.001—0.002 in.) Specification
Rocker Arm Push Rod
Shaft-to-Rocker Arm Bend—Distance.................................................................0.0—0.03 mm
Bushing—Oil Clearance (0.0—0.001 in.)
(Wear Limit)................................................................................ 0.13 mm
(0.005 in.)
Continued on next page OUMX258,0000BCF -19-15SEP14-4/5

TM130419 (24FEB16) 20-20-5 PN=105

030916
 Engine Repair—3TNV82A, 3TNV88

Inspect Rocker Arm Contact Surfaces

TCAL28550 —UN—29JUN12
1. Check the surface of the adjusting screw that contacts
the push rod (A) for wear. Replace the adjusting screw
(B) if it is worn or damaged.
2. Check the surface (C) of the rocker arm that comes in
contact with the valve cap for wear. Replace rocker
arm if necessary.
3. Check the socket portion of the push rod where the
valve clearance adjusting screw contacts the push
rod. Replace the push rod if it is worn or damaged. A—Push Rod C—Rocker Arm Surface
B—Adjusting Screw

OUMX258,0000BCF -19-15SEP14-5/5

Remove and Install Cylinder Head and

Valves—3TNV82A, 3TNV88
Remove
1. Remove the rocker arm cover. (See Remove and
Install Rocker Arm Cover—3TNV82A, 3TNV88.)
2. Remove the rocker arm assembly, push rods and valve
caps. (See Service Rocker Arm Assembly—3TNV82A,
3TNV88.)
3. Remove the exhaust and intake manifolds. (See

TCAL28552 —UN—29JUN12
Remove and Install Exhaust Manifold—3TNV82A,
3TNV88 and Remove and Install Intake
Manifold—3TNV82A, 3TNV88.)
4. Remove the water pump. (See Inspect, Remove, and
Install Water Pump—3TNV82A, 3TNV88.)
5. Remove the fuel injection nozzles. (See Remove and
Install Fuel Injection Nozzles—3TNV82A, 3TNV88.) TCAL28553 —UN—29JUN12

6. Remove the cylinder head bolts (A) in the order shown.

7. Remove the cylinder head from the engine block.
8. Disassemble and inspect the cylinder head and
valves. (See Disassemble and Assemble Cylinder
Head and Valves—3TNV82A, 3TNV88.)

A—Cylinder Head Bolt

Continued on next page OUMX258,0000BD1 -19-15SEP14-1/2

TM130419 (24FEB16) 20-20-6 030916

PN=106
 Engine Repair—3TNV82A, 3TNV88

Install
1. Assemble the cylinder head and valves. (See
Disassemble and Assemble Cylinder Head and
Valves—3TNV80F.)

TCAL28554 —UN—29JUN12
IMPORTANT: The oil passage in the gasket must be
located over the oil passage in cylinder block.
If cylinder head was resurfaced, check
piston-to-cylinder head clearance.
(See Check Piston-to-Cylinder Head
Clearance—3TNV82A, 3TNV88.)

2. Place a new cylinder head gasket on the engine block. 3TNV88 Cylinder Head
Dowels in the engine block will assist in aligning the Cap Screw—Second
gasket. Step Torque...................................................................................62 N·m
3. Place the cylinder head on the engine block. Dowels (45 lb.-ft.)
in the engine block will again assist in alignment. 3TNV88 Cylinder Head
Cap Screw—Final
4. Dip the head bolts in clean engine oil, install and Torque...........................................................................................88 N·m
tighten in the sequence shown, in three stages of (65 lb.-ft.)
gradually-increasing torque. Tighten the head bolts
to specification. IMPORTANT: Cylinder head bolts must be checked for
proper torque after 50 hours of engine operation.
Specification
3TNV82A Cylinder 5. Install the fuel injection nozzles. (See Remove and
Head Cap Screw—Initial Install Fuel Injection Nozzles—3TNV82A, 3TNV88.)
Torque...........................................................................................32 N·m
(24 lb.-ft.) 6. Install the water pump. (See Inspect, Remove, and
3TNV82A Cylinder Head Install Water Pump—3TNV82A, 3TNV88.)
Cap Screw—Second
Step Torque...................................................................................48 N·m
7. Install the exhaust and intake manifolds. (See Remove
(35 lb.-ft.)
and Install Exhaust Manifold—3TNV82A, 3TNV88
3TNV82A Cylinder
and Remove and Install Intake Manifold—3TNV82A,
Head Cap Screw—Final
3TNV88.)
Torque...........................................................................................64 N·m 8. Install the rocker arm assembly, push rods and valve
(47 lb.-ft.) caps.
3TNV88 Cylinder Head
Cap Screw—Initial
Torque...........................................................................................44 N·m
(33 lb.-ft.)
OUMX258,0000BD1 -19-15SEP14-2/2

TM130419 (24FEB16) 20-20-7 PN=107

030916
 Engine Repair—3TNV82A, 3TNV88

Disassemble and Assemble Cylinder Head

and Valves—3TNV82A, 3TNV88
Special or Required Tools

• JDE138 Valve Spring Compressor

• JDG504 Valve Guide Driver
NOTE: Order tools according to information given in
the U.S. SERVICEGARD™ Catalog or in the
European Microfiche Tool Catalog (MTC).

Disassembly, Assembly

TCAL28555 —UN—29JUN12
1. Check valve recession before disassembly. (See
Valve Recession—3TNV82A, 3TNV88.)
2. Compress valve springs (A) using JDE138 Valve
Spring Compressor.
NOTE: It may be necessary to tap on valve spring
retainer (C) while initially operating compressor
to break retainer free from valve stem.

3. Remove collet halves (B) from retainer. A—Valve Springs E—Valve Guides
B—Collet Halves F— Head
4. Slowly release compressor and valve spring. C—Valve Spring Retainer G—Valve
D—Stem Seal H—Valve
IMPORTANT: Do not reuse stem seals (D) if
removed. Used seals will leak.

5. Remove valve spring, stem seal (D), and valve (G or 9. Install springs with smaller pitch end or paint mark
H) from head (F). toward cylinder head.

NOTE: Valve seats are not replaceable. 10. Use valve spring compressor to compress spring and
retainer, and install collet as removed.
6. Intake and exhaust valve guides (E) are press fit. 11. After valve has been assembled, tap on top of valve
Remove guides only if replacement is necessary. stem with a plastic hammer to seat retainer.
7. Inspect all parts for wear or damage. Clean all carbon 12. Repeat for remaining valves.
deposits and measure all parts for proper clearances.
13. Measure valve recession if new valves were installed.
8. Apply clean engine oil on intake and exhaust valve (See Valve Recession—3TNV82A, 3TNV88.)
stems during assembly.
Continued on next page OUMX258,0000BD2 -19-16SEP14-1/2

TM130419 (24FEB16) 20-20-8 030916

PN=108
 Engine Repair—3TNV82A, 3TNV88

Cylinder Head Inspection, Replacement

TCAL28556 —UN—29JUN12
Before inspection, thoroughly clean all components of
carbon or dirt.
1. Measure the cylinder head flatness. Place a
straightedge along each of the four sides and each
diagonal. Measure clearance between straightedge
and gasket surface with a feeler gage.
• If the distortion exceeds specification, but is less
than wear limit, resurface the cylinder head.
Specification
Cylinder Head

TCAL28557 —UN—29JUN12
Distortion—Out-of-Flat.......................................................0.0—0.05 mm
(0.0—0.002 in.)

• If the distortion is in excess of wear limit, replace

the cylinder head.
Specification
Cylinder Head
Distortion—Out-of-Flat
(Maximum)................................................................................. 0.15 mm
(0.006 in.)
4. If the cylinder head was resurfaced, measure valve
2. Inspect for cracks or other damage. recession. (See Valve Recession—3TNV82A,
3. Inspect condition of valve seats and measure valve 3TNV88.)
seat width. (See Valve Seats—3TNV82A, 3TNV88.)
OUMX258,0000BD2 -19-16SEP14-2/2

Valve Seats—3TNV82A, 3TNV88

NOTE: The valve seats are not replaceable. If
inspection of the cylinder head reveals valve
seats that are damaged or worn beyond repair,
the cylinder head must be replaced.

TCAL28558 —UN—29JUN12
1. Measure valve seat width.
2. If necessary, grind the valve seats to meet
specifications. (See Grind Valve Seats—3TNV82A,
3TNV88.)
3TNV82A Valve Seats—Specification
3TNV82A Intake Valve
Seat—Width............................................................................... 1.44 mm
(0.057 in.) 3TNV88 Intake Valve
3TNV82A Intake Valve Seat Wear Limit—Width............................................................. 2.27 mm
Seat Wear Limit—Width............................................................. 1.94 mm (0.089 in.)
(0.076 in.) 3TNV88 Exhaust Valve
3TNV82A Exhaust Valve Seat—Width............................................................................... 1.34 mm
Seat—Width............................................................................... 1.15 mm (0.053 in.)
(0.045 in.) 3TNV88 Exhaust Valve
3TNV82A Exhaust Valve Seat Wear Limit—Width............................................................. 1.84 mm
Seat Wear Limit—Width............................................................. 1.65 mm (0.072 in.)
(0.065 in.)

3TNV88 Valve Seats—Specification

3TNV88 Intake Valve
Seat—Width............................................................................... 1.77 mm
(0.070 in.)
OUMX258,0000BD3 -19-15SEP14-1/1

TM130419 (24FEB16) 20-20-9 PN=109

030916
 Engine Repair—3TNV82A, 3TNV88

Intake and Exhaust Valves—3TNV82A,

3TNV88
1. Check the valves for out-of-round, bent or warped
condition using a valve inspection center. Replace
valve if necessary.

TCAL28559 —UN—29JUN12
OUMX258,0000BD4 -19-15SEP14-1/3

TCAL28560 —UN—29JUN12
2. If the valve faces are worn, burned or pitted, grind
valves to proper face angle.
• If the valve head margin (A) is less than specification
after grinding, replace the valve.
Valve Head Margins—Specification
Intake Valve Head
Margin—Width..................................................................1.24—1.44 mm
(0.049—0.057 in.)
Exhaust Valve Head
Margin—Width..................................................................1.35—1.55 mm A—Head Margin
(0.053—0.061 in.)
Valve Head
Margin—Width (Wear
Limit)........................................................................................... 0.50 mm
(0.020 in.)

Continued on next page OUMX258,0000BD4 -19-15SEP14-2/3

TM130419 (24FEB16) 20-20-10 030916

PN=110
 Engine Repair—3TNV82A, 3TNV88

3. Measure the valve stem diameter at two locations, as

shown.
• If the valve stem diameter is less than the wear
limit, replace the valve.
3TNV82A Valve Stems—Specification
3TNV82A Intake Valve
Stem —OD.......................................................................6.95—6.96 mm
(0.273—0.274 in.)
3TNV82A Intake Valve
Stem—OD (Wear Limit)............................................................. 6.90 mm
(0.272 in.)
3TNV82A Exhaust Valve
Stem—OD........................................................................6.94—6.96 mm
(0.273—0.274 in.)
3TNV82A Exhaust Valve

TCAL28561 —UN—29JUN12
Stem—OD (Wear Limit)............................................................. 6.90 mm
(0.272 in.)

3TNV88 Valve Stems—Specification

3TNV88 Intake Valve
Stem—OD........................................................................7.96—7.98 mm
(0.313—0.314 in.)
3TNV88 Intake Valve
Stem—OD (Wear Limit)............................................................. 7.90 mm
(0.311 in.)
3TNV88 Exhaust Valve 3TNV88 Exhaust Valve
Stem—OD........................................................................7.96—7.97 mm Stem—OD (Wear Limit)............................................................. 7.90 mm
(0.313—0.314 in.) (0.311 in.)

OUMX258,0000BD4 -19-15SEP14-3/3

Valve Recession—3TNV82A, 3TNV88

Measure valve recession (A) using a depth gage.
Valve Recession—Specification
3TNV82A Intake Valve
Recession—Distance.......................................................0.35—0.55 mm
(0.012—0.022 in.)
3TNV88 Intake Valve
Recession—Distance.......................................................0.30—0.50 mm
(0.012—0.020 in.)
Intake Valve Recession

TCAL28562 —UN—29JUN12
Wear Limit—Distance................................................................. 0.80 mm
(0.031 in.)
Exhaust Valve Recession
(all models)—Distance.....................................................0.30—0.50 mm
(0.012—0.020 in.)
Exhaust Valve Recession
Wear Limit—Distance................................................................. 0.80 mm
(0.031 in.)

A—Depth Gauge

OUMX258,0000BD5 -19-15SEP14-1/1

TM130419 (24FEB16) 20-20-11 PN=111

030916
 Engine Repair—3TNV82A, 3TNV88

Valve Guides—3TNV82A, 3TNV88

Special or Required Tools A

TCAL28563 —UN—29JUN12
• JDE118 Valve Guide Driver
• D20021WI Valve Guide Reamer
1. Clean the valve guides using a valve guide brush.
2. Measure the valve guide inside diameter.
Valve Guide ID—Specification
3TNV82A Intake Valve
Guide—ID.........................................................................7.00—7.02 mm
(0.275—0.276 in.) A—Valve Guide Projection
3TNV88 Intake Valve
Guide—ID.........................................................................8.01—8.03 mm
(0.315—0.316 in.) • The intake and exhaust valve guides are different.
The exhaust valve guide has one groove and the
3. Subtract the valve stem OD from the valve guide ID to intake valve guide has none.
obtain the oil clearance. • Install the valve guides with the tapered ends down.
• If the ID of the valve guide is within specification, Push the valve guides into the cylinder head until the
determine the guide-to-stem oil clearance (guide valve guide projection (A) is within specification.
diameter minus stem diameter). Valve Guide Height—Specification
Valve Stem Clearance—Specification 3TNV82A Valve
Intake Valve Guide—Installation
Stem-to-Guide—Oil Height.......................................12 mm (0.472 in.) Beyond Head Surface
Clearance.........................................................................0.04—0.07 mm 3TNV88 Valve
(0.001—0.003 in.) Guide—Installation
Valve Stem-To-Guide Height.......................................15 mm (0.591 in.) Beyond Head Surface
—Oil Clearance (Wear • Ream the inside diameter of valve guides using
Limit)........................................................................................... 0.20 mm appropriate valve guide reamer.
(0.008 in.)
Exhaust Valve
Stem-To-Guide—Oil
Clearance.........................................................................0.05—0.08 mm
(0.002—0.003 in.)
Valve Stem-To-
Guide—Oil Clearance
(Wear Limit)................................................................................ 0.20 mm
(0.008 in.)

• If clearance exceeds wear limit, replace valve guides

using JDE118 Valve Guide Driver.
• New valve guides must be cooled in a container
of liquid nitrogen or equivalent before driving into
cylinder head.
OUMX258,0000BD6 -19-16SEP14-1/1

TM130419 (24FEB16) 20-20-12 PN=112

030916
 Engine Repair—3TNV82A, 3TNV88

Valve Springs—3TNV82A, 3TNV88

1. Measure the valve spring free length.
Specification
3TNV82A Valve
Spring—Free Length.................................................................. 42.0 mm

TCAL28564 —UN—29JUN12
(1.650 in.)
3TNV82A Valve
Spring—Free Length
(Wear Limit)................................................................................ 41.5 mm
(1.630 in.)
3TNV88 Valve
Spring—Free Length.................................................................. 44.4 mm
(1.750 in.)
3TNV88 Valve
Spring—Free Length
(Wear Limit)................................................................................ 43.9 mm
(1.730 in.)

OUMX258,0000BD7 -19-15SEP14-1/2

2. Measure the spring inclination (A).

• Replace the spring if the measurement exceeds
specifications.
Specification
3TNV82A
Spring—Inclination..................................................................... 1.20 mm
(0.047 in.)
3TNV88 Spring
—Inclination................................................................................ 1.40 mm
(0.055 in.)

A—Spring Inclination

TCAL28565 —UN—29JUN12
OUMX258,0000BD7 -19-15SEP14-2/2

TM130419 (24FEB16) 20-20-13 030916

PN=113
 Engine Repair—3TNV82A, 3TNV88

Remove and Install Exhaust

Manifold—3TNV82A, 3TNV88
1. Remove the muffler and gasket (A).
2. Remove the exhaust manifold (B) and gasket (C).
3. Clean the mating surfaces, and replace the exhaust
manifold gasket.

TCAL28566 —UN—29JUN12
4. Install the exhaust manifold. Tighten all fasteners.

A—Muffler Gasket C—Exhaust Manifold Gasket

B—Exhaust Manifold

OUMX258,0000BD8 -19-27MAR13-1/1

Remove and Install Intake 5. Install the intake manifold.

Manifold—3TNV82A, 3TNV88
6. If intake air heater was removed, replace the gasket
1. Remove the fuel filter bracket. and install the intake air heater.
2. Remove the fuel injection lines. 7. Install the fuel injection lines.
3. Remove the intake manifold. 8. Tighten fasteners to general specification.
4. Clean the mating surfaces, and replace the intake
manifold gasket.
OUMX258,0000BD9 -19-29MAR13-1/1

Grind Valve Seats—3TNV82A, 3TNV88

NOTE: LIGHTLY grind the valve seats for only a few
seconds to avoid excessive valve seat width.(
see valve seats for specifications)

1. Grind the intake valve seat using a 30° seat grinder

and the exhaust valve seat using a 45° seat grinder.

TCAL28568 —UN—29JUN12
Follow the tool manufacturer’s instructions.
2. Measure the valve seat width after grinding.

Continued on next page OUMX258,0000BDA -19-27MAR13-1/2

TM130419 (24FEB16) 20-20-14 030916

PN=114
 Engine Repair—3TNV82A, 3TNV88

3. If the seat width (A) is too wide after grinding, grind the
lower seat surface (B) using a 70° seat grinder until
the seat width is close to specifications. B

4. Grind the upper seat surface (C) using a 15°

seat grinder until the seat width is narrowed to
specifications.
D
5. If the valve seats (D) are ground, measure valve C
recession. (See Valve Recession—3TNV82A,

TCAL28569 —UN—29JUN12
3TNV88.) 15˚ A

6. Lap the valves. (See Lap Valves—3TNV82A,

3TNV88.)
Cylinder
7. If the valve recession exceeds the maximum Head
specifications or the seats cannot be reconditioned,
replace the valves or the cylinder head.

A—Seat Width C—Upper Seat Surface

B—Lower Seat Surface D—Valve Seats

OUMX258,0000BDA -19-27MAR13-2/2

Lap Valves—3TNV82A, 3TNV88

NOTE: Use a rubber-type lapping tool for valves
without a lapping tool groove slit.

If the seat does not make proper contact, lap the valve
into the seat:

TCAL28570 —UN—29JUN12
1. Apply a small amount of fine lapping compound to the
face of the valve.
2. Turn the valve to lap the valve to the seat.
3. Lift the valve from the seat every 8 to 10 strokes. Lap
until a uniform ring appears around the surface of the
valve face.
4. Wash all parts in solvent to remove lapping compound.
Dry all parts.
5. Check the position of the lap mark on the valve face.
Lap marks must be on or near the center of the valve
face.
OUMX258,0000BDB -19-27MAR13-1/1

TM130419 (24FEB16) 20-20-15 030916

PN=115
 Engine Repair—3TNV82A, 3TNV88

Check Piston-to-Cylinder Head

Clearance—3TNV82A, 3TNV88
1. Place three 10 mm (0.4 in.) long pieces of 1.5 mm
(0.06 in.) diameter soft wire in three positions on the
flat part of the piston head.

TCAL28571 —UN—29JUN12
2. Install the cylinder head and old gasket. Install
cylinder head bolts and tighten in proper sequence.
(See Remove and Install Cylinder Head and
Valves—3TNV82A, 3TNV88.)
3. Slowly turn the crankshaft one complete revolution.
4. Remove the cylinder head and gasket.
5. Measure the thickness of the flattened section of each
piece of wire. Calculate the average thickness of the
wires to obtain the piston-to-cylinder head clearance
• If the clearance is less than specification, replace
cylinder head.
specification.
Specification
Piston-to-Cylinder
Head—Clearance.............................................................0.66—0.78 mm
(0.026—0.031 in.)
OUMX258,0000BDC -19-15SEP14-1/1

TM130419 (24FEB16) 20-20-16 030916

PN=116
 Engine Repair—3TNV82A, 3TNV88

Remove and Install Piston and Connecting

Rod—3TNV82A, 3TNV88
NOTE: The engine must be removed from the machine
to perform this procedure.

Removal
1. Remove the oil pan and oil pickup tube. (See Remove
and Install Oil Pan, Crankcase Extension, and
Strainer—3TNV82A, 3TNV88.)
2. Remove the cylinder head. (See Remove and Install
Cylinder Head and Valves—3TNV82A, 3TNV88.)
3. Check the cylinder bore for ridges. These ridges can
cause damage to piston if ridge is not removed.
4. If necessary, remove any ridge from the top of the
cylinder bore using a ridge reamer.
5. Measure the connecting rod side play. (See Check
Connecting Rod Side Play—3TNV82A, 3TNV88.)
6. Measure the crankshaft end play. (See Check
Crankshaft End Play—3TNV82A, 3TNV88.)

TCAL28572 —UN—29JUN12
7. Measure the connecting rod bearing clearance.
(See Check Crankshaft Main Bearing
Clearance—3TNV82A, 3TNV88.)
IMPORTANT: Keep the connecting rods and rod caps
together. Rods and caps are a matched set.
Note the alignment marks on each part.

8. Remove the rod bolts (A), connecting rod cap (B) and
bearing inserts (C). A—Rod Bolts C—Bearing Inserts
B—Rod Cap
IMPORTANT: The pistons and cylinders are matched.
Pistons must be installed in the cylinders
from which they are removed. • Always replace the connecting rod bolts. Do not reuse
the bolts.
9. Note the connecting rod alignment mark in relation to
the cylinders. Starting at the flywheel end with cylinder IMPORTANT: Pistons must be installed in the
number one, then two, etc. cylinders from which they were removed and in
the same direction. Be careful not to damage the
10. Push the piston and connecting rod out of the cylinder crankshaft rod journals while installing pistons.
bore using a wooden dowel.
11. Disassemble and inspect all parts for wear or damage. 1. Assemble the piston and connecting rod. (See
Disassembly under this Group.)
12. Inspect the cylinder bore. (See Cylinder
Bore—3TNV82A, 3TNV88.)
Installation

• Apply clean engine oil to all parts during installation.

Continued on next page OUMX258,0000BDD -19-15SEP14-1/6

TM130419 (24FEB16) 20-20-17 030916

PN=117
 Engine Repair—3TNV82A, 3TNV88

2. Install the piston and connecting rod into the cylinder

from which it was removed. The alignment mark on
the connecting rod (D) and/or the piston size mark (E)
on top of piston should point toward the fuel injection
pump.
IMPORTANT: Do not touch bearing insert surfaces.
Oil and acid from your fingers will corrode
the bearing surface.

3. Install the bearing inserts to the connecting rod and

rod cap, aligning tangs (F) with grooves (G).
IMPORTANT: Connecting rod caps must be
installed on the same connecting rods
they were removed from.

4. Match the connecting rods to caps using alignment

marks (H). Install the rod caps.
5. Dip the entire connecting rod bolt (A) in clean engine
oil. Install new bolts and tighten to specification.
Specification
3TNV82A Connecting
Rod Bolt—Torque.................................................................. 37—41 N·m

TCAL28573 —UN—29JUN12
(27—30 lb.-ft.)
3TNV88 Connecting Rod
Bolt—Torque.......................................................................... 44—54 N·m
(33—40 lb.-ft.)

6. If a new piston and connecting rod were installed,

stamp a number corresponding to the cylinder number
on the connecting rod and rod cap.
7. Install the cylinder head. (See Remove and Install
Cylinder Head and Valves—3TNV82A, 3TNV88.) A—Rod Bolts F— Tangs
D—Connecting Rod G—Grooves
8. Install the oil pan, and oil pickup tube. E—Piston Size mark H—Alignment Marks

Continued on next page OUMX258,0000BDD -19-15SEP14-2/6

TM130419 (24FEB16) 20-20-18 030916

PN=118
 Engine Repair—3TNV82A, 3TNV88

Disassembly
IMPORTANT: Pistons must be installed on the same
connecting rod they were removed from.

1. Put a mark on each piston and connecting rod to aid

in assembly.
2. Remove snap rings (I) from piston pin (J) and remove
pin.
3. The piston pin bushing (K) is a press fit in the
connecting rod. Remove the bushing only if
replacement is necessary.
4. Inspect all parts for wear or damage. Replace as
necessary.
5. Remove the 1st and 2nd compression rings (L) and
oil ring with expander (M).
Assembly

• Apply clean engine oil to all parts during assembly.

IMPORTANT: The pistons must be installed on the
same connecting rod they were removed from.

TCAL28574 —UN—29JUN12
I— Snap Rings L— Compression Rings
J— Piston Pin M—Oil Ring
K—Piston Pin Bushing

Continued on next page OUMX258,0000BDD -19-15SEP14-3/6

TM130419 (24FEB16) 20-20-19 030916

PN=119
 Engine Repair—3TNV82A, 3TNV88

1. Assemble the piston to the connecting rod with piston

mark (E) on the same side as the connecting rod
stamped mark (D). If a new connecting rod is used,
assemble the piston to the connecting rod with piston
mark opposite the connecting rod bearing insert
groove (G). Be sure the oil hole in the piston pin
bushing is aligned with the hole in the connecting rod.
2. Install the piston pin (J) and retaining/snap rings (I).
3. Install an oil ring expander (M) in the bottom ring
groove of the piston, with the ends above either end of
the piston pin.

D—Connecting Rod Stamped I— Retaining/Snap Rings

Mark J— Piston Pin
E—Pison Mark
G—Bearing Insert Groove

TCAL28575 —UN—29JUN12
OUMX258,0000BDD -19-15SEP14-4/6

4. Install the oil ring over the expander with the ring gap
(N) opposite (180°) of the expander ends (O).
5. Install the second compression ring, with the small
diameter of taper toward top of piston, in the middle
groove. Turn the ring until the gap (P) is 120° away
from the oil ring gap (N).

TCAL28576 —UN—29JUN12
N—Oil Ring Gap P—Compression Ring Gap
O—Expander Ends

Continued on next page OUMX258,0000BDD -19-15SEP14-5/6

TM130419 (24FEB16) 20-20-20 030916

PN=120
 Engine Repair—3TNV82A, 3TNV88

6. Install the first compression ring (chrome plated), with

the manufacturer's mark “R”, “T” or “RN” (near the ring
gap) toward the top of the piston, in the top groove.
Turn the ring until the gap (Q) is 120° away from the
second ring gap.

N—Gap Q—Gap
P—Gap R—Manufacturer’s Mark

TCAL28577 —UN—29JUN12
OUMX258,0000BDD -19-15SEP14-6/6

TM130419 (24FEB16) 20-20-21 030916

PN=121
 Engine Repair—3TNV82A, 3TNV88

Inspect Piston—3TNV82A, 3TNV88

Connecting Rod Bearing
1. Install the connecting rod cap and bearing inserts on
the connecting rod. Install the old connecting rod bolts
and tighten to specification.
Specification
Connecting Rod
Bolt—Torque.......................................................................... 44—54 N·m
(33—40 lb.-ft.)

2. Measure the connecting rod bearing diameter.

TCAL28578 —UN—29JUN12
Result
• Replace the bearing inserts if the bearing diameter
is not within specification.
Connecting Rod Bearing—Specification
3TNV82A Connecting
Rod Bearing—ID..........................................................42.95—42.96 mm
(1.690—1.691 in.)
3TNV88 Connecting Rod
Bearing—ID..................................................................47.95—47.96 mm Connecting Rod Bearing Oil Clearance—Specification
(1.888—1.889 in.) Connecting Rod
Bearing—Oil Clearance.....................................................0.04—0.07mm
3. Calculate the oil clearance between the bearing inserts (0.002—0.003 in.)
and the crankshaft, and verify that the clearance is Connecting Rod
within specification. Bearing—Oil Clearance
Result (Wear Limit)................................................................................ 0.16 mm
(0.006 in.)
• If the bearing oil clearance exceeds the wear limit,
grind the crankshaft connecting rod journals and
install undersized bearing inserts, or replace the
bearing inserts and the crankshaft.
OUMX258,0000BDE -19-16SEP14-1/7

Piston Ring Groove

1. With the rings installed on the piston, measure the
piston ring groove side clearance. Measure at several
places around each piston.
2. Replace the rings or the piston if the clearances
exceed specification.
Piston Ring Side Clearance—Specification
TCAL28579 —UN—29JUN12
First Compression
Ring Groove—Side
Clearance......................................................................... 0.07—0.11 mm
(0.003—0.004 in.)
Second Compression
Ring Groove—Side
Clearance.........................................................................0.04—0.07 mm
(0.001—0.003 in.)
Oil Control Ring
Groove—Side
Clearance.........................................................................0.03—0.06 mm
(0.001—0.002 in.)
Continued on next page OUMX258,0000BDE -19-16SEP14-2/7

TM130419 (24FEB16) 20-20-22 PN=122

030916
 Engine Repair—3TNV82A, 3TNV88

Piston Ring End Gap

Use a piston to push the ring (A) approximately 30 mm
(1.18 in.) from the bottom of the cylinder bore. Measure
the piston ring end gap (B).
Piston Ring End Gap—Specification
Piston Ring—End Gap.....................................................0.20—0.40 mm
(0.008—0.016 in.)
Piston Ring—End Gap
(Wear Limit)................................................................................ 0.49 mm
(0.019 in.)

A—Ring B—End Gap

TCAL28580 —UN—29JUN12
OUMX258,0000BDE -19-16SEP14-3/7

Piston Pin Diameter

Measure the piston pin diameter. Measure the diameter at
six places. Replace any pin that is not within specification.
Piston Pin OD—Specification
3TNV82A Piston
Pin—OD.......................................................................22.99—23.00 mm
(0.905—0.906 in.)
3TNV88 Piston
Pin—OD.......................................................................25.99—26.04 mm
(1.023—1.025 in.)

TCAL28581 —UN—29JUN12

Continued on next page OUMX258,0000BDE -19-16SEP14-4/7

TM130419 (24FEB16) 20-20-23 030916

PN=123
 Engine Repair—3TNV82A, 3TNV88

Piston Pin Bore

1. Measure the pin bore diameter in the piston.
Piston Pin Bore ID—Specification

TCAL28582 —UN—29JUN12
3TNV82A Piston Pin
Bore—ID.......................................................................23.00—23.01 mm
(0.906—0.906 in.)
3TNV88 Piston Pin
Bore—ID.......................................................................26.00—26.01 mm
(1.024—1.024 in.)
3TNV82A Piston Pin
Bore—ID (Wear Limit).............................................................. 23.04 mm
(0.907 in.)
3TNV88 Piston Pin
Piston Pin-to-Piston—Oil
Bore—ID (Wear Limit).............................................................. 26.04 mm
Clearance (Wear Limit).............................................................. 0.07 mm
(1.025 in.)
(0.003 in.)
2. Piston pin-to-piston oil clearance is the bore ID minus
the pin OD.
• If the piston pin bore exceeds the wear limit, replace
the piston.
Piston Pin Clearance—Specification • If the piston pin is less than the wear limit, replace
Piston Pin-to-Piston—Oil the piston pin.
Clearance.........................................................................0.00—0.01 mm • If the bore clearance exceeds the wear limit, replace
(0.00—0.001 in.) the piston, piston pin or both.
OUMX258,0000BDE -19-16SEP14-5/7

Piston Pin Bushing

1. Measure the piston pin bushing diameter in the
connecting rod.
• If the bushing diameter exceeds the wear limit,
replace bushing.
Piston Pin Bushing ID—Specification
3TNV82A Piston Pin
Bushing—ID.................................................................23.02—23.04 mm
(0.906—0.907 in.)

TCAL28583 —UN—29JUN12
3TNV88 Piston Pin
Bushing—ID.................................................................26.03—26.04 mm
(1.025—1.025 in.)
3TNV82A Piston Pin
Bushing—ID (Wear
Limit)......................................................................................... 23.07 mm
(0.908 in.)
3TNV88 Piston Pin
Bushing—ID (Wear
Limit)......................................................................................... 26.07 mm Piston Pin-to-Rod
(1.028 in.) Bore—Oil Clearance
(Wear Limit)................................................................................ 0.10 mm
2. Piston pin-to-rod bore oil clearance is the bore ID (0.004 in.)
minus the pin OD.
NOTE: The piston pin bushing is a press fit. Replace
• If the bushing clearance (bushing ID minus pin OD) the bushing using a driver set. When installing
exceeds specification, replace the bushing or the the bushing, make sure to align the oil hole in the
piston pin. bushing with the hole in the connecting rod.
Piston Pin Oil Clearance—Specification
Piston Pin-to-Rod
Bore—Oil Clearance........................................................0.03—0.04 mm
(0.001—0.002 in.)
Continued on next page OUMX258,0000BDE -19-16SEP14-6/7

TM130419 (24FEB16) 20-20-24 PN=124

030916
 Engine Repair—3TNV82A, 3TNV88

Piston Diameter
NOTE: If the engine has had a previous major overhaul,
oversize pistons and rings may have been
installed. Pistons and rings are available in
0.25 mm (0.010 in.) oversize.

TCAL28584 —UN—29JUN12
Measure the piston diameter perpendicular to the piston
pin bore 23 mm (0.905 in.) from the bottom of the piston
skirt.
• If the piston diameter is less than the wear limit, install a
new piston.
Piston Specifications, 3TNV82A—Specification
3TNV82A Standard
Piston—OD..................................................................81.95—81.98 mm
(3.226—3.228 in.)
3TNV82A Standard
Piston—OD (Wear

TCAL28585 —UN—29JUN12
Limit)......................................................................................... 81.91 mm
(3.225 in.)
3TNV82A Oversize
Piston—OD..................................................................82.20—82.25 mm
(3.236—3.238 in.)
3TNV82A Oversize
Piston—OD (Wear
Limit)......................................................................................... 82.10 mm
(3.238 in.)

Piston Specifications, 3TNV88—Specification 3TNV88 Oversize

3TNV88 Standard Piston—OD..................................................................88.20—88.25 mm
Piston—OD..................................................................87.95—87.98 mm (3.472—3.474 in.)
(3.462—3.464 in.) 3TNV88 Oversize
3TNV88 Standard Piston—OD (Wear
Piston—OD (Wear Limit)......................................................................................... 88.10 mm
Limit)......................................................................................... 87.90 mm (3.469 in.)
(3.461 in.)
OUMX258,0000BDE -19-16SEP14-7/7

TM130419 (24FEB16) 20-20-25 PN=125

030916
 Engine Repair—3TNV82A, 3TNV88

Cylinder Bore—3TNV82A, 3TNV88

NOTE: If the engine has had a previous major
overhaul, the cylinders may have been bored
oversize. Pistons and rings are available in
0.25 mm (0.010 in.) oversize.

Measure the cylinder bore diameter at three positions:

top, middle and bottom. At these three positions, measure
in both directions: along the crankshaft center line and the
direction of the crankshaft rotation.
• If the cylinder bore standard ID exceeds the wear limit,
have the cylinder rebored.
• If the cylinder is rebored, oversize pistons and rings
must be installed.
• If the cylinder bore exceeds the oversize bore ID,

TCAL28586 —UN—29JUN12
replace the cylinder block.
• If the piston-to-cylinder bore clearance (cylinder bore ID
minus piston OD) exceeds specification, replace the
cylinder block, piston or both; or rebore cylinder and
install oversize piston and rings.
• Slight uneven wear, flaws, or minor damage may be
corrected by deglazing. (See Deglazing under the
Group.)

Item Measurement Specification

Cylinder Bore, 3TNV82A
Amperage
3TNV82A Standard Cylinder Bore ID 82.00—82.03 mm
(3.228—3.030 in.)
3TNV82A Standard Cylinder Bore ID (Wear Limit) 82.20 mm
(3.236 in.)
3TNV82A Oversize Cylinder Bore ID 82.25—82.28 mm
(3.238—3.239 in.)
Piston-to-Cylinder Clearance 0.04—0.07 mm
(0.001—0.002 in.)
Cylinder Bore, 3TNV88
3TNV88 Standard Cylinder Bore ID 88.00—88.03 mm
(3.465—3.466 in.)
3TNV88 Standard Cylinder Bore ID (Wear Limit) 88.20 mm
(3.472 in.)
3TNV88 Oversize Cylinder Bore ID 88.25—88.28 mm
(3.474—3.476 in.)
Piston-to-Cylinder Clearance 0.04—0.07 mm
(0.001—0.002 in.)
Deglazing 1. Deglaze the cylinder bores using a flex-hone with 180
IMPORTANT: If the cylinder bores are to be deglazed grit stones.
with crankshaft installed in engine, put clean
shop towels over crankshaft to protect journal
and bearing surfaces from any abrasives.
Continued on next page OUMX258,0000BDF -19-15SEP14-1/3

TM130419 (24FEB16) 20-20-26 030916

PN=126
 Engine Repair—3TNV82A, 3TNV88

2. Use the flex-hone as instructed by the manufacturer to

obtain a 30-40° crosshatch pattern as shown.
IMPORTANT: Do not use gasoline, kerosene
or commercial solvents to clean cylinder
bores. Solvents will not remove all abrasives
from cylinder walls.

TCAL28587 —UN—29JUN12
3. Remove excess abrasive residue from the cylinder
walls using a clean dry rag. Clean the cylinder
walls using clean white rags and warm soapy water.
Continue to clean the cylinder until white rags show
no discoloration.
Reboring
NOTE: The cylinder block can be rebored to use oversize
pistons and rings. Pistons and rings are available 2. Adjust the hone so the lower end is even with the
lower end of cylinder bore.
in 0.25 mm (0.010 in.) oversize.
3. Adjust the rigid hone stones until they contact the
1. Align the center of bore to the drill press center. narrowest point of the cylinder.
IMPORTANT: Check stone for wear or damage. Use 4. Coat the cylinder with honing oil. The hone should
a rigid hone with 300 grit stones. turn by hand. Adjust the hone if it is too tight.
OUMX258,0000BDF -19-15SEP14-2/3

5. Run the drill press at about 250 rpm. Move the hone
up and down in order to obtain a 30-40° crosshatch
pattern.
NOTE: Measure the bore when the cylinder is cool.

6. Stop the press and check the cylinder diameter.

NOTE: Finish should not be smooth. It should have
a 30-40° crosshatch pattern.

7. Remove the rigid hone when the cylinder is within 0.03

mm (0.001 in.) of desired size.
8. Use a flex hone with 180 grit stones for honing to final

TCAL28588 —UN—29JUN12
size.
9. Check the bore for size, taper and out-of-round.
Cylinder General Specifications—Specification
Cylinder Round-
ness—Distance................................................................0.01—0.03 mm
(0.000—0.001 in.)
Cylinder Round-
ness—Out-of-Round
(Wear Limit)................................................................................ 0.03 mm IMPORTANT: Do not use solvents to clean the cylinder
(0.001 in.) bores. Solvents will not remove all the metal
Cylinder Taper—Dis- particles and abrasives produced during honing.
tance.................................................................................0.00—0.01 mm
(0.00—0.0004 in.) 10. Clean the cylinder thoroughly using warm soapy water
Cylinder Taper—Distance until clean white rags show no discoloration.
(Wear Limit)................................................................................ 0.03 mm
(0.001 in.) 11. Dry the cylinder and apply engine oil.
OUMX258,0000BDF -19-15SEP14-3/3

TM130419 (24FEB16) 20-20-27 030916

PN=127
 Engine Repair—3TNV82A, 3TNV88

Crankshaft Rear Oil Seal—3TNV82A, 3TNV88

Replacement
1. Remove the drive shaft.
2. Remove flywheel. (See Remove and Install Flywheel
and Flex Plate—3TNV82A, 3TNV88.)
3. Remove the rear oil seal (A), case-to-crankcase
extension cap screws and the oil seal
case-to-crankcase cap screws (B).

TCAL28589 —UN—29JUN12
4. Remove the rear oil seal case (C).
5. Replace the oil seal using an appropriate seal driver,
with the lip toward the cylinder block, flush with the
surface of the oil seal case.
NOTE: If the crankshaft is grooved at the oil seal
contact point, the seal can be installed 3 mm
(0.12 in.) farther into the oil seal case.
A—Rear Oil Seal C—Oil Seal Case
6. Install the oil seal case to the crankcase and crankcase B—Cap Screws
extension.
OUMX258,0000BE0 -19-27MAR13-1/1

Crankshaft Front Oil Seal—3TNV82A, 3TNV88

1. Remove the timing gear cover (A). (See Remove and
Install Timing Gear Cover—3TNV82A, 3TNV88.)
2. Replace the oil seal (B). Install new seal with the lip
toward inside of gear housing cover, flush with the

TCAL28590 —UN—29JUN12
surface of the cover.

A—Timing Gear Cover B—Oil Seal

OUMX258,0000BE1 -19-27MAR13-1/1

TM130419 (24FEB16) 20-20-28 030916

PN=128
 Engine Repair—3TNV82A, 3TNV88

Check Crankshaft End Play—3TNV82A,

3TNV88
Reason
To determine proper side clearance between the
crankshaft and the engine block.
Special or Required Tools

• Dial Indicator

TCAL28521 —UN—29JUN12
Procedure
1. Fasten the dial indicator (A) to engine and position
indicator tip on end of crankshaft (B).
IMPORTANT: Do not use excessive force when
moving crankshaft to avoid damaging bearings.

2. Push the crankshaft toward rear as far as possible.

A—Dial Indicator B—Crankshaft End
3. Zero the dial indicator.
4. Using a bar, gently pry the crankshaft as far forward
as possible. Specification
Crankshaft—End Play......................................................0.13—0.23 mm
Results (0.005—0.009 in.)

• If the end play exceeds specification, replace the thrust

bearings.
OUMX258,0000BF8 -19-15SEP14-1/1

TM130419 (24FEB16) 20-20-29 PN=129

030916
 Engine Repair—3TNV82A, 3TNV88

Remove and Install Crankshaft and Main

Bearings—3TNV82A, 3TNV88
Remove
1. Check the crankshaft end play.
2. Remove the cylinder head. (See Remove and Install
Cylinder Head and Valves—3TNV82A, 3TNV88.)
3. Remove the rear oil seal. (See Crankshaft Rear Oil
Seal—3TNV82A, 3TNV88.)
4. Remove the timing gear cover mounting plate. (See
Remove and Install Timing Gear Cover Mounting
Plate—3TNV82A, 3TNV88.)
5. Check the crankshaft rod bearing clearance.

TCAL28591 —UN—29JUN12
IMPORTANT: Connecting rod caps must be installed
on the same connecting rods from which
they were removed. Note the alignment
marks on the caps and rods.

6. Check the crankshaft main bearing clearance.

(See Check Crankshaft Main Bearing
Clearance—3TNV82A, 3TNV88.)
IMPORTANT: Main bearing caps must be installed A—Bolts D—Crankshaft
on the same main bearings from which B—Caps E—Main Bearing Inserts
C—Thrust Bearings
they were removed.

7. Remove the connecting rod bolts and rod caps.

Discard the connecting rod bolts. NOTE: The main bearing caps have “raised arrows” that
are stamped with numbers. Both correspond to
8. Push the pistons and connecting rods away from their location on the engine block. Install all bearing
crankshaft. caps with the “arrow” toward the flywheel end of
9. Remove the main bearing bolts (A), caps (B) and cap the engine. Install the bearing caps beginning
thrust bearings (C). with the thrust bearing cap (no number), number
1, then 2, etc. The main bearing cap at the gear
10. Remove the crankshaft (D). train end does not have a number.
11. Remove the block thrust bearings and main bearing
5. Install the thrust bearings, with the oil grooves facing
inserts (E).
away from the cap, in the number “1” main bearing cap.
12. Inspect all parts for wear or damage.
6. Install the main bearing caps in their original locations
Install with arrows pointing toward the flywheel side of the
engine.
• Apply clean engine oil to all parts during installation. IMPORTANT: Do not use high speed power tools or
IMPORTANT: Do not touch bearing insert surfaces. air wrenches to tighten main bearing bolts.
Oil and acid from your finger will corrode
the bearing surface. 7. Dip each main bearing bolt entirely in clean engine
oil. Install the bolts and tighten. Do not tighten to
1. Install the grooved bearing inserts in the crankshaft specifications.
bearing bores, aligning the tangs with the slots in the
bores. 8. Using a soft-faced hammer, tap the front end of the
crankshaft then the rear end of the crankshaft to align
2. Install the block thrust bearings with the oil grooves the thrust bearings.
facing away from the engine block.
3. Install the crankshaft.
4. Install the bearing inserts in the main bearing caps,
aligning the tangs with the slots in the caps.

Continued on next page OUMX258,0000BE2 -19-15SEP14-1/6

TM130419 (24FEB16) 20-20-30 030916

PN=130
 Engine Repair—3TNV82A, 3TNV88

3TNV88 Connecting Rod

9. Tighten the main bearing cap bolts to specification.
Bolt—Torque.......................................................................... 44—49 N·m
When tightening, start at the center main bearing
(33—36 lb.-ft.)
cap and work your way out, alternating to the ends.
Turn the crankshaft by hand. If it does not turn easily, 12. Install the timing gear cover mounting plate. (See
disassemble the parts and find the cause. Remove and Install Timing Gear Cover Mounting
Crankshaft Main Bearing Cap Bolt Torque—Specification Plate—3TNV82A, 3TNV88.)
3TNV82A Main Bearing
13. Install the rear oil seal. (See Crankshaft Rear Oil
Cap Bolt—Torque.................................................................. 77—80 N·m
Seal—3TNV82A, 3TNV88.)
(57—59 lb.-ft.)
3TNV88 Main Bearing 14. Install the flywheel. (See Remove and Install Flywheel
Cap Bolt—Torque.................................................................. 93—98 N·m and Flex Plate—3TNV82A, 3TNV88.)
(69—72 lb.-ft.)
15. Install the timing gear cover. (See Remove and Install
IMPORTANT: The connecting rod caps must be Timing Gear Cover—3TNV82A, 3TNV88.)
installed on the same connecting rods they
were removed from. Never reuse connecting 16. Install the front oil seal. (See Crankshaft Front Oil
rod bolts, replace with new. Seal—3TNV82A, 3TNV88.)
17. Install the oil pan.
10. Match the connecting rod caps to the rods using
alignment marks. Install the caps to the rods. Inspection/Replacement
11. Dip entire connecting rod bolt in clean engine oil. Install • Inspect the crankshaft gear for chipped or broken teeth.
new bolts to the rods, and tighten to specification. Replace if necessary.
Crankshaft Connecting Rod Bolt Torque—Specification
3TNV82A Connecting
Rod Bolt—Torque.................................................................. 37—41 N·m
(27—30 lb.-ft.)
OUMX258,0000BE2 -19-15SEP14-2/6

Gear Replacement
1. Remove the gear from crankshaft using a knife-edge
puller and a press.

CAUTION: Do not heat oil over 182° C (360° F).

Oil fumes or oil can ignite above 193° C (380°

TCAL28592 —UN—29JUN12
F). Use a thermometer. Do not allow a flame or
heating element to come in direct contact with
the oil. Heat the oil in a well-ventilated area. Plan
a safe handling procedure to avoid burns.

2. Heat new gear to approximately 150° C (302° F).

Install gear with timing mark (G) toward press table.
Align slot in gear with key (F) in shaft. Press crankshaft
into gear until gear is tight against crankshaft shoulder.
F— Key G—Timing Mark

OUMX258,0000BE2 -19-15SEP14-3/6

TCAL28593 —UN—29JUN12
3. Inspect the crankshaft for bend using V-blocks and
a dial indicator. Turn the crankshaft slowly and read
variations on the indicator. If the variation is greater
than specification, replace the crankshaft.
Specification
Crankshaft —Bend
(Maximum)................................................................................. 0.02 mm
(0.001 in.)

Continued on next page OUMX258,0000BE2 -19-15SEP14-4/6

TM130419 (24FEB16) 20-20-31 PN=131

030916
 Engine Repair—3TNV82A, 3TNV88

4. Measure the crankshaft connecting rod journal (I) and

main bearing journal (H) diameters at several places
around each journal.

TCAL28594 —UN—29JUN12
• If any journal diameter is less than the specification,
but greater than the wear limit, have the journals
ground undersize by a qualified machine shop.
• If journals are ground, undersize bearing inserts
must be installed. Bearing inserts are available in
0.25 mm (0.010 in.) undersize.
• If the journal diameter is less than the wear limit,
replace the crankshaft.
Crankshaft Journals, 3TNV82A—Specification
3TNV82A Connecting H—Main Bearing Journal I— Connecting Rod Journal
Rod Journal—OD.........................................................42.95—42.96 mm
(1.691—1.691 in.)
3TNV88 Main Bearing
3TNV82A Connecting
Journal—OD.................................................................53.95—53.96 mm
Rod Journal—OD (Wear
(2.124—2.124 in.)
Limit)......................................................................................... 42.91 mm
3TNV88 Main Bearing
(1.689 in.)
Journal—OD (Wear
3TNV82A Main Bearing
Limit)......................................................................................... 53.90 mm
Journal—OD.................................................................46.95—46.96 mm
(2.122 in.)
(1.848—1.849 in.)
3TNV82A Main Bearing 5. Install the bearing inserts and main bearing caps on
Journal—OD (Wear the main bearings. Tighten the main bearing cap bolts
Limit)......................................................................................... 46.91 mm to specification.
(1.847 in.)
Crankshaft Main Bearing Cap Bolt Torque—Specification
Crankshaft Journals, 3TNV88—Specification 3TNV82A Main Bearing
3TNV88 Connecting Rod Cap Bolt—Torque.................................................................. 77—80 N·m
Journal—OD.................................................................47.95—47.96 mm (57—59 lb.-ft.)
(1.888—1.888 in.) 3TNV88 Main Bearing
3TNV88 Connecting Cap Bolt—Torque.................................................................. 93—98 N·m
Rod Journal—OD (Wear (69—72 lb.-ft.)
Limit)......................................................................................... 47.90 mm
(1.886 in.)
OUMX258,0000BE2 -19-15SEP14-5/6

6. Measure the main bearing inner diameter.

• Subtract the main bearing journal OD of the
crankshaft from the main bearing ID to obtain the

TCAL28595 —UN—29JUN12
main bearing oil clearance.
• If the crankshaft is within specification, but the main
bearing oil clearance exceeds the wear limit, replace
the bearing inserts.
• If the crankshaft is not within specification, have
crankshaft journals ground undersize by a qualified
machine shop and install undersized bearing inserts.
• If the crankshaft is worn past the wear limit, replace
the crankshaft.
Crankshaft Main Bearing Oil Clearance—Specification 7. Clean and inspect the oil passages in the main bearing
Main Bearing Oil journals, connecting rod journals and main bearing
Clearance—Clearance.....................................................0.04—0.07 mm bores in cylinder block.
(0.002—0.003 in.)
Main Bearing Oil 8. Inspect the crankshaft for cracks or damage. Replace
Clearance—Clearance if necessary.
(Wear Limit)................................................................................ 0.15 mm
(0.006 in.)
OUMX258,0000BE2 -19-15SEP14-6/6

TM130419 (24FEB16) 20-20-32 PN=132

030916
 Engine Repair—3TNV82A, 3TNV88

Check Connecting Rod Side Play—3TNV82A,

3TNV88
Reason
To determine proper side clearance between the
crankshaft and the connecting rod.

TCAL28518 —UN—29JUN12
NOTE: The engine must be removed from the
machine to perform this test.

Procedure
1. Remove the oil pan, crankcase extension, oil pick-up,
and balancer assembly.
2. Insert a feeler gage, according to specifications,
between the connecting rod cap and the crankshaft.
Specification Results
Connecting Rod—Side
Play......................................................................................0.2—0.4 mm • If the side play exceeds specification, replace the
(0.008—0.016 in.) bearing inserts or the connecting rod.
OUMX258,0000BF9 -19-15SEP14-1/1

Check Crankshaft Main Bearing

Clearance—3TNV82A, 3TNV88
Reason

TCAL28596 —UN—29JUN12
To measure oil clearance between main bearing and
crankshaft journal.
Procedure
NOTE: The engine must be removed from the
tractor to perform this test.

1. Remove the oil pan, oil pick-up, crankcase extension,

and balancer assembly.
A—Gauge Material
IMPORTANT: Main bearing caps must be installed to
the same location and in the same direction to
prevent crankshaft and main bearing damage.
NOTE: Lightly lubricate bolts with engine oil
2. Remove the main bearing cap. before installing.
3. Wipe oil from the bearing insert and the crankshaft 5. Install main bearing cap and bolts. Tighten bolts to
journal. specification.
IMPORTANT: Rotating the crankshaft will cause 6. Remove bolts and main bearing cap.
PLASTIGAGE to smear, resulting in a false
reading. Do not allow crankshaft to rotate
after installing bearing cap.

4. Put a piece of Plastigage® (A), or equivalent, along

the full width of the bearing insert approximately 6 mm
(0.25 in.) off center.
Plastigage is a trademark of Perfect Circle Corporation
Continued on next page OUMX258,0000BE3 -19-15SEP14-1/2

TM130419 (24FEB16) 20-20-33 030916

PN=133
 Engine Repair—3TNV82A, 3TNV88

NOTE: The flattened Plastigage® will be found on either

the bearing insert or crankshaft journal.

7. Use the graduation marks on the envelope (B) to

compare the width of the flattened Plastigage® (C) at its

TCAL28597 —UN—29JUN12
widest point. The number within the graduation marks
indicates the bearing clearance in inches or millimeters
depending on which side of the envelope is used.
8. Main bearing clearance must be to specification.
Crankshaft Main Bearing Oil Clearance—Specification
Main Bearing—Oil
Clearance.........................................................................0.04—0.07 mm
(0.002—0.003 in.)
Main Bearing—Oil B—Graduation Marks C—Gauge Material
Clearance (Wear Limit).............................................................. 0.15 mm
(0.006 in.)

9. Remove Plastigage®.
Results
If the clearance exceeds maximum specification, replace
the bearing inserts.
OUMX258,0000BE3 -19-15SEP14-2/2

Remove and Install Flywheel and Flex

Plate—3TNV82A, 3TNV88
Removal and Installation
IMPORTANT: Always install new flywheel
mounting bolts.

TCAL28598 —UN—29JUN12
1. Remove eight cap screws (A) and flex plate (B).

A—Cap Screws (8 used) B—Flex Plate

Continued on next page OUMX258,0000BE4 -19-15SEP14-1/2

TM130419 (24FEB16) 20-20-34 030916

PN=134
 Engine Repair—3TNV82A, 3TNV88

IMPORTANT: Always install new flywheel

mounting cap screws.

2. Remove the flywheel mounting bolts (C) and remove

the flywheel (D) from crankshaft.
3. Use pin (E) in crankshaft to correctly locate the

TCAL28599 —UN—29JUN12
flywheel on the crankshaft.
4. Install the flywheel. Apply lubrication oil to the
mounting bolts and tighten to specification.
Specification
Flywheel Mounting
Bolts (Lubricating Oil
Applied)—Torque................................................................... 83—88 N·m
(62—65 lb.-ft.)
Flex Plate Mounting Cap C—Bolts E—Pin
Screws—Torque............................................................................41 N·m D—Flywheel
(30 lb.-ft.)

5. Install flex plate with raised hub facing away from 6. Install cap screws and tighten to specification.
flywheel.
OUMX258,0000BE4 -19-15SEP14-2/2

Check Camshaft End Play—3TNV82A,

3TNV88
Reason
To determine proper side clearance between camshaft
gear end journal and thrust plate.

TCAL28525 —UN—29JUN12
Special or Required Tools

• Dial Indicator
Procedure
1. Remove the timing gear cover. (See Remove and
Install Timing Gear Cover—3TNV82A, 3TNV88.)
2. Fasten the dial indicator to the engine and position
indicator tip on end of camshaft.
Specification
3. Push the camshaft toward the rear as far as possible. Camshaft—End Play........................................................0.05—0.20 mm
4. Zero the dial indicator. (0.002—0.008 in.)

5. Pull the camshaft forward as far as possible.

Results

• If the end play exceeds specification, remove the

camshaft and replace the thrust plate.
OUMX258,0000BFB -19-15SEP14-1/1

TM130419 (24FEB16) 20-20-35 PN=135

030916
 Engine Repair—3TNV82A, 3TNV88

Remove and Install Camshaft—3TNV82A,

3TNV88
Remove
1. Remove the rocker arm assembly and push rods. (See
Service Rocker Arm Assembly—3TNV82A, 3TNV88.)
2. Remove the timing gear cover. (See Remove and
Install Timing Gear Cover—3TNV82A, 3TNV88.)

TCAL28600 —UN—29JUN12
3. Check the camshaft end play. (See Check Camshaft
End Play—3TNV82A, 3TNV88.)
4. Check the backlash of the timing gears. (See Check
Timing Gear Backlash—3TNV82A, 3TNV88.)
NOTE: If a magnetic follower holder kit is not available,
turn engine until oil pan is upward, to hold cam
followers away from camshaft.
A—Timing Marks B—Cap Screws
5. Hold the cam followers away from the camshaft using
a magnetic follower holder kit such as D15001NU.
NOTE: Several rotations may be required to line Install
up all timing marks. Apply clean engine oil on all parts during installation.
6. Rotate the crankshaft and align the timing marks (A). IMPORTANT: DO NOT allow camshaft lobes
to hit bearing surfaces while installing
IMPORTANT: DO NOT allow the camshaft lobes to camshaft. Machined surfaces and bearings
hit any bearing surfaces while removing the can be damaged.
camshaft. Machined surfaces can be damaged.
NOTE: Several rotations may be required to line
7. Remove two thrust plate mounting cap screws (B), the up all timing marks.
thrust plate, and the camshaft.
8. Inspect all parts for wear or damage.
OUMX258,0000BE5 -19-15SEP14-1/2

1. Rotate the crankshaft to align the timing marks (A, B

and C).
2. Install the camshaft.
3. Install the thrust plate and thrust plate mounting cap
screws. Tighten cap screws to specification.
Specification
Thrust Plate Mounting TCAL28601 —UN—29JUN12
Cap Screws—Torque....................................................................26 N·m
(226 lb.-in.)

4. Install the timing gear cover.

5. Install push rods and rocker arm assembly.

A—Timing Mark C—Timing Mark

B—Timing Mark

OUMX258,0000BE5 -19-15SEP14-2/2

TM130419 (24FEB16) 20-20-36 030916

PN=136
 Engine Repair—3TNV82A, 3TNV88

Inspect Camshaft—3TNV82A, 3TNV88

Camshaft End Play
1. Check the camshaft end play (A) using a feeler gage.
2. If the end play exceeds specification, remove the
camshaft gear (B) and replace thrust plate (C). (See
Remove and Install Camshaft Gear—3TNV82A,
3TNV88.)
Specification
Camshaft—End Play........................................................0.05—0.20 mm
(0.002—0.010 in.)

TCAL28602 —UN—29JUN12
Camshaft—End Play
(Wear Limit)................................................................................ 0.30 mm
(0.012 in.)

A—Camshaft End Play C—Thrust Plate

B—Camshaft Gear

OUMX258,0000BE6 -19-15SEP14-1/7

Camshaft Bend
Inspect the camshaft for bend using V-blocks and a dial
indicator. Turn the camshaft slowly and read variation on
the indicator.
• If the variation is greater than specification, replace the
camshaft.

TCAL28603 —UN—29JUN12
Specification
Camshaft—Bend
(Maximum)................................................................................. 0.02 mm
(0.0021 in.)

OUMX258,0000BE6 -19-15SEP14-2/7

Camshaft Lobe Height

TCAL28604 —UN—29JUN12
Measure the camshaft lobe height (A) and compare with
specifications.
Camshaft Lobe Height—Specification
Camshaft Lobe—Height...............................................38.64—38.77 mm
(1.521—1.526 in.)
Camshaft Lobe—Height
(Wear Limit).............................................................................. 38.40 mm
(01.512 in.)

• If the lobe height is less than wear limit, replace the

camshaft.
Continued on next page OUMX258,0000BE6 -19-15SEP14-3/7

TM130419 (24FEB16) 20-20-37 030916

PN=137
 Engine Repair—3TNV82A, 3TNV88

Camshaft Journals
1. Measure gear housing (C) and flywheel end (A)
camshaft journal outside diameters and compare with
specifications.

TCAL28605 —UN—29JUN12
Specification
Gear Housing and
Flywheel End Camshaft
Journal—OD.................................................................44.93—44.95 mm
(1.769—1.770 in.)

2. Measure intermediate (B) camshaft journal outside

diameters and compare with specifications.
Specification
Intermediate Camshaft
A—Flywheel End Journal C—Gear Housing Journal
Journal—OD...................................44.91—44.94 mm (1.768—1.769 in.) B—Intermediate Journal
3. If journal diameters are less than wear limit, replace
the camshaft.
Specification
Camshaft Journal—OD
(Wear Limit).............................................................................. 44.88 mm
(1.766 in.)

OUMX258,0000BE6 -19-15SEP14-4/7

Camshaft Bushings
1. Measure the camshaft bushing (A) inside diameter at
the gear housing end and compare with specifications.
Camshaft Bushing ID—Specification

TCAL28606 —UN—29JUN12
Camshaft Bushing ID at
Gear Housing—ID........................................................44.99—45.06 mm
(1.771—1.774 in.)
Camshaft Bushing ID at
Gear Housing—ID (Wear
Limit)......................................................................................... 45.10 mm
(1.776 in.)

2. If bushing diameter exceeds wear limit, replace

bushing. A—Camshaft Bushing B—Oil Holes
3. If bushing clearance (bushing ID minus camshaft
journal OD) exceeds specification, replace bushing,
camshaft or both. b. Align the oil holes (B) in new bushing and cylinder
block. Install bushing using a driver set.
Specification
Camshaft Bushing- NOTE: Flywheel plate must be removed to measure
to-Camshaft camshaft intermediate and flywheel end
Journal—Clearance.................................................................... 0.23 mm bearing diameters.
(0.009 in.)
5. Remove flywheel plate.
4. If replacing the camshaft bushing
a. Use a chisel to remove the bushing. Be careful not
to push the bushing inside the engine.
Continued on next page OUMX258,0000BE6 -19-15SEP14-5/7

TM130419 (24FEB16) 20-20-38 030916

PN=138
 Engine Repair—3TNV82A, 3TNV88

6. Remove plug (C) using a long wooden dowel. Insert

wooden dowel through gear housing side.

C—Plug

TCAL28607 —UN—29JUN12
OUMX258,0000BE6 -19-15SEP14-6/7

7. Measure the intermediate (D) and flywheel end

(E) camshaft bore diameters and compare with
specifications.
Camshaft Bushing ID—Specification
Camshaft Bushing ID

TCAL28608 —UN—29JUN12
at Intermediate and
Flywheel End—ID.........................................................45.00—45.03 mm
(1.772—1.773 in.)
Camshaft Bushing ID
at Intermediate and
Flywheel End—ID (Wear
Limit)......................................................................................... 45.10 mm
(1.776 in.)
Camshaft Bushing-
to-Camshaft D—Intermediate Camshaft E—Flywheel End Camshaft
Journal—Clearance.................................................................... 0.23 mm Bore Bore
(0.009 in.)

8. Apply John Deere™ Form-In-Place Gasket, or an

equivalent, on the outer edge of the plug. Install the
plug until it bottoms in the bore.
John Deere is a trademark of Deere & Company
OUMX258,0000BE6 -19-15SEP14-7/7

TM130419 (24FEB16) 20-20-39 030916

PN=139
 Engine Repair—3TNV82A, 3TNV88

Remove and Install Camshaft

Gear—3TNV82A, 3TNV88

CAUTION: DO NOT heat oil over 182°C (360°F).

Oil fumes or oil can ignite above 193° C (380°

TCAL28609 —UN—29JUN12
F). Use a thermometer. Do not allow a flame or
heating element to come in direct contact with
the oil. Heat the oil in a well-ventilated area. Plan
a safe handling procedure to avoid burns.

1. Heat the gear in oil to approximately 150° C (300° F).

IMPORTANT: Be sure thrust plate is not between
camshaft gear and camshaft shoulder
while installing gear. A—Key C—Thrust Plate
B—Gear
NOTE: Thrust plate must spin freely on camshaft.

2. Install the thrust plate (C) if removed. Install the gear camshaft into gear until gear is tight against camshaft
(B) with timing mark “C” side toward press table. Align shoulder.
the slot in the gear with key (A) in shaft. Press the
OUMX258,0000BE7 -19-15SEP14-1/1

Remove and Install Camshaft

TCAL28610 —UN—29JUN12
Followers—3TNV82A, 3TNV88
Special or Required Tools

• Magnetic Pick-Up Tool

Removal and Installation
1. Remove the camshaft. (See Remove and Install
Camshaft—3TNV82A, 3TNV88.)
A—Normal Contact B—Abnormal Wear
2. Remove the oil pan and strainer.
IMPORTANT: Cam followers must be installed in the
same bores from which they were removed.

3. Put a mark on each cam follower and the cylinder

block bore to aid in installation.
4. Remove the cam followers.
5. Inspect all parts for wear or damage.
6. Apply clean engine oil to all parts during installation.
• Installation is done in the reverse order of removal.
Inspection
1. Inspect the cam follower contact surface for normal
contact (A) or abnormal wear (B). Replace if necessary.
Continued on next page OUMX258,0000BE8 -19-15SEP14-1/2

TM130419 (24FEB16) 20-20-40 030916

PN=140
 Engine Repair—3TNV82A, 3TNV88

2. Measure the cam follower stem diameter.

TCAL28611 —UN—29JUN12
• If the stem diameter is less than specification,
replace cam follower.
Camshaft Follower Stem—Specification
Camshaft Follower
Stem—OD.................................................................... 11.98—11.99 mm
(0.471—0.472 in.)
Camshaft Follower
Stem—OD (Wear Limit)............................................................11.96 mm
(0.471 in.)
• If the bore clearance (bore ID minus follower stem
3. Measure the cam follower bore diameter in the OD) exceeds specification, replace the cam follower,
cylinder block. cylinder block or both.
Camshaft Follower Oil Clearance—Specification
• If the cam follower bore diameter exceeds wear limit, Camshaft Follower
replace the cylinder block.
Stem-to-Bore—Oil
Camshaft Follower Bore—Specification Clearance.........................................................................0.01—0.05 mm
Camshaft Follower (0.001—0.002 in.)
Bore—ID.......................................................................12.00—12.03 mm Camshaft Follower
(0.472—0.474 in.) Stem-to-Bore—Oil
Camshaft Follower Clearance (Wear Limit).............................................................. 0.09 mm
Bore—ID (Wear Limit).............................................................. 12.05 mm (0.004 in.)
(0.474 in.)
OUMX258,0000BE8 -19-15SEP14-2/2

Remove and Install Timing Gear

Cover—3TNV82A, 3TNV88
Remove and Install
1. Remove oil pan and pan extension

TCAL28613 —UN—29JUN12
2. Remove the alternator and belt.
3. Remove the coolant pump pulley.
4. Remove the crankshaft pulley cap screw and washer.
5. Remove the crankshaft pulley using a puller.
NOTE: It is not necessary to remove end cover and
O-ring or fuel injection pump gear cover to
remove timing gear cover. K—Pin L— Hole

6. Remove timing gear cover.

7. Inspect the crankshaft oil seal for wear or damage. • Apply a thin bead of TY16135 RTV Form-in-Place
Replace if necessary. Gasket to timing gear cover prior to installation.
• Replace the seal washer.
• Replace the oil seal using a driver set. Install the • Align the pin (K) in crankshaft pulley with the hole (L)
seal with lip toward inside of gear housing cover. in the crankshaft gear. Install the crankshaft pulley.
Install the seal flush with surface of cover. • Adjust the fan/alternator drive belt tension.
8. Installation is done in the reverse order of removal.
OUMX258,0000BE9 -19-27MAR13-1/1

TM130419 (24FEB16) 20-20-41 PN=141

030916
 Engine Repair—3TNV82A, 3TNV88

Check Timing Gear Backlash—3TNV82A,

3TNV88
Reason
To check for wear between meshing gears, resulting in
excessive noise and poor engine performance.
Special or Required Tools

• Dial Indicator

TCAL28526 —UN—29JUN12
Procedure
Measure the backlash between meshing gears.
Results
If the backlash exceeds specifications, replace meshing
gears as a set:
Specification A—Fuel Injection Pump Gear C—Camshaft Gear
Timing Gear—Backlash....................................................0.07—0.15 mm B—Idler Gear D—Crankshaft Gear
(0.002—0.006 in.)

OUMX258,0000BFA -19-15SEP14-1/1

TM130419 (24FEB16) 20-20-42 030916

PN=142
 Engine Repair—3TNV82A, 3TNV88

Remove and Install Idler Gear—3TNV82A,

3TNV88
Remove and Install
1. Remove the timing gear cover. (See Remove and

TCAL28614 —UN—29JUN12
Install Timing Gear Cover—3TNV82A, 3TNV88.)
2. Check the backlash of timing gears. (See Check
Timing Gear Backlash—3TNV82A, 3TNV88.)
NOTE: Due to the odd number of teeth on the idler gear,
timing marks will only align periodically. When all
timing marks on gears align, the piston closest to
the water pump is at TDC on compression stroke.
Number one cylinder is closest to the flywheel.
A—Cap Screws C—43T Gear
3. Rotate the crankshaft and align the timing marks. B—Shaft

4. Remove two cap screws (A), shaft (B) and 43T gear
(C).
• Replace the bushing if diameter exceeds
5. Inspect all parts for wear or damage. specification.
Installation is done in the reverse order of removal. Idler Gear Bushings ID—Specification
Idler Gear Bushing—ID................................................46.00—46.03 mm
6. Inspect the gear for chipped or broken teeth. Replace (1.811—1.812 in.)
if necessary. Idler Gear Bushing—ID
• Measure the idler gear shaft diameter. (Wear Limit).............................................................................. 46.08 mm
• If the shaft diameter is less than specification, Idler Gear Bushing-to-
(1.814 in.)
replace idler gear shaft.
Bore—Clearance........................................................................ 0.18 mm
Idler Gear Shaft OD—Specification (0.007 in.)
Idler Gear Shaft—OD...................................................45.95—45.98 mm
(1.809—1.810 in.) • If the bore clearance (bushing ID minus shaft OD)
Idler Gear Shaft—OD exceeds specification, replace the bushing, shaft,
(Wear Limit).............................................................................. 45.90 mm or both.
(1.807 in.)

7. Measure the idler gear bushing diameter.

OUMX258,0000BEA -19-16SEP14-1/2

Replace Bushing
1. Replace the bushing using a driver set.

TCAL28615 —UN—29JUN12
2. Align the oil holes in bushing (D) and idler gear (C).
3. Install the bushing flush with surface of idler gear.

B—Driver D—Bushing
C—Idler Gear

OUMX258,0000BEA -19-16SEP14-2/2

TM130419 (24FEB16) 20-20-43 PN=143

030916
 Engine Repair—3TNV82A, 3TNV88

Remove and Install Timing Gear Cover 3. Remove the fuel injection pump.
Mounting Plate—3TNV82A, 3TNV88
4. Remove the oil pump. (See Remove, Inspect, and
Remove and Install Install Oil Pump—3TNV82A, 3TNV88.)
1. Remove the camshaft. (See Remove and Install 5. Remove the mounting cap screws and plate.
Camshaft—3TNV82A, 3TNV88.)
6. Replace the O-rings.
2. Remove the idler gear. (See Remove and Install Idler
Gear—3TNV82A, 3TNV88.) 7. Installation is the reverse of removal.
OUMX258,0000BEB -19-27MAR13-1/1

Remove and Install Oil Pan, Crankcase

Extension, and Strainer—3TNV82A, 3TNV88
Remove
NOTE: Engine must be removed from machine
to remove the oil pan.

1. Remove six (A) and sixteen (B) cap screws. Remove

oil pan (C).
2. Remove cap screws for strainer and remove strainer
(D) and gasket (E).

TCAL28616 —UN—29JUN12
3. If crankcase extension (F) is being removed, remove:
flywheel, three lower cap screws (G) in rear oil seal
housing, four flywheel housing cap screws (H), and
six cap screws (I) in front. Then remove crankcase
extension.
Install
Installation is done in the reverse order of removal.
A—Cap Screws (6 used) F— Crankcase Extension
• Clean all mounting surfaces. B—Cap Screws (16 used) G—Cap Screws (3 used)
• Replace strainer gasket. C—Oil Pan
D—Strainer
H—Cap Screws (4 used)
I— Cap Screws (6 used)
• Apply ULTRA BLUE® RTV Silicone Form-in-Place E—Gasket
Gasket to oil pan and crankcase extension.
ULTRA BLUE is a trademark of Loctite Corp.
OUMX258,0000BEC -19-19DEC13-1/1

TM130419 (24FEB16) 20-20-44 030916

PN=144
 Engine Repair—3TNV82A, 3TNV88

Remove, Inspect, and Install Oil

Pump—3TNV82A, 3TNV88
Removal and Installation
1. Remove the timing gear cover. (See Remove and

TCAL28625 —UN—29JUN12
Install Timing Gear Cover—3TNV82A, 3TNV88.)
2. Check the oil pump gear backlash. Replace the
entire oil pump assembly if backlash is not within
specification.
Specification
Oil Pump
Gear—Backlash............................................................... 0.11—0.19 mm
(0.004—0.007 in.)
Oil Pump A—Oil Pump Assembly
Gear—Backlash (Wear
Limit)........................................................................................... 0.21 mm
(0.008 in.) 4. Inspect all parts for wear or damage.
3. Remove the mounting cap screws, the oil pump
assembly (A) and gasket from the mounting plate.
OUMX258,0000BEE -19-15SEP14-1/6

Disassemble and Assemble

1. The gear (B) is press fit on rotor shaft (C). Remove
gear using a knife-edge puller and a press.
2. Inspect all parts for wear or damage.
3. Measure the rotor shaft outer diameter and the shaft

TCAL28626 —UN—29JUN12
hole diameter in cover.
• Replace the pump if the clearance is not within
specification.
Specification
Rotor Shaft OD-to-
Side Cover Bore
ID—Clearance..................................................................0.01—0.04 mm
(0.001—0.002 in.)
Rotor Shaft OD-to- B—Gear C—Rotor Shaft
Side Cover Bore
ID—Clearance (Wear
Limit)........................................................................................... 0.20 mm
(0.08 in.)
Continued on next page OUMX258,0000BEE -19-15SEP14-2/6

TM130419 (24FEB16) 20-20-45 030916

PN=145
 Engine Repair—3TNV82A, 3TNV88

4. Check the rotor recess with a straightedge and feeler

gauge.
• Replace the pump if the recess exceeds specification.
Specification

TCAL28627 —UN—29JUN12
Oil Pump Inner
Rotor—Recess.................................................................0.03—0.09 mm
(0.001—0.004 in.)
Oil Pump Inner
Rotor—Recess (Wear
Limit)........................................................................................... 0.15 mm
(0.006 in.)

OUMX258,0000BEE -19-15SEP14-3/6

5. Check clearance between outer rotor (D) and pump

body (E).
• Replace the pump if the clearance exceeds
specification.

TCAL28628 —UN—29JUN12
Specification
Oil Pump Outer
Rotor-to-Pump
Body—Clearance.............................................................0.10—0.16 mm
(0.004—0.006 in.)
Outer Rotor-to-Pump
Body—Clearance (Wear
Limit)........................................................................................... 0.25 mm
(0.010 in.) D—Outer Rotor E—Pump Body

OUMX258,0000BEE -19-15SEP14-4/6

6. Check clearance between inner rotor (F) and outer

rotor (D). Replace the pump if clearance is not within
specification.
Specification

TCAL28629 —UN—29JUN12
Inner Rotor-to-Outer
Rotor—Clearance (Wear
Limit)........................................................................................... 0.15 mm
(0.006 in.)

7. Coat all parts with clean engine oil.

8. Install the outer rotor with identification mark facing
toward rotor shaft assembly.

D—Outer Rotor F— Inner Rotor

Continued on next page OUMX258,0000BEE -19-15SEP14-5/6

TM130419 (24FEB16) 20-20-46 030916

PN=146
 Engine Repair—3TNV82A, 3TNV88

9. Check the oil pressure relief valve. If the relief valve

piston (G) is sticking in the pump body (H), clean parts
to allow movement of the piston.
10. Inspect the spring (I) for cracks. The spring is not
serviceable. If damage is identified, replace the oil
pump assembly.

TCAL28630 —UN—29JUN12
G—Piston I— Spring
H—Pump Body

OUMX258,0000BEE -19-15SEP14-6/6

Remove and Install Thermostat—3TNV82A,

3TNV88
Remove
1. Drain coolant from radiator.

TCAL28631 —UN—29JUN12
2. Remove air cleaner assembly.
3. Remove upper radiator hose (A).
4. Remove cap screws (B), thermostat flange and gasket.
5. Remove thermostat from housing.
6. Inspect all parts for wear or damage. Replace as
necessary.
7. Test thermostat. (See Test Thermostat A—Upper Radiator Hose B—Cap Screws
Opening—3TNV82A, 3TNV88.)
Install
Installation is done in reverse order of removal.
OUMX258,0000BEF -19-30DEC13-1/1

TM130419 (24FEB16) 20-20-47 030916

PN=147
 Engine Repair—3TNV82A, 3TNV88

Inspect, Remove, and Install Water

Pump—3TNV82A, 3TNV88
Inspect
1. Inspect the water pump for coolant leakage. If
the origin of the leak cannot be determined, test
the cooling system. (See Pressure Test Cooling
System—3TNV82A, 3TNV88.)
• If coolant is leaking at the pulley flange: The shaft
seal is defective. Replace the coolant pump.
• If coolant is leaking between the cylinder head and
the pump housing: The gasket between the head
and the pump is defective. Remove the pump and
replace the gasket.
2. Inspect the pump for a worn bearing shaft by removing

TCAL28632 —UN—29JUN12
the fan belt and checking for excessive movement of
the fan. Replace the pump if excessive movement is
noticed.
• If the bearing shaft is making noise when operating:
Check the fan belt tension. If adjustment does not
relieve the noise, the bearing shaft is defective.
Replace the water pump.
Remove
1. Drain engine coolant. 9. Remove the mounting cap screws, pump and gasket.
2. Remove air cleaner assembly. 10. Inspect the pump for wear or damage.
3. Remove the water pump/alternator drive belt. 11. Test the thermostat for proper operation.
4. Remove the coolant pump pulley. Install
5. Disconnect the upper and lower radiator hoses. Installation is done in the reverse order of removal.
6. Disconnect electrical connector from coolant • Adjust the water pump/alternator drive belt tension.
temperature sensor. (See Adjust Fan and Alternator Drive Belt—3TNV82A,
3TNV88.)
7. Remove coolant line and bracket securing line to pump.
8. Remove lines to coolant pump.
OUMX258,0000BF0 -19-30DEC13-1/1

TM130419 (24FEB16) 20-20-48 030916

PN=148
 Engine Repair—3TNV82A, 3TNV88

Remove, Install and Inspect

Radiator—3TNV82A, 3TNV88
Remove

CAUTION: Explosive release of fluids from

pressurized cooling system can cause serious
burns. Shut off engine. Remove filler cap
only when cool enough to touch with bare
hands. Slowly loosen cap to first stop to relieve

TCAL28633 —UN—29JUN12
pressure before removing cap.

1. Park machine safely.

2. Turn key switch to stop position and allow the engine
to cool.
3. Remove engine cover.
4. Loosen radiator cap to first stop to relieve pressure.
A—Drain Valve C—Hose
5. Remove radiator cap. B—Overflow Hose

6. Attach a 12-inch hose to drain valve (A) located on

lower right side of radiator.
8. Remove hose (C) from radiator.
7. Disconnect overflow hose (B) from radiator.
OUMX258,0000BF1 -19-15SEP14-1/3

9. Remove hose (D) from radiator.

10. Remove hose (E).
11. Remove shroud cap screws (F) and move shroud from
radiator.

D—Hose F— Cap Screws

E—Hose

TCAL28634 —UN—29JUN12
Continued on next page OUMX258,0000BF1 -19-15SEP14-2/3

TM130419 (24FEB16) 20-20-49 030916

PN=149
 Engine Repair—3TNV82A, 3TNV88

12. Disconnect oil cooler hoses (G) from oil cooler lines.
IMPORTANT: Avoid Damage! Use caution when
moving oil cooler aside to prevent damaging fins.

13. Peel back foam and remove four cap screws (H)
securing radiator and oil cooler to frame. Carefully
remove the radiator and oil cooler assembly from the

TCAL28635 —UN—29JUN12
machine.
14. Remove cap screws (I) and separate radiator (J) from
oil cooler and seal plate.
Install
Installation is done in the reverse order of removal.
• Start engine and watch coolant level in radiator. Add
coolant if necessary to bring coolant level up to filler
G—Oil Cooler Hoses I— Cap Screws
neck. H—Cap Screws J— Radiator
Specification
Cooling System—Capac-
ity (Approximately)............................................................................ 7.5 L IMPORTANT: Do not apply high-pressure spray
(8 qt.) directly at fins when cleaning the radiator,
Inspect as this could result in damage. Direct the
spray parallel to the fins.
CAUTION: Reduce compressed air to less
1. Check radiator for debris lodged in fins. Clean radiator
than 210 kPa (30 psi) when using for cleaning
using compressed air or pressure washer.
purposes. Clear area of bystanders, guard
against flying chips, and wear personal protection 2. Inspect radiator for bent fins, cracks, and damaged
equipment, including eye protection. seams. Repair or replace radiator if necessary.
OUMX258,0000BF1 -19-15SEP14-3/3

TM130419 (24FEB16) 20-20-50 030916

PN=150
 Engine Repair—3TNV82A, 3TNV88

Disassemble and Assemble Water

Separator—3TNV82A, 3TNV88
IMPORTANT: Replace all copper washers on
injection pump fittings. Damaged or used
washers will leak.
Always use new O-ring seals when
replacing separator.

1. Remove the retaining ring (A) from the mounting base

(B) while holding on to the separator bowl (C).
2. Remove the separator bowl from the mounting base.

TCAL28636 —UN—29JUN12
3. Remove and replace O-ring (D) and strainer (E).
4. Remove shutoff valve cover. Inspect and replace
wave washer (F) and O-ring (G) as necessary.
5. Before installing the bowl and strainer in the mounting
base, verify the O-ring is in the groove inside the
mounting base.
6. Install the separator bowl and the strainer in the
mounting base. A—Retaining Ring E—Strainer
B—Mounting Base F— Wave Washer
IMPORTANT: Tighten only enough to keep the C—Separator Bowl G—O-Ring
filter assembly from leaking. Overtightening D—O-Ring
the retaining nut may damage the filter
cover or retaining ring.

7. Place the retaining ring over separator bowl and screw

on the mounting base to retain bowl to mounting base.
OUMX258,0000BF2 -19-27MAR13-1/1

TM130419 (24FEB16) 20-20-51 030916

PN=151
 Engine Repair—3TNV82A, 3TNV88

Remove Fuel Injection Pump—3TNV82A,

3TNV88
CAUTION: Escaping fluid under pressure can
penetrate the skin causing serious injury.
Avoid the hazard by relieving pressure
before disconnecting hydraulic or other
high-pressure lines. Tighten all connections

TCAL28637 —UN—29JUN12
before applying pressure. Search for leaks
with a piece of cardboard. Protect hands and
body from high-pressure fluids.
If an accident occurs, see a doctor immediately.
Any fluid injected into the skin, must be
surgically removed within a few hours or
gangrene may result. Doctors unfamiliar
with this type of injury should reference a
knowledgeable source. Such information is A—Fuel Lines E—Coolant Lines
available from the Deere & Company Medical B—Fuel Lines F— Connector
C—Fuel Lines G—Foam Spacer
Department, Moline, Illinois, U.S.A. D—Coolant Lines

IMPORTANT: DO NOT attempt to service the injection

pump or governor. If unit is in need of repair,
it must be serviced by a qualified EPA/CARB 6. Disconnect fuel shutoff solenoid wire connector (F).
certified fuel injection repair shop.
7. Remove foam spacer (G).
DO NOT rotate engine while injection pump is
removed. If engine is rotated, timing gear cover
must be removed to ensure correct timing.

IMPORTANT: Never steam clean or pour cold water

on injection pump while the pump is running or
warm. Doing so can damage the pump.

1. Clean injection pump lines and area around pump

using a parts cleaning solvent or steam cleaner.
2. Drain engine coolant to level below injection pump.
3. Remove intake manifold. (See Remove and Install
Intake Manifold—3TNV82A, 3TNV88.)
4. Disconnect throttle cable.
5. Disconnect fuel lines (A-C) and coolant lines (D and E).
Continued on next page OUMX258,0000BF3 -19-30DEC13-1/5

TM130419 (24FEB16) 20-20-52 030916

PN=152
 Engine Repair—3TNV82A, 3TNV88

8. Remove cap screws (H) and remove access cover.

H—Cap Screws

TCAL28638 —UN—29JUN12
OUMX258,0000BF3 -19-30DEC13-2/5

9. Rotate engine in direction of rotation until timing mark

(I) on pump gear aligns with mark on idler gear (J).

I— Pump Gear Timing Mark J— Idler Gear Timing Mark

TCAL28639 —UN—29JUN12
Continued on next page OUMX258,0000BF3 -19-30DEC13-3/5

TM130419 (24FEB16) 20-20-53 030916

PN=153
 Engine Repair—3TNV82A, 3TNV88

IMPORTANT: Gear-to-hub adjustment is pre-set by

the engine manufacturer to comply with strict
California Air Resources Board/Environmental
Protection Agency (CARB/EPA) emissions
requirements and is NOT adjustable. Tampering
with the gear-to-hub adjustment may result
in severe fines or penalties. If hub or gear is
damaged, the entire engine must be replaced.

TCAL28640 —UN—29JUN12
DO NOT loosen or disturb cap screws (K)
securing gear to hub. This gear/hub assembly
times the injector pump camshaft in relation
with the crankshaft for precise timing of
EPA engines. This procedure is done at
the pump manufacturing plant and cannot
be duplicated in the field!

10. Remove nut (L) and lock washer from pump shaft.
11. Install puller using tapped M8 holes (M) in gear.
12. Remove gear from pump shaft. The gear will remain
in timing cover.

TCAL28641 —UN—29JUN12
K—Nuts M—M8 Holes
L— Nut

Continued on next page OUMX258,0000BF3 -19-30DEC13-4/5

TM130419 (24FEB16) 20-20-54 030916

PN=154
 Engine Repair—3TNV82A, 3TNV88

13. Note the position of timing marks on gear cover

mounting plate (N) and injection pump (O).
IMPORTANT: Pump must be installed at exact
location from which it was removed.

14. Remove lube line (P) from pump.

15. Remove cap screw (Q) from bracket.

TCAL28642 —UN—29JUN12
IMPORTANT: Do not attempt to service the injection
pump or governor. If unit is in need of
repair, it must be serviced by a qualified
fuel injection repair shop. If replacement is
necessary, replace the entire unit.

16. Remove three pump mounting nuts (R) and remove

pump.

N—Gear Cover Mounting Plate Q—Cap Screw

O—Injection Pump R—Nuts (3 used)
P—Lube Line

TCAL28643 —UN—29JUN12
OUMX258,0000BF3 -19-30DEC13-5/5

TM130419 (24FEB16) 20-20-55 030916

PN=155
 Engine Repair—3TNV82A, 3TNV88

Install Fuel Injection Pump—3TNV82A,

3TNV88
1. Install new O-ring on injection pump.
2. Put injection pump onto back of gear cover mounting
plate. Install three mounting nuts and one cap screw
through bracket. Do not tighten. Align key on shaft
with keyway in gear. Be sure to align marks on gears

TCAL28644 —UN—29JUN12
made during removal.
3. Install nut on timing gear. Tighten to specification.
Specification
Fuel Injection Pump
Drive Gear Nut (No
Lubricant)—Torque................................................................ 78—88 N·m
(58—65 lb.-ft.)

4. Align marks on mounting plate (A) and injection pump A—Mounting Plate B—Injection Pump
(B) to the exact location as when removed. Tighten
nuts and cap screw securely.
5. Place a thin bead of TY16367 John Deere™
Form-In-Place Gasket on access cover and install.
John Deere is a trademark of Deere & Company
OUMX258,0000BF4 -19-15SEP14-1/2

6. Install foam spacer (C).

7. Install fuel lines (D, E, and F).
8. Install coolant lines (G and H).
9. Connect fuel shutoff solenoid harness connector (I).

TCAL28645 —UN—29JUN12
10. Install intake manifold. (See Remove and Install Intake
Manifold—3TNV82A, 3TNV88.)
11. Install and adjust throttle cable. (See Adjust Throttle
Cable—3TNV82A, 3TNV88.)
IMPORTANT: If oil has been drained out of fuel
injection pump housing, add oil as necessary.
Fuel injection pump can become damaged if
operated dry or without proper amount of oil. C—Foam Spacer G—Coolant Line
D—Fuel Line H—Coolant Line
E—Fuel Line I— Connector
12. Add oil through external lube line inlet until oil begins F— Fuel Line
to drip out of inlet hole.
13. Install external lube line. When installing line, put one
copper washer between mounting cap screw head and 14. Fill engine coolant to proper level.
lube line and the other between lube line and housing.
OUMX258,0000BF4 -19-15SEP14-2/2

TM130419 (24FEB16) 20-20-56 030916

PN=156
 Engine Repair—3TNV82A, 3TNV88

Remove and Install Fuel Injection

Nozzles—3TNV82A, 3TNV88
Remove
IMPORTANT: Never steam clean or pour cold water
on injection pump while the pump is running or
warm. Doing so can damage the pump.

1. Clean the injection pump lines and area around the

pump using a parts cleaning solvent or steam cleaner.

CAUTION: Escaping fluid under pressure can

TCAL28646 —UN—29JUN12
penetrate the skin causing serious injury.
Avoid the hazard by relieving pressure
before disconnecting hydraulic or other
high-pressure lines. Tighten all connections
before applying pressure. Search for leaks
with a piece of cardboard. Protect hands and
body from high-pressure fluids.
If an accident occurs, see a doctor immediately.
Any fluid injected into the skin, must be
surgically removed within a few hours or A—Clamps E—Injection Nozzle
gangrene may result. Doctors unfamiliar B—Leak-Off Hoses F— Ring
C—Cap Screw and Washer G—Heat Protector
with this type of injury should reference a D—Retaining Plates
knowledgeable source. Such information is
available from the Deere & Company Medical
Department, Moline, Illinois, U.S.A.
5. Remove cap screw and washer (C) and retaining
2. Loosen fuel injection line connectors-to-nozzles plates (D).
slightly to relieve pressure in the fuel system.
6. Remove injection nozzle (E), ring (F), and TEFLON®
NOTE: Nozzles are matched to the cylinders. If removing heat protector (G). If ring and protector stay in cylinder
more than one nozzle, tag nozzles, according to head, thread a cap screw into protector and pull from
the cylinder from which it was removed. cylinder head.

3. Loosen line clamp(s) and remove fuel injection lines.

4. Remove clamps (A) and leak-off hoses (B).
TEFLON is a trademark of Du Pont Co.
Continued on next page OUMX258,0000BF5 -19-15SEP14-1/6

TM130419 (24FEB16) 20-20-57 030916

PN=157
 Engine Repair—3TNV82A, 3TNV88

7. If nozzles are stuck in cylinder head:

• Grind the head of a cap screw (J) so it fits inside a
nut from an old injection line (K).
• Use two nuts (I) to attach a large flat washer (H) to
the cap screw.

TCAL28647 —UN—29JUN12
• Install assembly onto nozzle (E) and use a puller
and slide hammer to pull nozzle from cylinder head.
8. Test injection nozzles.
Install
Installation is done in reverse order of removal.
• Install a new ring and heat protector when installing
injection nozzles. E—Nozzle J— Cap Screw
H—Flat Washer K—Injection Line
Disassemble/Assemble I— Nuts
NOTE: If servicing more than one nozzle, keep parts for
each nozzle separate from one another.
2. Clean and inspect nozzle assembly. (See Clean and
1. Remove retaining nut (S) and disassemble internal Inspect under this Group.)
parts of injection nozzle. Keep parts organized for
ease of assembly.
OUMX258,0000BF5 -19-15SEP14-2/6

3. Carefully clamp injector body (L) in a soft-jaw vice.

NOTE: Insert the same number of shims (M) that were
removed from injector. Number of shims will
affect the opening pressure of the fuel nozzle
and will be tested after assembly.

4. Reassemble fuel nozzle in the order shown above.

5. Tighten retaining nut to specification.
Specification
Fuel Injector Nozzle Case
Nut—Torque.......................................................................... 39—44 N·m
(29—32 lb.-ft.)

6. After assembly is complete, test injection nozzle.

K—Return Pipe P—Separator Plate

L— Injector Body Q—Nozzle Valve
M—Shim(s) R—Nozzle Body
N—Spring S—Nozzle Case Nut
TCAL28648 —UN—29JUN12

O—Spring Seat T— Index Pin

Continued on next page OUMX258,0000BF5 -19-15SEP14-3/6

TM130419 (24FEB16) 20-20-58 030916

PN=158
 Engine Repair—3TNV82A, 3TNV88

Cross Section
Clean and Inspect
NOTE: To clean nozzles properly, JDF13 Nozzle
Cleaning Kit is recommended. The Cleaning
Kit is available through the John Deere™
SERVICEGARD™ Catalog.

1. Remove anti-corrosive grease from new or

reconditioned nozzles by washing them thoroughly in
diesel fuel.
IMPORTANT: Never use a steel brush to clean nozzles
as this will distort the spray hole.

2. Remove carbon from used nozzles, and clean

by washing in diesel fuel. If parts are coated with
hardened carbon or lacquer, it may be necessary to use
a brass wire brush (supplied in Nozzle Cleaning Kit).

K—Return Pipe P—Separator Plate

L— Injector Body Q—Nozzle Valve
M—Shim(s) R—Nozzle Body
N—Spring S—Nozzle Case Nut
O—Spring Seat T— Index Pin

TCAL28649 —UN—29JUN12
John Deere is a trademark of Deere & Company
SERVICEGARD is a trademark of Deere & Company
Continued on next page OUMX258,0000BF5 -19-15SEP14-4/6

TM130419 (24FEB16) 20-20-59 030916

PN=159
 Engine Repair—3TNV82A, 3TNV88

3. After removing carbon or lacquer from the exterior of

nozzle, inspect sealing surfaces between separator
plate (P) and nozzle body (R) for nicks or scratches.
4. Contact area of separator plate (both parts) must not
be scored or pitted. Use an inspection magnifier (No.
16487 or equivalent) to aid in making the inspection.

TCAL28650 —UN—29JUN12
5. Check nozzle contact surface on separator plate for
wear. If contact surface is more than 0.10 mm (0.004
in.), replace nozzle assembly.

P—Separator Plate T— Pin

R—Nozzle Body

OUMX258,0000BF5 -19-15SEP14-5/6

6. Inspect the piston (large) part of nozzle valve (P)

to see that it is not scratched or scored and that
lower (tip) end of valve is not broken. If any of these
conditions are present, replace the nozzle assembly.

TCAL28651 —UN—29JUN12
7. Further inspect the nozzle assembly by performing a
slide test. Use the following procedure:
• Dip the nozzle valve (P) in clean diesel fuel. Insert
valve in nozzle body (Q).
• Hold nozzle vertical, and pull valve out about 1/3 of
its engaged length.
• Release valve. Valve should slide down to its seat
by its own weight.
Replace nozzle assembly if the valve does not slide P—Nozzle Valve R—Nozzle Body
freely to its seat.
OUMX258,0000BF5 -19-15SEP14-6/6

TM130419 (24FEB16) 20-20-60 030916

PN=160
 Group 30
Engine Repair—3TNV88C
Summary of References • Engine Install
• Engine Remove
OUMX258,0000BF7 -19-25SEP13-1/1

Engine Remove
1. Park machine safely.
2. Remove wing nuts (A) on each end of lower cover (B)
on right hand side of machine and remove cover.

A—Wing Nut B—Cover

TCT008068 —UN—24OCT13
BS62576,0001588 -19-19NOV13-1/14

3. Disconnect negative battery cable (C).

4. Remove right side panel. (See Remove and Install
Right Side Panel).
5. Remove fuel tank. (See Remove and Install Fuel
Tank).
6. Drain coolant from radiator and engine block into an
appropriate container.

TCT008069 —UN—24OCT13
C—Negative Cable

Continued on next page BS62576,0001588 -19-19NOV13-2/14

TM130419 (24FEB16) 20-30-1 030916

PN=161
 Engine Repair—3TNV88C

7. Loosen clamps (D) and disconnect air cleaner hose

from intake manifold and side panel. Disconnect strap
(E) and remove air cleaner assembly.

D—Clamps E—Strap

TCT008070 —UN—24OCT13
BS62576,0001588 -19-19NOV13-3/14

8. Remove bolts (F) and remove panel from ROPS.

9. Disconnect DPF wiring connectors (G).
10. Remove alternator. See

F— Bolts G—Connectors

TCT008071 —UN—08NOV13
Continued on next page BS62576,0001588 -19-19NOV13-4/14

TM130419 (24FEB16) 20-30-2 030916

PN=162
 Engine Repair—3TNV88C

11. Remove two bolts (H) from each side of fan shroud.
Remove bolts and nuts (I). Disconnect hose (J).
Loosen radiator hose clamps and disconnect hoses.

H—Shroud Bolts J— Coolant Recovery Hose

I— Radiator Mounting Bolt

TCT008072 —UN—24OCT13
BS62576,0001588 -19-19NOV13-5/14

12. Remove four bolts (K) from cooler mount assembly

and secure cooler assembly away from radiator.
13. Carefully slide radiator up and out.

K—Bolts

TCT008073 —UN—24OCT13
Continued on next page BS62576,0001588 -19-19NOV13-6/14

TM130419 (24FEB16) 20-30-3 030916

PN=163
 Engine Repair—3TNV88C

14. Disconnect four engine wiring connectors (L) and the

glow plug connector (M) on left front side of engine.

L— Engine Connectors M—Glow Plug Connector

TCT008074 —UN—24OCT13
BS62576,0001588 -19-19NOV13-7/14

15. Remove two nuts and bolts (N) from lower exhaust
pipe bracket.

N—Nuts

TCT008076 —UN—24OCT13
Continued on next page BS62576,0001588 -19-19NOV13-8/14

TM130419 (24FEB16) 20-30-4 030916

PN=164
 Engine Repair—3TNV88C

16. Remove four nuts (O) from exhaust pipe flange and
remove exhaust pipe (P).

O—Nuts P—Exhaust Pipe

TCT008075 —UN—24OCT13
BS62576,0001588 -19-19NOV13-9/14

17. Remove three bolts from drive coupling (Q). Loosen

two bolts (R) on driveshaft universal joint and slide
shaft away from engine.
18. Remove bolts from engine mounts (S).

Q—Bolts S—Bolts
R—Bolts

TCT008077 —UN—28OCT13
Continued on next page BS62576,0001588 -19-19NOV13-10/14

TM130419 (24FEB16) 20-30-5 030916

PN=165
 Engine Repair—3TNV88C

19. Remove bolt (T) from engine mount.

20. Disconnect and label fuel lines from fuel filter and fuel
cooler.

T— Bolt

TCT008078 —UN—04NOV13
BS62576,0001588 -19-19NOV13-11/14

21. Disconnect wire from engine oil pressure switch (U).

22. Attach hoist to engine lifting bracket and raise engine
just enough to lift it off of the engine mounts.

U—Oil Pressure Switch

TCT008080 —UN—04NOV13
Continued on next page BS62576,0001588 -19-19NOV13-12/14

TM130419 (24FEB16) 20-30-6 030916

PN=166
 Engine Repair—3TNV88C

NOTE: Rear engine mount bracket is a two piece

assembly that must be separated and removed
from engine block during engine removal.

23. Remove bolts (V) and nut (W) from left rear engine
mount bracket and remove bracket.

V—Bolts X—Bracket
W—Nut

TCT008079 —UN—04NOV13
Left Half of Rear Engine Mount

BS62576,0001588 -19-19NOV13-13/14

24. Remove bolts (Y) and right side bracket.

25. Have an assistant help guide engine out of machine.

Y—Bolts

TCT008081 —UN—04NOV13
BS62576,0001588 -19-19NOV13-14/14

TM130419 (24FEB16) 20-30-7 030916

PN=167
 Engine Repair—3TNV88C

Engine Install
1. Make sure flat washers (A) are in place on engine
mounts.
NOTE: Rear engine mount brackets cannot be installed
until engine is positioned 25—50 mm (1—2 in.)
from being seated on mounts.

2. Have an assistant help guide engine as it is lowered

into machine. Lower engine until it is 25—50 mm

TCT008082 —UN—30DEC13
(1—2 in.) above engine mounts.

A—Washers

OUO2003,0000007 -19-19NOV13-1/5

3. Install right and left halves of rear engine mount

brackets to engine block with all bolts finger tight only.
Tighten bolts securing right half of bracket to engine
block. Tighten bolt (B) that holds right and left halves
together and then tighten bolts (C) securing left half of
bracket to engine block.
4. Lower engine onto mounts and install flat washers,
bolts, and locknuts.

TCT008083 —UN—30DEC13
B—Bolt C—Bolts

Continued on next page OUO2003,0000007 -19-19NOV13-2/5

TM130419 (24FEB16) 20-30-8 030916

PN=168
 Engine Repair—3TNV88C

5. Connect driveshaft coupling to flywheel with three

bolts (D) and tighten to specification.
6. Tighten pinch bolts (E) on driveshaft universal joint.
7. Install new gasket on DPF and install exhaust pipe.
Tighten nuts on DPF first, then nuts on engine mount
bracket.
8. Connect all engine wiring.
9. Connect alternator wiring.

TCT008084 —UN—30DEC13
10. Connect positive battery cable, machine power wire,
and solenoid exciter wire to starting motor solenoid.
11. Lay engine fan shroud in position.
12. Hold cooler assembly away from radiator and install
radiator between shroud and cooler assembly.

D—Bolts E—Bolts

OUO2003,0000007 -19-19NOV13-3/5

13. Install radiator isolator rubbers and mounting bolts (F).

14. Secure shroud and cooler assemblies to radiator with
bolts (G). Connect radiator hoses and tighten clamps.

F— Radiator Mounts G—Bolts

TCT008085 —UN—30DEC13
Continued on next page OUO2003,0000007 -19-19NOV13-4/5

TM130419 (24FEB16) 20-30-9 030916

PN=169
 Engine Repair—3TNV88C

15. Install panel on ROPS and install bolts (H).

16. Install right side panel. (See Remove and Install Right
Side Panel
17. Install air cleaner assembly and tighten hose clamps.
18. Install fuel tank. (See Remove and Install Fuel Tank).
19. Fill radiator with approved coolant.
20. Fill or top off engine oil with recommended oil.

TCT008086 —UN—30DEC13
H—Bolts

OUO2003,0000007 -19-19NOV13-5/5

TM130419 (24FEB16) 20-30-10 030916

PN=170
 Section 30
Electrical Repair
Contents

Page
Page
Group 10—Electrical System Components
Summary of References................................ 30-10-1 Air Ride Seat Wiring Harness
Instrument Cluster, A100 ............................... 30-10-1 Splice Table ............................................. 30-20-43
Main Wiring Harness Component Air Ride Seat Wiring Harness Color
Location, Non-T4 ....................................... 30-10-2 Codes ...................................................... 30-20-43
Main Wiring Harness Component
Location, T4............................................... 30-10-3 Group 30—Repair
Upper Cab Wiring Harness Summary of References................................ 30-30-1
Component Location ................................. 30-10-4 Remove and Install Battery ........................... 30-30-1
Cab Relays .................................................... 30-10-4 Remove and Install Alternator ....................... 30-30-2
Lower Cab Wiring Harness Repair Alternator ........................................... 30-30-3
Component Location ................................. 30-10-5 Starting Motor ................................................ 30-30-7

Group 20—Wiring Harnesses

Summary of References................................ 30-20-1
Main Wiring Harness, Non-T4 ....................... 30-20-2
Main Wiring Harness Connectors,
Non-T4....................................................... 30-20-6
Main Wiring Harness Color Codes,
Non-T4....................................................... 30-20-7
Main Wiring Harness Splice Table,
Non-T4....................................................... 30-20-9
Main Wiring Harness, T4 ............................. 30-20-10
Main Wiring Harness Connectors,
T4 ............................................................ 30-20-15
Main Wiring Harness Color Codes,
T4 ............................................................ 30-20-16
Main Wiring Harness Splice Table,
T4 ............................................................ 30-20-18
Main Wiring Harness Terminal
Table, T4.................................................. 30-20-19
Keyswitch Jumper Harness ......................... 30-20-20
Cab Wiring Harness .................................... 30-20-21
Cab Wiring Harness Connectors ................. 30-20-25
Cab Wiring Harness Color Codes................ 30-20-26
Cab Wiring Harness Splice Table ................ 30-20-28
Beacon Lamp Wiring Harness..................... 30-20-29
Beacon Lamp Splice Table .......................... 30-20-29
Beacon Lamp Wiring Harness
Color Codes............................................. 30-20-30
Homologation Wiring Harness
Color Codes............................................. 30-20-31
Homologation Wiring Harness
Splice Table ............................................. 30-20-32
Homologation Wiring Harness..................... 30-20-34
Front Work Light Wiring Harness ................ 30-20-41
Work Light Wiring Harness Splice
Table ........................................................ 30-20-42
Work Light Wiring Harness Color
Codes ...................................................... 30-20-42
Backup Alarm Wiring Harness
Splice Table ............................................. 30-20-42
Backup Alarm Wiring Harness
Color Codes............................................. 30-20-42

TM130419 (24FEB16) 30-1 030916

PN=1
 Contents

TM130419 (24FEB16) 30-2 030916

PN=2
 Group 10
Electrical System Components
Summary of References • Upper Cab Wiring Harness Component Location
• Instrument Cluster, A100 • Cab Relays
• Lower Cab Wiring Harness Component Location
• Main Wiring Harness Component Location, Non-T4
• Main Wiring Harness Component Location, T4
SH24924,000022F -19-10JUN14-1/1

Instrument Cluster, A100 A

A—Battery LED E—Hydraulic Filter Restriction G B

B—Hydraulic Oil Temperature LED
LED F— Engine Oil Pressure LED
C—Hour Meter G—Engine Coolant
D—Preheat LED Temperature LED
C

TCT003819 —UN—28JUN12
F
D
E

Instrument Cluster - A100

OUMX258,0000C26 -19-04JUN14-1/1

TM130419 (24FEB16) 30-10-1 030916

PN=173
 Electrical System Components

Main Wiring Harness Component Location, Non-T4

J N O
F M
E L
K

B
A

P
G
C I Q
H
T
R
S U
ak V
W
aj

D ai
X
aa Y
ah ag
ab Z
an ao al af

TCT008665 —UN—17JUN14
am
ad

ae ac

A—Headlights Switch M—K4 PTO Shutdown Relay X—Glow Plugs Connector ag— M-1B Start Solenoid
B—Cruise Switch Connector Y—Fuel Solenoid Connector ah— M-1A and M-1C Fuseholder
C—Key Switch N—K7 Cruise Control Relay Z— T-40 to B2 Engine Oil Connectors
D—V1 Diode Pack Connector Connector Pressure Switch Connector ai— T-35 Ground Connector
E—PTO Switch Connector O—K8 Cab Power Relay aa— A2 Engine Preheat Timer aj— S2 Seat Switch Connector
F— A100 Instrument Cluster Connector Connector ak— X-4 Cab Power Connector
Connector P—G-2A Alternator Connector ab— B3A Hydraulic Oil al— S4 Brake Switch Connector
G—Buzzer Connector Q—G-2B Alternator Connector Temperature Connector am—Cruise Control Brake
H—C101 R101 Resistor R—Fuse Holder ac— ACT-1 Air Compressor Connector
Connector S—V2 Diode Pack Connector Connector an— Cruise Control Magnet
I— Homologation Kit Connector T— Coolant Temperature Switch ad— Y4 Fuel Transfer Pump ao— Headlight Harness
J— X-1 Cab Power Connector U—A1B Control Module Connector Connector
K—K6 Air Heater Relay V—A1A Control Module ae— PTO Solenoid Connector
Connector W—T-41 to A1C Control Module af— X-2 Power Outlet Harness
L— K5 Fuel Pull-In Relay Connector
Connector
OUMX258,0000199 -19-04JUN14-1/1

TM130419 (24FEB16) 30-10-2 030916

PN=174
 Electrical System Components

Main Wiring Harness Component Location, T4

F H
O P
N Q
M
B
A
C K

J R
G I T
D
aa U
ad S
E ae Z

af Y
an
ag V
am
ah
ao
al
ab W

TCT009621 —UN—23DEC13
ac
ak
aj

ai

A—Headlights Switch O—Start Relay Z— Ground Tie Point al— Power Port
B—Cruise Switch P—Fuse Block aa— X-4 Auxiliary Connector am—Park Brake Switch
C—Key Switch Q—Cab Power Relay ab— ECU Case Ground an— Cruise Control Magnet
D—PDU Ground R—Alternator ac— ECU ao— Headlight Harness
E—Accelerator Sensor S—DPF Inlet Temperature Sensor ad— Glow Plugs Connector Connector
F— PTO Switch T— DPF Mid Differential Pressure ae— Seat Switch ap— 12 Pin Yellow Connector
G—CAN Terminator Sensor af— VCU Case Ground aq— 12 Pin Red Connector
H—PDU U—DPF Mid Temperature Sensor ag— Hydraulic Temperature ar— 8 Pin Red Connector
I— Spare V—VCU Switch as— 12 Pin Gray Connector
J— Buzzer W—Oil Pressure Switch ah— Diode
K—CAN Diagnostic Connector X—80A Fuse ai— A/C Compressor
L— Cab Power Connector Y—Engine Connectors GroupSee aj— PTO Solenoid
detail above
M—EGR Relay ak— Fuel Pump
N—Glow Plug Relay
CB12260,000003C -19-04JUN14-1/1

TM130419 (24FEB16) 30-10-3 030916

PN=175
 Electrical System Components

Upper Cab Wiring Harness Component Location

TCT010566 —UN—09JUN14
A—RH Front Work Light H—High-Low Pressure Switch O—LH Blower Motor W—Beacon Light
B—(R2) RH Front Marker Light I— Roof Connector, Plug P—LH Rear Amber Light X—LH Front Work Light
C—RH Front Amber Light J— RH Rear Amber Light Q—LH Rear Work Light Y—Beacon Light Ground
D—Right Speaker K—RH Rear Work Light R—Radio
E—Relays (x6) L— Dome Light S—Wiper Motor
F— HVAC Enable Switch M—RH Blower Motor T— Left Speaker
G—Blower Switch N—HVAC Temperature Switch U—LH Front Amber Light
V—(R2) LH Front Marker Light
SH24924,000022D -19-10JUN14-1/1

Cab Relays

TCT010567 —UN—09JUN14
A—K09 Left High-Speed D—K12 LH Amber Lights Relay
Blower Relay E—K13 RH Amber Lights Relay
B—K10 Right High-Speed F— K14 Left Blower Relay
Blower Relay
C—K11 Right Blower Relay

CB12260,0000046 -19-10JUN14-1/1

TM130419 (24FEB16) 30-10-4 030916

PN=176
 Electrical System Components

Lower Cab Wiring Harness Component

Location
A—Work Light Switch G—Flasher Relay
B—Wiper Switch H—Fuse Holder
C—Turn Signal Switch I— Terminals T1, T2
D—Beacon Switch J— Firewall Bulkhead
E—Turn Signal Diode Connector
F— Turn Signal Diode K—Roof Connector,
Receptacle

TCT010568 —UN—09JUN14
SH24924,000022E -19-10JUN14-1/1

TM130419 (24FEB16) 30-10-5 030916

PN=177
 Electrical System Components

TM130419 (24FEB16) 30-10-6 030916

PN=178
 Group 20
Wiring Harnesses
Summary of References • Cab Wiring Harness Splice Table
• Main Wiring Harness, Non-T4 • Beacon Lamp Wiring Harness
• Beacon Lamp Splice Table
• Main Wiring Harness Connectors, Non-T4 • Beacon Lamp Wiring Harness Color Codes
• Main Wiring Harness Color Codes, Non-T4 • Homologation Wiring Harness Color Codes
• Main Wiring Harness Splice Table, Non-T4 • Homologation Wiring Harness Splice Table
• Main Wiring Harness, T4 • Homologation Wiring Harness
• Main Wiring Harness Connectors, T4 • Front Work Light Wiring Harness
• Main Wiring Harness Color Codes, T4 • Work Light Wiring Harness Splice Table
• Main Wiring Harness Splice Table, T4 • Work Light Wiring Harness Color Codes
• Main Wiring Harness Terminal Table, T4 • Backup Alarm Wiring Harness Splice Table
• Keyswitch Jumper Harness • Backup Alarm Wiring Harness Color Codes
• Cab Wiring Harness • Air Ride Seat Wiring Harness Splice Table
• Cab Wiring Harness Connectors • Air Ride Seat Wiring Harness Color Codes
• Cab Wiring Harness Color Codes
OUMX258,0000B64 -19-25FEB15-1/1

TM130419 (24FEB16) 30-20-1 030916

PN=179
 Wiring Harnesses

Main Wiring Harness, Non-T4

S1
A

F
B

E
C

Sp-1
X-5
ABC

S8
14
2
3 5

BA C
ED

E1
F

A
V1

T-40
to B2

T-39
to B1
A1A
D
A BC

T-41
to A1C
TCT009964 —UN—25JUN14

A1B
F
E
D
B

C
A

Main Wiring Harness (1 of 4)

Continued on next page OUMX258,0000197 -19-25JUL14-1/4

TM130419 (24FEB16) 30-20-2 030916

PN=180
 Wiring Harnesses

Main Wiring Harness, Non-T4

S7

A
C
B
D
R1 B-3A
BA
ACT-1

B
C
B
A

A
Y4
Sp-4
Y2

Sp-10
F
E
D

A2 X-2
A

Y1
TCT009965 —UN—27DEC13

AB

S2

Main Wiring Harness (2 of 4)

Continued on next page OUMX258,0000197 -19-25JUL14-2/4

TM130419 (24FEB16) 30-20-3 030916

PN=181
 Wiring Harnesses

Main Wiring Harness, Non-T4

H7

Y3
B
A
H2
H1
Sp-6 BA C101
AB

Sp-12
Sp-5

Sp-3 Sp-8
C D

X-4 B
A B

A Sp-11
S4
T-35

M-1B
TCT009966 —UN—27DEC13

M-1A

M-1C

Main Wiring Harness (3 of 4)

Continued on next page OUMX258,0000197 -19-25JUL14-3/4

TM130419 (24FEB16) 30-20-4 030916

PN=182
 Wiring Harnesses

Main Wiring Harness, Non-T4

A BCD
C100

S3

X-1

Sp-13
K6
87a
85
87
K5

30 K4
86
K7

85 86
87
30
F

K8
E

Sp-2 Sp-7 Sp-9

D
C
B
A

Sp-14

V2 Sp-15

F1
A B

G-2B
TCT009967 —UN—27DEC13

G-2A

Main Wiring Harness (4 of 4)

OUMX258,0000197 -19-25JUL14-4/4

TM130419 (24FEB16) 30-20-5 030916

PN=183
 Wiring Harnesses

Main Wiring Harness Connectors, Non-T4 S3 — PTO Switch

S4 — Brake Switch
A1A — Control Module Connector S7 — Cruise Control Brake
A1B — Control Module Connector S8 — Headlights Switch
ACT-1 — Air Compressor T-4 — EF-1 Fuse Holder
B3A — Hydraulic Oil Temp. T-5 — Alternator
C100 — A100 Instrument Cluster T-8 — EF-1 Fuse Holder
C101 — C101 Capacitor T-35 — Ground Connector to W2
E1 — Headlights Harness T-39 — B1 Coolant Temperature Switch
F1 — Fuse Holder T-40 — B2 Engine Oil Pressure Switch
G-2A — Alternator T-41 — A1C Control Module Connector
H1 — H2 Homologation Kit Connector V1 — Diode Pack
H7 — Buzzer V2 — Diode Pack
K4 — PTO Shutdown Relay X-1 — Cab Power
K5 — Fuel Pull-In Relay X-2 — Power Outlet Harness Connector
K6 — Air Heater Relay X-4 — Cab Power
K7 — Cruise Control Relay X-5 — S5 Cruise Control Switch
K8 — Cab Power Relay Y1 — PTO Solenoid
M-1B — Start Motor Solenoid Y2 — Fuel Solenoid
R1 — Glow Plugs Y3 — Cruise Control Magnet
S1 — Key Switch Y4 — Fuel Transfer Pump
S2 — Seat Switch
OUMX258,0000198 -19-26JUN14-1/1

TM130419 (24FEB16) 30-20-6 030916

PN=184
 Wiring Harnesses

Size/No./Color Wire Connection Points

Main Wiring Harness Color Codes, Non-T4
0.8 408 Yel C101 (B), Sp-15
Size/No./Color Wire Connection Points
0.8 409 Yel Sp-2, K6 (86)
14.0 100 Blk Sp-5, T-35
1.0 410 Yel S3 (3), Sp-2
3.0 101 Blk Y2 (C), Sp-5
1.0 411 Yel S2 (A), Sp-2
3.0 103 Blk Sp-5, X-4 (B)
0.8 412 Yel C100 (A), Sp-2
1.0 107 Blk Sp-6, H1 (B)
0.8 413 Yel G-2A (B), Sp-15
0.8 109 Blk A2 (D), Sp-5
0.8 430 Yel Sp-2, K4 (86)
5.0 110 Blk Sp-6, Sp-5
2.0 450 Yel S8 (1), A-1B (D)
1.0 111 Blk V2 (B), Sp-11
2.0 452 Yel S8 (2), E1 (A)
0.8 112 Blk Sp-6, C100 (D)
0.8 456 Yel Y4 (A), Sp-2
1.0 113 Blk E1 (B), Sp-6
0.8 480 Yel Sp-2, K8 (86)
1.0 115 Blk V2 (A), Sp-11
3.0 490 Yel K8 (87), Sp-13
1.0 116 Blk V2 (C), Sp-11
1.0 491 Yel X-1 (1), Sp-13
1.0 120 Blk Sp-12, Y1 (B)
1.0 492 Yel X-2 (A), F1 (B)
0.8 121 Blk Sp-12, B-3a (B)
1.0 493 Yel X-1 (2), Sp-13
1.0 122 Blk Sp-5, Sp-11
1.0 494 Yel X-1 (5), Sp-13
3.0 123 Blk Sp-6, X-2 (B)
3.0 503 Yel Sp-13, X-4 (A)
1.0 124 Blk Sp-12, Sp-5
0.8 525 Blu C100 (H), Sp-4
0.8 125 Blk T-41, Sp-5
0.8 526 Blu V1 (D), Sp-4
0.8 126 Blk Sp-12, Y4 (B)
0.8 527 Blu Sp-4, B-3A (A)
0.8 130 Blk Sp-6, K7 (86)
0.8 610 Brn C100 (G), Sp-14
1.0 135 Blk Y3 (B), Sp-6
0.8 611 Brn C101 (A), Sp-14
0.8 155 Blk Sp-12, K8 (85)
0.8 612 Brn Sp-14, G-2A (A)
1.0 190 Blk S1 (S1), Sp-6
0.8 625 Tan T-40, C100 (E)
14.0 191 Blk Sp-5, X-1 (4)
0.8 626 Tan V1 (B), T-40
1.0 195 Blk S1 (S2), A-1A (E)
0.8 630 Grn A2 (C), Sp-3
14.0 200 Red T-5, T-4
1.0 640 Grn A-1A (H), Sp-3
3.0 210 Red Sp-8, K5 (30)
1.0 650 Grn Y2 (A), Sp-3
3.0 220 Red Sp-9, K6 (30)
0.8 700 Pur S4 (D), K4 (87A)
3.0 225 Red Sp-8,Sp-9
0.8 743 Pur A-1A (A), S4 (A)
8.0 230 Red Sp-8, T-4
3.0 747 Pur A-1B (F), M-1B (A)
5.0 240 Red Sp-1, Sp-8
0.8 748 Pur A-1A (D), S3 (9)
3.0 241 Red Sp-9, F1 (A)
1.0 750 Pur A-1B (E), S3 (1)
3.0 242 Red S1 (B), Sp-1
0.8 751 Pur A2 (B), K5 (85)
3.0 243 Red Sp-1, K8 (30)
0.8 752 Pur S4 (C), S3 (9)
14.0 250 Red X-1 (3), T-8
0.8 760 Pur S3 (1), K4 (30)
0.8 310 Org T-39, C100 (F)
1.0 770 Pur Y1 (A), S3 (4)
0.8 311 Org V1 (E), T-39
1.0 771 Gry Y1 (A), V2 (E)
0.8 315 Grn V1 (C), H7 (B)
1.0 775 Grn ACT-1, X-1 (6)
1.0 320 Blu V1 (F), A-1A (C)
0.8 788 Pur A-1A (F), S4 (B)
0.8 330 Grn A2 (F), C100 (C)
1.0 830 Pnk S7 (B), A-1A (B)
0.8 350 Org A2 (E), K6 (85)
1.0 831 Pnk S7 (B), S2 (B)
0.8 360 Org H7 (B0, K4 (85)
1.0 832 Pnk X-5 (A), S7 (D)
3.0 400 Yel S1 (A), A-1B (A)
1.0 833 Pnk X-5 (B), K7 (87)
3.0 402 Yel A-1B (C), Sp-2
1.0 834 Pnk Sp-7, K7 (30)
0.8 403 Yel H7 (A), Sp-2
0.8 835 Pnk Y3 (A), K7 (85)
0.8 404 Yel Sp-2, Sp-15
1.0 836 Pnk Y3 (A), Sp-7
0.8 405 Yel H1 (A), Sp-2
1.0 837 Pnk X-5 (C), Sp-7
0.8 406 Yel A2 (A), Sp-2
1.0 840 Gry V2 (D), Sp-7
0.8 407 Yel Sp-2, K5 (86)

Continued on next page OUMX258,000019A -19-06JUN14-1/2

TM130419 (24FEB16) 30-20-7 030916

PN=185
 Wiring Harnesses

Size/No./Color Wire Connection Points

3.0 900 Wht R1, K6 (87)
3.0 901 Wht Sp-10, Y2 (B)
3.0 911 Wht Sp-10, K5 (87)
3.0 912 Wht Sp-10, V2 (F)
OUMX258,000019A -19-06JUN14-2/2

TM130419 (24FEB16) 30-20-8 030916

PN=186
 Wiring Harnesses

Splice No. Circuit No./Color

Main Wiring Harness Splice Table, Non-T4
Sp-8 230 Red
Splice No. Circuit No./Color
240 Red
Sp-1 240 Red
210 Red
242 Red
225 Red
243 Red
Sp-9 225 Red
Sp-2 402 Yel
220 Red
410 Yel
241 Red
411 Yel
Sp-10 911 Wht
412 Yel
912 Wht
456 Yel
910 Wht
405 Yel
Sp-11 122 Blk
403 Yel
111 Blk
404 Yel
115 Blk
406 Yel
116 Blk
407 Yel
Sp-12 124 Blk
409 Yel
155 Blk
430 Yel
120 Blk
480 Yel
121 Blk
Sp-3 640 Grn
126 Blk
650 Grn
Sp-13 490 Yel
630 Grn
503 Yel
Sp-4 527 Blu
491 Yel
525 Blu
493 Yel
526 Blu
494 Yel
Sp-5 101 Blk
Sp-14 610 Brn
122 Blk
611 Brn
100 Blk
612 Brn
110 Blk
Sp-15 408 Yel
103 Blk
413 Yel
124 Blk
404 Yel
109 Blk
125 Blk
191 Blk
Sp-6 110 Blk
123 Blk
130 Blk
113 Blk
107 Blk
135 Blk
190 Blk
112 Blk
Sp-7 840 Gry
834 Pnk
836 Pnk
836 Pnk

OUMX258,000019B -19-06JUN14-1/1

TM130419 (24FEB16) 30-20-9 030916

PN=187
 Wiring Harnesses

Main Wiring Harness, T4

C23

F
B

E
C

D
C7

C37

T-1

C34
C10
1
2

C31
654321

1
2

C33

TCT009624 —UN—23JUN14

Main Wiring Harness (1 of 5)

Continued on next page CB12260,0000040 -19-06JUN14-1/5

TM130419 (24FEB16) 30-20-10 030916

PN=188
 Wiring Harnesses

Main Wiring Harness, Tier 4

C38 T-6 1 15

A5501
46 60

T-19

C6

M
L 1
JK
H 2
G
EF 3
D
C
B 4
A

Sp-14
Sp-10 T-7

Sp-6
8

X5057
4
5
1

Sp-7 B3A

B
A
C13
Sp-8
X5059
TCT009625 —UN—03JAN14

X5058

X5060
C26
Main Wiring Harness (2 of 5)
Continued on next page CB12260,0000040 -19-06JUN14-2/5

TM130419 (24FEB16) 30-20-11 030916

PN=189
 Wiring Harnesses

Main Wiring Harness, Tier 4

C9

1
2 A5502
7

5
6
73

28

T-9
94

A
B
C22

Sp-13 Sp-5 Sp-9 Sp-12

C14

A B
TCT009626 —UN—03JAN14

C19 C17
A
B

Main Wiring Harness (3 of 5)

Continued on next page CB12260,0000040 -19-06JUN14-3/5

TM130419 (24FEB16) 30-20-12 030916

PN=190
 Wiring Harnesses

Main Wiring Harness, Tier 4

9 C24
7

H
B J
4

1
G
C A
5

F
D E
3
6

10
8

C21

A
C8
Sp-2

C20
6 4
(C41)
1 3
C36

C40

S-CAN8

Sp-20 S-CAN3 S-CAN4 S-CAN5 S-CAN6

S-CAN7

Sp-11

X4
Sp-1

TCT009627 —UN—20JUN14

C25
D C

B A

Continued on next page CB12260,0000040 -19-06JUN14-4/5

TM130419 (24FEB16) 30-20-13 030916

PN=191
 Wiring Harnesses

Main Wiring Harness, Tier 4

C12

Sp-16

C1

85 87
a 87
30
86 C3
C2

2
4 3

20A
25A

1
85 87a 87

10A
5
87 15A
87a 30 7 8

6
85 86
86
30

C15

Sp-15 Sp-4 Sp-3

C11
T-5
C18

T-8

T-4

C16
TCT009628 —UN—23DEC13

T-34

T-35

T-33

Main Wiring Harness (5 of 5)

CB12260,0000040 -19-06JUN14-5/5

TM130419 (24FEB16) 30-20-14 030916

PN=192
 Wiring Harnesses

Main Wiring Harness Connectors, T4 C31 — DPF Differential Pressure Sensor

C33 — DPF Inlet Temp Sensor
A5501 — Engine Control Unit (ECU) C34 — DPF Mid Temp Sensor
A5502 — Engine Control Unit (ECU) C36 — CAN Terminator Resistor
B3A — Hydraulic Oil Temp. C37 — Headlights Switch
C1 — Glow Plug Relay C38 — Headlights
C2 — EGR Valve Relay C40 — Spare
C3 — Start Relay C41 — Spare
C6 — Vehicle Control Unit (VCU) GT-1A — Starter Motor
C7 — Cruise Control Switch G-2A — Alternator
C8 — Buzzer G-2B — Alternator
C9 — Cruise Control Magnet M-1B — Start Motor Solenoid
C10 — Accelerator Sensor T-1 — Console Ground
C11 — Cab Power Relay T-4 — Fuse
C12 — Cab Power T-5 — Battery
C13 — Diode T-6 — ECU Case Ground
C14 — Power Outlet T-7 — VCU Case Ground
C15 — Fuse Block T-8 — Cab Power
C16 — Start Solenoid T-9 — A/C Compressor
C17 — Seat Switch T-19 — Engine Oil Pressure Switch
C18 — Alternator T-33 — Ground
C19 — PTO Solenoid T-34 — Ground
C20 — Primary Display Unit (PDU) T-35 — Ground
C21 — PTO Switch X-4 — Auxiliary Power
C22 — Fuel Pump X5057 — To Engine Harness B (Red Connector)
C23 — Key Switch X5058 — To Engine Harness B (Red Connector)
C24 — Service X5059 — To Engine Harness B (Gray Connector)
C25 — Park Brake Switch X5060 — To Engine Harness C (Yellow Connector)
C26 — Glow Plugs
CB12260,0000038 -19-19MAR15-1/1

TM130419 (24FEB16) 30-20-15 030916

PN=193
 Wiring Harnesses

Size/No./Color Wire Connection Points

Main Wiring Harness Color Codes, T4
0.5 401 Pnk X5057 (1), A5502 (45)
Size/No./Color Wire Connection Points
0.5 402 Pur C7 (2), A5502 (85)
1.0 100 Blk Sp-20, T-33
0.5 403 Wht X5057 (3), A5502 (39)
0.8 101 Blk Sp-20, C20 (2)
0.5 404 Brn X5057 (4), A5502 (74)
0.8 102 Blk B3A (B), Sp-20
0.5 405 Pnk X5057 (5), A5502 (79)
3.0 103 Blk Sp-11, X-4 (B)
0.5 406 Brn X5057 (60, A5502 (21)
0.8 107 Blk Sp-20, C6 (L2)
0.5 407 Grn X5057 (7), A5501 (28)
0.8 108 Blk C22 (B), Sp-20
0.5 408 Blu X5057 (8), A5501 (29)
0.8 120 Blk Sp-20, T-1
1.0 420 Org X5058 (1), C2 (87)
5.0 121 Blk Sp-5, T-34
0.5 421 Pnk X5058 (5), A5502 (23)
1.0 122 Blk Sp-5, X5058 (4)
0.5 422 Grn X5058 (6), A5502 (20)
3.0 123 Blk C14 (B), Sp-20
0.5 423 Brn X5058 (7), A5502 (52)
2.0124 Blk Sp-5, A5502 (4)
1.0 424 Org X5058 (6), A5501 (19)
2.0 125 Blk Sp-5, A5502 (6)
1.0 425 Wht X5058 (9), A5501 (20)
0.8 126 Blk Sp-11, C1 (86)
0.5 426 Pu6 X5058 (10), A5501 (59)
0.8 127 Blk Sp-11, C2 (86)
0.5 427 Pnk X5058 (11), A5502 (23)
2.0 128 Blk Sp-5, A5502 (2)
0.5 440 Pnk X5059 (1), A5501 (7)
0.5 129 Blk Sp-5, A5502 (86)
0.5 441 Grn C2 (2), A5501 (26)
0.8 130 Blk Sp-20, C24 (A)
0.5 442 Wht X5059 (3), A5501 (25)
0.8 135 Blk C9 (B), Sp-20
0.5 443 Pnk X5059 (4), A5501 (8)
0.8 142 Blk Sp-11, C11 (86)
0.5 443 Pnk X5059 (4), A5501 (8)
0.8 143 Blk Sp-20, C8 (B)
0.5 444 Blu X5059 (5), A5501 (37)
0.8 145 Blk Sp-20, Sp-11
0.5 445 Wht X5059 (6), A5501 (52)
0.8 146 Blk Sp-12, T-6
0.5 446 Pnk X5059 (7), A5501 (39)
0.8 147 Blk Sp-12, T-7
0.5 447 Org X5059 (8), A5501 (47)
0.8 148 Blk Sp-12, Sp-20
0.5 448 Blk X5059 (9), A5501 (38)
1.0 150 Blk C40 (B), Sp-11
0.5 449 Blu X5059 (11), A5501 (11)
3.0 153 Blk C38 (B), Sp-20
0.5 450 Brn X5059 (12), A5501 (51)
13.0 191 Blk C12 (4), T-35
0.5 451 Pur X5059 (10), A5502 (56)
13.0 200 Red T-5, T-4
1.0 460 Grn X5060 (3), A5501 (48)
8.0 201 Red Sp-15, T-4
1.0 461 Grn X5060 (4), A5501 (18)
13.0 202 Red C12 (4), T-8
1.0 462 Wht X5060 (5), A5501 (47)
3.0 203 Red Sp-1. C15 (1)
1.0 463 Blu X5059 (11), A5501 (17)
3.0 205 Red Sp-1, C15 (3)
1.0 464 Gry X5060 (7), A5501 (33)
3.0 207 Red Sp-4, C3 (30)
1.0 465 Brn X5060, (8), A5501 (16)
0.8 208 Red C15 (8), C6 (L1)
1.0 466 Grn X5060 (9), S7 (2)
3.0 209 Red Sp-3, C17 (7)
1.0 467 Grn X5060 (10), S7 (2)
3.0 211 Red C15 (4), Sp-6
1.0 468 Grn S7 (1), A5501 (4)
1.0 212 Red C2 (30), Sp-6
1.0 469 Wht X5060 (11), Sp-8
2.0 213 Red Sp-6, A5502 (1)
1.0 470 Wht X5060 (12), Sp-8
2.0 214 Red Sp-6, A5502 (3)
1.0 471 Wht Sp-8, A5501 (5)
2.0 214 Red Sp-6, A5502 (5)
0.5 480 Pnk C31 (3), A5502 (24)
3.0 220 Red Sp-3, C1 (30)
0.5 481 Blu C31 (5), A5502 (63)
5.0 225 Red Sp-4, Sp-3
0.5 482 Grn C31 (4), A5501 (12)
5.0 230 Red Sp-1, Sp-15
0.5 4823 Blk Sp-10, A5502 (77)
3.0 240 Red SP-1, Sp-4
0.5 485 Wht C33 (1), A5502 (81)
3.0 241 Red Sp-3, C15 (5)
0.5 486 Brn C34 (1), A5502 (80)
3.0 242 Red C23 (B), C15 (2)
0.5 487 Blk Sp-10, C31 (2)
3.0 243 Red Sp-4, C11 (30)
0.5 489 Blk Sp-10, C33 (2)
0.5 302 Org C8 (A), C6 (E4)
0.5 490 Blk Sp-10, C34 (2)
3.0 492 Red C14 (A), C15 (6)

Continued on next page CB12260,0000039 -19-04JUN14-1/4

TM130419 (24FEB16) 30-20-16 030916

PN=194
 Wiring Harnesses

Size/No./Color Wire Connection Points Size/No./Color Wire Connection Points

3.0 500 Yel C23 (A), Sp-2 0.5 F101 Grn S-CAN4, C6 (81)
0.8 501 Yel Sp-2, C20 (1) 0.5 F103 Grn S-CAN4, C20 (5)
1.0 502 Yel Sp-2, C40 (A) 0.5 F104 Grn S-CAN4, S-CAN6
3.0 503 Yel Sp-16, X-4 (A) 0.5 F105 Grn S-CAN6, C24 (D)
0.8 506 Yel Sp-2, C18 (B) 0.5 F106 Grn S-CAN6, S-CAN8
0.8 507 Yel Sp-2, C25 (6) 0.5 F107 Grn S-CAN8, A5502 (53)
0.8 510 Yel Sp-2, C17 (A) 0.5 F108 Grn C36 (8), S-CAN8
0.5 513 Yel Sp-13, A5502 (88) 0.5 F150 Grn A5502 (76), X5058 (3)
0.5 514 Yel Sp-13, C6 (H1) 0.5 F201 Yel S-CAN3, C6 (A1)
0.8 516 Yel C21 (2), Sp-2 0.5 F203 Yel S-CAN3, C20 (4)
0.8 518 Yel C7 (A), Sp-2 0.5 F204 Yel S-CAN3, S-CAN5
0.8 525 Yel C23 (S2) 0.5 F205 Yel S-CAN5, C24 (C)
3.0 551 Yel C37 (1), Sp-2 0.5 F206 Yel S-CAN5, S-CAN7
3.0 553 Yel C37 (2), C38 (A) 0.5 F207 Yel S-CAN7, A5502 (75)
1.0 540 Yel Sp-16, C12 (2) 0.5 F208 Yel C36 (A), S-CAN7
1.0 561 Yel Sp-16, C12 (1) 0.5 F250 Yel X5058 (2), A5502 (54)
1.0 562 Yel Sp-16, C12 (5)
3.0 590 Yel C11 (87), Sp-16
0.8 599 Yel C23 (S2), Sp-13
0.5 600 Brn A5502 (66)
0.5 620 Tan T-19, A5502 (15)
0.5 640 Grn C-17 (B), C6 (C1)
0.5 651 Pnk C6 (F4), A5502 (32)
0.5 670 Blu C13 (B), A5502 (68)
0.5 671 Blu C13 (A), C2 (85)
0.5 680 Gry C19 (A), C6 (M3)
0.5 681 Pnk C22 (A), C6 (K3)
0.8 703 Pur C23 (S1), Sp-9
0.5 704 Pur Sp-9, C6 (C2)
0.8 705 Pur Sp-14, C3 (85)
0.5 706 Pur C3 (86), A5502 (28)
0.5 707 Pur Sp-14, A5502 (14)
0.5 708 Pur C25 (C), C6 (J1)
0.5 709 Pur Sp-9, A5502 (35)
0.5 710 Pur Sp-14, C6 (63)
3.0 747 Pur C16 (A), C3 (87)
0.5 755 Blu C19 (A), C6 (J4)
0.5 760 Pnk C21 (3), C6 (K1)
0.8 775 Grn T-9, C12 (6)
0.5 833 Pnk C7 (B), C6 (H1)
0.5 836 Pnk C9 (A), C6 (J3)
0.5 837 Org C7 (C), C6 (G1)
0.5 901 Gry 8-3A (A), C6 (G4)
0.5 910 Grn C11 (85), C6 (82)
3.0 920 Red C26 (1), C1 (87)
0.5 921 Wht C1 (85), A5502 (70)
0.5 990 Brn C10 (A), A5502 (62)
0.5 991 Org C10 (C), A5502 (43)
0.5 992 Pur C10 (B), A5502 (61)
Continued on next page CB12260,0000039 -19-04JUN14-2/4

TM130419 (24FEB16) 30-20-17 030916

PN=195
 Wiring Harnesses

Splice No. Circuit No./Color

Main Wiring Harness Splice Table, T4
Sp-11 103 Blk
Splice No. Circuit No./Color
150 Blk
Sp-1 230 Red
145 Blk
203 Red
126 Blk
205 Red
127 Blk
240 Red
142 Blk
Sp-2 500 Yel
Sp-12 148 Blk
551 Yel
146 Blk
501 Yel
147 Blk
507 Yel
Sp-13 514 Yel
510 Yel
513 Yel
516 Yel
599 Yel
530 Yel
Sp-14 710 Pur
506 Yel
707 Pur
502 Yel
705 Pur
518 Yel
Sp-15 225 Red
Sp-3 209 Red
230 Red
220 Red
201 Red
241 Red
Sp-16 503 Yel
Sp-4 225 Red
590 Yel
207 Red
560 Yel
243 Red
561 Yel
240 Red
562 Yel
Sp-5 121 Blk
Sp-20 100 Blk
122 Blk
123 Blk
124 Blk
108 Blk
125 Blk
120 Blk
128 Blk
135 Blk
129 Blk
148 Blk
Sp-6 211 Red
153 Blk
212 Red
101 Blk
213 Red
102 Blk
214 Red
107 Blk
215 Red
130 Blk
Sp-7 468 Grn
143 Blk
466 Grn
145 Blk
457 Grn
Sp-8 471 Wht
469 Wht
470 Wht
Sp-9 704 Pur
709 Pur
703 Pur
Sp-10 483 Blk
487 Blk
489 Blk
490 Blk

Continued on next page CB12260,000003A -19-04JUN14-1/2

TM130419 (24FEB16) 30-20-18 030916

PN=196
 Wiring Harnesses

Splice No. Circuit No./Color

S-CAN3 F201 Yel
F203 Yel
F204 Yel
S-CAN4 F101 Grn
F103 Grn
F104 Grn
S-CAN5 F204 Yel
F205 Yel
F206 Yel
S-CAN6 F104 Grn
F105 Grn
F106 Grn
S-CAN7 F206 Yel
F207 Yel
F208 Yel
S-CAN8 F106 Grn
F107 Grn
F108 Grn
CB12260,000003A -19-04JUN14-2/2

Main Wiring Harness Terminal Table, T4

Terminal Circuit No./Color
T-1 120 Blk
T-4 200 Red
201 Red
T-5 200 Red
T-6 146 Blk
T-7 147 Blk
T-8 202 Red
T-9 775 Grn
T-19 620 Tan
T-33 100 Blk
T-34 121 Blk
T-35 191 Blk

CB12260,000003B -19-21JUL14-1/1

TM130419 (24FEB16) 30-20-19 030916

PN=197
 Wiring Harnesses

Keyswitch Jumper Harness

206 Red 101 Wht 535 Yel

C2 C1 501 Yel 206 Red
501 Yel

TCT010569 —UN—25JUN14
D E F
535 Yel C B A

736 Pur 100 Blk 100 Blk 101 Wht

736 Pur

C1—Main Harness Connector C2—Keyswitch Connector

SH24924,0000231 -19-28JUL14-1/1

TM130419 (24FEB16) 30-20-20 030916

PN=198
 Wiring Harnesses

Cab Wiring Harness

X-E25

X27-W20

X-E20

X-E24 X-M08

X-E26
X-H04

X-S23

Sp-225 Sp-120 Sp-227 Sp-052 Sp-147

Sp-135

Sp-221 Sp-010E Sp-272B

Sp-282

X55

X-RFP

X-S22 X-S24
TCT009616 —UN—23DEC13

Continued on next page CB12260,0000041 -19-23JUL14-1/4

TM130419 (24FEB16) 30-20-21 030916

PN=199
 Wiring Harnesses

X-WP

X-M07

X-E22 X-A01
2 8

1 7

10 16

9 15

X-H03

T14
T23 T24 X-E21

X-E23

A
X26-W20
Sp-157 Sp-010F Sp-145

X-E16

X-S52

3 4
X-E16-CAP
1 2

X-E19

B C
TCT009617 —UN—06JUN14

Continued on next page CB12260,0000041 -19-23JUL14-2/4

TM130419 (24FEB16) 30-20-22 030916

PN=200
 Wiring Harnesses

X-FH 1 2

< (T1)
T2
< (T2)
X-D1
11 12

T1
D

Sp-272 Sp-122 Sp-103A

Sp-072
X-FR
6
5
X-D2
1
2 4
3
Sp-010G

X-FWH

C
TCT009618 —UN—23DEC13

Continued on next page CB12260,0000041 -19-23JUL14-3/4

TM130419 (24FEB16) 30-20-23 030916

PN=201
 Wiring Harnesses

X-S12
B

C
A
D
E

X-S09

S103B S103C

X-S20

X-S08
TCT009619 —UN—06DEC13

CB12260,0000041 -19-23JUL14-4/4

TM130419 (24FEB16) 30-20-24 030916

PN=202
 Wiring Harnesses

Cab Wiring Harness Connectors X-E25 — RH Front Amber Light

X-E26 — RH Rear Amber Light
T1 — Switched Power X-FR — Flasher Relay
T2 — Battery Power X-H03 — Left Speaker
T14 — Beacon Ground X-H04 — Right Speaker
T23 — HVAC Temp Switch X-M08 — RH Blower Motor
T24 — HVAC Temp Switch X-M07 — LH Blower Motor
X26-W20 — LH Front Marker Light X-RFR — Roof Connector - Receptacle
X27-W20 — RH Front Marker Light X-RFP — Roof Connector - Plug
X55 — Power and Blower Light Relays X-S08 — Light Switch
X-A01 — Radio X-S09 — Cruise Control Switch
X-D1 — Turn Signal Diode 1 X-S12 — Beacon Switch
X-D2 — Turn Signal Diode 2 X-S20 — Wiper Switch
X-E16 — Connector X-S22 — HVAC Enable Switch
X-E16-CAP — Beacon Connector Cap X-S23 — Hi-Lo Pressure Switch
X-E19 — LH Front Work Light X-S24 — Blower Switch
X-E20 — RH Front Work Light X-S52 — Dome Light
X-E21 — LH Front Amber Light X-WP — Wiper Motor
X-E22 — LH Rear Amber Light X-FH — Fuse Holder
X-E23 — LH Rear Work Light X-FW — Firewall Bulkhead
X-E24 — RH Rear Work Light
CB12260,000003E -19-16JUL14-1/1

TM130419 (24FEB16) 30-20-25 030916

PN=203
 Wiring Harnesses

Size/No./Color Wire Connection Points

Cab Wiring Harness Color Codes
2.0 103G Org Sp-103B (1), X-S09 (C)
Size/No./Color Wire Connection Points
2.0 103H Org Sp-103C (2), X-D2 (B)
3.0 072 Yel Sp-072 (2), T1 (1)
2.0 103J Org Sp-103C (1), X-S09 (E)
0.8 214 Yel X-S22 (3), T23 (1)
0.8 103K Red Sp-103B (1), X-RFR (3)
0.8 215 Grn X-S23 (A), T24 (1)
0.8 103L Red Sp-103C (2), X-RFR (2)
1.0 224 Yel X-RFP (13), X-WP (3)
2.0 103M Org X-FR (1), Sp-103A (2)
1.0 225 Blu X-RFP (11), X-WP (5)
2.0 103N Org X-D1 (B), Sp-103B (2)
3.0 292 Red X55 (K9-30), X55 (K14-87)
0.8 103P Red X55 (K13-86), X-RFP (3)
13.0 002A Red X-FW (3), T2 (1)
0.8 103R Red X55 (K12-86), X-RFP (2)
5.0 010AE Blk Sp-010E (2), X-RFP (14)
2.0 120A Org X-Fr (3), X-RFP (4)
5.0 010AF Blk X-RFR (14), Sp-010G (2)
1.0 120B Org X55 (K13-87A), Sp-120 (1)
0.8 010BK Blk X-S12 (7), Sp-010G (2)
1.0 120C Org X55 (K12-87A), Sp-120 (1)
2.0 010BL Blk Sp-010F (2), T14 (1)
2.0 120D Org X-FR (3), X-RFR (4)
0.8 010BP Blk Sp-010F (2), X-E19 (B)
5.0 122A Red Sp-122 (1), X-FH (7)
0.8 010BR Blk Sp-010E (2), X-E20 (B)
3.0 122C Red Sp-122 (2), X-S08 (B)
0.8 010BT Blk Sp-010F (2), X-E21 (B)
2.0 122E Red Sp-122 (2), X-S12 (2)
0.8 010BU Blk Sp-010E (2), X-E-E22 (B)
0.8 135D Grn X55 (K13-30), Sp-135 (1)
0.8 010BV Blk Sp-010F (2), X-E23 (B)
0.8 135E Grn Sp-135 (2), X-E25 (A)
0.8 010BW Blk Sp-010E (2), X-E24 (B)
0.8 135F Grn Sp-135 (2), X-E26 (A)
0.8 010BX Blk Sp-010E (2), X-E25 (B)
0.5 145D Grn X55 (K12-30), Sp-145 (1)
0.8 010BY Blk Sp-010E (2), X-E26 (B)
0.8 145E Grn Sp-145 (1), X-E21 (A)
0.8 010CA Blk X-S09 (A), X-S12 (7)
0.8 145F Grn Sp-145 (2), X-E22 (A)
5.0 010CB Blk X-RFP (16), Sp-010G (2)
1.0 147G Pur X-RFP (6), Sp-147 (1)
1.0 010CC Blk Sp-010F (2), X-WP (2)
0.8 147H Pur X-E23 (A), Sp-147 (2)
0.8 010CE Blk Sp-010G (2), X-FR (4)
0.8 147J Pur X-E24 (A), Sp-147 (2)
3.0 010CF Blk Sp-010F (2), X-M07 (A)
1.0 147K Pur X-S08 (4), X-RFR (6)
3.0 010CG Blk Sp-010E (2), X-M08 (A)
1.0 157C Pur X-RFP (5), Sp-157 (1)
0.8 010CH Blk X55 (K9-85), Sp-010E (1)
0.8 157D Pur Sp-157 (2), X-E19 (A)
0.8 010CJ Blk X55 (K9-85), X55 (K10-85)
0.8 157E Pur Sp-157 (2), X-E20 (A)
0.8 010CK Blk X55 (K10-85), X55 (K11-85)
0.8 157F Pur Sp-157 (1), X-A01 (3)
0.8 010CL Blk X55 (K11-85), X55 (K12-85)
0.8 157G Pur Sp-157 (2), X26-W20 (1)
0.8 010CM Blk Sp-010F (2), X-S52 (lll)
0.8 157H Pur Sp-157 (2), X27-W20 (1)
0.8 010CN Blk X55 (K12-85), X55 (K13-85)
1.0 157J Grn X55 (K13-87), Sp-157 (1)
5.0 010CR Blk X-RFP (16), Sp-010F (2)
1.0 157K Grn X55 (K12-87), Sp-157 (2)
0.8 010CW Blk X55 (K13-85), X55 K14-85)
1.0 157L Pur X-S08 (3), X-RFR (5)
13.0 010PT Blk X-FW (4), Sp-010G (1)
2.0 163D Org X-RFP (7), X-E16 (1)
3.0 052A Red X-RFR (8), Sp-052 (1)
0.8 163E Org X-S12 (3), X-S12 (8)
3.0 052B Red X-RFP (8), Sp-052 (1)
2.0 163F Org X-S12 (3), X-RFR (7)
3.0 052C Red X55 (K14-30), Sp-052 (2)
3.0 213A Org X55 (K9-87), X-M07 (D)
0.8 052D Red Sp-052 (1), X-A01 (7)
3.0 213B Org X55 (K10-87), X-M08 (D)
0.8 052E Red Sp-052 (2), X-S52 (ll)
0.8 216A Grn X-RFR (1), X-FW (6)
3.0 062A Red X-RFR (10), X-FH (9)
0.8 216B Grn X-S23 (B), X-RFP (1)
3.0 062B Red X55 (K11-30), X-RFP (10)
2.0 221A Brn Sp-221 (1), X-S24 (2)
3.0 072A Yel Sp-272A (1), X-FH (1)
2.0 221B Brn Sp-221 (2), X-M07 (B)
1.0 072B Yel Sp-072 (1), X-FW (1)
2.0 221C Brn Sp-221 (2), X-M08 (C)
1.0 072C Yel Sp-072 (1), X-FW (2)
1.0 224A Yel X-S20 (P), X-RFR (13)
1.0 072D Yel Sp-072 (1), X-FW (5)
0.8 225A Grn Sp-225 (2), X-S24 (3)
2.0 103D Org Sp-103A (1), X-S08 (2)
0.8 225B Grn Sp-225 (1), X55 (K9-86)
2.0 103E Org X-D1 (A), Sp-103A (2)
0.8 225C Grn Sp-225 (1), X55 (K10-86)
2.0 103F Org Sp-103A (1), X-D2 (A)
1.0 226A Blu X-S10 (2), X-RFR (11)

Continued on next page CB12260,000003D -19-17JUL14-1/3

TM130419 (24FEB16) 30-20-26 030916

PN=204
 Wiring Harnesses

Size/No./Color Wire Connection Points

1.0 227B Pur Sp-227 (1), X-S24 (1)
1.0 227C Pur Sp-227 (2), X-S22 (2)
1.0 227D Pur Sp-227 (2), X-M08 (B)
1.0 227E Pur Sp-227 (2), X-M07 (B)
0.8 230A Blk Sp-010F (1), X-A01 (8)
0.8 234A Yel X-A01 (11), X-H04 (B)
0.8 235A Grn X-A01 (12), X-H04 (A)
0.8 236A Blu X-H03 (B), X-A01 (13)
0.8 237A Pur X-H03 (A), X-A01 (14)
1.0 245A Grn X-RFP (9), X-WP (4)
1.0 245B Grn X-S20 (1), X-S20 (L)
1.0 245D Grn S-20 (1), X-RFR (9)
3.0 272C Yel X-RFR (12), Sp-272A (2)
1.0 272D Yel Sp-272A (2), X-S20 (B)
3.0 272E Yel X-RFP (12), Sp-272B (1)
0.8 272F Yel Sp-272B (2), X-A01 (6)
0.8 272G Yel Sp-272B (2), X-A01 (4)
1.0 272H Yel Sp-272B (2), X-WP (6)
0.8 272J Yel X55 (K11-86), Sp-272B (2)
0.8 272K Red X55 (K11-86), X55 (K14-86)
2.0 272L Red Sp-272A (2), X-S09 (D)
3.0 282A Red Sp-282 (1), X-S24 (B)
3.0 282B Red X55 (K10-30), Sp-282 (2)
3.0 282C Red X55 (K11-87), Sp-282 (2)
Continued on next page CB12260,000003D -19-17JUL14-2/3

TM130419 (24FEB16) 30-20-27 030916

PN=205
 Wiring Harnesses

Splice No. Circuit No./Color

Cab Wiring Harness Splice Table
Sp-135 135D Grn
Splice No. Circuit No./Color
135E Grn
Sp-010E 010CH Blk
135F Grn
010AE Blk
Sp-145 145D Grn
010BR Blk
145E Grn
010BU Blk
145F Grn
010BW Blk
Sp-147 147G Pur
010BX Blk
147H Pur
010BY Blk
147J Pur
010CG Blk
Sp-157 157C Pur
Sp-010F 230A Blk
157F Pur
010BL Blk
157J Dk Grn
010BP Blk
157D Pur
010BT Blk
157E Pur
010BV Blk
157G Pur
010CC Blk
157H Pur
010CF Blk
157K Dk Grn
010CM Blk
Sp-221 221A Brn
010CR Blk
221B Brn
Sp-010G 010PT Blk
221C Brn
010AF Blk
Sp-225 225B Grn
010BK Blk
225C Grn
010CB Blk
225A Grn
010CE Blk
Sp-227 227B Pur
Sp-052 052B Red
227C Pur
052D Red
227D Pur
052C Red
227E Pur
052E Red
Sp-272A 072A Yel
Sp-072 072 Yel
272C Yel
072A Yel
272D Yel
072B Yel
272L Red
072C Yel
Sp-272B 272E Yel
072D Yel
272F Yel
Sp-103A 103D Org
272G Yel
103F Org
272H Yel
103E Org
272J Yel
103M Org
Sp-282 282A Red
Sp-103B 103G Org
282B Red
103K Red
282C Red
103N Org
Sp-103C 103J Org
103H Org
103L Red
Sp-120 120B Org
120C Org
120A Org
Sp-122 122A Red
122C Red
122E Red

CB12260,000003F -19-14JUL14-1/1

TM130419 (24FEB16) 30-20-28 030916

PN=206
 Wiring Harnesses

Beacon Lamp Wiring Harness

X-8

T-13

T-12

C-42

C-41

TCT009623 —UN—27DEC13
Sp-1 Sp-2

BC-41—Power From Vehicle BSp-2—Ground Splice BT-13—Beacon Lamp Ground

BC-42—Power Out BT-12—Beacon Lamp Power Terminal
BSp-1—Switched Power Splice Terminal BX-8— Beacon Lamp Switch
Connector
CB12260,0000042 -19-22JUL14-1/1

Beacon Lamp Splice Table

Splice No. Circuit No./Color
BSp-2 113 Blk
150 Blk
151 Blk
152 Blk
BSp-1 502 Yel
503 Yel
504 Yel

CB12260,000011C -19-28JUL14-1/1

TM130419 (24FEB16) 30-20-29 030916

PN=207
 Wiring Harnesses

Beacon Lamp Wiring Harness Color Codes

Circuit Size/No./Color Connection Points
1.0 113 Blk BT-13, BSp-2
1.0 150 Blk BC-41 (B), BSp-2
0.8 151 Blk BSp-2, BX-8 (6)
1.0 152 Blk BSp-2, BX-42 (B)
1.0 302 Grn BT-12, BX-8 (1)
1.0 502 Yel BC-41 (A), BSp-1
1.0 503 Yel BSp-1, BX-42 (A)
1.0 504 Yel BSp-1, BX-8 (2)

CB12260,0000045 -19-22JUL14-1/1

TM130419 (24FEB16) 30-20-30 030916

PN=208
 Wiring Harnesses

Size/No./Color Wire Connection Points

Homologation Wiring Harness Color Codes
1.0 700 Pur SPL-11, X-5 (1)
Size/No./Color Wire Connection Points
1.0 701 Pur X-11 (6), X-15 (H)
5.0 100 Blk W-1 (1), SPL-5
0.8 702 Pur X-11 (4), X-15 (F)
0.8 101 Blk SPL-1A, T-18
0.8 703 Pur X-7A (A), X-15 (H)
1.0 102 Blk SPL-1A, X-4A (B)
0.8 704 Pur X-6A (A), X-15 (F)
0.8 103 Blk X-16 (F), SPL-6
0.8 705 Pur X-10 (4), X-1B (C)
1.0 104 Blk SPL-1A, X-6A (C)
1.0 706 Pur X-17 (A), X-10 (6)
1.0 105 Blk X-7A (C), SPL-1A
1.0 707 Pur SPL-11, X-15 (E)
1.0 106 Blk SPL-1A, X-5A (B)
1.0 708 Pur SPL-11, X-15 (G)
0.8 107 Blk K-1 (86), SPL-6
0.8709 Pur T-7, X-5 (1)
1.0 108 Blk SPL-9, X-5B (B)
0.8 710 Pur X-17 (A), X-5B (C)
1.0 109 Blk SPL-9, X-1B (B)
0.8 800 Pnk X-11 (5), X-4 (3)
3.0 110 Blk SPL-6, SPL-5
0.8 801 Pnk X-6A (B), X-7 (1)
3.0 111 Blk SPL-5, SPL-2
0.8 802 Pnk X-11 (3), X-4 (1)
2.0 112 Blk X-11 (2), SPL-6
0.8 803 Pnk V-1 (A), X-7A (B)
2.0 113 Blk SPL-9, X-10 (2)
0.8 804 Pnk V-1 (A), X-4 (1)
0.8 115 Blk T-6, SPL-2
0.8 805 Pnk X-4 (3), X-7 (1)
0.8 118 Blk X-17 (B), SPL-9
0.8 806 Pnk X-10 (3), X1-1B (A)
0.8 122 Blk X-4 (5), X-7 (3)
0.8 807 Pnk X-10 (5), X-5B (A)
1.0 125 Blk SPL-2, X-7 (3)
1.0 808 Pnk V-1 (B), X-7 (4)
3.0 126 Blk SPL-1A, SPL-5
1.0 900 Pnk X-3B (B), X-3A (B)
1.0 200 Red SPL-7, T-15
1.0 901 Pnk X-3B (D), X-3A (D)
1.0 201 Red SPL-8, T-15
3.0 202 Red SPL-7, X-15 (C)
2.0 203 Red SPL-8, X-15 (A)
3.0 204 Red K-1 (30), X-15 (D)
2.0 205 Red SPL-3, X-15 (B)
1.0 207 Red X-16 (C), X-15 (B)
1.0 214 Red SPL-3, X-5 (2)
0.8 218 Red SPL-3, T-1
1.0 300 Grn X-4A (A), X-14 (F)
1.0 301 Grn X-5A (A), X-14 (A)
1.0 302 Grn X-11 (1), X-3A (C)
1.0 304 Grn X-10 (1), X-1B (D)
0.8 305 Grn X-1B (D), X-5B (D)
1.0 306 Grn X-3A (A), X-14 (B)
3.0 403 Yel K-1 (87), SPL-4
0.8 404 Yel H-1 (A), K-1 (85)
2.0 405 Yel SPL-4, X-5 (5)
2.0 407 Yel SPL-10, X-5 (4)
1.0 409 Yel X-16 (A), X-4 (2)
1.0 410 Yel X-4 (2), XC-7 (2)
0.8 411 Yel X-7 (2), X-7 (5)
1.0 421 Yel SPL-4, X-14 (A)
2.0 422 Yel SPL-10, X-14 (G)
2.0 423 Yel SPL-10, X-14 (E)
0.8 500 Blu T-16, T-17

Continued on next page CB12260,000010F -19-18AUG14-1/2

TM130419 (24FEB16) 30-20-31 030916

PN=209
 Wiring Harnesses

Homologation Wiring Harness Splice Table

Splice No. Circuit No./Color
SPL-2 111 Blk
125 Blk
115 Blk
SPL-3 205 Red
214 Red
218 Red
SPL-4 403 Yel
405 Yel
421 Yel
SPL-5 100 Blk
110 Blk
111 Blk
126 Blk
SPL-6 110 Blk 112 Blk
103 Blk
107 Blk
SPL-7 202 Red
200 Fuselink
SPL-8 203 Red
201 Fuselink
SPL-9 113 Blk
108 Blk
109 Blk
118 Blk
SPL-10 407 Yel
422 Yel
423 Yel
SPL-11 700 Pur
707 Pur
708 Pur
SPL-1A 126 Blk
102 Blk
104 Blk
105 Blk
106 Blk
101 Blk

CB12260,0000110 -19-28JUL14-1/1

TM130419 (24FEB16) 30-20-32 030916

PN=210
 Wiring Harnesses

TM130419 (24FEB16) 30-20-33 030916

PN=211
 Wiring Harnesses

Homologation Wiring Harness

X-4B

B C

X-6A

X-5A

T-1 T-16

X-5B

T-6

T-7
Spl-3

X-5
1 4
3
25

1 4
25
3

X-7
TCT011511 —UN—20JUN14
1 5
4
2
3

X-4

Continued on next page CB12260,0000111 -19-26FEB15-1/7

TM130419 (24FEB16) 30-20-34 030916

PN=212
 Wiring Harnesses

X-6A— Left Turn and Position X-4B— RH Headlight X-5— Headlight Switch T-1— Horn Switch
X-5B CO—Cap X-4— Turn Switch T-7— Green LED Power T-16— Horn Switch
X-5A— LH Headlight X-7— Hazard Switch T-6— Green LED Ground
Continued on next page CB12260,0000111 -19-26FEB15-2/7

TM130419 (24FEB16) 30-20-35 030916

PN=213
 Wiring Harnesses

X-7A A

Spl-1A

A B

C D T-17
X-3A
A C T-18
D

X-3B

Spl-2

TCT011512 —UN—20JUN14

X-7A— Right Turn and Position X-3A— Brake Switch T-17— Horn Unit
X-3B— Cruise Interface T-18— Horn Unit
Continued on next page CB12260,0000111 -19-26FEB15-3/7

TM130419 (24FEB16) 30-20-36 030916

PN=214
 Wiring Harnesses

K-1

F
C

X-16

Spl-5

TCT011513 —UN—20JUN14

K-1— Headlight Relay X-16— Flasher Unit

Continued on next page CB12260,0000111 -19-26FEB15-4/7

TM130419 (24FEB16) 30-20-37 030916

PN=215
 Wiring Harnesses

F
G
B
X-14

Spl-10

Spl-4 Spl-11
Spl-7
Spl-8
B

A
H
D X-16
F
G
W -1 T-15

Spl-6
H-1

V-1

TCT011514 —UN—20JUN14

X-14— Fuse Block T-15— +12 Power V-1— Diode

X-16— Fuse Block W-1— Ground H-1— Switched Power
Continued on next page CB12260,0000111 -19-26FEB15-5/7

TM130419 (24FEB16) 30-20-38 030916

PN=216
 Wiring Harnesses

X-5B
B C
X-17

D A

X-11

X-10
TCT011515 —UN—20JUN14

X-5B— LH Brake Light X-17— Front Coupler

X-17— License Plate Light X-10— Rear Coupler
Continued on next page CB12260,0000111 -19-26FEB15-6/7

TM130419 (24FEB16) 30-20-39 030916

PN=217
 Wiring Harnesses

Spl-9

X-1B
A D

C B
TCT011519 —UN—20JUN14

X-1B— RH Brake Light

CB12260,0000111 -19-26FEB15-7/7

TM130419 (24FEB16) 30-20-40 030916

PN=218
 Wiring Harnesses

Front Work Light Wiring Harness

Right C-4
Column Right
A
Column
Light B
Light
Harness
Interface
203 YEL
A 202 YEL
B 101 BLK
100 BLK
C-3

C-5
F-1 85 86 S-1
30 87 1 2
15A 204 YEL 206 YEL
A B
87A
Fuse Holder Work Light
with Cover Relay

S-2
1 2

C-1
Right
A 200 YEL
X-1 Work B 102 BLK
Light

TCT011520 —UN—12SEP14
(+) A 205 YEL
(-) B 104 BLK
X-1 Connexts to Switched Power Reft C-2
Connector on Main Harness Work A 201 YEL
B 103 BLK
Light

WC-1— RH Work Light WC-4— Column Light WSp-1—Switched Power Splice

WC-2— LH Work Light WF-1— Fuse Holder WSp-2—Ground Splice
WC-3— Column Light Interface WK-5— Work Light Relay WX-1— To Vehicle Switched
Power
CB12260,0000116 -19-22JUL14-1/1

TM130419 (24FEB16) 30-20-41 030916

PN=219
 Wiring Harnesses

Work Light Wiring Harness Splice Table

Splice No. Circuit No./Color
WSp-1 206 Yel
200 Yel
201 Yel
WSp-2 104 Blk
102 Blk
103 Blk

CB12260,0000117 -19-22JUL14-1/1

Work Light Wiring Harness Color Codes

Size/No./Color Wire Connection Points
0.8 100 Blk WC-5 (86), WC-3 (B)
0.8 101 Blk WC-3 (B), WC-4 (B)
1.0 102 Blk WC-1 (A), WSp-2
1.0 103 Blk WC-2 (A), WSp-2
2.0 104 Blk WX-1 (B), WSp-1
1.0 200 Yel WC-1 (B), WSp-1
1.0 201 Yel W-1 (B), WSp-1C
0.8 202 Yel WC-5 (85), WC-3 (A)
0.8 203 Yel WC-3 (A), WC-4 (A)
2.0 204 Yel WC-5 (30), WF-1 (B)
2.0 205 Yel WX-1 (A), WF-1 (A)
2.0 206 Yel WC-5 (87), WSp-1

CB12260,0000118 -19-22JUL14-1/1

Backup Alarm Wiring Harness Splice Table

Splice No. Circuit No./Color
BACSp-01 401 Yel
402 Yel
403 Yel
BACSp-02 101 Blk
102 Blk
103 Blk

CB12260,000011A -19-23JUL14-1/1

Backup Alarm Wiring Harness Color Codes

Size/No./Color Wire Connection Points
1.0 101 Blk BAC-04 (B), BASp-02
0.8 102 Blk BASp-02, BAC-05 (B)
1.0 103 Blk BAC-02 (B), BASp-02
1.0 401 Yel BAC-04 (A), BASp-01
0.8 402 Yel BASp-01, BAC-01 (B)
1.0 403 Yel BAC-02 (A), BASp-01
0.8 601 Org BAC-01 (D), BAC-05 (A)

CB12260,000011B -19-23JUL14-1/1

TM130419 (24FEB16) 30-20-42 030916

PN=220
 Wiring Harnesses

Air Ride Seat Wiring Harness Splice Table

Splice No. Circuit No./Color
ASp-1 490A Yel
49oB Yel
490C Yel
ASp-2 191A Blk
191B Blk
191C Blk

CB12260,000011E -19-28JUL14-1/1

Air Ride Seat Wiring Harness Color Codes

Size/No./Color Wire Connection Points
0.8 411 Yel AC-3 (A), AC-1 (A)
1.0 831 Pnk AC-5 (3), AC-1 (B)
5.0 191A Blk AC-2 (B), ASp-2
5.0 191B Blk AC-4 (B), ASp-2
0.8 191C Blk AC-5 (5), ASp-2
0.8 411A Yel AC-5 (1), AC-3 (B)
5.0 490A Yel ASp-1, AC-2 (A)
5.0 490B Yel ASp-1, AC-4 (A)
0.8 490C Yel AC-5 (4), ASp-1

CB12260,000011F -19-28JUL14-1/1

TM130419 (24FEB16) 30-20-43 030916

PN=221
 Wiring Harnesses

TM130419 (24FEB16) 30-20-44 030916

PN=222
 Group 30
Repair
Summary of References • Repair Alternator
• Remove and Install Battery • Starting Motor
• Remove and Install Alternator
OUMX258,0000B65 -19-15SEP14-1/1

Remove and Install Battery

CAUTION: A battery explosion can be caused by

sparks when removing or installing battery:
• Do not smoke.

TCAL29061 —UN—22JUN12
• Wear eye protection and gloves.
• Do not allow direct metal contact across
battery posts.
• Disconnect negative (—) cable first
when removing battery.
• Connect positive (+) cable to battery first
when installing battery.

Removal:
A—Negative (—) Battery Cable C—Wing Nuts
1. Park machine safely. B—Red Plastic Cover D—Battery Hold-Down Bracket
2. Raise operator’s seat platform.
3. Disconnect negative (-) battery cable (A).
Installation:
4. Pull up red plastic cover (B) and disconnect positive
(+) battery cable clamp from battery post. • Installation is done in the reverse order of removal.
• Install battery J-bolts, battery hold down bracket and
5. Remove wing nuts (C) from left and right side of wing nuts.
battery hold-down bracket (D). • Install positive (+) cable clamp onto positive (+) battery
post. Replace plastic cover.
6. Remove battery from machine.
• Install negative (-) battery cable onto negative (-) battery
7. Clean and inspect battery for damage. Replace post.
battery if necessary. • Lower operator’s seat platform.
8. Check battery electrolyte level. Add as needed.
OUMX258,0000C1C -19-29MAR13-1/1

TM130419 (24FEB16) 30-30-1 030916

PN=223
 Repair

Remove and Install Alternator

Removal:
IMPORTANT: Always disconnect the negative (—)
cable from the battery before working on
any electrical components.

1. Disconnect the negative (—) cable from the battery.

2. Remove the engine cover.

TCAL29063 —UN—22JUN12
3. Disconnect ground lead (A).
4. Lift the plastic protective cover from the positive (RED)
lead (B). Remove the nut and washer, and disconnect
the lead from the alternator stud.
5. Disconnect the wire harness connector (C) from the
alternator.

A—Ground Lead C—Wire Harness Connector

B—Positive Lead

OUMX258,0000C1D -19-26FEB15-1/2

6. Remove mounting cap screws (D and F). Remove

bracket (H).
7. Remove lower nut (E) and belt (G) from alternator.
8. Remove alternator from stud.
Installation:

TCAL29064 —UN—22JUN12
1. Install alternator. Installation is done in the reverse
order of removal.
2. Tighten the drive belt. (See “Fan Belt and Alternator
Drive Belt Adjustment” in the appropriate engine
section.)

D—Mounting Cap Screws G—Belt

E—Lower Nut H—Bracket
F— Mounting Cap Screw

OUMX258,0000C1D -19-26FEB15-2/2

TM130419 (24FEB16) 30-30-2 030916

PN=224
 Repair

Repair Alternator • Air Impact Wrench

• Bearing Puller Set
Special or Required Tools • Ohmmeter (Sensitive to 0—1 Ohm)
• Soft Jaw Vise • 400-grit Silicon Carbide Sandpaper

TCAL29065 —UN—22JUN12
A—Nut I— Rotor P—Brush Holder W—Regulator
B—Pulley J— Bearing Q—Brush X—Rectifier
C—Spacer K—Bearing Cover R—Spring Y—Cap Screw
D—Frame Assembly L— Thrust Washer S—Nut Z— Rear Frame
E—Stud M—Cap Screw T— Bushing AA—Nut (2 used)
F— Bearing N—Rear Cover U—Screw
G—Plate O—Screw (6 used) V—Cap Screw with Washer
H—Screw (4 used)
OUMX258,0000C1E -19-15SEP14-1/11

Disassemble:
NOTE: Clamp pulley in a soft-jaw vise and use an air
impact wrench to remove pulley nut.

1. Remove pulley nut (A).

2. User a puller to remove pulley (B).
TCAL29066 —UN—22JUN12

A—Pulley Nut B—Pulley

Continued on next page OUMX258,0000C1E -19-15SEP14-2/11

TM130419 (24FEB16) 30-30-3 030916

PN=225
 Repair

3. Remove nut, washer and insulator from battery

terminal post (D).
4. Remove three screws (C) securing rear cover (E) to
rear frame. Remove rear cover.

C—Screws (3 used) E—Rear Cover

D—Battery Terminal Post

TCAL29067 —UN—22JUN12
OUMX258,0000C1E -19-15SEP14-3/11

5. Remove the short screw (I) and the long screw (J)
securing brush holder (F) to body. Remove brush
holder.
NOTE: Remember location of short screw on regulator tab.

6. Remove two screws (G) securing regulator to rear

TCAL29068 —UN—22JUN12
frame. Remove regulator (H).

F— Brush Holder I— Short Screw

G—Screws (2 used) J— Long Screw
H—Regulator

OUMX258,0000C1E -19-15SEP14-4/11

7. Remove screw and straighten wire leads (K).

8. Remove rectifier (L).

K—Wire Leads L— Rectifier

TCAL29069 —UN—22JUN12

Continued on next page OUMX258,0000C1E -19-15SEP14-5/11

TM130419 (24FEB16) 30-30-4 030916

PN=226
 Repair

9. Remove rear frame (M).

10. Press rotor shaft (N) from frame assembly.

M—Rear Frame N—Rotor Shaft

TCAL29070 —UN—22JUN12
OUMX258,0000C1E -19-15SEP14-6/11

11. Remove retainer plate (O).

12. Press bearing (P) from frame assembly.

O—Retainer Plate P—Bearing

TCAL29071 —UN—22JUN12
OUMX258,0000C1E -19-15SEP14-7/11

Inspection:
1. Inspect bearing (A) for smooth rotation. Replace if
necessary.
2. Inspect slip rings (B) for dirt or rough spots. If
necessary, use 400-grit silicon carbide paper to polish

TCAL29072 —UN—22JUN12
rings.
3. Measure outer diameter of slip rings. Replace rotor
if less than specification.
Specification
Alternator Rotor Slip
Rings—OD (Minimum).................................................................. 14 mm
(0.55 in.)

4. Check continuity between slip rings using ohmmeter. A—Bearing C—Rotor Core
Replace rotor assembly if there is no continuity. B—Slip Rings

5. Check continuity between slip rings and rotor core (C).

Replace rotor assembly if there is continuity.
7. Check for continuity between each stator lead and
6. Inspect stator for defective insulation, discoloration, body. Replace stator if there is continuity.
or burned odor.
Continued on next page OUMX258,0000C1E -19-15SEP14-8/11

TM130419 (24FEB16) 30-30-5 030916

PN=227
 Repair

NOTE: Set ohmmeter range to k-ohm.

8. Check continuity between main lead (D) and each

diode lead (E). Reverse the multimeter leads and
check again. There should be continuity in only one
direction when checking each diode lead. Replace

TCAL29073 —UN—22JUN12
diodes or rectifier plate if continuity is not correct.

D—Main Lead E—Diode Lead

OUMX258,0000C1E -19-15SEP14-9/11

9. Measure length of brush (F) protruding from

brush holder. Replace brush if length is not within
specification.

TCAL29074 —UN—22JUN12
Specification
Alternator—Exposed
Brush Length......................................................................4.5—10.5 mm
(0.17—0.41 in.)

F— Exposed Brush Length

Continued on next page OUMX258,0000C1E -19-15SEP14-10/11

TM130419 (24FEB16) 30-30-6 030916

PN=228
 Repair

10. Check continuity between brush and terminal (G).

Check continuity between brush and terminal (H).
There should be continuity only at these points.

TCAL29075 —UN—22JUN12
Assembly:
Assembly procedure is the reverse of disassembly.
IMPORTANT: Check that rotor fan does not
contact case and that rotor assembly turns
smoothly in bearing.
If the short screw (I) and longer screw (J) are
interchanged, the longer screw will contact the
frame and damage the charging system. G—Brush and Terminal H—Brush and Terminal

• Install short screw (I) in regulator tab and longer screw

(J) as shown.
• Clamp pulley in a soft-jaw vise. Install pulley nut and
tighten to specification.
Specification
Alternator Pulley

TCAL29076 —UN—22JUN12
Nut—Torque..................................................................................69 N·m
(51 lb.-ft.)

I— Short Screw J— Longer Screw

OUMX258,0000C1E -19-15SEP14-11/11

Starting Motor
Removing
IMPORTANT: Always disconnect the negative (—)
cable from the battery before working on
any electrical components.

1. Disconnect the negative (—) battery cable.

2. Slide back the protective boot (A) and remove the nut
securing the battery cable and wires on the starting
motor.
3. Disconnect the starting motor solenoid wire (B). TCAL29078 —UN—22JUN12

4. Remove the cap screws (C) securing the starting

motor to the backplate. Remove the starting motor.
Installing:
Installation is done in the reverse order of removal.
• Do not overtighten the starting motor cap screws!
Tighten the starting motor cap screws to specification. A—Protective Boot C—Cap Screws
B—Starter Motor Solenoid Wire
Specification
Starting Motor Mounting
Cap Screws—Torque....................................................................47 N·m
(35 lb.-ft.)

Continued on next page OUMX258,0000C1F -19-15SEP14-1/23

TM130419 (24FEB16) 30-30-7 030916

PN=229
 Repair

Starting Motor Component Location

A—Motor G—Solenoid
B—Field Coil H—Overrunning Clutch
C—Armature I— Pinion
D—Brush Spring J— Idler Gear
E—Brush K—Drive Gear
F— Plunger

TCAL29079 —UN—22JUN12
OUMX258,0000C1F -19-15SEP14-2/23

Disassemble:
1. Disconnect the field lead (A).
2. Remove the cover screws (B).
3. Remove the cap screws (C) that secure the motor to
the clutch housing.

TCAL29080 —UN—22JUN12
A—Field Lead C—Cap Screws
B—Cover Screws

Continued on next page OUMX258,0000C1F -19-15SEP14-3/23

TM130419 (24FEB16) 30-30-8 030916

PN=230
 Repair

4. Separate the cover (D) from the motor (E).

D—Cover E—Motor

TCAL29081 —UN—22JUN12
OUMX258,0000C1F -19-15SEP14-4/23

5. Remove motor (E), armature (F), and brush holder (G)

as a unit from the clutch housing (H).

E—Motor G—Brush Holder

F— Armature H—Clutch Housing

TCAL29082 —UN—22JUN12
OUMX258,0000C1F -19-15SEP14-5/23

NOTE: Brushes are not serviceable separately. If the

brushes require replacement, the entire brush
holder, with brushes attached, must be replaced.

6. Pry the brush springs (I) away and pull the negative
(-) brushes (J) up enough to allow the springs to hold
the brushes in place.
7. Remove the brush holder (K). TCAL29083 —UN—22JUN12

I— Brush Springs K—Brush Holder

J— Brushes

Continued on next page OUMX258,0000C1F -19-15SEP14-6/23

TM130419 (24FEB16) 30-30-9 030916

PN=231
 Repair

8. Remove the armature (L) from the field coil housing

(M).
9. Inspect and test the brushes, holder, field coil and
armature. (See Starting Motor Inspection and Test

TCAL29084 —UN—22JUN12
within this Group.)
Assemble
Assembly is done in the reverse order of disassembly.
NOTE: Apply multipurpose grease to bearing cup
inside rear cover.

IMPORTANT: When installing the rear cover, be sure

the field coil brush wires (N) do not touch the L— Armature M—Field Coil Housing
cover. Turn the brush holder (K) slightly to
take up slack in the brush wires. Press the
wires inward to clear the rear cover.

K—Brush Holder N—Field Coil Brush Wires

TCAL29085 —UN—22JUN12
OUMX258,0000C1F -19-15SEP14-7/23

Starting Motor Inspect and Test

1. Measure brush (A) lengths. Replace brush if length is
below minimum specified length.
Specification
Starting Motor
Brushes—Length
(Minimum).................................................................................... 8.5 mm

TCAL29086 —UN—22JUN12
(0.335 in.)

NOTE: Test brush holder using an ohmmeter or test light.

2. Test brush holder (B):

• Touch one probe of tester to negative (—) brush
holder (C) and other probe to field brush holder (D).
• If there is continuity, replace the brush holder.
3. Inspect springs (E) for wear or damage. Replace if A—Brush D—Brush Holder
necessary. B—Brush Holder E—Springs
C—Brush Holder

Continued on next page OUMX258,0000C1F -19-15SEP14-8/23

TM130419 (24FEB16) 30-30-10 030916

PN=232
 Repair

NOTE: Test field coil using an ohmmeter or test light.

4. Test for grounded field winding:

• Touch one probe of tester to field coil brush (F) and
other probe to field coil housing (G).
• Be sure the brush lead is not touching the frame. If
there is continuity, the coil is grounded and the field
coil housing assembly must be replaced.
IMPORTANT: Do not clean armature with solvent.
Solvent can damage insulation on windings.
Use only mineral spirits and a soft bristle brush.

TCAL29087 —UN—22JUN12
5. Test for open field coil:
• Touch one probe of tester to each field coil brush.
• If there is no continuity, the field coil is open and the
field coil housing assembly must be replaced.
6. Inspect armature. Look for signs of dragging against
pole shoes.
7. Inspect commutator. Look for roughness, burned F— Field Coil Brush G—Field Coil Housing
bars, or any material which might cause short circuits
between bars. If necessary, clean and touch up with
400 sandpaper. NEVER use emery cloth. Clean all
dust from armature when finished.
OUMX258,0000C1F -19-15SEP14-9/23

NOTE: Test armature windings using an ohmmeter

or test light.

8. Test for grounded windings:

• Touch probes on one commutator bar (H) and

TCAL29088 —UN—22JUN12
armature shaft (I). Armature windings are connected
in series, so only one commutator bar needs to be
checked.
• If test shows continuity, a winding is grounded and
the armature must be replaced.
9. Test for open circuit windings:
• Touch probes on two different commutator bars.
• If test shows no continuity, there is an open circuit
and the armature must be replaced. H—Commutator Bar I— Armature Shaft

Continued on next page OUMX258,0000C1F -19-15SEP14-10/23

TM130419 (24FEB16) 30-30-11 030916

PN=233
 Repair

10. Test for short circuit windings using a growler.

• Put armature in a growler and hold a hacksaw blade
above each slot while slowly rotating armature.
• If coil is shorted, the blade will vibrate on the slot.

TCAL29089 —UN—22JUN12
NOTE: A short circuit most often occurs because of copper
dust or filings between two commutator segments.

11. If test indicates short circuit windings, clean the

commutator of dust and filings. Check the armature
again. If the test still indicates a short circuit, replace
the armature.
12. Inspect armature cover and housing bearings for wear
or damage. Replace if necessary.
OUMX258,0000C1F -19-15SEP14-11/23

To Replace Bearings
NOTE: The bearings are press fit.

1. Remove the bearings using a knife-edge puller set.

TCAL29090 —UN—22JUN12
IMPORTANT: Install both bearings with the sealed
side toward armature.

2. Install a new housing bearing (J) tight against the

shoulder of the shaft using an appropriate size socket
that only presses on the inner race of the bearing.
3. Install a new cover bearing (K) tight against the
shoulder of the shaft using a driver set.
J— Housing Bearing K—Cover Bearing

OUMX258,0000C1F -19-15SEP14-12/23

Starting Motor Gear Train Disassemble and Inspect

1. Remove the field wire (A) and two motor-to-clutch
housing cap screws (B).
2. Remove the motor (C) from the clutch housing (D).

A—Field Wire C—Motor

B—Cap Screws (2 used) D—Clutch Housing
TCAL29091 —UN—22JUN12

Continued on next page OUMX258,0000C1F -19-15SEP14-13/23

TM130419 (24FEB16) 30-30-12 030916

PN=234
 Repair

3. Remove two clutch housing-to-solenoid housing

screws (E) to separate the clutch housing from the
solenoid/motor assembly.

E—Screws (2 used)

TCAL29092 —UN—22JUN12
OUMX258,0000C1F -19-15SEP14-14/23

4. Remove the plunger spring (F).

F— Plunger Spring

TCAL29093 —UN—22JUN12
OUMX258,0000C1F -19-15SEP14-15/23

5. Remove the retainer (G), five rollers (H), and pinion

gear (I).
6. Remove the steel ball (J).

G—Retainer I— Pinion Gear

H—Five Rollers J— Steel Ball

TCAL29094 —UN—22JUN12

Continued on next page OUMX258,0000C1F -19-15SEP14-16/23

TM130419 (24FEB16) 30-30-13 030916

PN=235
 Repair

7. Put the clutch housing assembly into a soft-jawed

vice, as shown.
8. Tighten the vise slowly, until the drive gear compresses.
9. While holding the clutch assembly, slowly open the
vise until all spring compression is relieved.

TCAL29095 —UN—22JUN12
CAUTION: The shaft could be propelled from the
clutch unit with considerable force if the spring
is not allowed to extend fully while in the vise!

10. Remove the circlip (K) and retainer (L).

K—Circlip L— Retainer

OUMX258,0000C1F -19-15SEP14-17/23

11. Remove the drive gear (A), spring (B), and clutch (C)
assembly from the housing (D).

A—Drive Gear C—Clutch Assembly

B—Spring D—Housing

TCAL29096 —UN—22JUN12
OUMX258,0000C1F -19-15SEP14-18/23

12. Remove the toothed washer (E), spring (F), and clutch
shaft (G).
13. Inspect all parts for wear or damage.
Starting Motor Gear Train Assembly:
Assembly is done in the reverse order of disassembly.
TCAL29097 —UN—22JUN12
• Apply multipurpose grease to bearings, clutch shaft,
springs, pinion gears, retainer, rollers and steel ball.
• Install the large washer with the flat side toward the
clutch assembly.
• Install the retainer with the cupped side away from the
clutch assembly.

B—Clutch Housing F— Spring

E—Toothed Washer G—Clutch Shaft

Continued on next page OUMX258,0000C1F -19-15SEP14-19/23

TM130419 (24FEB16) 30-30-14 030916

PN=236
 Repair

Starting Motor Solenoid Disassemble and inspect:

1. Disconnect the field lead (A).
2. Remove three screws (B), the cover and gasket (C).

A—Field Lead C—Cover and Gasket

B—Screws (3 used)

TCAL29098 —UN—22JUN12
OUMX258,0000C1F -19-15SEP14-20/23

3. Remove the plunger (D).

4. Inspect the copper washer (E) and spring (F).

D—Plunger F— Spring
E—Copper Washer

TCAL29099 —UN—22JUN12
OUMX258,0000C1F -19-15SEP14-21/23

5. Inspect the contact plates (G) for excessive burning

or pitting. Contacts and plunger come as a kit. If
contacts or plunger are defective, replace all the parts
with the kit.

G—Contact Plates
TCAL29100 —UN—22JUN12

Continued on next page OUMX258,0000C1F -19-15SEP14-22/23

TM130419 (24FEB16) 30-30-15 030916

PN=237
 Repair

Starting Motor Solenoid Assemble:

Assembly is done in the reverse order of disassembly.
NOTE: The assembly sequence of the left and right
terminals is similar. Be sure solenoid terminal
lead (H) is installed between terminal bolt and
contact plate. Also, be sure smaller contact
plate (I) is on the left side.

H—Solenoid Terminal Lead I— Contact Plate

TCAL29101 —UN—22JUN12
OUMX258,0000C1F -19-15SEP14-23/23

TM130419 (24FEB16) 30-30-16 030916

PN=238
 Section 40
Power Train Repair
Contents

Page
Page
Group 10—Power Train Components—Sin-
gle Speed Separate and Install Hydrostatic
Summary of References................................ 40-10-1 Assembly and Differential
Transaxle Component Assembly—2 Speed .................................. 40-40-7
Location—Single Speed Remove, Disassemble, Inspect,
Range ........................................................ 40-10-1 and Assemble Hydraulic
Hydrostatic Pedal and Neutral Pump—2 Speed ...................................... 40-40-11
Safety Linkage Component Disassemble, Inspect, and
Location ..................................................... 40-10-2 Assemble Charge Pump—2
4WD Component Location ............................ 40-10-3 Speed ...................................................... 40-40-17
Remove, Inspect, and Install 2
Group 20—Power Train Components—2 Speed Speed Range—2 Speed.......................... 40-40-21
Summary of References................................ 40-20-1 Remove, Inspect, and Assemble
Transaxle Component Location—2 4WD Drive Output Unit—2
Speed ........................................................ 40-20-1 Speed ...................................................... 40-40-39
Hydrostatic Pedal and Neutral Disassemble, Inspect, and
Safety Linkage Component Assemble Hydrostatic
Location—2 Speed .................................... 40-20-2 Assembly—2 Speed ................................ 40-40-43
4WD Component Location—2 Disassemble, Inspect, and
Speed ........................................................ 40-20-3 Assemble Differential—2
Speed ...................................................... 40-40-59
Group 30—Power Train Repair—Single Speed Disassemble, Inspect, and
Summary of References................................ 40-30-1 Assemble PTO—2 Speed ....................... 40-40-79
Remove and Install Engine Remove and Install 4WD
Driveshaft .................................................. 40-30-1 Driveshaft—2 Speed ............................... 40-40-98
Remove and Install Transaxle ....................... 40-30-2 Remove and Install 4WD Axle—2
Separate and Install Hydrostatic Speed ...................................................... 40-40-99
and Differential Assemblies ....................... 40-30-4 Disassemble, Inspect, and
Disassemble, Inspect, and Assemble 4WD Axle—2 Speed.............. 40-40-101
Assemble Charge Pump............................ 40-30-7
Disassemble, Inspect, and
Assemble Hydrostatic
Assembly ................................................. 40-30-11
Disassemble, Inspect, and
Assemble Differential
Assembly ................................................. 40-30-28
Disassemble, Inspect, and
Assemble PTO ........................................ 40-30-47
Remove and Install 4WD Drive
Shaft ........................................................ 40-30-64
Remove and Install 4WD Gear
Case ........................................................ 40-30-65
Disassemble, Inspect, and
Assemble 4WD Gear Case ..................... 40-30-67
Remove and Install 4WD Axle..................... 40-30-77
Disassemble, Inspect, and
Assemble 4WD Axle................................ 40-30-79

Group 40—Power Train Repair—2 Speed

Summary of References................................ 40-40-1
Remove and Install Engine
Driveshaft—2 Speed ................................. 40-40-1
Remove and Install Transaxle—2
Speed ........................................................ 40-40-2

TM130419 (24FEB16) 40-1 030916

PN=1
 Contents

TM130419 (24FEB16) 40-2 030916

PN=2
 Group 10
Power Train Components—Single Speed
Summary of References • 4WD Component Location
• Transaxle Component Location—Single Speed Range
• Hydrostatic Pedal and Neutral Safety Linkage
Component Location
OUMX258,0000A9E -19-28MAR13-1/1

Transaxle Component Location—Single Speed Range

TCAL29173 —UN—02JUL12

A—Left Brake Arm D—Tow Valves G—4WD Gear Case J— PTO Assembly
B—Hydrostatic Assembly E—Right Brake Arm H—Input Shaft
C—Differential Assembly F— 4WD Output Shaft I— PTO Solenoid

OUMX258,0000A8E -19-28MAR13-1/1

TM130419 (24FEB16) 40-10-1 030916

PN=241
 Power Train Components—Single Speed

Hydrostatic Pedal and Neutral Safety Linkage Component Location

TCAL29174 —UN—02JUL12

A—Neutral Safety Arm D—Hydrostatic Control Arm G—Forward Pedal K—Reverse Cable
B—F-N-R Bellcrank E—Hydrostatic Control Link H—Reverse Pedal
C—Linkage Support Bracket F— Brake Pedal I— Forward Cable
J— Neutral Safety Link
OUMX258,0000A8F -19-22MAR13-1/1

TM130419 (24FEB16) 40-10-2 030916

PN=242
 Power Train Components—Single Speed

4WD Component Location

TCAL29175 —UN—02JUL12

A—4WD Axle E—PTO Shaft H—4WD Gear Case

B—Engine F— Differential Assembly I— 4WD Drive Shaft
C—Drive Shaft G—Front Axle Housing
D—Hydrostatic Assembly
OUMX258,0000A90 -19-22MAR13-1/1

TM130419 (24FEB16) 40-10-3 030916

PN=243
 Power Train Components—Single Speed

TM130419 (24FEB16) 40-10-4 030916

PN=244
 Group 20
Power Train Components—2 Speed
Summary of References • 4WD Component Location—2 Speed
• Transaxle Component Location—2 Speed
• Hydrostatic Pedal and Neutral Safety Linkage
Component Location—2 Speed
OUMX258,0000ABA -19-22MAR13-1/1

Transaxle Component Location—2 Speed

TCAL29446 —UN—09JUL12
A—Left Brake Arm D—Vent I— Right Brake Arm M—PTO Solenoid
B—Hydrostatic Assembly E—Oil Fill Cap J— 4WD Selector Shaft N—PTO Assembly
C—Forward/Reverse Lever F— Dipstick K—4WD Output Shaft
G—Differential Assembly L— Input Shaft
H—2-Speed Selector Shaft

OUMX258,0000AB7 -19-22MAR13-1/1

TM130419 (24FEB16) 40-20-1 030916

PN=245
 Power Train Components—2 Speed

Hydrostatic Pedal and Neutral Safety Linkage Component Location—2 Speed

TCAL29447 —UN—09JUL12

A—Neutral Safety Arm D—Hydrostatic Control Arm G—Forward Pedal K—Reverse Cable
B—F-N-R Bellcrank E—Hydrostatic Control Link H—Reverse Pedal
C—Linkage Support Bracket F— Brake Pedal I— Forward Cable
J— Neutral Safety Link
OUMX258,0000AB8 -19-22MAR13-1/1

TM130419 (24FEB16) 40-20-2 030916

PN=246
 Power Train Components—2 Speed

4WD Component Location—2 Speed

TCAL29448 —UN—09JUL12

A—4WD Axle E—PTO Shaft H—4WD Gear Case

B—Engine F— Differential Assembly I— 4WD Drive Shaft
C—Drive Shaft G—Front Axle Housing
D—Hydrostatic Assembly
OUMX258,0000AB9 -19-22MAR13-1/1

TM130419 (24FEB16) 40-20-3 030916

PN=247
 Power Train Components—2 Speed

TM130419 (24FEB16) 40-20-4 030916

PN=248
 Group 30
Power Train Repair—Single Speed
Summary of References • Disassemble, Inspect, and Assemble Differential
Assembly
• Remove and Install Engine Driveshaft • Disassemble, Inspect, and Assemble PTO
• Remove and Install Transaxle • Remove and Install 4WD Drive Shaft
• Separate and Install Hydrostatic and Differential • Remove and Install 4WD Gear Case
Assemblies
• Disassemble, Inspect, and Assemble 4WD Gear Case
• Disassemble, Inspect, and Assemble Charge Pump • Remove and Install 4WD Axle
• Disassemble, Inspect, and Assemble Hydrostatic • Disassemble, Inspect, and Assemble 4WD Axle
Assembly
OUMX258,0000A9D -19-17SEP14-1/1

Remove and Install Engine Driveshaft

Removal
1. Park machine safely. See the “Safety Section”
2. Raise front of machine. Support both sides of frame
just behind transaxle with 2-ton jackstands or wooden
block for safety reasons.

TCT011767 —UN—11SEP14
3. Remove three bolts (A) securing drive shaft to flywheel.

A—Bolt

BS62576,00017E4 -19-11SEP14-1/2

4. Remove bolts (B) securing drive shaft to transaxle

input shaft.
5. Remove drive shaft from machine.
Installation
1. Installation is reverse of removal.
2. Install drive shaft onto input shaft of transaxle.
3. Install bolts (B) securing shaft to input on transaxle.

TCT011768 —UN—11SEP14
4. Install three bolts (A) securing drive shaft to flywheel.
5. Lower machine to ground.

B—Bolt

BS62576,00017E4 -19-11SEP14-2/2

TM130419 (24FEB16) 40-30-1 030916

PN=249
 Power Train Repair—Single Speed

Remove and Install Transaxle

Special or Required Tools

• JT01748 Lifting Bracket

IMPORTANT: Absolute cleanliness is essential
when working on hydraulic components.
Contamination can result in serious damage
or inadequate operation. Clean all lines and

TCAL29183 —UN—02JUL12
fittings prior to opening hydraulic system.

Procedure
1. Remove front attachment.
2. Put wedge blocks in front of and behind both rear
drive wheels.
3. Loosen front drive wheel lug nuts.
A—PTO/Hydrostatic Housing C—Differential Housing
4. Raise front of machine. Support both sides of frame B—4WD Housing
just behind transaxle with 2-ton jackstands or wooden
blocks for safety reasons.
5. Remove front drive wheels.
6. Remove engine drive shaft. (See Remove and Install
Engine Driveshaft.)
7. Remove 4WD drive shaft, if equipped. (See Remove
and Install 4WD Drive Shaft.)
NOTE: Use shop cloths or paper towels to immediately
catch and clean up any spilled oil. Close all
ports and lines using caps or plugs.

8. Remove drain plugs at PTO/hydrostatic housing (A),

4WD housing (B), and differential housing (C).
OUMX258,0000A92 -19-17SEP14-1/5

9. Disconnect pedal linkage (F).

10. Remove three mounting cap screws (E) for linkage
pivot. Move pedal linkage aside.
11. Disconnect hydraulic hose (D).
12. Disconnect PTO solenoid harness (G).
13. Disconnect right and left brake links and springs (H).
NOTE: Power steering hose (I) will rotate at
TCAL29184 —UN—02JUL12

power steering valve.

14. Disconnect power steering hose (I).

15. Remove cap screw (J) and move wire harness aside.
Attach JT01748 Lifting Bracket in place of cap screw.

D—Hydraulic Hose H—Right and Left Brake Links

E—Mounting Cap Screws and Springs
F— Pedal Linkage I— Power Steering Hose
G—PTO Solenoid Harness J— Cap Screw

Continued on next page OUMX258,0000A92 -19-17SEP14-2/5

TM130419 (24FEB16) 40-30-2 030916

PN=250
 Power Train Repair—Single Speed

16. Disconnect implement lift cylinders (K).

17. Disconnect differential lock linkage (M).
18. Disconnect 4WD linkage (L), if equipped.
19. Connect an overhead hoist to lifting bracket on
transaxle.
20. Remove eight transaxle mounting cap screws (O) and
implement lift arm mounts (N).

TCAL29185 —UN—02JUL12
21. Remove transaxle.
22. Raise transaxle to frame.

K—Implement Lift Cylinders N—Implement Lift Arm Mounts

L— 4WD Linkage O—Transaxle Mounting Cap
M—Differential Lock Linkage Screws

OUMX258,0000A92 -19-17SEP14-3/5

IMPORTANT: Locating pins on rear side of

transaxle must be positioned in frame
locating holes before tightening of transaxle
mounting cap screws.

23. Install eight mounting cap screws (O) and implement

lift arm mounts (N). Position locating pins on transaxle
into locating holes of frame and tighten mounting cap
screws to specification.

TCAL29186 —UN—02JUL12
Specification
Transaxle Mounting Cap
Screw—Torque............................................................................142 N·m
(105 lb.-ft.)

24. Remove overhead hoist.

25. Connect 4WD linkage (L), if equipped.
26. Connect differential lock linkage (M).
27. Connect implement lift cylinders (K). K—Implement Lift Cylinders N—Implement Lift Arm Mounts
L— 4WD Linkage O—Transaxle Mounting Cap
M—Differential Lock Linkage Screws

Continued on next page OUMX258,0000A92 -19-17SEP14-4/5

TM130419 (24FEB16) 40-30-3 030916

PN=251
 Power Train Repair—Single Speed

28. Remove lifting bracket and install cap screw (J) and
wiring harness.
29. Connect power steering hose (I).
30. Connect right and left brake links and springs (H).
31. Connect PTO solenoid harness (G).
32. Connect hydraulic hose (D).
33. Install pedal linkage pivot using three mounting cap

TCAL29187 —UN—02JUL12
screws (E).
34. Connect pedal linkage (F). Check that all pedals
operate properly.
35. Install 4WD drive shaft, if equipped. (See Remove and
Install 4WD Drive Shaft.)
36. Install engine drive shaft. (See Remove and Install
Engine Driveshaft.)
D—Hydraulic Hose H—Right and Left Brake Links
37. Install front drive wheels. Tighten mounting cap E—Mounting Cap Screws and Springs
screws to specification. F— Pedal Linkage I— Power Steering Hose
G—PTO Solenoid Harness J— Cap Screw
Specification
Front Drive Wheel
Mounting Cap
Screw—Torque............................................................................225 N·m 39. Fill transaxle with proper fluid. (See “Machine
(165 lb.-ft.) Specifications”.)

38. Lower machine to ground.

OUMX258,0000A92 -19-17SEP14-5/5

Separate and Install Hydrostatic and

Differential Assemblies
IMPORTANT: Absolute cleanliness is essential
when working on hydraulic components.
Contamination can result in serious damage
or inadequate operation. Clean all lines and
fittings prior to opening hydraulic system.

TCAL29188 —UN—02JUL12
1. Remove transaxle. (See Remove and Install
Transaxle.)
2. Disconnect return hose (A).
3. Remove two cap screws (B), two cap screws (D), and
L-bracket (C).
4. Remove charge pump. (See Disassemble, Inspect,
and Assemble Charge Pump.)
A—Return Hose C—L-Bracket
B—Cap Screws D—Cap Screws

Continued on next page OUMX258,0000A93 -19-30DEC13-1/7

TM130419 (24FEB16) 40-30-4 030916

PN=252
 Power Train Repair—Single Speed

5. Remove five cap screws (E) and cover plate, or 4WD

gearbox, if equipped.

E—Cap Screws

TCAL29189 —UN—02JUL12
4WD Gearbox Shown

OUMX258,0000A93 -19-30DEC13-2/7

6. Remove two front cap screws (F).

F— Front Cap Screws

TCAL29190 —UN—02JUL12
OUMX258,0000A93 -19-30DEC13-3/7

7. Remove rear cap screw (G) and two nuts (H).

8. Separate hydrostatic assembly from differential
assembly.
9. Repair each assembly as necessary.
10. Clean gasket surfaces.
11. Replace gaskets.

TCAL29191 —UN—02JUL12
G—Rear Cap Screw H—Nuts

Continued on next page OUMX258,0000A93 -19-30DEC13-4/7

TM130419 (24FEB16) 40-30-5 030916

PN=253
 Power Train Repair—Single Speed

12. Install hydrostatic assembly to differential assembly.

13. Install cap screws (F and G) and nuts (H).

F— Front Cap Screws H—Nuts

G—Rear Cap Screw

TCAL29192 —UN—02JUL12
TCAL29193 —UN—02JUL12
OUMX258,0000A93 -19-30DEC13-5/7

14. Install cover plate or 4WD gearbox using cap screws

(E).
15. Install charge pump. (See Disassemble, Inspect, and
Assemble Charge Pump.)

E—Cap Screws

TCAL29194 —UN—02JUL12

4WD Gearbox Shown

Continued on next page OUMX258,0000A93 -19-30DEC13-6/7

TM130419 (24FEB16) 40-30-6 030916

PN=254
 Power Train Repair—Single Speed

16. Install L-bracket (C) using cap screws (B and D).

17. Connect return hose (A).
18. Install transaxle. (See Remove and Install Transaxle.)

A—Return Hose C—L-Bracket

B—Cap Screws D—Cap Screws

TCAL29195 —UN—02JUL12
OUMX258,0000A93 -19-30DEC13-7/7

Disassemble, Inspect, and Assemble Charge

Pump
Disassembly/Inspection
IMPORTANT: Absolute cleanliness is essential
when working on hydraulic components.
Contamination can result in serious damage
or inadequate operation.

TCAL29196 —UN—02JUL12
DO NOT use shop towels or rags to dry
cleaned parts. Lint will clog passages in the
hydraulic/hydrostatic system and cause damage.

NOTE: You do not need to remove transaxle to repair

charge pump only. Charge pump can be removed
without disassembly of transaxle.
Transaxle is shown removed for clarity.
A—Cap Screws D—L-Bracket
Use shop cloths or paper towels to immediately B—Port E—Hose Clamp
catch and clean up any spilled oil. Close all C—Cap Screws F— Suction Tube
ports and lines using caps or plugs.

1. If transaxle is in machine, drain transaxle. (See

Changing the Transaxle Oil and Filter in the operator’s 3. Remove four cap screws (C) and L-bracket (D).
manual.) 4. Loosen hose clamp (E).
NOTE: Power steering hose will rotate at power 5. Remove three cap screws (A) and remove suction
steering valve. tube (F).
2. If transaxle is in machine, disconnect and plug power
steering at port (B).
Continued on next page OUMX258,0000A94 -19-15SEP14-1/7

TM130419 (24FEB16) 40-30-7 030916

PN=255
 Power Train Repair—Single Speed

NOTE: Charge pump gears may fall out when

removing charge pump. Do not allow gears
to fall and become damaged.

6. Remove three cap screws (G).

7. Remove charge pump (H). Do not drop charge pump
gears.

TCAL29197 —UN—02JUL12
G—Cap Screws H—Charge Pump

OUMX258,0000A94 -19-15SEP14-2/7

8. Remove outer gear (K) from pump housing (J).

9. Remove O-rings (I) from pump housing.
10. Remove inner gear (L) and key (M) from pump shaft.
11. Inspect pump shaft bushing (O) for wear. If bushing
shows excessive wear, replace charge pump.

TCAL29198 —UN—02JUL12
12. Inspect machined surfaces of charge pump and
hydrostatic center section for severe scoring. If scoring
is noted, replace charge pump and center section.

I— O-Rings M—Key
J— Pump Housing N—Dimple
K—Outer Gear O—Pump Shaft Bushing
L— Inner Gear

Continued on next page OUMX258,0000A94 -19-15SEP14-3/7

TM130419 (24FEB16) 40-30-8 030916

PN=256
 Power Train Repair—Single Speed

13. Remove charge pump relief valve (P) and lube

reduction valve (Q).
14. Inspect valve spools and bores for severe scoring
or damage. If scoring or damage is noted, replace
charge pump and valves.
15. Clean and dry all parts.

P—Relief Valve Q—Reduction Valve

TCAL29199 —UN—02JUL12
TCAL29200 —UN—02JUL12
TCAL29201 —UN—02JUL12

Continued on next page OUMX258,0000A94 -19-15SEP14-4/7

TM130419 (24FEB16) 40-30-9 030916

PN=257
 Power Train Repair—Single Speed

Assembly
1. Apply clean transmission oil on all internal parts.
NOTE: Always replace O-rings. Old O-rings may be
worn or damaged resulting in leaks.

2. Replace O-rings and install charge pump relief (P)

TCAL29202 —UN—02JUL12
and lube reduction (Q) valves. Tighten valves to
specification.
Specification
Charge Pump Relief
Valve—Torque....................................................................... 22—27 N·m
(195—240 lb.-in.)
Lube Reduction
Valve—Torque....................................................................... 27—32 N·m
(240—284 lb.-in.) I— O-Rings M—Key
J— Pump Housing N—Dimple
3. Install key (M) on pump shaft. K—Outer Gear O—Pump Shaft Bushing
L— Inner Gear
NOTE: Dimples on inner and outer gear of charge pump
must face in same direction. If gears are installed
incorrectly, damage to pump will occur.
NOTE: Always replace O-rings. Old O-rings may be
4. With dimple (N) facing front of transaxle, install inner worn or damaged resulting in leaks.
gear (L) on pump shaft.
6. Replace O-rings (I).
5. With dimple facing front of pump housing (J), install
outer gear (K) into pump housing.
OUMX258,0000A94 -19-15SEP14-5/7

7. Install charge pump (H) using three cap screws (G).

G—Cap Screws H—Charge Pump

TCAL29203 —UN—02JUL12

Continued on next page OUMX258,0000A94 -19-15SEP14-6/7

TM130419 (24FEB16) 40-30-10 030916

PN=258
 Power Train Repair—Single Speed

8. Install suction tube (F) using three cap screws (A).

9. Tighten hose clamp (E).
10. Install L-bracket (D) using four cap screws (C).
11. If transaxle is in machine, connect power steering
hose to port (B).
12. If transaxle is in machine, fill transaxle. (See Changing
the Transaxle Oil and Filter in the operator’s manual.)

TCAL29204 —UN—02JUL12
A—Cap Screws D—L-Bracket
B—Port E—Hose Clamp
C—Cap Screws F— Suction Tube

OUMX258,0000A94 -19-15SEP14-7/7

Disassemble, Inspect, and Assemble

Hydrostatic Assembly
Disassembly/Inspection
IMPORTANT: Absolute cleanliness is essential
when working on hydraulic components.
Contamination can result in serious damage
or inadequate operation.

TCAL29205 —UN—02JUL12
DO NOT use shop towels or rags to dry
cleaned parts. Lint will clog passages in the
hydraulic/hydrostatic system and cause damage.

1. Remove transaxle. (See Remove and Install

Transaxle.)
2. Separate hydrostatic assembly. (See Separate and
Install Hydrostatic and Differential Assemblies.)
A—Spacer C—Gear
3. Remove snap ring (D), gear (C), bearing (B), and B—Bearing D—Snap Ring
spacer (A).
Continued on next page OUMX258,0000A95 -19-15SEP14-1/40

TM130419 (24FEB16) 40-30-11 030916

PN=259
 Power Train Repair—Single Speed

NOTE: Use shop cloths or paper towels to immediately

catch and clean up any spilled oil. Close all
ports and lines using caps or plugs.

4. Remove five hex socket screws (E) and one cap

screw (F).
IMPORTANT: Do not allow internal parts to fall free
when removing center section.

TCAL29206 —UN—02JUL12
Do not nick or scratch lapped or machined
surfaces of the center section, valve plates,
or cylinder blocks and pistons.

5. Carefully separate center section (G) from housing.

Take care not to let the gasket get hung up on the
guide pins. You may have to gently pry it off.

E—Hex Socket Screws G—Center Section

F— Cap Screw

OUMX258,0000A95 -19-15SEP14-2/40

NOTE: If valve plates do not come off with center section,

remove valve plates from cylinder block assemblies.
It may be necessary to apply diesel fuel between
valve plates and cylinder blocks to cut oil film.

6. Remove motor valve plate (H) and pump valve plate

(J). If valve plates stick to the center section, it may be
necessary to pry valve plates loose from the center

TCAL29207 —UN—02JUL12
section. Use a wood dowel and pry only at dowel pin
grooves (I).

H—Motor Valve Plate J— Dowel Pin Grooves

I— Pump Valve Plate

OUMX258,0000A95 -19-15SEP14-3/40

NOTE: Scoring is indicated by fine scratches or grooves

cut into the smooth plated surface of the valve
plate. Use a close visual inspection with a
magnifying glass or feel with your fingertips,
fingernail, or a sharpened lead pencil.
If scratches or grooves are detected, the
plate must be replaced.

7. Inspect valve plates. Valve plates should be flat, free

TCAL29208 —UN—02JUL12

of all nicks, burrs, scratches, and erosion around

the ports. The plated side should show no scoring,
smearing, or discoloration (a sign of overheating).

Continued on next page OUMX258,0000A95 -19-15SEP14-4/40

TM130419 (24FEB16) 40-30-12 030916

PN=260
 Power Train Repair—Single Speed

8. Inspect motor shaft seal (K). Replace if necessary.

9. Inspect both bearings (L) in the center section.
Replace if necessary. Remove bearing using a
two-jaw, slide-hammer puller.

K—Motor Shaft Seal L— Bearings

TCAL29209 —UN—02JUL12
OUMX258,0000A95 -19-15SEP14-5/40

10. Remove tow valves (M), forward check valve (N),

implement relief valve (O), and reverse check valve
(P) as required.

TCAL29210 —UN—02JUL12
11. Inspect valves and seats for damage. Valves must
slide freely in their bores. Valve seals must not be cut
or damaged. Replace valves as necessary. Tighten
valves to specification.
Specification
Tow Valve—Torque........................................................................34 N·m
(25 lb.-ft.)
Forward and Reverse
Check Valve—Torque....................................................................34 N·m
M—Tow Valves O—Implement Relief Valve
(25 lb.-ft.) N—Forward Check Valve P—Reverse Check Valve
Implement Relief
Valve—Torque...............................................................................24 N·m
(212 lb.-in.)
OUMX258,0000A95 -19-15SEP14-6/40

12. Remove drain tube (Q) and PTO supply tube (R).

Q— Drain Tube R—PTO Supply Tube

TCAL29211 —UN—02JUL12

Continued on next page OUMX258,0000A95 -19-15SEP14-7/40

TM130419 (24FEB16) 40-30-13 030916

PN=261
 Power Train Repair—Single Speed

IMPORTANT: Do not nick or scratch lapped

surface of cylinder blocks.

13. Reach in to grab pump assembly piston retainer rim

(T) to ensure none of the pistons slip out of the cylinder
block as you remove assembly from the pump shaft.

TCAL29212 —UN—02JUL12
14. In the same manner, reach in to grab motor assembly
piston retainer rim (S) and remove assembly from the
motor shaft.

S—Piston Retainer Rim T— Piston Retainer Rim

OUMX258,0000A95 -19-15SEP14-8/40

NOTE: Piston-to-bore relationship need not be maintained.

Pistons and cylinder blocks are not matched sets.

15. Inspect cylinder block assemblies.

• Lift piston retainer and pistons from cylinder block.
• Check for free movement of pistons in cylinder bores

TCAL29213 —UN—02JUL12
as you remove them.
• If any dragging is detected, replace entire cylinder
block assembly.

OUMX258,0000A95 -19-15SEP14-9/40

16. Remove and inspect all pistons

• Check barrel (W) for scoring, discoloration, or any
signs of separation of slippers.
• Check slipper (U) for scoring, smearing, rolled

TCAL29214 —UN—02JUL12
edges, and a full 360° free rotation on barrel.
• Check lubrication hole (V) for blockage. Clean with
compressed air.
• If any component of the piston is damaged, replace
the entire cylinder block assembly.

U—Slipper W—Barrel
V—Lubrication Hole

Continued on next page OUMX258,0000A95 -19-15SEP14-10/40

TM130419 (24FEB16) 40-30-14 030916

PN=262
 Power Train Repair—Single Speed

17. Remove and inspect both piston retainers

• Check retainer for flatness, nicks, burrs, and
discoloration.
• Check area around piston slipper (X) for scoring.

TCAL29215 —UN—02JUL12
• If any part of the piston retainer is damaged, replace
the entire cylinder block assembly.

X—Piston Slipper

OUMX258,0000A95 -19-15SEP14-11/40

18. Inspect both cylinder blocks

• Check ball guide area (Y) for scoring, wear, and
damage.
• Check nine cylinder bores (Z) for burns and scoring.
• Check lapped surface (AA) for wear and damage.
• Check spring assembly (AB) for damage and free

TCAL29216 —UN—02JUL12
axle movement.
• If any part of the cylinder block is damaged, replace
the entire cylinder block assembly.

Y—Ball Guide Area AA—Lapped Surface

Z— Cylinder Bores AB—Spring Assembly

TCAL29217 —UN—02JUL12
Continued on next page OUMX258,0000A95 -19-15SEP14-12/40

TM130419 (24FEB16) 40-30-15 030916

PN=263
 Power Train Repair—Single Speed

19. Remove return spring assembly (AD). Inspect plunger

for excessive tip wear and that plunger does not bind.
If plunger binds or has excessive tip wear, replace
return spring assembly.
20. Remove locknut and washer (AC).
21. Remove cap screw and washer (AE) and arm (AF).
22. Remove seven cap screws (AG).

TCAL29218 —UN—02JUL12
IMPORTANT: Control cover has centering pins
and may stick to them. If gentle prying
of cover is required, pry under cover, not
under plate below cover.

23. Carefully remove control cover (AH) while pushing

neutral adjust screw (AI) down through cover.

AC—Locknut And Washer AG—Cap Screws (7 used)

AD—Return Spring Assembly AH—Control Cover
AE—Cap Screw And Washer AI— Neutral Adjust Screw
AF—Arm

OUMX258,0000A95 -19-15SEP14-13/40

24. Remove neutral adjust screw (AJ) and washer (AL).

CAUTION: Neutral centering spring is under

tension. Use caution when removing to
prevent bodily injury.

TCAL29219 —UN—02JUL12
25. Carefully pry neutral centering spring (AM) over top of
centering pin (AK). Remove spring.

AJ—Neutral Adjust Screw AL—Washer

AK—Centering Pin AM—Neutral Centering Spring

OUMX258,0000A95 -19-15SEP14-14/40

26. Remove upper support plate (AN).

27. Inspect swash plate bearing (AO) for excessive wear
or scoring. Replace if necessary.

AN—Upper Support Plate AO—Swash Plate Bearing

TCAL29220 —UN—02JUL12

Continued on next page OUMX258,0000A95 -19-15SEP14-15/40

TM130419 (24FEB16) 40-30-16 030916

PN=264
 Power Train Repair—Single Speed

28. Remove snap ring (AP).

29. Remove seal (AQ) by prying out. Remove seal spacer.
30. Remove snap ring (AR).

AP—Snap Ring AR—Snap Ring

AQ—Seal

TCAL29221 —UN—02JUL12
TCAL29222 —UN—02JUL12
Continued on next page OUMX258,0000A95 -19-15SEP14-16/40

TM130419 (24FEB16) 40-30-17 030916

PN=265
 Power Train Repair—Single Speed

NOTE: Pump shaft rear bearing will be removed with shaft.

PTO drive gear will remain in housing until
swash plate is removed.
Swash plate thrust washer and shim location and
direction must be noted for reassembly.

31. Remove snap ring (AS).

TCAL29223 —UN—02JUL12
32. Using a plastic hammer, gently tap pump shaft (AT)
out rear of housing and PTO drive gear.
33. Carefully lift swash plate (AU) while retaining lower
thrust washer (AY) to bottom of swash plate. Remove
swash plate from housing.
34. Remove PTO drive gear from housing.
35. Note direction and location of upper shim (AW), upper
thrust washer (AX), and lower thrust washer (AY) and
remove from swash plate.

TCAL29224 —UN—02JUL12
36. Inspect thrust washers and shim for scoring or
damage. If scoring or damage is detected, replace
thrust washers and shim.
37. Remove thrust plate (AV) from swash plate using a
brass O-ring pick.
38. Inspect thrust plate for scoring or smeared plated
material. If scoring or smearing is detected, replace
thrust plate.
AS—Snap Ring AW—Upper Shim
39. Inspect all machined surfaces of swash plate for AT— Pump Shaft AX—Upper Thrust Washer
scoring or damage. If scoring or damage is detected, AU—Swash Plate AY—Lower Thrust Washer
AV—Thrust Plate
replace swash plate.
OUMX258,0000A95 -19-15SEP14-17/40

40. Remove motor shaft rear bearing retaining snap ring

(AZ).

AZ—Snap Ring

TCAL29225 —UN—02JUL12

Continued on next page OUMX258,0000A95 -19-15SEP14-18/40

TM130419 (24FEB16) 40-30-18 030916

PN=266
 Power Train Repair—Single Speed

NOTE: Motor shaft rear bearing will be removed

with motor shaft.

41. Using a plastic hammer, gently tap motor shaft and

bearing (BA) out rear of housing.

BA—Motor Shaft

TCAL29226 —UN—02JUL12
OUMX258,0000A95 -19-15SEP14-19/40

42. Remove motor thrust plate (BB) using a brass O-ring

pick.
43. Inspect lower swash plate bearing (BC) for excessive
wear or scoring.
44. If excessive wear or scoring is detected, remove snap
ring (BD) and cap seal (BE) and replace lower swash
plate bearing.

TCAL29227 —UN—02JUL12
BB—Motor Thrust Plate BD—Snap Ring
BC—Lower Swash Plate BE—Cap Seal
Bearing

OUMX258,0000A95 -19-15SEP14-20/40

45. Inspect input shaft and motor shaft bearings (BF).

Replace as necessary.
46. If repairing or inspecting PTO, see Disassemble,
Inspect, and Assemble PTO.
47. If repairing or inspecting 4WD gear case, see
Disassemble, Inspect, and Assemble 4WD Gear Case.
48. Remove all gaskets and clean all gasket surfaces.
TCAL29228 —UN—02JUL12

BF—Motor Shaft Bearings

Continued on next page OUMX258,0000A95 -19-15SEP14-21/40

TM130419 (24FEB16) 40-30-19 030916

PN=267
 Power Train Repair—Single Speed

Assembly
1. Clean and dry all parts.
NOTE: Apply clean hydrostatic oil to all parts
when assembling.

TCAL29229 —UN—02JUL12
2. If lower swash plate bearing was replaced, install new
cap seal (A) and install snap ring (B).

A—Cap Seal B—Snap Ring

OUMX258,0000A95 -19-15SEP14-22/40

3. Install PTO drive gear (D) into housing with shoulder

(C) facing rear of housing.

C—Shoulder D—PTO Drive Gear

TCAL29230 —UN—02JUL12
TCAL29231 —UN—02JUL12

Continued on next page OUMX258,0000A95 -19-15SEP14-23/40

TM130419 (24FEB16) 40-30-20 030916

PN=268
 Power Train Repair—Single Speed

NOTE: Swash plate thrust washers must be installed

with flat edge facing center of swash plate.

4. Install thrust washers (G) onto swash plate (E) with flat
edge facing center of swash plate.
5. Install shims (F) onto swash plate.

E—Swash Plate G—Thrust Washers

F— Shims

TCAL29232 —UN—02JUL12
OUMX258,0000A95 -19-15SEP14-24/40

6. Install swash plate (H) with thrust washers and shims

into housing.

H—Swash Plate

Continued on next page TCAL29233 —UN—02JUL12

OUMX258,0000A95 -19-15SEP14-25/40

TM130419 (24FEB16) 40-30-21 030916

PN=269
 Power Train Repair—Single Speed

NOTE: Top cover is being temporarily installed to set

swash plate end play. Parts normally contained
inside of top cover need not be installed at this point.

7. Install upper support plate (K) and top cover (I) with
gaskets (J) using seven cap screws (L).

I— Top Cover K—Upper Support Plate

J— Gaskets L— Cap Screw (7 used)

TCAL29234 —UN—02JUL12
OUMX258,0000A95 -19-15SEP14-26/40

8. Check swash plate end play between bottom of

support plate and top of shim. End play must be within
specification.
Specification
Swash Plate—End Play...................................................0.20—0.50 mm
(0.007—0.019 in.)

9. If end play is not within specification, remove top

cover, support plate, and gaskets.

TCAL29235 —UN—02JUL12
10. Add or subtract shims from top of swash plate to
obtain specification.
11. Reinstall support plate, top cover, and gaskets. Check
end play again.
12. Repeat steps 9—11 until correct specification is
obtained.
13. Remove top cover and gasket only.
OUMX258,0000A95 -19-15SEP14-27/40

14. Install motor shaft (M) into housing.

15. Carefully install pump shaft (O) through PTO drive
gear (N) and into housing.

M—Motor Shaft O—Pump Shaft

N—PTO Drive Gear
TCAL29236 —UN—02JUL12

Continued on next page OUMX258,0000A95 -19-15SEP14-28/40

TM130419 (24FEB16) 40-30-22 030916

PN=270
 Power Train Repair—Single Speed

16. Install pump shaft bearing snap ring (P).

17. Install seal spacer and new pump shaft seal (Q) using
snap ring (R).

P—Pump Shaft Bearing Snap R—Snap Ring

Ring
Q—Pump Shaft Seal

TCAL29237 —UN—02JUL12
TCAL29238 —UN—02JUL12
OUMX258,0000A95 -19-15SEP14-29/40

18. Install motor shaft bearing snap ring (S).

S—Snap Ring

TCAL29239 —UN—02JUL12

Continued on next page OUMX258,0000A95 -19-15SEP14-30/40

TM130419 (24FEB16) 40-30-23 030916

PN=271
 Power Train Repair—Single Speed

NOTE: Do not scratch machined surfaces of thrust

plates or swash plate.

19. Install PTO drive gear snap ring (V).

20. Install motor thrust plate (T) and pump thrust plate (U).

T— Motor Thrust Plate V—Drive Gear Snap Ring

U—Pump Thrust Plate

TCAL29240 —UN—02JUL12
OUMX258,0000A95 -19-15SEP14-31/40

CAUTION: Installing centering spring will put

it under tension. Use caution when installing
to prevent bodily injury.

21. Install neutral centering spring (Y) with flat arm (W)
down and to the rear of centering pin (Z).
22. Carefully pry bent arm (X) up and forward over the
top of centering pin.

TCAL29241 —UN—02JUL12
23. Install washer (AB).
24. Replace O-ring on neutral adjust screw (AA).
25. Install neutral adjust screw between arms of neutral
centering spring.
26. Rotate neutral adjust screw until adjusting cam (AC)
faces centering pin.

W—Flat Arm AA—Neutral Adjust Screw

X—Bent Arm AB—Washer
Y—Neutral Centering Spring AC—Adjusting Cam
Z— Centering Pin

TCAL29242 —UN—02JUL12

Continued on next page OUMX258,0000A95 -19-15SEP14-32/40

TM130419 (24FEB16) 40-30-24 030916

PN=272
 Power Train Repair—Single Speed

27. Replace upper swash plate seal (AD). Install with top
of seal against snap ring (AE).

AD—Upper Swash Plate Seal AE—Snap Ring

TCAL29243 —UN—02JUL12
OUMX258,0000A95 -19-15SEP14-33/40

28. Install cover (AK) using seven cap screws (AF).

29. Install washer and nut (AG).
30. Install return spring assembly (AH).
31. Install arm (AI) using cap screw and washer (AJ).

AF—Cap Screws (7 used) AI— Arm

AG—Washer and Nut AJ—Cap Screw and Washer

TCAL29244 —UN—02JUL12
AH—Return Spring Assembly AK—Cover

OUMX258,0000A95 -19-15SEP14-34/40

IMPORTANT: Do not nick or scratch lapped surface

of cylinder blocks. Piston-to-bore relationship
need not be maintained.

32. Install pistons into piston retainer, then into cylinder

block.
33. Lift piston retainer and pistons from cylinder block two TCAL29245 —UN—02JUL12
or three times to check for free movement of pistons
in cylinder block before you install the assembly into
the housing.

Continued on next page OUMX258,0000A95 -19-15SEP14-35/40

TM130419 (24FEB16) 40-30-25 030916

PN=273
 Power Train Repair—Single Speed

34. Install pump (AN) and motor (AL) cylinder blocks.

Hold onto the retainer rim to ensure pistons remain in
their bores.
35. Install new O-rings on drain tube (AM) and PTO supply
tube (AO) and install tubes into housing.

AL—Motor Cylinder Block AN—Pump Cylinder Block

AM—Drain Tube AO—PTO Supply Tube

TCAL29246 —UN—02JUL12
OUMX258,0000A95 -19-15SEP14-36/40

IMPORTANT: Use extreme care when assembling

the center section, valve plates, and cylinder
blocks to avoid dropping, nicking, or
scratching lapped surfaces.
Pump valve plate has two slotted ports (AP).
Motor valve plate (AS) has no slotted ports.

36. Put clean hydrostatic oil on valve plates and housing

TCAL29247 —UN—02JUL12
surfaces.
37. Align slots on back sides of plates with pins (AQ) in
center section and install pump valve plate (AR), with
slotted ports (AP), and motor valve plate (AS) over
their respective protruding bearings.
38. Install new center section to housing gasket onto
housing.

AP—Slotted Ports AR—Pump Valve Plate

AQ—Pins AS—Motor Valve Plate

TCAL29248 —UN—02JUL12

Continued on next page OUMX258,0000A95 -19-15SEP14-37/40

TM130419 (24FEB16) 40-30-26 030916

PN=274
 Power Train Repair—Single Speed

39. Align bearings of center section with pump and motor

shafts (AT). Slide center section on shafts until valve
plates contact cylinder blocks.
40. Apply pressure to center section and install two socket
head screws (AU) to hold center section in place.

AT— Pump And Motor Shafts AU—Socket Head Screws

TCAL29249 —UN—02JUL12
OUMX258,0000A95 -19-15SEP14-38/40

IMPORTANT: Check for proper internal assembly

by slowly rotating pump and motor shafts
while tightening cap screws.

NOTE: Center section will seem springy. This is

because the springs inside the cylinder blocks
are being compressed.

41. Install three remaining hex socket screws (AV) and

TCAL29250 —UN—02JUL12
one cap screw (AW). Tighten cap screws evenly in a
crossing pattern until they are snug - do not tighten to
specification at this time.
42. Check that both pump and motor shafts turn without
any binding or roughness.
43. Tighten five hex socket screws and one cap screw
to specification.
Specification AV—Hex Socket Screws AW—Cap Screw
Center Section-to-
Housing Hex Socket and
Cap Screw—Torque.............................................................. 34—49 N·m
(25—36 lb.-ft.)
Continued on next page OUMX258,0000A95 -19-15SEP14-39/40

TM130419 (24FEB16) 40-30-27 030916

PN=275
 Power Train Repair—Single Speed

44. Install spacer (AX), bearing (AY), gear (AZ), and snap
ring (BA).
45. Install new gasket (BB) to hydrostatic assembly.
46. Install hydrostatic assembly to differential assembly.
(See Separate and Install Hydrostatic and Differential
Assemblies.)

TCAL29251 —UN—02JUL12
AX—Spacer BA—Snap Ring
AY—Bearing BB—New Gasket
AZ—Gear

OUMX258,0000A95 -19-15SEP14-40/40

Disassemble, Inspect, and Assemble

Differential Assembly
Special or Required Tools

• Hoist
• Knife-Edge Puller
• 50.8 mm (2 in.) ID Pipe
• Punch
• Snap Ring Removal Tool1 1

TCAL29252 —UN—02JUL12
• Snap Ring Installation Tool
• Press
Axle Shaft Housing Disassembly
IMPORTANT: Absolute cleanliness is essential
when working on hydraulic components.
Contamination can result in serious damage
or inadequate operation.
DO NOT use shop towels or rags to dry 2. Remove oil filter and hose.
cleaned parts. Lint will clog passages in the
hydraulic/hydrostatic system and cause damage. 3. Mount one wheel to axle flange. Lift axle using a hoist
and support axle on wheel.
1. Separate hydrostatic assembly from differential
assembly. (See Separate and Install Hydrostatic and
Differential Assemblies.)
1
For instructions on making tool, see Fabricated Tools in this section.
Continued on next page OUMX258,0000A96 -19-15SEP14-1/52

TM130419 (24FEB16) 40-30-28 030916

PN=276
 Power Train Repair—Single Speed

NOTE: This disassembly procedure is for the left axle

shaft housing. The procedure for the right side is
similar, but some parts are not interchangeable,
left to right for example. Do not mix parts
from the right or left sides.

4. Remove two M10 x 60 cap screws (A).

TCAL29253 —UN—02JUL12
5. Remove seven M10 x 45 cap screws (B).
6. Remove axle shaft housing (C) using a hoist.

A—M10 X 60 Cap Screws C—Axle Shaft Housing

B—M10 X 45 Cap Screws

OUMX258,0000A96 -19-15SEP14-2/52

7. Remove snap ring (F).

8. Remove brake disks (E) and brake separator plates
(D).

D—Brake Separator Plates F— Snap Ring

E—Brake Disks

TCAL29254 —UN—02JUL12
OUMX258,0000A96 -19-15SEP14-3/52

9. Remove snap ring (H).

10. Remove brake camshaft (G).

G—Brake Camshaft H—Snap Ring

TCAL29255 —UN—02JUL12

Continued on next page OUMX258,0000A96 -19-15SEP14-4/52

TM130419 (24FEB16) 40-30-29 030916

PN=277
 Power Train Repair—Single Speed

11. Remove flat washer (I) and bushing (J).

12. Turn axle shaft housing over and allow it to rest on
the mounting flange.

I— Flat Washer J— Bushing

TCAL29256 —UN—02JUL12
OUMX258,0000A96 -19-15SEP14-5/52

13. Remove oil seal (K).

NOTE: Oil seals (L) and bushing (M) are located
only on left axle shaft housing.

14. Remove oil seals (L) and bushing (M).

TCAL29257 —UN—02JUL12
K—Oil Seal M—Bushing
L— Oil Seals

OUMX258,0000A96 -19-15SEP14-6/52

15. Remove four cap screws (N).

N—Cap Screws

TCAL29258 —UN—02JUL12

Continued on next page OUMX258,0000A96 -19-15SEP14-7/52

TM130419 (24FEB16) 40-30-30 030916

PN=278
 Power Train Repair—Single Speed

16. Drive the axle out of the housing using a soft-faced

hammer.

TCAL29259 —UN—02JUL12
OUMX258,0000A96 -19-15SEP14-8/52

17. Remove snap ring (O) and spacer (P).

O—Snap Ring P—Spacer

TCAL29260 —UN—02JUL12
OUMX258,0000A96 -19-15SEP14-9/52

18. Remove bearing (Q) from axle using a knife-edge

puller.

Q—Bearing

TCAL29261 —UN—02JUL12

Continued on next page OUMX258,0000A96 -19-15SEP14-10/52

TM130419 (24FEB16) 40-30-31 030916

PN=279
 Power Train Repair—Single Speed

19. Remove axle seal housing (R) from axle shaft.

R—Axle Seal Housing

TCAL29262 —UN—02JUL12
OUMX258,0000A96 -19-15SEP14-11/52

20. Remove oil seal (S) and O-ring (T).

S—Oil Seal T— O-Ring

TCAL29263 —UN—02JUL12
OUMX258,0000A96 -19-15SEP14-12/52

21. Inspect sleeve (U) for wear or damage. Remove the

sleeve using a knife-edge puller if replacement is
required.
22. Inspect all parts for wear or damage. Replace parts
as needed.

TCAL29264 —UN—02JUL12
U—Sleeve

Continued on next page OUMX258,0000A96 -19-15SEP14-13/52

TM130419 (24FEB16) 40-30-32 030916

PN=280
 Power Train Repair—Single Speed

Axle Shaft Housing Assembly

1. Install new sleeve (A) on axle shaft (if needed). Press
sleeve into place using a length of pipe (B) with an
inside diameter of 50.8 mm (2 in.).

A—Sleeve B—Length Of Pipe

TCAL29265 —UN—02JUL12
OUMX258,0000A96 -19-15SEP14-14/52

2. Install new axle oil seal (C) and O-ring (D).

C—Axle Oil Seal D—O-Ring

TCAL29266 —UN—02JUL12
OUMX258,0000A96 -19-15SEP14-15/52

3. Install axle seal housing (E) onto axle.

E—Axle Seal Housing

TCAL29267 —UN—02JUL12

Continued on next page OUMX258,0000A96 -19-15SEP14-16/52

TM130419 (24FEB16) 40-30-33 030916

PN=281
 Power Train Repair—Single Speed

IMPORTANT: Press on inner race only to avoid

damaging bearing.

4. Install bearing (F) onto axle. Press the bearing into

place using a length of pipe (G) with an inside diameter
of 50.8 mm (2 in.).

TCAL29268 —UN—02JUL12
F— Bearing G—Length of Pipe

OUMX258,0000A96 -19-15SEP14-17/52

5. Install spacer (H) and snap ring (I).

H—Spacer I— Snap Ring

TCAL29269 —UN—02JUL12
OUMX258,0000A96 -19-15SEP14-18/52

6. Install axle into housing until bearing bottoms against

axle housing.
7. Install seal housing (J) into axle housing. Install four
cap screws (K). Tighten to specification.
Specification
Axle Seal Housing-

TCAL29270 —UN—02JUL12
to-Axle Housing Cap
Screw—Torque..............................................................................27 N·m
(20 lb.-ft.)

J— Seal Housing K—Cap Screws

Continued on next page OUMX258,0000A96 -19-15SEP14-19/52

TM130419 (24FEB16) 40-30-34 030916

PN=282
 Power Train Repair—Single Speed

8. Install new brake camshaft oil seal (L).

NOTE: Oil seals (M) and bushing (N) are located
only on left axle shaft housing.

9. Install bushing (N) and oil seals (M).

TCAL29271 —UN—02JUL12
L— Brake Camshaft Oil Seal N—Bushing
M—Oil Seals

OUMX258,0000A96 -19-15SEP14-20/52

10. Install bushing (P) and flat washer (O).

O—Flat Washer P—Bushing

TCAL29272 —UN—02JUL12
OUMX258,0000A96 -19-15SEP14-21/52

11. Install brake camshaft (Q).

12. Install snap ring (R).

Q—Brake Camshaft R—Snap Ring

TCAL29273 —UN—02JUL12

Continued on next page OUMX258,0000A96 -19-15SEP14-22/52

TM130419 (24FEB16) 40-30-35 030916

PN=283
 Power Train Repair—Single Speed

13. Install two brake separator plates (S) and brake disks
(T).
14. Install snap ring (U).

S—Separator Plates U—Snap Ring

T— Brake Disks

TCAL29274 —UN—02JUL12
OUMX258,0000A96 -19-15SEP14-23/52

NOTE: install paper gasket prior to installing axle housing.

15. Using a hoist, install axle housing. Install two M10 x

60 cap screws (V) and seven M10 x 45 cap screws
(W). Tighten to specification.

TCAL29275 —UN—02JUL12
Specification
Axle Housing-to-
Differential Cap Screw
(M10 x 60)—Torque.......................................................................52 N·m
(38 lb.-ft.)
Axle Housing-to-
Differential Cap Screw
(M10 x 45)—Torque.......................................................................52 N·m
(38 lb.-ft.)
V—M10 X 60 Cap Screws (2 W—M10 X 45 Cap Screws (7
used) used)

OUMX258,0000A96 -19-15SEP14-24/52

Disassemble/Inspect Differential
1. Remove both axle shaft housings. (See Axle Shaft
Housing Disassembly under Disassemble, Inspect,
and Assemble Differential Assembly.)
2. Remove cap screws and washers (A). TCAL29276 —UN—02JUL12

3. Remove brake actuator disk (B).

A—Cap Screws And Washers B—Brake Actuator Disk

Continued on next page OUMX258,0000A96 -19-15SEP14-25/52

TM130419 (24FEB16) 40-30-36 030916

PN=284
 Power Train Repair—Single Speed

4. Remove six brake actuator balls (C).

5. Repeat steps 2-4 on opposite side.

C—Brake Actuator Balls (6

used)

TCAL29277 —UN—02JUL12
OUMX258,0000A96 -19-15SEP14-26/52

6. Remove nine M8 x 35 cap screws (D).

7. Remove differential side cover (E).

D—M8 X 35 Cap Screw (9 used) E—Differential Side Cover

TCAL29278 —UN—02JUL12
Continued on next page OUMX258,0000A96 -19-15SEP14-27/52

TM130419 (24FEB16) 40-30-37 030916

PN=285
 Power Train Repair—Single Speed

8. Remove oil return tube (F), dipstick (G), and washer (I).
9. Lift out idler gear shaft (H).
10. Lift out differential lock fork (J) and differential
assembly (K) as one assembly.

F— Oil Return Tube I— Washer

G—Dipstick J— Differential Lock Fork
H—Idler Gear Shaft K—Differential Assembly

TCAL29279 —UN—02JUL12
OUMX258,0000A96 -19-15SEP14-28/52

11. Remove differential lock shaft seal (L).

L— Differential Lock Shaft Seal

TCAL29280 —UN—02JUL12
OUMX258,0000A96 -19-15SEP14-29/52

12. Remove ten cap screws (M).

13. Remove ring gear (N).

M—Cap Screws (10 used) N—Ring Gear TCAL29281 —UN—02JUL12

Continued on next page OUMX258,0000A96 -19-15SEP14-30/52

TM130419 (24FEB16) 40-30-38 030916

PN=286
 Power Train Repair—Single Speed

14. Using a knife-edge puller, remove bearings (O).

15. Remove shift collar (P).

O—Bearings P—Shift Collar

TCAL29282 —UN—02JUL12
OUMX258,0000A96 -19-15SEP14-31/52

16. Using a punch, drive spring pin (Q) from the pinion
cross shaft.

Q—Spring Pin

TCAL29283 —UN—02JUL12
OUMX258,0000A96 -19-15SEP14-32/52

17. Remove pinion cross shaft (X), bevel washers (R),

pinion gears (S), right side gear (U), left side gear (W),
and flat thrust washers (T) from differential housing (V).
18. Inspect all parts for wear or damage. Replace parts
as needed.

R—Bevel Washers V`— Differential Housing

S—Pinion Gears W—Left Side Gear
T— Flat Thrust Washers X—Pinion Cross Shaft
U—Right Side Gear
TCAL29284 —UN—02JUL12

Continued on next page OUMX258,0000A96 -19-15SEP14-33/52

TM130419 (24FEB16) 40-30-39 030916

PN=287
 Power Train Repair—Single Speed

Disassemble/Inspect Idler Shaft

1. Remove bearing (A) using a knife-edge puller.

A—Bearing

TCAL29285 —UN—02JUL12
OUMX258,0000A96 -19-15SEP14-34/52

2. Remove bearing (B) using a knife-edge puller.

B—Bearing

TCAL29286 —UN—02JUL12
OUMX258,0000A96 -19-15SEP14-35/52

3. Remove ring gear (C) from idler shaft (D).

C—Ring Gear D—Idler Shaft

TCAL29287 —UN—02JUL12

Continued on next page OUMX258,0000A96 -19-15SEP14-36/52

TM130419 (24FEB16) 40-30-40 030916

PN=288
 Power Train Repair—Single Speed

Disassemble/Inspect Differential Lock Lever

NOTE: The differential lock lever assembly does not
have to be disassembled unless repair is required.
Inspect components for wear or damage.

1. Compress spring (C) using snap ring removal tool (A). 1

TCAL29288 —UN—02JUL12
2. Remove snap ring (B) from its groove while spring is
compressed.

A—Snap Ring Removal Tool C—Spring

B—Snap Ring

1
Snap ring removal tool is a fabricated tool. For instructions to
make tool, see Fabricated Tools in this section.
OUMX258,0000A96 -19-15SEP14-37/52

3. Remove washer (D), spring (E), fork (F), and spring

pins (G) if replacement is required.

D—Washer F— Fork
E—Spring G—Spring Pins

TCAL29289 —UN—02JUL12
OUMX258,0000A96 -19-15SEP14-38/52

4. Slide snap ring (I) on shaft.

5. Using snap ring installation tool1 (H), compress spring
(J) until snap ring locks in its groove.

H—Snap Ring Installation Tool J— Spring

I— Snap Ring
TCAL29290 —UN—02JUL12

1
Snap ring installation tool is a fabricated tool. For instructions to
make tool, see Fabricated Tools in this section.
Continued on next page OUMX258,0000A96 -19-15SEP14-39/52

TM130419 (24FEB16) 40-30-41 030916

PN=289
 Power Train Repair—Single Speed

Idler Shaft Assembly

1. Install ring gear (A) onto idler shaft (B).

A—Ring Gear B—Idler Shaft

TCAL29291 —UN—02JUL12
OUMX258,0000A96 -19-15SEP14-40/52

IMPORTANT: Press on inner race only to avoid

damaging bearing.

2. Install bearing (C) using a press.

TCAL29292 —UN—02JUL12
C—Bearing

OUMX258,0000A96 -19-15SEP14-41/52

IMPORTANT: Press on inner race only to avoid

damaging bearing.

3. Place a washer (E) to contact bearing inner race to

prevent bearing damage while applying pressure.
4. Install bearing (D) using a press.

TCAL29293 —UN—02JUL12
D—Bearing E—Washer

Continued on next page OUMX258,0000A96 -19-15SEP14-42/52

TM130419 (24FEB16) 40-30-42 030916

PN=290
 Power Train Repair—Single Speed

Differential Assembly
1. Install side gears (B and D) with flat thrust washers (A)
inside housing (C).

A—Flat Thrust Washers C—Housing

B—Side Gears D—Side Gears

TCAL29294 —UN—02JUL12
OUMX258,0000A96 -19-15SEP14-43/52

2. Install pinion gears (F) between side gears.

3. Slide the bevel thrust washers (E) between pinion
gears and differential housing.

E—Bevel Thrust Washers F— Pinion Gears

TCAL29295 —UN—02JUL12
OUMX258,0000A96 -19-15SEP14-44/52

4. Install pinion shaft (H) and secure it with spring pin (G).

G—Spring Pin H—Pinion Shaft TCAL29296 —UN—02JUL12

Continued on next page OUMX258,0000A96 -19-15SEP14-45/52

TM130419 (24FEB16) 40-30-43 030916

PN=291
 Power Train Repair—Single Speed

5. Clean threads of cap screws (I) and threads of gear

(J) with PM37509 Cure Primer.
6. Apply PM37477 Thread Lock and Sealer (Medium
Strength) to threads of cap screws.

TCAL29297 —UN—02JUL12
I— Cap Screws J— Gear

OUMX258,0000A96 -19-15SEP14-46/52

7. Install gear with ridge side (K) facing differential

housing.
8. Install ten cap screws and tighten to specification.
Specification
Differential Ring

TCAL29298 —UN—02JUL12
Gear-to-Housing Cap
Screw—Torque..............................................................................52 N·m
(38 lb.-ft.)

K—Ridge Side

OUMX258,0000A96 -19-15SEP14-47/52

9. Install differential lock shaft seal (L).

L— Differential Lock Shaft Seal

TCAL29299 —UN—02JUL12

Continued on next page OUMX258,0000A96 -19-15SEP14-48/52

TM130419 (24FEB16) 40-30-44 030916

PN=292
 Power Train Repair—Single Speed

10. Install differential lock shaft (Q) and differential

assembly (R) into case as an assembly.
11. Install washer (P) on differential lock shaft.
12. Install idler shaft assembly (O).
13. Install oil return tube (M) and dipstick (N).

M—Oil Return Tube P—Washer

N—Dipstick Q—Differential Lock Shaft
O—Idler Shaft Assembly R—Differential Assembly

TCAL29300 —UN—02JUL12
OUMX258,0000A96 -19-15SEP14-49/52

14. Apply PM38655 John Deere™ Form-in-Place Gasket

on side cover (T) and differential housing mating
surfaces.
15. Install side cover and nine M8 x 35 cap screws (S).
Tighten cap screws to specification.
Specification
Differential Side
Cover-to-Differential
Case Cap Screw (M8 x
35)—Torque...................................................................................27 N·m

TCAL29301 —UN—02JUL12
(20 lb.-ft.)

S—M8 X 35 Cap Screw T— Side Cover

John Deere is a trademark of Deere & Company

Continued on next page OUMX258,0000A96 -19-15SEP14-50/52

TM130419 (24FEB16) 40-30-45 030916

PN=293
 Power Train Repair—Single Speed

16. Install six brake actuator balls (U).

U—Six Brake Actuator Balls (6

used)

TCAL29302 —UN—02JUL12
OUMX258,0000A96 -19-15SEP14-51/52

17. Install brake actuator disk (W).

18. Install cap screws and washers (V).
19. Repeat steps 16-18 on opposite side.
20. Install both axle housings. (See Axle Shaft Housing

TCAL29303 —UN—02JUL12
Assembly under Disassemble, Inspect, and Assemble
Differential Assembly.)

V—Cap Screws and Washers W—Brake Actuator Disk

OUMX258,0000A96 -19-15SEP14-52/52

TM130419 (24FEB16) 40-30-46 030916

PN=294
 Power Train Repair—Single Speed

Disassemble, Inspect, and Assemble PTO

Special or Required Tools

• Clutch Piston Compression Tool1

• M8 x 30 Cap Screw (2 used)
• Knife-Edge Puller
Disassemble/Inspect

TCAL29304 —UN—02JUL12
IMPORTANT: Absolute cleanliness is essential
when working on hydraulic components.
Contamination can result in serious damage
or inadequate operation.
DO NOT use shop towels or rags to dry
cleaned parts. Lint will clog passages in the
hydraulic/hydrostatic system and cause damage.
A—Drain Plug C—O-Ring
NOTE: You do not need to remove transaxle to B—Solenoid Coil D—Solenoid Nut
repair PTO only. PTO can be removed without
disassembly of transaxle.
Transaxle is shown removed for clarity. 2. Remove solenoid nut (D).
Use shop cloths or paper towels to immediately 3. Remove O-ring (C) and solenoid coil (B).
catch and clean up any spilled oil.

1. Drain PTO housing at drain plug (A).

1
For instructions on making tool, see Fabricated Tools in this section.
OUMX258,0000A97 -19-15SEP14-1/44

NOTE: PTO solenoid valve, relief valve, and

accumulator may be repaired without complete
disassembly of PTO.

TCAL29305 —UN—02JUL12
All valves have small parts; take note of order
and direction of disassembly. Use caution not
to drop or lose small parts.

4. Remove solenoid stud (E).

5. Remove solenoid valve parts (F-J).
6. Inspect parts for scoring or damage. Replace as
necessary.

E—Solenoid Stud H—Spring TCAL29306 —UN—02JUL12

F— Washer I— Inner Spool
G—Outer Spool J— Pin

Continued on next page OUMX258,0000A97 -19-15SEP14-2/44

TM130419 (24FEB16) 40-30-47 030916

PN=295
 Power Train Repair—Single Speed

NOTE: Valve adjustment shims may stick inside of valve

cap and fall out when removing cap. Remove
cap slowly to prevent loss of shims.

7. Remove relief valve cap (K).

K—Relief Valve Cap

TCAL29307 —UN—02JUL12
OUMX258,0000A97 -19-15SEP14-3/44

TCAL29308 —UN—02JUL12
8. Remove relief valve parts (L-O).
9. Inspect parts for scoring or damage. Replace as
necessary.

L— Piston N—Seal
M—Spring O—Shims

OUMX258,0000A97 -19-15SEP14-4/44

CAUTION: Accumulator spring is compressed.

Do not remove cover without properly
relieving spring pressure.

10. Remove ONE cap screw from accumulator cover (P).

TCAL29309 —UN—02JUL12
NOTE: M8 x 30 cap screw will bottom in thread
hole. Do not overtighten.

11. Install an M8 x 30 cap screw (Q) and tighten until snug.

12. Carefully remove remaining original cap screw (R) and
replace with an M8 x 30 cap screw. Tighten until snug.

P—Accumulator Cover R—Cap Screw

Q—Cap Screw

Continued on next page OUMX258,0000A97 -19-15SEP14-5/44

TM130419 (24FEB16) 40-30-48 030916

PN=296
 Power Train Repair—Single Speed

13. Slowly loosen both cap screws (S) evenly until spring
pressure is relieved. Remove cover (T).

S—Cap Screws T— Cover

TCAL29310 —UN—02JUL12
OUMX258,0000A97 -19-15SEP14-6/44

TCAL29311 —UN—02JUL12
14. Remove accumulator parts (U-W).
15. Inspect parts for scoring or damage. Replace as
necessary.

U—Piston W—Spring
V—Sleeve

OUMX258,0000A97 -19-15SEP14-7/44

16. Remove seven cap screws (X).

17. Remove PTO cover (Y).

X—Cap Screws (7 used) Y—PTO Cover

Continued on next page TCAL29312 —UN—02JUL12

OUMX258,0000A97 -19-15SEP14-8/44

TM130419 (24FEB16) 40-30-49 030916

PN=297
 Power Train Repair—Single Speed

18. Remove PTO assembly (Z).

Z— PTO Assembly

TCAL29313 —UN—02JUL12
OUMX258,0000A97 -19-15SEP14-9/44

19. Remove brake disk and spacer ring (AA).

20. Remove PTO supply tube (AB).

AA—Brake Disk And Spacer AB—PTO Supply Tube

Ring

TCAL29314 —UN—02JUL12
OUMX258,0000A97 -19-15SEP14-10/44

21. Remove fiber seals (AC).

AC—Fiber Seals

TCAL29315 —UN—02JUL12

Continued on next page OUMX258,0000A97 -19-15SEP14-11/44

TM130419 (24FEB16) 40-30-50 030916

PN=298
 Power Train Repair—Single Speed

22. Remove bearing (AD) using a knife-edge puller.

Remove spacer (AE).

AD—Bearing AE—Spacer

TCAL29316 —UN—02JUL12
OUMX258,0000A97 -19-15SEP14-12/44

23. Remove clutch gear (AF).

AF—Clutch Gear

TCAL29317 —UN—02JUL12
OUMX258,0000A97 -19-15SEP14-13/44

24. Inspect bearings (AG and AI) and snap ring (AH).
Remove and replace as necessary.

AG—Bearing AI— Bearing

AH—Snap Ring
TCAL29318 —UN—02JUL12

Continued on next page OUMX258,0000A97 -19-15SEP14-14/44

TM130419 (24FEB16) 40-30-51 030916

PN=299
 Power Train Repair—Single Speed

25. Slide clutch assembly (AJ) partway off shaft and

remove three brake pins (AK). Remove clutch
assembly.
26. Remove key (AL).
27. Remove brake pack (AM).

TCAL29319 —UN—02JUL12
AJ—Clutch Assembly AL—Key
AK—Brake Pins AM—Brake Pack

OUMX258,0000A97 -19-15SEP14-15/44

28. Inspect bearing (AN) and shaft (AO). Use knife-edge

puller if replacement is necessary.

TCAL29320 —UN—02JUL12
AN—Bearing AO—Shaft

OUMX258,0000A97 -19-15SEP14-16/44

29. Holding all the clutch disks together, measure the

space between the bottom separator plate and
the PTO cylinder. If space measured exceeds
specification, replace all the clutch disks.
Specification
Bottom Separator
Plate-to-PTO

TCAL29321 —UN—02JUL12
(Maximum)—Gap......................................................................... 9.1 mm
(0.36 in.)

Continued on next page OUMX258,0000A97 -19-15SEP14-17/44

TM130419 (24FEB16) 40-30-52 030916

PN=300
 Power Train Repair—Single Speed

30. Disassemble clutch if required. Remove large snap

ring (AP). Lift top plate (AQ) off clutch assembly.
Measure thickness of the top plate. A minimum
thickness specification is required and the plate must
be flat; replace plate if necessary.
Specification
Clutch Top Plate
(Minimum)—Thickness............................................................... 3.03 mm

TCAL29322 —UN—02JUL12
(0.119 in.)

31. Remove five clutch disks (AS) and five separator

plates (AR). Measure clutch disks (five used) and
separator plates (five used) for minimum thickness
requirement. The separator plates must be flat;
replace plates if necessary.
Specification
Clutch Disk
(Minimum)—Thickness................................................................. 2.0 mm
(0.08 in.)
Clutch Separator Plate
(Minimum)—Thickness................................................................. 1.0 mm
(0.04 in.)

AP—Large Snap Ring AR—Separator Plates

AQ—Top Plate AS—Clutch Disks

TCAL29323 —UN—02JUL12
OUMX258,0000A97 -19-15SEP14-18/44

32. Disassemble clutch piston by placing piston and clutch

piston compression tool (AT) in a vise. 1
33. Tighten vise to compress spring (AU) and flat washer
(AV) to remove snap ring (AW).
34. Slowly back off on vise to remove spring (AU).

AT— Clutch Piston AV—Flat Washer

Compression Tool AW—Snap Ring TCAL29324 —UN—02JUL12
AU—Spring

1
Clutch piston compression tool is a fabricated tool. For instructions
to make tool, see Fabricated Tools in this section.
Continued on next page OUMX258,0000A97 -19-15SEP14-19/44

TM130419 (24FEB16) 40-30-53 030916

PN=301
 Power Train Repair—Single Speed

35. Remove piston (AX). Remove O-ring (AY) and discard.

Piston must be free of nicks and scratches; if not,
replace it.
36. Check free length of piston return spring (AZ). Replace
if required.
Specification
Piston Return
Spring—Free Length

TCAL29325 —UN—02JUL12
(Minimum)..................................................................................... 75 mm
(2.95 in.)
Piston Return Spring Test
Length @ 499 N (112
lb-force)—Length........................................................................ 28.6 mm
(1.13 in.)

AX—Piston AZ—Piston Return Spring

AY—O-Ring

OUMX258,0000A97 -19-15SEP14-20/44

37. Inspect brake pressure plate (BA). Plate must be flat

and not damaged.
38. The top plate (BB) must be flat; replace if necessary.

TCAL29326 —UN—02JUL12
39. Inspect brake disks (BE) (three used) and brake
separator plates (BC) (two used). The separator plates
must be flat; replace if necessary. If oil grooves of
brake disks are worn down, replace disks. If oil grooves
have disappeared, replace all plates and disks.
40. Inspect brake spacer ring (BD). Spacer ring must be
flat and not damaged.

BA—Brake Pressure Plate BD—Brake Spacer Ring

BB—Top Plate BE—Brake Disks
BC—Brake Separator Plates

OUMX258,0000A97 -19-15SEP14-21/44

41. Remove two cap screws (BF) and plate (BG).

BF—Cap Screws BG—Plate

TCAL29327 —UN—02JUL12

Continued on next page OUMX258,0000A97 -19-15SEP14-22/44

TM130419 (24FEB16) 40-30-54 030916

PN=302
 Power Train Repair—Single Speed

42. Remove shaft seal (BH).

BH—Shaft Seal

TCAL29328 —UN—02JUL12
OUMX258,0000A97 -19-15SEP14-23/44

Assemble
NOTE: Clean, dry, and lubricate all parts with clean
hydrostatic fluid before assembly.

1. Install new seal (A) flush with surface of housing.

TCAL29329 —UN—02JUL12
A—Seal

OUMX258,0000A97 -19-15SEP14-24/44

2. Install plate (B) and cap screws (C).

B—Plate C—Cap Screws

TCAL29330 —UN—02JUL12

Continued on next page OUMX258,0000A97 -19-15SEP14-25/44

TM130419 (24FEB16) 40-30-55 030916

PN=303
 Power Train Repair—Single Speed

NOTE: Clutch piston must be positioned so that three

spokes cover three pin holes in drum. If improperly
installed, PTO brake will not work.

3. Replace O-ring (E) and install piston (D) into drum (F).
Three piston spokes (H) must cover three pin holes
(G) in drum.

TCAL29331 —UN—02JUL12
D—Piston G—Pin Holes
E—O-Ring H—Piston Spokes
F— Drum

OUMX258,0000A97 -19-15SEP14-26/44

4. Install piston spring (I), washer (J), and snap ring (K)
using clutch piston compression tool (L). 1

I— Piston Spring K—Snap Ring

J— Washer L— Clutch Piston Compression
Tool

TCAL29332 —UN—02JUL12
1
Clutch piston compression tool is a fabricated tool. For instructions
to make tool, see Fabricated Tools in this section.
OUMX258,0000A97 -19-15SEP14-27/44

5. Install one separator plate (O) in clutch, then one disk

(N). Repeat until all five separator plates and five disks
are alternately installed in clutch.
6. Install top plate (M) in clutch.

M—Top Plate O—Separator Plate

N—Disk
TCAL29333 —UN—02JUL12

Continued on next page OUMX258,0000A97 -19-15SEP14-28/44

TM130419 (24FEB16) 40-30-56 030916

PN=304
 Power Train Repair—Single Speed

IMPORTANT: Position the snap ring (P) so that

the open portion is against one of the
sides of the cylinder wall.

7. Install snap ring (P) with open end facing drum wall.

P—Snap Ring

TCAL29334 —UN—02JUL12
OUMX258,0000A97 -19-15SEP14-29/44

8. Alternately install two brake separator plates (T) and

two brake disks (R).
9. Install brake top plate (S).
10. Install brake pressure plate (Q).

Q—Brake Pressure Plate S—Brake Top Plate

R—Brake Disks T— Brake Separator Plates

TCAL29335 —UN—02JUL12
Continued on next page OUMX258,0000A97 -19-15SEP14-30/44

TM130419 (24FEB16) 40-30-57 030916

PN=305
 Power Train Repair—Single Speed

11. Install key (W) into shaft.

12. Slide clutch (U) partially onto shaft.
13. Install three pins (V) into clutch.
14. Install clutch fully onto shaft.

U—Clutch W—Key

TCAL29336 —UN—02JUL12
V—Pins

OUMX258,0000A97 -19-15SEP14-31/44

NOTE: Aligning clutch disks with a small O-ring pick and

rotating gear and hub will aid in installation.

15. Install PTO gear and hub (X) to clutch.

X—PTO Gear and Hub

TCAL29337 —UN—02JUL12
OUMX258,0000A97 -19-15SEP14-32/44

16. Install spacer (Z) and bearing (Y) onto shaft.

Y—Bearing Z— Spacer

TCAL29338 —UN—02JUL12

Continued on next page OUMX258,0000A97 -19-15SEP14-33/44

TM130419 (24FEB16) 40-30-58 030916

PN=306
 Power Train Repair—Single Speed

17. Install two fiber seals (AA).

AA—Fiber Seals

TCAL29339 —UN—02JUL12
OUMX258,0000A97 -19-15SEP14-34/44

18. Install brake spacer ring (AC) and then brake disk
(AB) into housing.
19. Replace O-rings and install PTO supply tube (AD).

AB—Brake Disk AD—PTO Supply Tube

AC—Spacer Ring

TCAL29340 —UN—02JUL12
OUMX258,0000A97 -19-15SEP14-35/44

20. Install two medium rubber bands (AF) behind brake

disk tab (AE). Spread legs of rubber band and pull
them over gear (AG). Wrap ends of rubber bands
around shaft end (AH).
21. Check that brake disk tabs and brake separator plate
are all in alignment. TCAL29341 —UN—02JUL12

AE—Brake Disk Tab AF—Gear

AF—Rubber Bands AH—Shaft End

Continued on next page OUMX258,0000A97 -19-15SEP14-36/44

TM130419 (24FEB16) 40-30-59 030916

PN=307
 Power Train Repair—Single Speed

22. Position PTO assembly so that brake disk tabs align

with previously installed brake disk in housing.
23. Carefully guide PTO assembly (AI) into housing until
PTO gears (AJ) are even.

TCAL29342 —UN—02JUL12
24. Cut rubber bands and gently wiggle PTO assembly
while pulling on rubber bands to remove rubber bands.
25. Install new PTO cover-to-PTO housing gasket to PTO
housing.

AI— PTO Assembly AJ—PTO Gears

OUMX258,0000A97 -19-15SEP14-37/44

26. Install PTO cover (AK) using seven cap screws (AL).

AK—PTO Cover AL—Cap Screws

TCAL29343 —UN—02JUL12
OUMX258,0000A97 -19-15SEP14-38/44

27. Install piston (AM), then sleeve (AN), and then spring

TCAL29344 —UN—02JUL12
(AO) into PTO cover.

AM—Piston AO—Spring
AN—Sleeve

Continued on next page OUMX258,0000A97 -19-15SEP14-39/44

TM130419 (24FEB16) 40-30-60 030916

PN=308
 Power Train Repair—Single Speed

28. Install cover gasket (AR) to cover (AQ).

29. Install cover using two M8 x 30 (AP) cap screws.
Tighten cap screws evenly until snug.

AP—Cap Screws (2 used) AR—Cover Gasket

AQ—Cover

TCAL29345 —UN—02JUL12
OUMX258,0000A97 -19-15SEP14-40/44

30. Remove one M8 x 30 cap screw (AS) and replace it

with an original cover cap screw. Tighten cap screw.
31. Repeat for other M8 x 30 cap screw.

AS—Cap Screw

TCAL29346 —UN—02JUL12
Continued on next page OUMX258,0000A97 -19-15SEP14-41/44

TM130419 (24FEB16) 40-30-61 030916

PN=309
 Power Train Repair—Single Speed

TCAL29347 —UN—02JUL12
32. Install PTO relief piston (AT) and then spring (AU) into
PTO cover.
33. Install shims (AW) and new seal (AV) into relief cap
(AX).
34. Carefully install cap into PTO cover, taking care not
to drop shims out of cap.

AT— PTO Relief Piston AW—Shims

AU—Spring AX—Relief Cap
AV—Seal

TCAL29348 —UN—02JUL12
Continued on next page OUMX258,0000A97 -19-15SEP14-42/44

TM130419 (24FEB16) 40-30-62 030916

PN=310
 Power Train Repair—Single Speed

35. Install washer (AY) and then outer spool (AZ), with
large boss (BE) up, into PTO cover.

TCAL29349 —UN—02JUL12
36. Install spring (BA) and then inner spool (BB), with
fingers (BD) down, into PTO.
37. Install new O-ring (BF).
38. Install pin (BC) into solenoid stud (BH).
39. Install new seal (BG) and install solenoid stud. Tighten
to specification.
Specification
Solenoid Stud—Torque.................................................................23 N·m
(203 lb.-in.)

TCAL29350 —UN—02JUL12
AY—Washer BD—Fingers
AZ—Outer Spool BE—Large Boss
BA—Spring BF—O-Ring
BB—Inner Spool BG—Seal
BC—Pin BH—Solenoid Stud

TCAL29351 —UN—02JUL12
OUMX258,0000A97 -19-15SEP14-43/44

40. Install solenoid coil (BI) with wires toward threaded

end of solenoid stud, and then new O-ring (BJ) and
nut (BK). Tighten nut to specification.
Specification
Solenoid Coil
Nut—Torque....................................................................................5 N·m
(44 lb.-in.)

41. Fill transaxle. (See Checking the Transaxle Oil Level

TCAL29352 —UN—02JUL12

in operator’s manual.)

BI— Solenoid Coil BK—Nut

BJ—O-Ring

OUMX258,0000A97 -19-15SEP14-44/44

TM130419 (24FEB16) 40-30-63 030916

PN=311
 Power Train Repair—Single Speed

Remove and Install 4WD Drive Shaft

Special or Required Tools

• Floor Jack
• Jackstand (2 used)
Removal

TCAL29353 —UN—02JUL12
1. Park machine safely.
2. Stop engine.
3. Remove engine cover.
4. Disconnect battery (-) negative cable.
5. Block rear tires to prevent machine from rolling.
1— Band Clamps C—Cap Screw and Washer
CAUTION: Support machine properly. B—Boots

6. Raise front of machine using a floor jack and support

with jackstands. 1. Slide rear universal joint of drive shaft onto 4WD axle
7. Loosen band clamps (1) on front and rear universal input shaft.
joint boots (B). NOTE: Holes for cap screw and washer in front universal
8. Slide boots away from front and rear universal joints. joint and transaxle 4WD output shaft must be
aligned when installing drive shaft.
9. Remove cap screw and washer (C) from front
universal joint connection. 2. Align hole in front universal joint with hole in transaxle
4WD output shaft.
10. Slide drive shaft rearward to remove universal joint
from transaxle output shaft. 3. Slide universal joint onto spline until the holes are
aligned.
11. Lower and slide drive shaft forward to remove drive
shaft from 4WD axle input shaft. 4. Install washer and cap screw in front universal joint.
Tighten cap screw.
12. Inspect the splines of the universal joints and drive
shafts for wear or damage. Replace parts as needed.
Installation
IMPORTANT: Always install new gaskets, O-rings, and
seals. Replace all damaged or rough moving
parts. Damaged or worn parts will leak.
Continued on next page OUMX258,0000A98 -19-22MAR13-1/2

TM130419 (24FEB16) 40-30-64 030916

PN=312
 Power Train Repair—Single Speed

5. Slide the front rubber boot (E) forward over the output
shaft (C) on the gearbox.
6. Turn the rubber boot so that the white painted dot (B)
is on top of the rubber boot. Tighten the front hose
clamp (D) on the rubber boot.
7. Slide the shield tube (G) in the rubber boot until the

TCAL29354 —UN—02JUL12
white line (A) is showing at the edge of the rubber boot.
8. Tighten the rear hose clamp (F).
9. Slide the rear rubber boot rearward over the rear axle
input shaft, rotate boot until white dot is on top, and
tighten both hose clamps.
10. Remove jackstands and lower machine.
11. Connect battery negative (-) cable.
A—Line E—Rubber Boot
12. Install engine cover. B—Dot F— Hose Clamp
C—Output Shaft G—Shield Tube
D—Hose Clamp

OUMX258,0000A98 -19-22MAR13-2/2

Remove and Install 4WD Gear Case

IMPORTANT: Absolute cleanliness is essential
when working on hydraulic components.
Contamination can result in serious damage
or inadequate operation. Clean all lines and
fittings prior to opening hydraulic system.

NOTE: You do not need to remove transaxle to

TCAL29355 —UN—02JUL12
repair 4WD gear case only.

1. Remove 4WD drive shaft. (See Remove and Install

4WD Drive Shaft.)
2. Remove carriage bolt and locknut (A) to disconnect
4WD linkage.

A—Carriage Bolt and Locknut

Continued on next page OUMX258,0000A99 -19-30DEC13-1/3

TM130419 (24FEB16) 40-30-65 030916

PN=313
 Power Train Repair—Single Speed

NOTE: Use shop cloths or paper towels to immediately

catch and clean up any spilled oil.

3. Place drain pan below 4WD gear case, remove drain

plug (B), and drain gear case.
4. Install drain plug.

B—Drain Plug

TCAL29356 —UN—02JUL12
OUMX258,0000A99 -19-30DEC13-2/3

NOTE: Transaxle is shown removed for clarity.

5. Remove five cap screws (C).

6. Remove 4WD gear case; repair as necessary.
7. Replace 4WD gear case-to-hydrostatic assembly
gasket.

TCAL29357 —UN—02JUL12
NOTE: Turning 4WD gear case output shaft will
aid in installation.

8. Install 4WD gear case.

9. Install five cap screws.
10. Connect 4WD linkage.
11. Install 4WD drive shaft. (See Remove and Install 4WD
Drive Shaft.)
C—Cap Screws (5 used)
12. Fill transaxle. (See Checking the Transaxle Oil Level
in operator’s manual.)
OUMX258,0000A99 -19-30DEC13-3/3

TM130419 (24FEB16) 40-30-66 030916

PN=314
 Power Train Repair—Single Speed

Disassemble, Inspect, and Assemble 4WD

Gear Case
Special or Required Tools

• Snap Ring Pliers Set

• Hydraulic Press

TCAL29358 —UN—02JUL12
Disassemble/Inspect
IMPORTANT: Absolute cleanliness is essential
when working on hydraulic components.
Contamination can result in serious damage
or inadequate operation.
DO NOT use shop towels or rags to dry
cleaned parts. Lint will clog passages in the
hydraulic/hydrostatic system and cause damage.
A—Gasket B—Splines

1. Remove 4WD gear case from transaxle case. (See

Remove and Install 4WD Gear Case.)
2. Remove gasket (A) and clean gasket mating surfaces.
3. Inspect splines (B). If splines are worn or damaged,
replace gear.
OUMX258,0000A9A -19-15SEP14-1/24

4. Remove spring pin (C) to remove arm (D).

5. Inspect splines (E) on clutch shaft.
6. Remove drain plug and washer (G). Drain any
remaining oil into a properly marked container.
7. Remove five cap screws (F) and washers to remove

TCAL29359 —UN—02JUL12
cover. It may be necessary to tap on case cover to
remove it.

C—Spring Pin F— Cap Screws (5 used)

D—Arm G—Drain Plug and Washer
E—Splines

Continued on next page OUMX258,0000A9A -19-15SEP14-2/24

TM130419 (24FEB16) 40-30-67 030916

PN=315
 Power Train Repair—Single Speed

8. Remove idler gear (I) and drive gear (H).

NOTE: When removing 4WD clutch assembly, do not lose
the shift collar located inside clutch housing.

9. Remove clutch assembly (J). Do not lose shift collar (K)

located inside case when removing clutch assembly.

TCAL29360 —UN—02JUL12
H—Drive Gear J— Clutch Assembly
I— Idler Gear K—Shift Collar

TCAL29361 —UN—02JUL12
OUMX258,0000A9A -19-15SEP14-3/24

10. Remove cap screw and lock washer (L) to remove

strap (M) securing shift arm (N).
11. Remove shift arm.

L— Cap Screw and Lock N—Shift Arm

TCAL29362 —UN—02JUL12
Washer
M—Strap

Continued on next page OUMX258,0000A9A -19-15SEP14-4/24

TM130419 (24FEB16) 40-30-68 030916

PN=316
 Power Train Repair—Single Speed

12. Remove and discard O-ring (O).

13. Inspect shift arm and collar for wear or damage.
Replace as necessary.

TCAL29363 —UN—02JUL12
K—Collar O—O-Ring

OUMX258,0000A9A -19-15SEP14-5/24

14. Remove gasket material from mating surfaces (P).

15. Clean inside of case and cover.
16. Remove and discard oil seal (Q).
17. Inspect idler and drive gears and bearings for wear,
damage, or rough movement. Replace parts as
needed.

TCAL29364 —UN—02JUL12
P—Mating Surfaces Q—Oil Seal

OUMX258,0000A9A -19-15SEP14-6/24

NOTE: Steps for removing bearings from idler and

drive gears are the same.

18. If bearings require replacement, remove bearings

using a knife-edge puller and press.

TCAL29365 —UN—02JUL12

Continued on next page OUMX258,0000A9A -19-15SEP14-7/24

TM130419 (24FEB16) 40-30-69 030916

PN=317
 Power Train Repair—Single Speed

Disassemble and Inspect 4WD Clutch

1. Put clutch assembly in a press and remove bearing
on drive shaft end.

TCAL29366 —UN—02JUL12
OUMX258,0000A9A -19-15SEP14-8/24

2. Remove roller bearing (A), washer (B), and needle

bearing (C). Inspect for damage, wear, or rough
movement. Replace as needed.
3. Remove clutch assembly (D) from shaft.

A—Roller Bearing C—Needle Bearing

B—Washer D—Clutch Assembly

TCAL29367 —UN—02JUL12
Continued on next page OUMX258,0000A9A -19-15SEP14-9/24

TM130419 (24FEB16) 40-30-70 030916

PN=318
 Power Train Repair—Single Speed

4. Remove snap ring (E) to remove clutch (F) from

housing (G). Inspect clutch for wear, damage, or rough
movement. Replace as needed.
5. Inspect clutch housing for wear or damage. Replace
as needed.

TCAL29368 —UN—02JUL12
E—Snap Ring G—Housing
F— Clutch

TCAL29369 —UN—02JUL12
OUMX258,0000A9A -19-15SEP14-10/24

6. Remove opposite bearing (H) from clutch shaft.

Inspect bearing for wear, damage, or rough movement.
Replace bearing as needed.

H—Bearing

TCAL29370 —UN—02JUL12

Continued on next page OUMX258,0000A9A -19-15SEP14-11/24

TM130419 (24FEB16) 40-30-71 030916

PN=319
 Power Train Repair—Single Speed

NOTE: When removing the shifter (I) from the clutch

shaft, do not lose the detent balls (K) and spring
(J) located internally in the shaft.

7. Remove shifter (I) from clutch shaft. Use care not to

lose spring (J) and detent balls (K) when removing
shifter.

TCAL29371 —UN—02JUL12
8. Inspect shifter, spring, and detent balls for wear or
damage. Replace parts as needed.

I— Shifter K—Detent Balls

J— Spring

OUMX258,0000A9A -19-15SEP14-12/24

9. Remove snap ring (L) to remove bearing (M). Inspect

for wear, damage, or rough movement. Replace as
needed.

L— Snap Ring M—Bearing

TCAL29372 —UN—02JUL12
OUMX258,0000A9A -19-15SEP14-13/24

4WD Clutch Assembly

IMPORTANT: Always install new gaskets, O-rings, and
seals. Replace all damaged or rough moving
parts. Damaged or worn parts will leak.

NOTE: When installed correctly, clutch should turn

clockwise only. Verify clutch is installed correctly.

TCAL29373 —UN—02JUL12
1. Install clutch in housing with flange (A) toward housing.
Rotate clutch inside housing. Clutch should turn
clockwise. If clutch rotates counterclockwise, remove
clutch and reinstall with flange inward.

A—Flange

Continued on next page OUMX258,0000A9A -19-15SEP14-14/24

TM130419 (24FEB16) 40-30-72 030916

PN=320
 Power Train Repair—Single Speed

2. Install snap ring (B).

B—Snap Ring

TCAL29374 —UN—02JUL12
OUMX258,0000A9A -19-15SEP14-15/24

3. Install bearing (C) and snap ring (D) on shaft.

C—Bearing D—Snap Ring

TCAL29375 —UN—02JUL12
OUMX258,0000A9A -19-15SEP14-16/24

4. Install spring (E) in hole (F) of shaft. Put a ball (G) on

each end of spring.
5. While compressing balls and spring, install shifter (H)
on shaft with teeth of shifter toward bearing.

E—Spring G—Ball
F— Hole H—Shifter

TCAL29376 —UN—02JUL12

Continued on next page OUMX258,0000A9A -19-15SEP14-17/24

TM130419 (24FEB16) 40-30-73 030916

PN=321
 Power Train Repair—Single Speed

6. Install bearing (I) on shifter end of shaft.

7. Install clutch assembly (J) on shaft.
8. Install needle bearing (K), washer (L) and bearing (M).
4WD Gear Case Assembly

TCAL29377 —UN—02JUL12
IMPORTANT: Press on inner race only to avoid
damaging bearing.

NOTE: Steps for installing bearings on idler gear

and drive gear are the same.

1. Install bearings by pressing on inner race until tight

against shoulder of gear.
I— Bearing L— Washer
J— Clutch Assembly M—Bearing
K—Needle bearing

TCAL29378 —UN—02JUL12
OUMX258,0000A9A -19-15SEP14-18/24

2. Install new oil seal (A) in cover. Be sure spring side of

seal is toward inside of case. Push seal into bore is
specified distance below top surface of bore.
Specification
4WD Gear Case Oil
Seal—Installation Depth
(Approximate).................................................................................. 3 mm

TCAL29379 —UN—02JUL12
(0.12 in.)

A—Oil Seal

Continued on next page OUMX258,0000A9A -19-15SEP14-19/24

TM130419 (24FEB16) 40-30-74 030916

PN=322
 Power Train Repair—Single Speed

3. Install new O-ring (B) on shift arm (C).

B—O-Ring C—Shift Arm

TCAL29380 —UN—02JUL12
OUMX258,0000A9A -19-15SEP14-20/24

4. Install shift arm (C) in case.

5. Install strap (D), cap screw and washer (E) to secure
shift arm.

C—Shift Arm E—Washer

D—Strap

TCAL29381 —UN—02JUL12
OUMX258,0000A9A -19-15SEP14-21/24

6. Install shift collar (F) on arm.

F— Shift Collar

TCAL29382 —UN—02JUL12

Continued on next page OUMX258,0000A9A -19-15SEP14-22/24

TM130419 (24FEB16) 40-30-75 030916

PN=323
 Power Train Repair—Single Speed

7. Install clutch assembly (G). Shift collar must fit inside

groove of shifter.
8. Install idler gear (H) and drive gear (I).
9. Clean all cover cap screws and housing threads with
PM37509 John Deere™ Cure Primer.

TCAL29383 —UN—02JUL12
10. Apply a bead of PM38655 John Deere Flexible
Form-in-Place Gasket to mating surface of case
toward the inside of all cap screw holes.

G—Clutch Assembly I— Drive Gear

H—Idler Gear

John Deere is a trademark of Deere & Company

OUMX258,0000A9A -19-15SEP14-23/24

11. Install cover and five cap screws and lock washers
(L). Tighten cap screws.
12. Install washer and drain plug (M).
13. Install clutch arm (J) and spring pin (K).
14. Install gear case on transaxle. (See Remove and
Install 4WD Gear Case.)

TCAL29384 —UN—02JUL12
J— Clutch Arm L— Lock Washers
K—Spring Pin M—Drain Plug

OUMX258,0000A9A -19-15SEP14-24/24

TM130419 (24FEB16) 40-30-76 030916

PN=324
 Power Train Repair—Single Speed

Remove and Install 4WD Axle

Special or Required Tools

• Floor Jack
• Jackstand (2 used)
• Hoist

TCAL29385 —UN—02JUL12
Removal

CAUTION: 4WD axle is heavy. An additional

person is required when removing 4WD
axle from machine.

IMPORTANT: Absolute cleanliness is essential

when working on hydraulic components.
Contamination can result in serious damage
A—Steering Cylinder
or inadequate operation. Clean all lines and
fittings prior to opening hydraulic system.

1. Park machine safely.

2. Stop engine.
3. Remove engine cover.
4. Disconnect battery negative (-) cable.
NOTE: Muffler and exhaust pipes must be removed
to remove and install 4WD axle.

5. Remove muffler and exhaust pipes. (See the

appropriate engine section.)
6. Block front wheels.

CAUTION: Support machine properly.

7. Raise rear of machine with floor jack and support

frame with jackstands.
8. Remove rear wheels.
9. Remove steering cylinder (A). (See Remove and
Install Steering Cylinder.)
OUMX258,0000A9B -19-25FEB14-1/6

10. Support axle to relieve weight of axle on axle pin (B).

11. Remove two cap screws (C).
12. Remove axle pin.

B—Axle Pin C—Cap Screws (2 used)

TCAL29386 —UN—02JUL12

Continued on next page OUMX258,0000A9B -19-25FEB14-2/6

TM130419 (24FEB16) 40-30-77 030916

PN=325
 Power Train Repair—Single Speed

13. Use a hoist and lift sling to raise right side of axle (D).
14. With an assistant, lift axle, rotate clockwise, and
remove axle out right side of machine.

D—Axle

TCAL29387 —UN—02JUL12
OUMX258,0000A9B -19-25FEB14-3/6

Installation

CAUTION: 4WD axle is heavy. An additional

person is required when installing 4WD
axle in machine.

IMPORTANT: Always install new gaskets, O-rings, and

TCAL29388 —UN—02JUL12
seals. Replace all damaged or rough moving
parts. Damaged or worn parts will leak.

1. Use a hoist and lift sling to lift the right side of 4WD
axle (A).
2. With an assistant, install 4WD axle into right side of
machine.
3. Support axle in position.
A—Axle
4. Align axle pin pivot point with axle pin flange.
OUMX258,0000A9B -19-25FEB14-4/6

5. Install 4WD axle pin (B).

6. Install and tighten two cap screws (C).
7. Remove support from axle.

B—Axle Pin C—Cap Screws (2 used)

TCAL29389 —UN—02JUL12

Continued on next page OUMX258,0000A9B -19-25FEB14-5/6

TM130419 (24FEB16) 40-30-78 030916

PN=326
 Power Train Repair—Single Speed

8. Install steering cylinder (D). (See Remove and Install

Steering Cylinder.)
9. Install rear wheels. Tighten wheel bolts to specification.
Specification
Rear Wheels -
4WD—Torque..............................................................................122 N·m

TCAL29390 —UN—02JUL12
(90 lb.-ft.)

10. Remove jackstands and use floor jack to lower

machine.
11. Install muffler and exhaust pipes. (See the appropriate
engine section.)
12. Connect battery negative (—) cable.
13. Install engine cover and remove wheel blocks.
D—Steering Cylinder

OUMX258,0000A9B -19-25FEB14-6/6

Disassemble, Inspect, and Assemble 4WD

Axle
Special or Required Tools

• Floor Jack
• Jackstand (2 used)
• Hoist

TCAL29391 —UN—02JUL12
• Snap Ring Pliers Set
• Hydraulic Press
• Bushing, Bearing, and Seal Driver Set
• 3-Jaw Puller
• Knife-Edge Puller
Procedure
IMPORTANT: Absolute cleanliness is essential
when working on hydraulic components. A—Drain Plug
Contamination can result in serious damage
or inadequate operation.
DO NOT use shop towels or rags to dry Specification
cleaned parts. Lint will clog passages in the 4WD Axle Oil—Capacity
hydraulic/hydrostatic system and cause damage. (Approximate)................................................................................... 2.1 L
(2.25 qt.)
1. Remove axle from machine. (See Remove and install
4WD Axle.)
2. Remove drain plug (A) at differential housing. Drain
oil into a properly marked container of sufficient size
to hold oil from axle.
Continued on next page OUMX258,0000A9C -19-15SEP14-1/49

TM130419 (24FEB16) 40-30-79 PN=327

030916
 Power Train Repair—Single Speed

IMPORTANT: When removing tie rod (B), keep ball

joints clean. Dirt and contaminants can damage
ball joint seals and shorten service life.

3. Remove cotter pin and nut from each end of tie rod

TCAL29392 —UN—02JUL12
(B). Tie rod ends have a tapered joint. Remove tie rod.

B—Tie Rod

OUMX258,0000A9C -19-15SEP14-2/49

Disassemble Final Drive Hub

1. Remove drain plug (D) from lower gear case. Drain oil
into a properly marked container.
2. Remove eight cap screws and lock washers (A) from
lower gear case cover (B).

TCAL29393 —UN—02JUL12
3. Remove cover assembly. It may be necessary to tap
on cover with a soft-faced hammer to separate it from
the lower gear case (C).

A—Cap Screws and Lock C—Lower Gear Case

Washers (8 used) D—Drain Plug
B—Gear Case Cover

OUMX258,0000A9C -19-15SEP14-3/49

NOTE: Remove bearing (E) with a bearing puller only

if bearing requires replacement.

4. Inspect bearing (E) for wear, damage, or rough

movement. Replace bearing as needed.
5. Remove gasket (F) and clean gasket mating surfaces.

TCAL29394 —UN—02JUL12
6. Remove snap ring (G) to remove ring gear (H).
7. Inspect ring gear for wear or damage. Replace as
needed.

E—Bearing G—Snap Ring

F— Gasket H—Ring Gear

Continued on next page OUMX258,0000A9C -19-15SEP14-4/49

TM130419 (24FEB16) 40-30-80 030916

PN=328
 Power Train Repair—Single Speed

8. Use a press to remove hub shaft (I) from cover.

I— Hub Shaft

TCAL29395 —UN—02JUL12
OUMX258,0000A9C -19-15SEP14-5/49

9. Inspect oil seal wear sleeve (J) for wear or damage.

Replace as needed.

J— Oil Seal Wear Sleeve

TCAL29396 —UN—02JUL12
OUMX258,0000A9C -19-15SEP14-6/49

10. Remove bearing (K). Inspect for wear, damage, or

rough movement. Replace as needed.
11. Remove oil seal (L).

K—Bearing L— Oil Seal

TCAL29397 —UN—02JUL12

Continued on next page OUMX258,0000A9C -19-15SEP14-7/49

TM130419 (24FEB16) 40-30-81 030916

PN=329
 Power Train Repair—Single Speed

Disassemble Final Drive

1. Remove five axle housing-to-final drive cap screws
and lock washers (A).
2. Remove final drive assembly. It may be necessary to
tap on spindle gear case with a soft-faced hammer to
separate final drive assembly from axle housing.

TCAL29398 —UN—02JUL12
A—Cap Screws and Lock
Washers (5 used)

OUMX258,0000A9C -19-15SEP14-8/49

3. Remove four cap screws and lock washers (B) to

remove steering arm. It may be necessary to use
a soft-faced hammer to separate steering arm from
spindle gear case.

B—Cap Screws and Lock

Washers (4 used)

TCAL29399 —UN—02JUL12
OUMX258,0000A9C -19-15SEP14-9/49

4. Inspect oil seal wear sleeve (C) on steering arm for

wear or damage. Replace as needed.

C—Oil Seal Wear Sleeve

TCAL29400 —UN—02JUL12

Continued on next page OUMX258,0000A9C -19-15SEP14-10/49

TM130419 (24FEB16) 40-30-82 030916

PN=330
 Power Train Repair—Single Speed

NOTE: When spindle and lower gear cases are separated,

a spacer, gear, and bearing from the spindle shaft
will be loose in the spindle gear case.

5. Put final drive assembly in a press. Press on spindle

shaft in spindle gear case to separate spindle and
lower gear cases. Support lower gear case so it does

TCAL29401 —UN—02JUL12
not fall and cause injury or damage.

OUMX258,0000A9C -19-15SEP14-11/49

6. Remove spacer (G), bearing (I), and gear (H) from

spindle gear case.
7. Remove upper oil seal (D), bearing (E), and snap ring
(F) from top of spindle gear case.
8. Inspect parts for wear or damage. Inspect bearings for
wear, damage, or rough movement. Replace parts
as needed.

TCAL29402 —UN—02JUL12
D—Upper Oil Seal G—Spacer
E—Bearing H—Gear
F— Snap Ring I— Bearing

OUMX258,0000A9C -19-15SEP14-12/49

9. Remove shim (L), lower oil seal (J), and bearing (K)
from lower gear case. Discard oil seal.
10. Inspect bearing for wear, damage, or rough movement.
Replace as needed.
11. Remove spindle shaft (N) from lower gear case.

TCAL29403 —UN—02JUL12
12. Inspect spindle shaft and splines on shaft for wear or
damage. Replace as needed.

J— Lower Oil Seal M—Bearing

K—Bearing N—Spindle Shaft
L— Shim

Continued on next page OUMX258,0000A9C -19-15SEP14-13/49

TM130419 (24FEB16) 40-30-83 030916

PN=331
 Power Train Repair—Single Speed

13. Inspect bearing (M) on spindle shaft for wear,

damage, or rough movement. Replace as needed.
Remove bearing from spindle shaft only if it requires
replacement.
Assemble Final Drive
IMPORTANT: Always install new gaskets, O-rings, and

TCAL29404 —UN—02JUL12
seals. Replace all damaged or rough moving
parts. Damaged or worn parts will leak.
Press on inner bearing race only to avoid
damaging bearing.

NOTE: Steps for assembly of left and right final

drives are same.

M—Bearing

OUMX258,0000A9C -19-15SEP14-14/49

1. Press on inner race of bearing (A) to install new

TCAL29405 —UN—02JUL12
bearing on spindle shaft (B).

A—Bearing B—Spindle Shaft

TCAL29406 —UN—02JUL12
Continued on next page OUMX258,0000A9C -19-15SEP14-15/49

TM130419 (24FEB16) 40-30-84 030916

PN=332
 Power Train Repair—Single Speed

2. Install spindle shaft (C) in lower gear case. It may be

necessary to tap shaft to seat bearing to bottom of
bore.
3. Install bearing (D) and seal (E). Install seal with spring
side into bore first and flush with mounting surface.

TCAL29407 —UN—02JUL12
C—Spindle Shaft E—Seal
D—Bearing F— Shim

OUMX258,0000A9C -19-15SEP14-16/49

4. Install shim (F) on lower gear case.

5. If removed, press new sleeve (G) onto spindle gear
case (H).
6. Put spindle gear case (H) over spindle shaft. Do not

TCAL29408 —UN—02JUL12
install into lower gear case at this time.

F— Shim H—Spindle Gear case

G—Sleeve

OUMX258,0000A9C -19-15SEP14-17/49

7. Install gear (I) on spindle shaft with gear teeth toward

lower gear case.

I— Gear

TCAL29409 —UN—02JUL12

Continued on next page OUMX258,0000A9C -19-15SEP14-18/49

TM130419 (24FEB16) 40-30-85 030916

PN=333
 Power Train Repair—Single Speed

IMPORTANT: Push on inner race only to avoid

damaging bearing.

8. Install bearing (J) on spindle shaft. Tap on inner race

of bearing to install bearing onto spindle shaft.

J— Bearing

TCAL29410 —UN—02JUL12
OUMX258,0000A9C -19-15SEP14-19/49

9. Install snap ring (K).

10. Install spacer (L) with stepped side against snap ring.
Keep spacer against snap ring while holding spindle
(H) and lower (M) gear cases upright. Tap on spindle
gear case with a soft-face hammer to install into lower
gear case. use care not to damage seal in lower gear
case.
11. Hold upper (H) and lower (M) gear cases upright.
Install upper gear case in lower gear case by tapping
on upper case with a soft-faced hammer. Use care not
to damage seal in lower gear case.

K—Snap Ring H—Upper Gear Case

L— Spacer M—Lower Gear Case

TCAL29411 —UN—02JUL12
Continued on next page OUMX258,0000A9C -19-15SEP14-20/49

TM130419 (24FEB16) 40-30-86 030916

PN=334
 Power Train Repair—Single Speed

12. Install bearing (N) in upper gear case tight against

snap ring. It may be necessary to tap on inner race to
install bearing.
13. Install new oil seal (O) with spring side toward bearing.

N—Bearing O—Oil Seal

TCAL29412 —UN—02JUL12
OUMX258,0000A9C -19-15SEP14-21/49

14. Hold final drive assembly upright and install steering

arm (P). Tap on steering arm with a soft-faced hammer
to install steering arm on final drive assembly. Use
care not to damage seal.
15. Install and tighten four cap screws and washers (Q).

TCAL29413 —UN—02JUL12
P—Steering Arm Q—Cap Screws and Washers

Continued on next page OUMX258,0000A9C -19-15SEP14-22/49

TM130419 (24FEB16) 40-30-87 030916

PN=335
 Power Train Repair—Single Speed

Assemble Final Drive Hub

IMPORTANT: Always install new gaskets, O-rings, and
seals. Replace all damaged or rough moving
parts. Damaged or worn parts will leak.

1. Install new hub shaft seal (A) with seal spring into
bore first. Push seal to the specified depth (B) below
top of bore.
Specification
Final Drive Hub Shaft
Seal—Installation Depth..................6.5 mm (0.25 in.) Below Top of Bore

A—Install Hub Shaft Seal B—Depth

TCAL29414 —UN—02JUL12
OUMX258,0000A9C -19-15SEP14-23/49

2. Carefully put lower gear case cover (C) over hub shaft
(D) so as not to damage seal.
IMPORTANT: Press on inner race only to avoid
damaging bearing.

3. Press on inner race of bearing to install bearing on

TCAL29415 —UN—02JUL12
hub shaft in lower gear case cover. Push bearing tight
against shoulder of hub shaft.

C—Lower Gear Case Cover D—Hub Shaft

Continued on next page OUMX258,0000A9C -19-15SEP14-24/49

TM130419 (24FEB16) 40-30-88 030916

PN=336
 Power Train Repair—Single Speed

4. Install ring gear (E) and snap ring (F) on hub shaft.
5. Install new gasket (G).
6. Install bearing (H).

E—Ring Gear G—Gasket

TCAL29416 —UN—02JUL12
F— Snap Ring H—Bearing

OUMX258,0000A9C -19-15SEP14-25/49

7. Install cover assembly on lower gear case. Install and

tighten eight cap screws and lock washers (I) and
tighten to specification.
Specification
Final Drive Cover Cap
Screw—Torque..............................................................................52 N·m

TCAL29417 —UN—02JUL12
(38 lb.-ft.)

8. Install drain plug (J) in final drive and tighten to

specification.
Specification
Final Drive Drain
Plug—Torque.........................................................................39 ± 10 N·m
(29 ± 10 lb.-ft.)

I— Cap Screws and Lock J— Drain Plug

Washers

OUMX258,0000A9C -19-15SEP14-26/49

Disassemble Differential Input Shaft and Cover

1. Remove three cap screws and lock washers (A).
2. Remove differential input cover (B). Remove gasket
material from mating surfaces.

A—Cap Screws and Lock B—Differential Input Cover

TCAL29418 —UN—02JUL12

Washers (3 used)

Continued on next page OUMX258,0000A9C -19-15SEP14-27/49

TM130419 (24FEB16) 40-30-89 030916

PN=337
 Power Train Repair—Single Speed

3. Remove snap ring (D).

4. Remove input shaft assembly (C) from differential
housing.

C—Input Shaft Assembly D—Snap Ring

TCAL29419 —UN—02JUL12
OUMX258,0000A9C -19-15SEP14-28/49

5. Inspect gear (E), inner and outer bearings (F), and

spline (G) of input shaft for wear, damage, or rough
movement. Replace parts as needed.

E—Gear G—Spline
F— Bearings

TCAL29420 —UN—02JUL12
OUMX258,0000A9C -19-15SEP14-29/49

6. Remove bearings from input shaft only if they require

replacement.

TCAL29421 —UN—02JUL12

Continued on next page OUMX258,0000A9C -19-15SEP14-30/49

TM130419 (24FEB16) 40-30-90 030916

PN=338
 Power Train Repair—Single Speed

7. Remove and discard oil seal (H) from input housing

cover.

H—Oil Seal

TCAL29422 —UN—02JUL12
OUMX258,0000A9C -19-15SEP14-31/49

Disassemble/Inspect Differential and 4WD

Axle Housing
1. Remove left and right final drive assemblies from axle.
For final drive disassembly, see Disassemble Final
Drive under this Group.

TCAL29423 —UN—02JUL12
Continued on next page OUMX258,0000A9C -19-15SEP14-32/49

TM130419 (24FEB16) 40-30-91 030916

PN=339
 Power Train Repair—Single Speed

2. Remove seven cap screws (A) to separate right

axle/differential case (B) and left axle case (C).

A—Cap Screws (7 used) C—Left Axle Case

B—Right Axle/Differential Case

TCAL29424 —UN—02JUL12
TCAL29425 —UN—02JUL12
OUMX258,0000A9C -19-15SEP14-33/49

3. Remove pinion shaft with pinion gears (D), axle inner

gear (E) and ring gear (F). Inspect for wear or damage.
Replace parts as needed.
4. Remove left axle shaft (J) from axle case.

TCAL29426 —UN—02JUL12
NOTE: Remove bearing (G) with a bearing puller only
if bearing needs to be replaced.

5. Inspect inner bearing (G) for wear, damage, or rough

movement. Replace bearing as needed.
6. Remove axle outer gear (H) from left axle. Inspect
splines in gear and axle. Replace gear or axle as
needed.
D—Pinion Gears H—Outer gear
E—Axle Inner Gear I— Outer Bearing
F— Ring Gear J— Left Axle Shaft
G—Inner Bearing

Continued on next page OUMX258,0000A9C -19-15SEP14-34/49

TM130419 (24FEB16) 40-30-92 030916

PN=340
 Power Train Repair—Single Speed

7. Check outer bearing (I) on left axle for wear, damage,

or rough movement. Replace bearing if necessary
using a press.

I— Outer Bearing

TCAL29427 —UN—02JUL12
OUMX258,0000A9C -19-15SEP14-35/49

8. Remove large (J) and small (K) O-rings, axle gear (L),
and bearing (M). Inspect gear and splines of gear for
wear or damage. Inspect bearing for wear, damage,
or rough movement. Replace parts as needed.
9. Remove right axle shaft (N) from axle case.
10. Remove axle outer gear (O) on right axle. Inspect

TCAL29428 —UN—02JUL12
gear and splines of gear for wear or damage. Replace
gear or axle as needed.

J— Large O-Ring N—Right Axle Shaft

K—Small O-Ring O—Outer Gear
L— Axle Gear P—Outer Bearing
M—Bearing

TCAL29429 —UN—02JUL12

Continued on next page OUMX258,0000A9C -19-15SEP14-36/49

TM130419 (24FEB16) 40-30-93 030916

PN=341
 Power Train Repair—Single Speed

11. Inspect outer bearing (P) on right axle for wear,

damage, or rough movement. Replace bearing if
necessary, using a press.

P—Outer Bearing

TCAL29430 —UN—02JUL12
OUMX258,0000A9C -19-15SEP14-37/49

Right Axle Housing Assembly

IMPORTANT: Always install new gaskets, O-rings, and
seals. Replace all damaged or rough moving
parts. Damaged or worn parts will leak.
Push on inner race only to avoid
damaging bearing.

TCAL29431 —UN—02JUL12
1. Install new outer bearing (A) on right axle (B) if
removed. Support inner race of bearing and press
axle into bearing until tight against shoulder.

A—Outer Bearing B—Right Axle

Continued on next page OUMX258,0000A9C -19-15SEP14-38/49

TM130419 (24FEB16) 40-30-94 030916

PN=342
 Power Train Repair—Single Speed

2. Install small (C) and large (D) O-rings on right axle

case (E).
3. Install outer axle gear (F) on axle assembly (G).
4. Install axle assembly in axle case.
IMPORTANT: Push on inner race only to avoid
damaging bearing.

TCAL29432 —UN—02JUL12
5. Stand axle case on end and install bearing (H). It may
be necessary to tap on inner race of bearing to install
tight against bottom of bore in case.
6. Install axle gear (I) on axle shaft.

C—Small O-Ring G—Axle Assembly

D—Large O-Ring H—Bearing
E—Right Axle Case I— Axle Gear
F— Outer Axle Gear

TCAL29433 —UN—02JUL12
OUMX258,0000A9C -19-15SEP14-39/49

Assemble Left Axle and Differential Housing

IMPORTANT: Always install new gaskets, O-rings, and
seals. Replace all damaged or rough moving
parts. Damaged or worn parts will leak.
Push on inner race only to avoid
damaging bearing.

TCAL29434 —UN—02JUL12
1. Install new outer bearing (A) on left axle, if removed.
Support inner race of bearing and press axle into
bearing until tight against axle shoulder.

A—Outer Bearing

Continued on next page OUMX258,0000A9C -19-15SEP14-40/49

TM130419 (24FEB16) 40-30-95 030916

PN=343
 Power Train Repair—Single Speed

2. Install axle outer gear (G).

3. Install bearing (F) and ring gear (E) in axle housing.
4. Install left axle assembly (H) in housing.
5. Install axle inner gear (D), pinion gears (C) and pinion
shaft (B).

TCAL29435 —UN—02JUL12
A—Outer Bearing E—Ring Gear
B—Pinion Shaft F— Bearing
C—Pinion Gears G—Outer Gear
D—Inner Gear H—Left Axle Assembly

OUMX258,0000A9C -19-15SEP14-41/49

Assemble Differential and 4WD Axle Housing

1. Be sure O-ring (A) is on axle housing.

A—O-Ring

TCAL29436 —UN—02JUL12
OUMX258,0000A9C -19-15SEP14-42/49

2. Align gears and housings. Put housings together.

Install cap screws and lock washers between axle
housings. Be sure to install two longer cap screws (B)
in holes adjacent to input shaft. Tighten all cap screws.
3. Be sure O-ring is on end of axle housing.
4. Align final drive with axle housing.

TCAL29437 —UN—02JUL12
5. Install five cap screws and lock washers (C) housing
between final drive assembly and axle housing.
Tighten cap screws to specification.
Specification
Axle Housing-to-Final
Drive Assembly Cap
Screw—Torque..............................................................................68 N·m
(39 lb.-ft.)
B—Longer Cap Screws C—Cap Screws and Lock
6. Repeat steps 3—5 for opposite end of axle housing. Washers (5 used)

Continued on next page OUMX258,0000A9C -19-15SEP14-43/49

TM130419 (24FEB16) 40-30-96 030916

PN=344
 Power Train Repair—Single Speed

Assemble Differential Input Shaft and Cover

IMPORTANT: Always install new gaskets, O-rings, and
seals. Replace all damaged or rough moving
parts. Damaged or worn parts will leak.

TCAL29438 —UN—02JUL12
1. Install new seal (A) in input shaft cover. Install seal
with seal spring toward inside of cover. Push seal to
bottom of bore.

A—Seal

OUMX258,0000A9C -19-15SEP14-44/49

IMPORTANT: Push on inner race only to avoid

damaging bearing.

2. Install new bearings on input shaft by pressing on inner

race of bearing. Install inner bearing first, then outer
bearing. Push bearings tight against shoulder of shaft.

TCAL29439 —UN—02JUL12
OUMX258,0000A9C -19-15SEP14-45/49

3. Install input shaft in differential case.

4. Install snap ring (B).

B—Snap Ring

TCAL29440 —UN—02JUL12

Continued on next page OUMX258,0000A9C -19-15SEP14-46/49

TM130419 (24FEB16) 40-30-97 030916

PN=345
 Power Train Repair—Single Speed

5. Ensure the mating surfaces between the differential

input cover (D) and housing are clean.
6. Clean the differential input cover cap screws (C) with
PM37509 John Deere™ Cure Primer.
7. Apply PM38655 John Deere™ Form-in-Place Gasket
to mating surface of cover.

TCAL29441 —UN—02JUL12
8. Install differential input shaft cover. Install and tighten
three cap screws to specification.
Specification
Differential Input Cover
Cap Screw—Torque......................................................................26 N·m
(19 lb.-ft.)

C—Cap Screws D—Differential Input Cover

John Deere is a trademark of Deere & Company

OUMX258,0000A9C -19-15SEP14-47/49

Final Assembly
1. Install tie rod (A). Install and tighten tie rod castellated
nuts to specification. Continue to turn nut clockwise to
align with drilled hole and install cotter pin.

TCAL29442 —UN—02JUL12
Specification
Tie Rod Castellated
Nut—Torque..................................................................................53 N·m
(39 lb.-ft.)

OUMX258,0000A9C -19-15SEP14-48/49

2. Install differential housing drain plug (B) and tighten

to specification.
Specification
Differential Housing Drain
Plug—Torque.........................................................................39 ± 10 N·m
(29 ± 10 lb.-ft.)

TCAL29443 —UN—02JUL12
3. Remove oil filler cap and fill 4WD axle with oil to
proper level.
4. Install filler cap.
5. Install 4WD axle assembly in machine. (See Remove
and Install 4WD Axle.)

B—Differential Housing Drain

Plug

OUMX258,0000A9C -19-15SEP14-49/49

TM130419 (24FEB16) 40-30-98 030916

PN=346
 Group 40
Power Train Repair—2 Speed
Summary of References • Disassemble, Inspect, and Assemble Hydrostatic
Assembly—2 Speed
• Remove and Install Engine Driveshaft—2 Speed • Disassemble, Inspect, and Assemble Differential—2
• Remove and Install Transaxle—2 Speed Speed
• Separate and Install Hydrostatic Assembly and • Disassemble, Inspect, and Assemble PTO—2 Speed
Differential Assembly—2 Speed
• Remove and Install 4WD Driveshaft—2 Speed
• Remove, Disassemble, Inspect, and Assemble • Remove and Install 4WD Axle—2 Speed
Hydraulic Pump—2 Speed • Disassemble, Inspect, and Assemble 4WD Axle—2
• Disassemble, Inspect, and Assemble Charge Pump—2 Speed
Speed
• Remove, Inspect, and Install 2 Speed Range—2 Speed
• Remove, Inspect, and Assemble 4WD Drive Output
Unit—2 Speed
OUMX258,0000AC8 -19-30DEC13-1/1

Remove and Install Engine Driveshaft—2

Speed
Removal
1. Park machine safely. See the “Safety Section”
2. Raise front of machine. Support both sides of frame
just behind transaxle with 2-ton jackstands or wooden

TCT011767 —UN—11SEP14
block for safety reasons.
3. Remove three bolts (A) securing drive shaft to flywheel.

A—Bolt

OUMX258,0000ABB -19-11SEP14-1/2

4. Remove bolts (B) securing drive shaft to transaxle

input shaft.
5. Remove drive shaft from machine.
Installation
1. Installation is reverse of removal.
2. Install drive shaft onto input shaft of transaxle.
3. Install bolts (B) securing shaft to input on transaxle.
TCT011768 —UN—11SEP14
4. Install three bolts (A) securing drive shaft to flywheel.
5. Lower machine to ground.

B—Bolt

OUMX258,0000ABB -19-11SEP14-2/2

TM130419 (24FEB16) 40-40-1 030916

PN=347
 Power Train Repair—2 Speed

Remove and Install Transaxle—2 Speed

Special or Required Tools

TCAL29456 —UN—09JUL12
• JT01748 Lifting Bracket
IMPORTANT: Absolute cleanliness is essential
when working on hydraulic components.
Contamination can result in serious damage
or inadequate operation. Clean all lines and
fittings prior to opening hydraulic system.

NOTE: Record transaxle serial number (above right

axle housing) for obtaining correct parts. Some
early models are slightly different.
OUMX258,0000ABC -19-15SEP14-1/12

Procedure
1. Remove front attachment.
2. Put wedge blocks in front of and behind both rear
drive wheels.
3. Loosen front drive wheel lug nuts.
4. Raise front of machine. Support both sides of frame
just behind transaxle with 2-ton jackstands or wooden
blocks for safety reasons.

TCAL29457 —UN—09JUL12
5. Remove front drive wheels.
6. Remove engine driveshaft. (See Remove and Install
Engine Driveshaft—2 Speed.)
7. Remove 4WD driveshaft, if equipped. (See Remove
and Install 4WD Driveshaft—2 Speed.)
NOTE: Use shop cloths or paper towels to immediately
catch and clean up any spilled oil. Close all A—PTO/Hydrostatic Housing C—Differential Housing
ports and lines using caps or plugs. B—4WD Housing

8. Remove drain plugs at PTO/hydrostatic housing (A),

4WD housing (B), and differential housing (C).
Continued on next page OUMX258,0000ABC -19-15SEP14-2/12

TM130419 (24FEB16) 40-40-2 030916

PN=348
 Power Train Repair—2 Speed

9. Remove nut (D) from pedal linkage ball joint and

disconnect pedal linkage.
10. Remove three mounting cap screws (E) for linkage
pivot. Move pedal linkage aside.

D—Nut E—Mounting Cap Screws (3

used)

TCAL29458 —UN—09JUL12
OUMX258,0000ABC -19-15SEP14-3/12

11. Disconnect hydraulic hoses (F) and (G).

12. Disconnect PTO solenoid harness.

F— Hydraulic Hose G—Hydraulic Hose

TCAL29459 —UN—09JUL12
OUMX258,0000ABC -19-15SEP14-4/12

13. Disconnect linkage from Hi-Lo lever (H) and 4WD

lever (I).

H—Hi-Lo Lever Linkage I— 4WD Lever Linkage

TCAL29460 —UN—09JUL12

Continued on next page OUMX258,0000ABC -19-15SEP14-5/12

TM130419 (24FEB16) 40-40-3 030916

PN=349
 Power Train Repair—2 Speed

14. Disconnect differential lock linkage (J).

J— Differential Lock Linkage

TCAL29461 —UN—09JUL12
OUMX258,0000ABC -19-15SEP14-6/12

15. Remove each lift cylinder pin (K) and secure lift
cylinders up out of the way.
16. Remove wire clamp (L) and move wire harness aside.
17. Support transaxle with a transmission jack or rolling
transmission stand.
18. Remove eight transaxle mounting cap screws (M) and
implement lift arm mounts (N).
19. Remove transaxle.

TCAL29462 —UN—09JUL12
K—Lift Cylinder Pin M—Mounting Cap Screws (8
L— Wire Clamp used)
N—Lift Arm Mounts

Continued on next page OUMX258,0000ABC -19-15SEP14-7/12

TM130419 (24FEB16) 40-40-4 030916

PN=350
 Power Train Repair—2 Speed

Install
1. Raise transaxle to frame.
IMPORTANT: Locating pins on rear side of
transaxle must be positioned in frame
locating holes before tightening of transaxle
mounting cap screws.

2. Install eight mounting cap screws (A) and implement

TCAL29463 —UN—09JUL12
lift arm mounts (B). Position locating pins on transaxle
into locating holes of frame and tighten mounting cap
screws to specification.
Specification
Transaxle Mounting Cap
Screw—Torque............................................................................142 N·m
(105 lb.-ft.)

3. Remove transmission jack.

A—Mounting Cap Screws (8 C—Differential Lock Linkage
4. Connect differential lock linkage (C). used) D—Implement Lift Cylinders
B—Implement Lift Aem Mounts
5. Connect implement lift cylinders (D).
OUMX258,0000ABC -19-15SEP14-8/12

6. Connect 4WD linkage (E) and Hi-Lo Lever linkage (F).

E—4WD Linkage F— Hi-Lo Lever Linkage

TCAL29464 —UN—09JUL12
Continued on next page OUMX258,0000ABC -19-15SEP14-9/12

TM130419 (24FEB16) 40-40-5 030916

PN=351
 Power Train Repair—2 Speed

7. Install cap screw and wiring harness clamp (G).

8. Connect power steering hose (H).
9. Connect right and left brake links and springs.
10. Connect PTO solenoid harness.
11. Connect hydraulic hose (I).

G—Wiring Harness Clamp I— Hydraulic Hose

H—Power Steering Hose

TCAL29465 —UN—09JUL12
OUMX258,0000ABC -19-15SEP14-10/12

12. Install pedal linkage pivot using three mounting cap

screws (J). Make sure brake/neutral return linkage is
properly engaged in cam slot (K) before tightening cap
screws (J).
13. Connect pedal linkage (L). Check that all pedals
operate properly.
14. Install 4WD driveshaft. (See Remove and Install 4WD
Driveshaft—2 Speed.)
15. Install engine driveshaft. (See Remove and Install

TCAL29466 —UN—09JUL12
Engine Driveshaft—2 Speed.)
16. Install front drive wheels. Tighten mounting cap
screws to specification.
Specification
Front Drive Wheel
Mounting Cap
Screw—Torque............................................................................225 N·m
(165 lb.-ft.)
J— Mounting Cap Screws (3 L— Pedal Linkage
17. Lower machine to ground. used)
K—Cam Slot

Continued on next page OUMX258,0000ABC -19-15SEP14-11/12

TM130419 (24FEB16) 40-40-6 030916

PN=352
 Power Train Repair—2 Speed

18. Fill transaxle with proper fluid. (See “Machine

Specifications”.) Remove fill plug (M) from hydro/PTO
section and fill specification. Remove fill plug (N) from
differential section and fill to specification. After running
unit recheck oil with dipstick and add oil if necessary.

TCAL29467 —UN—09JUL12
Specification
Hydro/PTO Section
Oil—Capacity................................................................................... 3.4 L
(3.6 qt.)
Differential Section
Oil—Capacity................................................................................... 6.2 L
(6.6 qt.)

M—Hydro/PTO Fill Plug N—Differential Fill Plug

OUMX258,0000ABC -19-15SEP14-12/12

Separate and Install Hydrostatic Assembly

and Differential Assembly—2 Speed
IMPORTANT: Absolute cleanliness is essential
when working on hydraulic components.
Contamination can result in serious damage
or inadequate operation.
DO NOT use shop towels or rags to dry

TCAL29468 —UN—09JUL12
cleaned parts. Lint will clog passages in the
hydraulic/hydrostatic system and cause damage.

Separation
1. Remove transaxle. (See Remove and Install
Transaxle—2 Speed.)
2. Disconnect return hose (A).
A—Return Hose

OUMX258,0000ABD -19-30DEC13-1/10

3. Remove two cap screws (B) from L-bracket (C).

B—Cap Screws (2 used) C—L-Bracket

TCAL29469 —UN—09JUL12

Continued on next page OUMX258,0000ABD -19-30DEC13-2/10

TM130419 (24FEB16) 40-40-7 030916

PN=353
 Power Train Repair—2 Speed

4. Remove two front cap screws (D).

D—Front Cap Screws (2 used)

TCAL29470 —UN—09JUL12
OUMX258,0000ABD -19-30DEC13-3/10

5. Remove rear cap screw (E) and two nuts (F).

E—Rear Cap Screw F— Nuts (2 used)

TCAL29471 —UN—09JUL12
OUMX258,0000ABD -19-30DEC13-4/10

6. Separate hydrostatic assembly (G) from differential

assembly (H).
7. Repair assemblies as necessary.
8. Clean gasket surfaces.

TCAL29472 —UN—09JUL12
G—Hydrostatic Assembly H—Differential Assembly

Continued on next page OUMX258,0000ABD -19-30DEC13-5/10

TM130419 (24FEB16) 40-40-8 030916

PN=354
 Power Train Repair—2 Speed

Installation
1. Replace gaskets.
2. Install hydrostatic assembly (I) to differential assembly
(J).

I— Hydrostatic Assembly J— Differential Assembly

TCAL29473 —UN—09JUL12
OUMX258,0000ABD -19-30DEC13-6/10

3. Install cap screw (K) and nuts (L).

K—Cap Screw L— Nuts (2 used)

TCAL29474 —UN—09JUL12
OUMX258,0000ABD -19-30DEC13-7/10

4. If removed, install cover plate using cap screws (M).

5. Install hydraulic pump. (See Remove, Disassemble,
Inspect, and Assemble Hydraulic Pump—2 Speed.)

M—Cap Screws

TCAL29475 —UN—09JUL12

Continued on next page OUMX258,0000ABD -19-30DEC13-8/10

TM130419 (24FEB16) 40-40-9 030916

PN=355
 Power Train Repair—2 Speed

6. Install L-bracket (N) using two cap screws (O).

N—L-Bracket O—Cap Screws (2 used)

TCAL29476 —UN—09JUL12
OUMX258,0000ABD -19-30DEC13-9/10

7. Install and connect return hose (P).

8. Install transaxle. (See Remove and Install
Transaxle—2 Speed.)

P—Return Hose

TCAL29477 —UN—09JUL12
OUMX258,0000ABD -19-30DEC13-10/10

TM130419 (24FEB16) 40-40-10 030916

PN=356
 Power Train Repair—2 Speed

Remove, Disassemble, Inspect, and

Assemble Hydraulic Pump—2 Speed
Remove
IMPORTANT: Absolute cleanliness is essential
when working on hydraulic components.
Contamination can result in serious damage
or inadequate operation.
DO NOT use shop towels or rags to dry

TCAL29478 —UN—09JUL12
cleaned parts. Lint will clog passages in the
hydraulic/hydrostatic system and cause damage.

NOTE: It is not necessary to remove transaxle to repair

hydraulic pump only. Hydraulic pump can be
removed without disassembly of transaxle.
Transaxle is shown removed for clarity.
Use shop cloths or paper towels to immediately A—Hose Clamps (4 used) C—Bolt
catch and clean up any spilled oil. Close all B—Hoses
ports and lines using caps or plugs.

1. If transaxle is in machine, drain transaxle. (See

Changing the Transaxle Oil and Filter in the operator’s 3. Remove bolt (C) holding the hydraulic line support
manual.) bracket.

2. Loosen the four hose clamps (A) and remove the two
hoses (B) from the intake manifold.
OUMX258,0000ABE -19-15SEP14-1/16

4. Remove the three hex head screws (D) holding the

intake manifold to the top of the hydraulic pump.
Remove the manifold assembly.

TCAL29479 —UN—09JUL12
D—Hex Head Screws (3 used)

Continued on next page OUMX258,0000ABE -19-15SEP14-2/16

TM130419 (24FEB16) 40-40-11 030916

PN=357
 Power Train Repair—2 Speed

5. Remove the hydraulic line and pressure fitting (E) from

the bottom of the hydraulic pump by removing the
three cap screws (F).

E—Hydraulic Line and F— Cap Screws (3 used)

Pressure Fitting

TCAL29480 —UN—09JUL12
OUMX258,0000ABE -19-15SEP14-3/16

6. Mark cover and pump (arrows) for reassembly

purposes. Remove four cap screws (G) that are
marked in the photo, and remove the hydraulic pump.
Do not remove the remaining four cap screws at this
time, as the pump components could separate during
removal.

TCAL29481 —UN—09JUL12
G—Cap Screws (4 used)

OUMX258,0000ABE -19-15SEP14-4/16

Disassemble
1. Remove the four remaining pump body cap screws
and separate the cover (H) from the body of the pump.

H—Cover

TCAL29482 —UN—09JUL12

Continued on next page OUMX258,0000ABE -19-15SEP14-5/16

TM130419 (24FEB16) 40-40-12 030916

PN=358
 Power Train Repair—2 Speed

2. Remove the front thrust plate (I) from the gears. Check
the brass side (inside) for signs of damage such as
gouging, scoring or pitting. Replace pump if damage
or wear is evident.

I— Front Thrust Plate

TCAL29483 —UN—09JUL12
OUMX258,0000ABE -19-15SEP14-6/16

3. Remove the pump drive gear (J) and idler gear (K)
assemblies from the pump body noting the location
of the gears.
4. Inspect gear faces (L) for wear such as chipping,
pitting or spalling of the gear faces. Replace pump
as required.
5. Inspect internal shaft splines on the drive gear.
Replace pump if gear is worn or damaged.

J— Pump Drive Gear L— Gear Faces

TCAL29484 —UN—09JUL12
K—Idler Gear

Continued on next page OUMX258,0000ABE -19-15SEP14-7/16

TM130419 (24FEB16) 40-40-13 030916

PN=359
 Power Train Repair—2 Speed

6. Remove the rear thrust plate (M) from the pump body.
Check the brass side for wear or damage. Replace
pump as required.
7. Inspect the bushing surfaces (N) in the pump body
for wear or damage. Inspect the pump body internal
surfaces for scoring, scratching or excessive wear.
Replace pump if damaged.

M—Rear Thrust Plate N—Bushing Surfaces

TCAL29485 —UN—09JUL12
OUMX258,0000ABE -19-15SEP14-8/16

Assembly
1. Install the rear thrust plate in the pump body with the
brass side facing out (towards gear). Note that the
lubrication groove (O) goes toward the top (intake
side) of pump.

O—Lubrication Groove

TCAL29486 —UN—09JUL12
Continued on next page OUMX258,0000ABE -19-15SEP14-9/16

TM130419 (24FEB16) 40-40-14 030916

PN=360
 Power Train Repair—2 Speed

2. Install the pump drive gear (P) and idler gear (Q) in
the pump body.

P—Pump Drive Gear Q—Idler Gear

TCAL29487 —UN—09JUL12
Idler gear (Q) is symmetrical and can be placed in body either end first.

OUMX258,0000ABE -19-15SEP14-10/16

3. Place front thrust plate (R) over shaft ends with the
brass surface to the inside. Thrust plate should be
flush with pump body gasket surface (S) when all
components are installed correctly.

R—Front Trust Plate S—Pump Body Gasket Surface

TCAL29488 —UN—09JUL12
OUMX258,0000ABE -19-15SEP14-11/16

4. If removed, install formed O-ring gasket (T) in the

grooves on the front cover.

T— O-Ring Gasket
TCAL29489 —UN—09JUL12

Continued on next page OUMX258,0000ABE -19-15SEP14-12/16

TM130419 (24FEB16) 40-40-15 030916

PN=361
 Power Train Repair—2 Speed

5. Install the front cover using four cap screws (U). Note
that the cover has an OUT (V) marking that must be
oriented on the bottom (outlet side) of pump. Tighten
cap screws to specification.
Specification
Hydraulic Pump Cover
Cap Screws—Torque....................................................................15 N·m
(113 lb.-in.)

TCAL29490 —UN—09JUL12
6. Install a new gasket on the hydraulic pump.

U—Cap Screws (4 used) V—OUT Marking on Cover

OUMX258,0000ABE -19-15SEP14-13/16

7. Align the pump drive gear shaft internal splines with

the splined shaft (W) on the transaxle and install the
hydraulic pump with the remaining four cap screws.

W—Splined Shaft on Transaxle

TCAL29491 —UN—09JUL12
OUMX258,0000ABE -19-15SEP14-14/16

8. Replace O-ring and install the hydraulic line (X) and

pressure fitting (Y) to the bottom of the hydraulic pump
with three cap screws.

X—Hydraulic Line Y—Presure Fitting

TCAL29492 —UN—09JUL12

Continued on next page OUMX258,0000ABE -19-15SEP14-15/16

TM130419 (24FEB16) 40-40-16 030916

PN=362
 Power Train Repair—2 Speed

9. Install the intake manifold (Z) to the top of the pump

with three hex head screws. Install the bolt (AA) that
holds the hydraulic line support bracket and the two
rubber hoses (AE). Secure hoses with screw clamps.
10. If transaxle is mounted in the machine, refill with oil.
(See operators manual.)

Z— Intake Manifold AE—Rubber Hoses

AA—Bolt

TCAL29493 —UN—09JUL12
OUMX258,0000ABE -19-15SEP14-16/16

Disassemble, Inspect, and Assemble Charge

Pump—2 Speed
IMPORTANT: Absolute cleanliness is essential
when working on hydraulic components.
Contamination can result in serious damage
or inadequate operation.
DO NOT use shop towels or rags to dry

TCAL29494 —UN—09JUL12
cleaned parts. Lint will clog passages in the
hydraulic/hydrostatic system and cause damage.

Disassembly/Inspection
1. Remove transaxle. (See Remove and Install
Transaxle—2 Speed.)
2. Remove hydrostatic assembly from differential
assembly. (See Separate and Install Hydrostatic
Assembly and Differential Assembly—2 Speed.) A—Cap Screw B—Hex Socket Head Screw (3
used)
3. Remove Hydraulic Pump from the Hydrostatic Sub
Plate. (See Remove, Disassemble, Inspect, and
Assemble Hydraulic Pump—2 Speed.)
4. Remove one cap screw (A) and three hex socket head
screws (B) from the hydrostatic sub plate. Separate
hydrostatic sub plate from hydrostatic center plate.
Continued on next page OUMX258,0000ABF -19-30DEC13-1/10

TM130419 (24FEB16) 40-40-17 030916

PN=363
 Power Train Repair—2 Speed

5. Remove O-rings (C) from hydrostatic sub plate.

Inspect pump shaft bushing (D). If bushing shows
signs of excessive wear or damage, replace the
hydrostatic sub plate assembly.

C—O-Rings D—Pump Shaft Bushing

TCAL29495 —UN—09JUL12
OUMX258,0000ABF -19-30DEC13-2/10

6. Remove the outer gear (E) and inner gear (F) from the
drive pin on the pump shaft. Inspect both gears for
damage or excessive wear. If any sign of grooving,
scoring, bluing or surface flaking is evident, replace
the pump gears as a set.

E—Outer Gear F— Inner Gear

TCAL29496 —UN—09JUL12
OUMX258,0000ABF -19-30DEC13-3/10

7. Remove gear drive pin (G) from pump shaft. Inspect

the condition of the pin. If it is a loose fit in the bore, is
deformed or bent, or shows signs of surface damage,
replace the pin.
8. Inspect the pump wear surface (H) on the machined
face of the hydrostatic center plate. If any scoring or
damage is visible, replace the center plate.
TCAL29497 —UN—09JUL12

G—Gear Drive Pin H—Pump Wear Surface

Continued on next page OUMX258,0000ABF -19-30DEC13-4/10

TM130419 (24FEB16) 40-40-18 030916

PN=364
 Power Train Repair—2 Speed

9. Remove the priority valve assembly (I) from the

hydrostatic sub plate. Check the valve bores for signs
of clogging or damage. If any sign of damage or
scoring is evident, replace the priority valve.

I— Priority Valve Assembly

TCAL29498 —UN—09JUL12
OUMX258,0000ABF -19-30DEC13-5/10

10. Check the suction hose fitting (J) on the hydrostatic

sub plate. If the fitting is deformed or damaged, or
shows signs of leakage, remove the location strap (K)
and pull the fitting from the bore. Remove the O-Rings
from the fitting.
11. Clean and dry all parts.

J— Suction Hose Fitting K—Location Strap

TCAL29499 —UN—09JUL12

Continued on next page OUMX258,0000ABF -19-30DEC13-6/10

TM130419 (24FEB16) 40-40-19 030916

PN=365
 Power Train Repair—2 Speed

Assemble
1. Apply clean transmission oil to all internal parts.
2. Install new O-rings on the suction hose fitting and
reinstall in the sub plate.
NOTE: Always replace O-rings. Old O-rings may be
worn or damaged and will result in leaks.

3. Replace the O-ring on the valve bore plug (L) and

install the spring and the priority valve in hydrostatic
sub plate and install plug (L).
4. Install the gear drive pin in the pump shaft.

TCAL29500 —UN—09JUL12
L— Valve Bore Plug

OUMX258,0000ABF -19-30DEC13-7/10

5. Install the inner gear on the pin and pump shaft with
the identification dimple (M) facing out. Install the
outer gear over the inner, with the identification dimple
(N) in the position shown.

M—Inner Gear Identification N—Outer Gear Identification

Dimple Dimple

TCAL29501 —UN—09JUL12
OUMX258,0000ABF -19-30DEC13-8/10

6. Replace the O-rings (O) in the face of the hydrostatic

sub plate.

O—O-Rings
TCAL29502 —UN—09JUL12

Continued on next page OUMX258,0000ABF -19-30DEC13-9/10

TM130419 (24FEB16) 40-40-20 030916

PN=366
 Power Train Repair—2 Speed

7. Install hydrostatic sub plate on hydrostatic center plate

with one cap screw (P) and three hex socket head
screws (Q).

P—Cap Screw Q—Hex Socket Head Screws (3

used)

TCAL29503 —UN—09JUL12
OUMX258,0000ABF -19-30DEC13-10/10

Remove, Inspect, and Install 2 Speed

Range—2 Speed
Special or Required Tools

• Snap Ring Pliers Set

• Hydraulic Press
IMPORTANT: Absolute cleanliness is essential
when working on hydraulic components.
Contamination can result in serious damage
or inadequate operation.

TCAL29504 —UN—09JUL12
DO NOT use shop towels or rags to dry
cleaned parts. Lint will clog passages in the
hydraulic/hydrostatic system and cause damage.

Disassemble and Inspect

1. Remove transaxle. (See Remove and Install
Transaxle—2 Speed.)
A—Two Speed Range Case C—Splines
2. Separate hydrostatic assembly. (See Separate B—Mating Surface
and Install Hydrostatic Assembly and Differential
Assembly—2 Speed.)
3. Remove two speed range case (A) from the transaxle 4. Inspect splines (C). If splines are worn or damaged,
case. Remove any gasket material and clean the replace gear.
mating surface (B).
Continued on next page OUMX258,0000AC0 -19-15SEP14-1/49

TM130419 (24FEB16) 40-40-21 030916

PN=367
 Power Train Repair—2 Speed

5. Remove the four-wheel drive output unit (E). (See

Remove, Inspect, and Assemble 4WD Drive Output
Unit—2 Speed.) Remove six cap screws (D) from the
front case half of the two-speed range transaxle.
6. Drive the roll pins (F) from the high-low and four-wheel
drive actuator arm levers and remove the levers from

TCAL29505 —UN—09JUL12
the shafts.

D—Cap Screws (6 used) F— Roll Pins

E—Four-Wheel Drive Unit

OUMX258,0000AC0 -19-15SEP14-2/49

7. Slide the clutch shoe (G) down off the pin on the
actuator lever.

G—Clutch Shoe

TCAL29506 —UN—09JUL12
OUMX258,0000AC0 -19-15SEP14-3/49

8. Remove the cap screws (H) lock washers and straps

(I) securing the actuator shaft to the cases. Remove
the four-wheel drive actuator shaft (J) and the O-ring
from the front case half. Discard O-ring.

H—Cap Screws J— Four-Wheel Drive Actuator

I— Lock Washers and Straps Shaft
TCAL29507 —UN—09JUL12

Continued on next page OUMX258,0000AC0 -19-15SEP14-4/49

TM130419 (24FEB16) 40-40-22 030916

PN=368
 Power Train Repair—2 Speed

9. Separate the two-speed range unit cases by using an

appropriate tool at the pry points (K) on the cases.

K—Pry Points

TCAL29508 —UN—09JUL12
OUMX258,0000AC0 -19-15SEP14-5/49

10. Remove the spacer collar (L) from the high-low output
shaft bearing in the front case half to access snap ring.

L— Spacer Collar

TCAL29509 —UN—09JUL12
OUMX258,0000AC0 -19-15SEP14-6/49

11. Remove the snap ring (M) and washer from the output
shaft.
12. Press the output shaft (N) down through the bearing
(O), until the shaft end is flush with the bearing.
13. Turn the case over and drive the bearing and shaft
assembly up, until the locator ring on the outside of
the bearing is accessible. Remove the locator ring
TCAL29510 —UN—09JUL12
from the groove in the outer bearing race.
14. Turn the case back over and press the complete
bearing/gear/shaft assembly down out of the case.

M—Snap Ring O—Bearing

N—Output Shaft

Continued on next page OUMX258,0000AC0 -19-15SEP14-7/49

TM130419 (24FEB16) 40-40-23 030916

PN=369
 Power Train Repair—2 Speed

15. Press the shaft and gear assembly (P) completely out
of the bearing using a hydraulic press.

P—Shaft and Gear Assembly

TCAL29511 —UN—09JUL12
OUMX258,0000AC0 -19-15SEP14-8/49

16. Remove the shifter gear (Q) and spacer (R) from the
output shaft. Check gears on shifter gear and output
shaft for signs of wear or damage, replace if necessary.

Q—Shifter Shaft R—Spacer

TCAL29512 —UN—09JUL12
OUMX258,0000AC0 -19-15SEP14-9/49

17. Remove the needle bearing (S) from the output clutch
shaft.

S—Needle Bearing

TCAL29513 —UN—09JUL12

Continued on next page OUMX258,0000AC0 -19-15SEP14-10/49

TM130419 (24FEB16) 40-40-24 030916

PN=370
 Power Train Repair—2 Speed

18. Remove the inner bearing locator snap ring (T) from
the output clutch shaft.

T— Snap Ring

TCAL29514 —UN—09JUL12
OUMX258,0000AC0 -19-15SEP14-11/49

19. Remove the outer bearing (U) from the output clutch
gear hub.

U—Outer Bearing

TCAL29515 —UN—09JUL12
OUMX258,0000AC0 -19-15SEP14-12/49

20. Turn the output clutch gear hub over and remove the
bearing (V) from the clutch shaft.

V—Bearing

TCAL29516 —UN—09JUL12

Continued on next page OUMX258,0000AC0 -19-15SEP14-13/49

TM130419 (24FEB16) 40-40-25 030916

PN=371
 Power Train Repair—2 Speed

21. Remove the snap ring (W) from the inner bearing.
22. Put the clutch hub assembly in a press, and press the
inner bearing from the shaft.
23. Check all four output clutch bearings that were
removed for damage, wear or rough movement.
Replace if necessary.

W—Snap Ring

TCAL29517 —UN—09JUL12
OUMX258,0000AC0 -19-15SEP14-14/49

24. Remove the snap ring (X) from the clutch in the clutch
hub.

X—Snap Ring

TCAL29518 —UN—09JUL12
Continued on next page OUMX258,0000AC0 -19-15SEP14-15/49

TM130419 (24FEB16) 40-40-26 030916

PN=372
 Power Train Repair—2 Speed

25. Lift the clutch (Y) out of the clutch housing. Inspect
clutch cage and engagement rollers for wear or
damage. Inspect the clutch housing for wear or
damage. Note particularly the condition of the clutch
housing ears (Z). Replace as needed.

Y—Clutch Z— Clutch Housing Ears

TCAL29519 —UN—09JUL12
OUMX258,0000AC0 -19-15SEP14-16/49

26. Remove the Idler gear assembly (aa) by disengaging

the actuator arm pin from the shifter fork (ab) as the
gear assembly is lifted out of the case.
27. Press bearing off both ends of the idler gear assembly

TCAL29520 —UN—09JUL12
(aa) to remove the idler gears.

aa— Idler Gear Assembly ab— Shifter Fork

Continued on next page OUMX258,0000AC0 -19-15SEP14-17/49

TM130419 (24FEB16) 40-40-27 030916

PN=373
 Power Train Repair—2 Speed

CAUTION: Detent ball is under tension. Use

caution when removing actuator arm to
prevent bodily injury.

28. Disassemble shifter fork assembly, by pulling the

actuator arm (ac) out of the fork (ad). Take care not to
lose either the detent ball or spring that will be released
when the actuator arm is pulled out of the fork.

ac— Actuator Arm ad— Fork

TCAL29521 —UN—09JUL12
OUMX258,0000AC0 -19-15SEP14-18/49

29. Slide the upper needle bearing and two bushings off
the end of the reduction shaft.
30. Remove the two C-rings (ae) from the reduction shaft
and slide the second needle bearing (af) and bushings
(ag) off the shaft.

ae— C-Rings ag— Bushings

TCAL29522 —UN—09JUL12
af— Needle Bearing

Continued on next page OUMX258,0000AC0 -19-15SEP14-19/49

TM130419 (24FEB16) 40-40-28 030916

PN=374
 Power Train Repair—2 Speed

31. Remove the snap ring located above the reduction

gear (ah) on the reduction shaft.

ah— Reduction Gear

TCAL29523 —UN—09JUL12
OUMX258,0000AC0 -19-15SEP14-20/49

32. Slide the reduction gear off the shaft. Remove the
second snap ring (ai) located beneath reduction gear.

ai— Snap Ring

TCAL29524 —UN—09JUL12
OUMX258,0000AC0 -19-15SEP14-21/49

33. Remove the reduction shaft and bearing from the case.
Press the bearing (aj) off the reduction shaft (ak) using
a knife-edge bearing separator to support the bearing.
34. Inspect the gear teeth on the bevel gear. If teeth are
worn, chipped or damaged, replace the reduction
shaft. Inspect the splines on the reduction shaft and
the reduction gear. If splines are worn or damaged
on either component, replace the gear and shaft as a
TCAL29525 —UN—09JUL12

set. Inspect the bearing for wear, damage, or rough

movement. Replace as needed.

aj— Bearing ak— Reduction Shaft

Continued on next page OUMX258,0000AC0 -19-15SEP14-22/49

TM130419 (24FEB16) 40-40-29 030916

PN=375
 Power Train Repair—2 Speed

Reassembly
1. Install bearing (A) on reduction shaft (B) using a
hydraulic press. Press the bearing races tight against
the reduction shaft gear shoulder.
2. Install the reduction shaft and bearing into the case
from the front.

TCAL29526 —UN—09JUL12
A—Bearing B—Reduction Shaft

OUMX258,0000AC0 -19-15SEP14-23/49

3. Install the bottom snap ring (C) on the reduction shaft

from inside the case. Slide the reduction gear down
into position with the toothed collar (D) pointing up.

C—Snap Ring D—Toothed Collar

TCAL29527 —UN—09JUL12
OUMX258,0000AC0 -19-15SEP14-24/49

4. Install the upper snap ring (E) above the reduction gear.

E—Upper Snap Ring

TCAL29528 —UN—09JUL12

Continued on next page OUMX258,0000AC0 -19-15SEP14-25/49

TM130419 (24FEB16) 40-40-30 030916

PN=376
 Power Train Repair—2 Speed

5. Slide a bushing, a roller bearing and then a bushing

down on the shaft. Secure the first roller bearing
set with a C-ring (F). Install the second C-ring (G),
bushings (H) and roller bearing (I) on shaft.

F— C-Ring H—Bushing
G—C-Ring I— Roller Bearing

TCAL29529 —UN—09JUL12
OUMX258,0000AC0 -19-15SEP14-26/49

6. Install the shift collar (J) with recess to the bottom,

meshing it with the reduction gear.

J— Shift Collar

TCAL29530 —UN—09JUL12
OUMX258,0000AC0 -19-15SEP14-27/49

7. When installing the top bushing (K) on the reduction

shaft, use heavy grease to hold it in position. This is
necessary to prevent dislodging the bushing during
case assembly.

K—Top Bushing

TCAL29531 —UN—09JUL12

Continued on next page OUMX258,0000AC0 -19-15SEP14-28/49

TM130419 (24FEB16) 40-40-31 030916

PN=377
 Power Train Repair—2 Speed

8. Install the detent spring and ball (L) in the shift fork
(M). Assemble the shift fork, by pressing down on
the detent ball with a flat-end punch while sliding the
actuator arm (N) into the fork.

L— Detent Spring and Ball N—Actuator Arm

M—Shift Fork

TCAL29532 —UN—09JUL12
OUMX258,0000AC0 -19-15SEP14-29/49

9. Install the idler gears on the idler shaft. Note that

the shoulder (O) on the upper gear is mounted down
(away from bearing). Press bearing on both ends, so
that races are flush with the gear faces.

O—Upper Gear Shoulder

TCAL29533 —UN—09JUL12
OUMX258,0000AC0 -19-15SEP14-30/49

10. Install a new O-ring in the cover and install the 4-wheel
drive actuator shaft (P) in the case.
11. Lower the idler gear assembly (Q) and the shift fork
assembly (R) down into the case simultaneously. The
ears on the shift fork (S) must be meshed with the
shift collar (T) and the shift pin (U) must be fitted into
the actuator arm as the idler gear is positioned in the
case bore.
TCAL29534 —UN—09JUL12

P—4-Wheel Drive Actuator S—Shift Fork

Shaft T— Shift Collar
Q—Idler Gear Assembly U—Shift Pin
R—Shift Fork Assembly

Continued on next page OUMX258,0000AC0 -19-15SEP14-31/49

TM130419 (24FEB16) 40-40-32 030916

PN=378
 Power Train Repair—2 Speed

12. Install the outer bearing (V) on the output clutch gear
hub.
13. Install the clutch into the clutch housing with the
flange on the clutch (W) to the inside. Clutch should
free-wheel when rotated clockwise and lock when
rotated counter-clockwise.

V—Outer Bearing W—Clutch Flange

TCAL29535 —UN—09JUL12
OUMX258,0000AC0 -19-15SEP14-32/49

14. Install the clutch retention snap ring (X) in the clutch
hub.

X—Snap Ring

TCAL29536 —UN—09JUL12
OUMX258,0000AC0 -19-15SEP14-33/49

15. Install bearing (Y) on output clutch shaft assembly and

secure with snap ring.

Y—Bearing
TCAL29537 —UN—09JUL12

Continued on next page OUMX258,0000AC0 -19-15SEP14-34/49

TM130419 (24FEB16) 40-40-33 030916

PN=379
 Power Train Repair—2 Speed

16. Insert the output clutch shaft assembly (Z) into the
clutch hub, meshing with the clutch. Install the inner
bearing locator snap ring (aa).

Z— Output Clutch Shaft aa— Inner Bearing Locator

Assembly Snap Ring

TCAL29538 —UN—09JUL12
OUMX258,0000AC0 -19-15SEP14-35/49

17. Turn the clutch hub over and install the inner bearing
(ab) with a press. Press the bearing into the hub until
the outer race is flush with the top of the hub.

ab— Inner Bearing

TCAL29539 —UN—09JUL12
OUMX258,0000AC0 -19-15SEP14-36/49

18. Install snap ring (ac).

19. Press the outer bearing onto the output shaft until it is
flush with the inner clutch hub bearing.

ac— Snap Ring TCAL29540 —UN—09JUL12

Continued on next page OUMX258,0000AC0 -19-15SEP14-37/49

TM130419 (24FEB16) 40-40-34 030916

PN=380
 Power Train Repair—2 Speed

20. Turn the clutch hub over and install the needle bearing
(ad) into the output clutch shaft.

ad— Needle Bearing

TCAL29541 —UN—09JUL12
OUMX258,0000AC0 -19-15SEP14-38/49

21. Install the shifter gear (ae) and spacer (af) on the
high-low output shaft.

ae— Shifter Gear af— Spacer

TCAL29542 —UN—09JUL12
OUMX258,0000AC0 -19-15SEP14-39/49

22. Install the high low shaft assembly in the case from
the back. Install the locator ring on the outside of the
bearing. Turn the case over and press the bearing
(ag) and locator ring (ah) assembly onto the high-low

TCAL29543 —UN—09JUL12
shaft until the bearing is flush with the end of the shaft.

ag— Bearing ah— Locator Ring

Continued on next page OUMX258,0000AC0 -19-15SEP14-40/49

TM130419 (24FEB16) 40-40-35 030916

PN=381
 Power Train Repair—2 Speed

23. Turn over the case and block up securely in a press.

Support the inner bearing race with an appropriate
bearing collar (ai) and press the high-low input shaft
through the bearing until the bearing locator ring is
seated on the cases.

TCAL29544 —UN—09JUL12
ai— Bearing Collar

OUMX258,0000AC0 -19-15SEP14-41/49

24. Turn the case back over. Check that the snap ring
groove (aj) is fully accessible when the bushing (ak) is
installed on the high-low input shaft. Install the snap
ring (al).

aj— Snap Ring Groove al— Snap Ring

ak— Bushing

TCAL29545 —UN—09JUL12
OUMX258,0000AC0 -19-15SEP14-42/49

25. Install the spacer collar (am) over the high-low output
shaft with the recess facing down.
26. Rotate the input gear assembly to check that the
shifter gear does not contact the cases. If the gear
binds on the cases, the input shaft has been pressed
too deeply into the bearing.
TCAL29546 —UN—09JUL12
am—Spacer Collar

Continued on next page OUMX258,0000AC0 -19-15SEP14-43/49

TM130419 (24FEB16) 40-40-36 030916

PN=382
 Power Train Repair—2 Speed

27. Install a new O-ring (an) on the four-wheel drive

actuator arm (ao) and reinstall the arm in the front
case half.

an— O-Ring ao— Four-Wheel Drive

Actuator Arm

TCAL29547 —UN—09JUL12
OUMX258,0000AC0 -19-15SEP14-44/49

28. Apply grease to the clutch shoe and install it on the

actuator arm pin with the curve (ap) facing down.

ap— Actuator Arm Pin with

Curve Facing Down

TCAL29548 —UN—09JUL12
OUMX258,0000AC0 -19-15SEP14-45/49

29. Install a new gasket on the front case half and

reassemble the range unit cases. Turning the
high-low output shaft may help in meshing the splines
as the cases are reassembled. Fasten the cases
together with the six cap screws (aq) and tighten to
specifications.

TCAL29549 —UN—09JUL12
Specification
Center Section-to-
Housing Hex Socket and
Cap Screw—Torque......................................................................42 N·m
(31 lb.-ft.)

aq— Cap Screws (6 used)

Continued on next page OUMX258,0000AC0 -19-15SEP14-46/49

TM130419 (24FEB16) 40-40-37 030916

PN=383
 Power Train Repair—2 Speed

30. Secure the actuator shafts to the cases with cap

screws (ar), lock washers and straps (as).

ar— Cap Screws as— Lock Washers and Straps

TCAL29550 —UN—09JUL12
OUMX258,0000AC0 -19-15SEP14-47/49

31. Install the high-low and four-wheel drive actuator

levers on the range unit with the levers positioned to
the outside. Secure with roll pins (at).
32. Install the four-wheel drive output unit. (See Remove,
Inspect, and Assemble 4WD Drive Output Unit—2
Speed.)

at— Roll Pins

TCAL29551 —UN—09JUL12
OUMX258,0000AC0 -19-15SEP14-48/49

33. Install a new gasket on the mating surface (au) of the

two speed range case. Slide the range case onto the
mounting studs until against transaxle.
34. Tighten valves to specifications.
Specification
Make-Up Oil Check
Valve—Torque...............................................................................34 N·m
(25 lb.-ft.)
TCAL29552 —UN—09JUL12

Charge Pump Relief

Valve Torque—Torque...................................................................24 N·m
(212 lb.-in.)

au— Mating Surface

OUMX258,0000AC0 -19-15SEP14-49/49

TM130419 (24FEB16) 40-40-38 030916

PN=384
 Power Train Repair—2 Speed

Remove, Inspect, and Assemble 4WD Drive

Output Unit—2 Speed
IMPORTANT: Absolute cleanliness is essential
when working on hydraulic components.
Contamination can result in serious damage
or inadequate operation.

TCAL29553 —UN—09JUL12
DO NOT use shop towels or rags to dry
cleaned parts. Lint will clog passages in the
hydraulic/hydrostatic system and cause damage.

Disassembly/Inspection
1. Remove transaxle. (See Remove and Install
Transaxle—2 Speed.)
2. Separate hydrostatic assembly. (See Separate A—Cap Screws (6 used) B—Four Wheel Drive Actuator
and Install Hydrostatic Assembly and Differential Arm
Assembly—2 Speed.)
3. Remove two-speed range transaxle. (See Remove,
Inspect, and Install 2 Speed Range—2 Speed.)
NOTE: Use shop cloths or paper towels to immediately
catch and clean up any spilled oil. Close all
ports and lines using caps or plugs.

4. Remove six cap screws (A) holding the four-wheel

drive output unit to the transaxle and pull off cover.
OUMX258,0000AC1 -19-27FEB14-1/11

NOTE: Rotating the four wheel drive actuator arm (B)

forward will help in breaking the cover seal.

5. Remove the needle bearing (C) from the end of the

output shaft.

C—Needle Bearing

TCAL29554 —UN—09JUL12

Continued on next page OUMX258,0000AC1 -19-27FEB14-2/11

TM130419 (24FEB16) 40-40-39 030916

PN=385
 Power Train Repair—2 Speed

CAUTION: Detent balls are under tension. Use

caution when removing to prevent bodily injury.
Removing the clutch shifter gear will release
the detent balls and spring. Cover the unit with
a rag or perform this operation in a closed box

TCAL29555 —UN—09JUL12
to prevent loss of components.

6. Lever the clutch shifter gear (D) off the output shaft.

D—Clutch Shifter Gear

OUMX258,0000AC1 -19-27FEB14-3/11

7. Remove the bearing location snap ring from the cover.

TCAL29556 —UN—09JUL12
OUMX258,0000AC1 -19-27FEB14-4/11

8. Remove the output shaft and bearing from the cover

as a unit. Take care not to damage the cover seal
while removing the output shaft.

TCAL29557 —UN—09JUL12

Continued on next page OUMX258,0000AC1 -19-27FEB14-5/11

TM130419 (24FEB16) 40-40-40 030916

PN=386
 Power Train Repair—2 Speed

9. Inspect the seal (E) in the nose of the cover for signs
of damage or leakage. Press seal out of cover and
replace if necessary. Remove old sealing compound
from the cover and case, including the grooves (F) in
the cover. Prepare cover and case surface by cleaning
with TY16285 John Deere™ Clean and Cure Primer.
10. Inspect the bearing on the output shaft for signs of
damage, wear or rough movement. Replace bearing
as necessary. Inspect the output shaft and clutch
shifter gear splines and gear teeth. If damaged or
worn, replace unit as a set.

TCAL29558 —UN—09JUL12
E—Seal F— Grooves in Cover

John Deere is a trademark of Deere & Company

OUMX258,0000AC1 -19-27FEB14-6/11

Assembly
1. Apply grease to the lips of the cover seal and insert
the output shaft and bearing assembly through the
seal, seating the bearing in the cover.
2. Install the bearing location snap ring (G) in the cover.

G—Snap Ring

TCAL29559 —UN—09JUL12
Continued on next page OUMX258,0000AC1 -19-27FEB14-7/11

TM130419 (24FEB16) 40-40-41 030916

PN=387
 Power Train Repair—2 Speed

3. Grease the components thoroughly and insert the

detent spring with one ball on each side of the spring
into the bore (H) in the output shaft.

H—Bore

TCAL29560 —UN—09JUL12
OUMX258,0000AC1 -19-27FEB14-8/11

4. Squeeze the detent balls into the bore with large pliers
(I) while lowering the clutch shifter gear (J) down to
the detent recess.
5. Install the needle bearing on the output shaft.
6. Apply a bead of PM38655 John Deere™ Flexible
Form-in-Place Gasket to the cover sealing surface.

TCAL29561 —UN—09JUL12
I— Large Pliers J— Clutch Shifter Gear

John Deere is a trademark of Deere & Company

OUMX258,0000AC1 -19-27FEB14-9/11

7. Position the four-wheel drive actuator arm shift collar

(K) in a forward position. Position the shift collar in the
clutch shifter gear channel (L) as the output shaft is
meshed with the clutch shaft on the range transaxle.

K—Four-Wheel Drive Actuator L— Clutch Shifter Gear Channel

TCAL29562 —UN—09JUL12
Arm Shift Collar

Continued on next page OUMX258,0000AC1 -19-27FEB14-10/11

TM130419 (24FEB16) 40-40-42 030916

PN=388
 Power Train Repair—2 Speed

8. When the four-wheel drive unit has meshed correctly

with the range transaxle, install the six cap screws (M).

M—Cap Screws (6 used)

TCAL29563 —UN—09JUL12
OUMX258,0000AC1 -19-27FEB14-11/11

Disassemble, Inspect, and Assemble

Hydrostatic Assembly—2 Speed
IMPORTANT: Absolute cleanliness is essential
when working on hydraulic components.
Contamination can result in serious damage

TCAL29564 —UN—09JUL12
or inadequate operation.
DO NOT use shop towels or rags to dry
cleaned parts. Lint will clog passages in the
hydraulic/hydrostatic system and cause damage.

Disassemble and Inspect

1. Remove transaxle. (See Remove and Install
Transaxle—2 Speed.)
A—Hex Socket Screws (4 used) B—Transmission Center Plate
2. Separate hydrostatic assembly. (See Separate
and Install Hydrostatic Assembly and Differential
Assembly—2 Speed.)
IMPORTANT: Do not allow internal parts to fall free
3. Remove hydraulic pump. (See Remove, Disassemble, when removing center section.
Inspect, and Assemble Hydraulic Pump—2 Speed.)
Do not nick or scratch lapped or machined
NOTE: Use shop cloths or paper towels to immediately surfaces of the center section, valve plates,
catch and clean up any spilled oil. Close all or cylinder blocks and pistons.
ports and lines using caps or plugs.
6. Carefully separate center section (B) from housing.
4. Remove hydrostatic sub plate. (See Disassemble, Take care not to let the gasket get hung up on the
Inspect, and Assemble Charge Pump—2 Speed.) guide pins. You may have to gently pry it off.
5. Remove four hex socket screws (A) holding the
transmission center plate (B) to the transmission
center housing.
Continued on next page OUMX258,0000AC2 -19-15SEP14-1/47

TM130419 (24FEB16) 40-40-43 030916

PN=389
 Power Train Repair—2 Speed

NOTE: If valve plates do not come off with center section,

remove valve plates from cylinder block assemblies.
It may be necessary to apply diesel fuel between
valve plates and cylinder blocks to cut oil film.

7. Remove motor valve plate (C) and pump valve plate

TCAL29565 —UN—09JUL12
(D). If valve plates stick to the center section, it may
be necessary to pry valve plates loose from the center
section. Use a wooden dowel and pry only at dowel
pin grooves (E).

C—Motor Valve Plate E—Dowel Pin Grooves

D—Pump Valve Plate

OUMX258,0000AC2 -19-15SEP14-2/47

NOTE: Scoring is indicated by fine scratches or grooves

cut into the smooth plated surface of the valve
plate. Use a close visual inspection with a
magnifying glass, or feel with your fingertips,
fingernail, or a sharpened lead pencil.
If scratches or grooves are detected, the
plate must be replaced.

TCAL29566 —UN—09JUL12
8. Inspect valve plates. Valve plates should be flat, free
of all nicks, burrs, scratches, and erosion around
the ports. The plated side should show no scoring,
smearing, or discoloration (a sign of overheating).

OUMX258,0000AC2 -19-15SEP14-3/47

9. Inspect strainer screen (F). Clean screen or replace

if damaged.
10. Inspect both bearings (G) in the center section.
Replace if necessary. Remove bearing using a
two-jaw, slide-hammer puller.

TCAL29567 —UN—09JUL12
F— Strainer Screen G—Bearings

Continued on next page OUMX258,0000AC2 -19-15SEP14-4/47

TM130419 (24FEB16) 40-40-44 030916

PN=390
 Power Train Repair—2 Speed

11. Remove make-up oil valves (H) and charge pressure

relief valve (J).

TCAL29568 —UN—09JUL12
NOTE: Forward and reverse valves are different
and cannot be interchanged.

12. Mark forward valve (I) and reverse valve (K) for proper
placement during reassembly. Remove forward and
reverse relief valves.

H—Make-Up Valves I— Forward Valve

J— Charge Pressure Relief K—Reverse Valve
Valve

OUMX258,0000AC2 -19-15SEP14-5/47

13. The reverse valve can be identified by a small orifice in

TCAL29569 —UN—09JUL12
internal part of valve (arrow). Internal valve may have
to be rotated with a soft piece of wire to observe orifice.

OUMX258,0000AC2 -19-15SEP14-6/47

14. Inspect valves (L) and seats for damage. Valves must
slide freely in their bores. Valve seals must not be cut
or damaged. Replace valves as necessary. Tighten

TCAL29570 —UN—09JUL12
valves to specification.
Specification
Forward and Reverse
Relief Valves—Torque...................................................................34 N·m
(25 lb.-ft.)

L— Valves

OUMX258,0000AC2 -19-15SEP14-7/47

15. Remove PTO supply tube (M).

M—PTO Supply Tube

TCAL29571 —UN—09JUL12

Continued on next page OUMX258,0000AC2 -19-15SEP14-8/47

TM130419 (24FEB16) 40-40-45 030916

PN=391
 Power Train Repair—2 Speed

IMPORTANT: Do not nick or scratch lapped

surface of cylinder blocks.

16. Reach in to grab pump assembly piston retainer rim

(O) to ensure none of the pistons slip out of the cylinder
block as you remove assembly from the pump shaft.

TCAL29572 —UN—09JUL12
17. In the same manner, reach in to grab motor assembly
piston retainer rim (N) and remove assembly from the
motor shaft.

N—Motor Assembly Piston O—Pump Assembly Piston

Retainer Rim Retainer Rim

OUMX258,0000AC2 -19-15SEP14-9/47

NOTE: Piston-to-bore relationship need not be maintained.

Pistons and cylinder blocks are not matched sets.

18. Inspect cylinder block assemblies.

• Lift piston retainer and pistons from cylinder block.
• Check for free movement of pistons in cylinder bores

TCAL29573 —UN—09JUL12
as you remove them.
• If any dragging is detected, replace entire cylinder
block assembly.

OUMX258,0000AC2 -19-15SEP14-10/47

19. Remove and inspect all pistons.

• Check barrel (R) for scoring, discoloration, or any
signs of separation of slippers.
• Check slipper (P) for scoring, smearing, rolled

TCAL29574 —UN—09JUL12
edges, and a full 360° free rotation on barrel.
• Check lubrication hole (Q) for blockage. Clean with
compressed air.
• If any component of the piston is damaged, replace
the entire cylinder block assembly.

P—Slipper R—Barrel
Q—Lubrication Hole

Continued on next page OUMX258,0000AC2 -19-15SEP14-11/47

TM130419 (24FEB16) 40-40-46 030916

PN=392
 Power Train Repair—2 Speed

20. Remove and inspect both piston retainers.

• Check retainer (S) for flatness, nicks, burrs, and
discoloration or scoring.
• If any part of the piston retainer is damaged, replace

TCAL29575 —UN—09JUL12
the entire cylinder block assembly.

S—Piston Retainer

OUMX258,0000AC2 -19-15SEP14-12/47

21. Check cylinder blocks.

• Check ball guide area (T) for scoring, wear, and
damage.
• Check nine cylinder bores (U) for burns and scoring.
T— Ball Guide Area U—Cylinder Bores

TCAL29576 —UN—09JUL12
OUMX258,0000AC2 -19-15SEP14-13/47

22. Inspect both cylinder blocks.

• Check lapped surface (V) for wear and damage.
• Check spring assembly (W) for damage and free
axle movement.
• If any part of the cylinder block is damaged, replace
the entire cylinder block assembly.

TCAL29577 —UN—09JUL12
V—Lapped Surface W—Spring Assembly

Continued on next page OUMX258,0000AC2 -19-15SEP14-14/47

TM130419 (24FEB16) 40-40-47 030916

PN=393
 Power Train Repair—2 Speed

23. Remove return spring assembly (X). Inspect plunger

for excessive tip wear and that plunger does not bind.
If plunger binds or has excessive tip wear, replace
return spring assembly.
24. Remove locknut and washer (Y).
25. Remove cap screw and washer (Z) and arm (AA).
26. Remove seven cap screws (AB).

TCAL29578 —UN—09JUL12
IMPORTANT: Control cover has centering pins
and may stick to them. If gentle prying
of cover is required, pry under cover, not
under plate below cover.

27. Carefully remove control cover (AC) while pushing

neutral adjust screw (AD) down through cover.

X—Return Spring Assembly AB—Cap Screws (7 used)

Y—Locknut and Washer AC—Control Cover
Z— Cap Screw and Washer AD—Neutral Adjust Screw
AA—Arm

OUMX258,0000AC2 -19-15SEP14-15/47

28. Remove neutral adjust screw (AE) and washer (AF).

CAUTION: Neutral centering spring is under

tension. Use caution when removing to
prevent bodily injury.

TCAL29579 —UN—09JUL12
29. Carefully pry neutral centering spring (AG) over top of
centering pin (AH). Remove spring.

AE—Neutral Adjust Screw AG—Neutral Centering Spring

AF—Washer AH—Centering Spring

OUMX258,0000AC2 -19-15SEP14-16/47

30. Remove upper support plate (AI).

31. Inspect swash plate bearing (AJ) for excessive wear
or scoring. Replace if necessary.

AI— Upper Support Plate AJ—Swash Plate Bearing

TCAL29580 —UN—09JUL12

Continued on next page OUMX258,0000AC2 -19-15SEP14-17/47

TM130419 (24FEB16) 40-40-48 030916

PN=394
 Power Train Repair—2 Speed

32. Remove snap ring (AK).

33. Remove seal (AL) by prying out. Remove seal spacer.

AK—Snap Ring AL—Seal

TCAL29581 —UN—09JUL12
OUMX258,0000AC2 -19-15SEP14-18/47

34. Remove snap ring (AM).

AM—Snap Ring

TCAL29582 —UN—09JUL12
OUMX258,0000AC2 -19-15SEP14-19/47

NOTE: Pump shaft rear bearing will be removed with shaft.

PTO drive gear will remain in housing until
swash plate is removed.
Swash plate thrust washer and shim location and
direction must be noted for reassembly.

35. Remove snap ring (AN). TCAL29583 —UN—09JUL12

36. Using a plastic hammer, gently tap pump shaft (AO)

out rear of housing and PTO drive gear.

AN—Snap Ring AO—Pump Shaft

Continued on next page OUMX258,0000AC2 -19-15SEP14-20/47

TM130419 (24FEB16) 40-40-49 030916

PN=395
 Power Train Repair—2 Speed

37. Carefully lift swash plate (AP) while retaining lower

thrust washer (AQ) to bottom of swash plate. Remove
swash plate from housing.

TCAL29584 —UN—09JUL12
38. Remove PTO drive gear from housing.
39. Note direction and location of upper shim (AR), upper
thrust washer (AS), and lower thrust washer (AQ) and
remove from swash plate.
40. Inspect thrust washers and shim for scoring or
damage. If scoring or damage is detected, replace
thrust washers and shim.
41. Remove thrust plate (AT) from swash plate using a AP—Swash Plate AS—Upper Thrust Washer
brass O-ring pick. AQ—Lower Thrust Plate AT— Thrust Plate
AR—Upper Shim
42. Inspect thrust plate for scoring or smeared plated
material. If scoring or smearing is detected, replace
thrust plate.
43. Inspect all machined surfaces of swash plate for
scoring or damage. If scoring or damage is detected,
replace swash plate.
OUMX258,0000AC2 -19-15SEP14-21/47

44. Remove motor shaft rear bearing retaining snap ring

(AU).

AU—Snap Ring

TCAL29585 —UN—09JUL12
OUMX258,0000AC2 -19-15SEP14-22/47

NOTE: Motor shaft rear bearing will be removed

with motor shaft.

45. Using a plastic hammer, gently tap motor shaft and

bearing (AV) out rear of housing.
TCAL29586 —UN—09JUL12

AV—Motor Shaft and Bearing

Continued on next page OUMX258,0000AC2 -19-15SEP14-23/47

TM130419 (24FEB16) 40-40-50 030916

PN=396
 Power Train Repair—2 Speed

46. Remove motor thrust plate (AW) using a brass O-ring

pick.
47. Inspect lower swash plate bearing (AX) for excessive
wear or scoring.
48. If excessive wear or scoring is detected, remove snap
ring (AY) and cap seal (AZ) and replace lower swash
plate bearing.

TCAL29587 —UN—09JUL12
AW—Motor Thrust Plate AY—Snap Ring
AX—Lower Swash Plate AZ—Cap Seal
Bearing

OUMX258,0000AC2 -19-15SEP14-24/47

49. Inspect input shaft (BA) and motor shaft (BB) bearings.
Replace as necessary.
50. If repairing or inspecting PTO, (See Disassemble,
Inspect, and Assemble PTO—2 Speed.)
51. If repairing or inspecting 4WD gear case, (See
Disassemble, Inspect, and Assemble 4WD Axle—2
Speed.)
52. Remove all gaskets and clean all gasket surfaces.

BA—Input Shaft Bearing BB—Motor Shaft Bearing

TCAL29588 —UN—09JUL12
OUMX258,0000AC2 -19-15SEP14-25/47

Assembly
1. Clean and dry all parts.
NOTE: Apply clean hydrostatic oil to all parts
when assembling.
TCAL29589 —UN—09JUL12

2. If lower swash plate bearing was replaced, install new

cap seal (A) and install snap ring (B).

A—Cap Seal B—Snap Ring

Continued on next page OUMX258,0000AC2 -19-15SEP14-26/47

TM130419 (24FEB16) 40-40-51 030916

PN=397
 Power Train Repair—2 Speed

3. Install PTO drive gear (C) into housing with shoulder

(D) facing rear of housing.

C—PTO Drive Gear D—PTO Drive Gear Shoulder

Location

TCAL29590 —UN—09JUL12
TCAL29591 —UN—09JUL12
OUMX258,0000AC2 -19-15SEP14-27/47

NOTE: Swash plate thrust washers must be installed

with flat edge facing center of swash plate.

4. Install thrust washers (E) onto swash plate (F) with flat
edge facing center of swash plate.
5. Install shims (G) onto swash plate.

E—Thrust Washers G—Shims

F— Swash Plate

TCAL29592 —UN—09JUL12

Continued on next page OUMX258,0000AC2 -19-15SEP14-28/47

TM130419 (24FEB16) 40-40-52 030916

PN=398
 Power Train Repair—2 Speed

6. Install swash plate (H) with thrust washers and shims

into housing.

H—Swash Plate

TCAL29593 —UN—09JUL12
OUMX258,0000AC2 -19-15SEP14-29/47

NOTE: Top cover is being temporarily installed to set

swash plate end play. Parts normally contained
inside of top cover need not be installed at this point.

7. Install upper support plate (I) and top cover (J) with
gaskets (K) using seven cap screws (L).

I— Upper Support Plate K—Gaskets

J— Top Cover L— Cap Screws (7 used)

TCAL29594 —UN—09JUL12
OUMX258,0000AC2 -19-15SEP14-30/47

8. Check swash plate end play between bottom of

support plate and top of shim. End play must be within
specification.
Specification
Swash Plate—End Play....................................................0.20—050 mm
(0.007—0.19 in.)

9. If end play is not within specification, remove top

cover, support plate, and gaskets.
TCAL29595 —UN—09JUL12

10. Add or subtract shims from top of swash plate to

obtain specification.
11. Reinstall support plate, top cover, and gaskets. Check
end play again.
12. Repeat steps 9—11 until correct specification is
obtained.
13. Temporarily, remove top cover and gasket only.
Continued on next page OUMX258,0000AC2 -19-15SEP14-31/47

TM130419 (24FEB16) 40-40-53 030916

PN=399
 Power Train Repair—2 Speed

14. Install motor shaft (M) into housing.

M—Motor Shaft

TCAL29596 —UN—09JUL12
OUMX258,0000AC2 -19-15SEP14-32/47

15. Carefully install pump shaft (N) through PTO drive

gear (O) and into housing.

N—Pump Shaft O—PTO Drive Gear

TCAL29597 —UN—09JUL12
OUMX258,0000AC2 -19-15SEP14-33/47

16. Install pump shaft bearing snap ring (P).

P—Pump Shaft Bearing Snap

Ring

TCAL29598 —UN—09JUL12

Continued on next page OUMX258,0000AC2 -19-15SEP14-34/47

TM130419 (24FEB16) 40-40-54 030916

PN=400
 Power Train Repair—2 Speed

17. Install seal spacer.

TCAL29599 —UN—09JUL12
OUMX258,0000AC2 -19-15SEP14-35/47

18. Install new pump shaft seal (Q) flush against spacer.
Secure using snap ring (R).

Q—Pump Shaft Seal R—Snap Ring

TCAL29600 —UN—09JUL12
OUMX258,0000AC2 -19-15SEP14-36/47

19. Install motor shaft bearing snap ring (S).

S—Snap Ring

TCAL29601 —UN—09JUL12

Continued on next page OUMX258,0000AC2 -19-15SEP14-37/47

TM130419 (24FEB16) 40-40-55 030916

PN=401
 Power Train Repair—2 Speed

NOTE: Do not scratch machined surfaces of thrust plates

or swash plates when installing components.

20. Install PTO drive gear snap ring (T).

21. Install motor thrust plate (U) and pump thrust plate (V).

TCAL29602 —UN—09JUL12
T— PTO Drive Gear Snap Ring V—Pump Thrust Plate
U—Motor Thrust Plate

OUMX258,0000AC2 -19-15SEP14-38/47

CAUTION: Installing centering spring will put

it under tension. Use caution when installing
to prevent bodily injury.

22. Install neutral centering spring (W) with flat arm (X)
down and to the rear of centering pin (Y).

W—Neutral Centering Spring Y—Centering Pin

TCAL29603 —UN—09JUL12
X—Flat Arm

OUMX258,0000AC2 -19-15SEP14-39/47

23. Carefully pry bent arm (Z) up and forward over the
top of centering pin.
24. Install washer (AA).
25. Replace O-ring (AB) on neutral adjust screw (AC).
26. Install neutral adjust screw between arms of neutral
centering spring. TCAL29604 —UN—09JUL12

27. Rotate neutral adjust screw until adjusting cam (AD)

faces centering pin.

Z— Arm AC—Neutral Adjust Screw

AA—Washer AD—Adjusting Cam
AB—O-Ring

Continued on next page OUMX258,0000AC2 -19-15SEP14-40/47

TM130419 (24FEB16) 40-40-56 030916

PN=402
 Power Train Repair—2 Speed

28. Replace upper swash plate seal (AE). Install with face
of seal against snap ring (AF).

AE—Upper Swash Plate Seal AF—Snap Ring

TCAL29605 —UN—09JUL12
OUMX258,0000AC2 -19-15SEP14-41/47

29. Install cover (AG) using seven cap screws (AH).

30. Install washer and nut (AI).
31. Install return spring assembly (AJ).
32. Install arm (AK) using cap screw and washer (AL).

AG—Cover AJ—Return Spring Assembly

AH—Cap Screws (7 used) AK—Arm

TCAL29606 —UN—09JUL12
AI— Washer and Nut AL—Cap Screw and Washer

OUMX258,0000AC2 -19-15SEP14-42/47

IMPORTANT: Do not nick or scratch lapped

surface of cylinder blocks.
Piston to cylinder block relationship is not
unit specific. A matched piston-to-bore
relationship need not be maintained.

33. Install pistons into piston retainer, then into cylinder TCAL29607 —UN—09JUL12
block.
34. Lift piston retainer and pistons from cylinder block two
or three times to check for free movement of pistons
in cylinder block before installing the assembly into
the housing.

Continued on next page OUMX258,0000AC2 -19-15SEP14-43/47

TM130419 (24FEB16) 40-40-57 030916

PN=403
 Power Train Repair—2 Speed

35. Install pump (AM) and motor (AN) cylinder blocks.

Hold onto the retainer rim to ensure pistons remain in
their bores.
36. Install new O-rings on PTO supply tube (AO) and
install tube into housing.
37. Put clean hydrostatic oil on valve plates and housing
surfaces.

TCAL29608 —UN—09JUL12
AM—Pump Cylinder Block AO—PTO Supply Tube
AN—Motor Cylibder Block

OUMX258,0000AC2 -19-15SEP14-44/47

IMPORTANT: Use extreme care when assembling

the center section, valve plates, and cylinder
blocks to avoid dropping, nicking, or
scratching lapped surfaces.
Pump valve plate has two slotted ports.

TCAL29609 —UN—09JUL12
Motor valve plate has no slotted ports.

38. Align slots on back sides of plates with pins (AP) in

center section and install pump valve plate (AQ), with
slotted ports (AR), and motor valve plate (AS) over
their respective protruding bearings.
39. Install new center section to housing gasket onto
housing.
AP—Pins AR—Slotted Ports
AQ—Pump Valve Plate AS—Motor Valve Plate

OUMX258,0000AC2 -19-15SEP14-45/47

40. Align bearings of center section with pump and motor

shafts (AT). Slide center section on shafts until valve
plates contact cylinder blocks.
IMPORTANT: Check for proper internal assembly
by slowly rotating pump and motor shafts
TCAL29610 —UN—09JUL12

while tightening cap screws.

41. Apply pressure to center section and install two socket

head screws (AU) to hold center section in place.

AT— Pump and Motor Shafts AU—Socket Head Screws (2

Used)

Continued on next page OUMX258,0000AC2 -19-15SEP14-46/47

TM130419 (24FEB16) 40-40-58 030916

PN=404
 Power Train Repair—2 Speed

NOTE: Center section will seem springy. This is

because the springs inside the cylinder blocks
are being compressed.

42. Install two remaining hex socket screws (AV). Tighten

all four hex socket screws evenly in a crossing pattern
until they are snug. Do not tighten to specification at
this time.
43. Check that both pump and motor shafts turn without
any binding or roughness.

TCAL29611 —UN—09JUL12
44. Tighten four hex socket screws to specification.
Specification
Center Section-
to-Housing Hex
Socket—Torque.............................................................................42 N·m
(31 lb.-ft.)

45. Install new gasket to hydrostatic assembly.

46. Install hydrostatic assembly to differential assembly. AV—Hex Socket Screws
(See Separate and Install Hydrostatic Assembly and
Differential Assembly—2 Speed.)
Charge Relief
47. Tighten valves to specifications. Valve—Torque...............................................................................24 N·m
(212 lb.-in.)
Specification
Make-Up Oil Check
Valve—Torque...............................................................................34 N·m
(25 lb.-ft.)
OUMX258,0000AC2 -19-15SEP14-47/47

Disassemble, Inspect, and Assemble

Differential—2 Speed
Special or Required Tools

• Hoist
• Knife-Edge Puller
• 50.8 mm (2 in.) ID Pipe
• Punch

TCAL29612 —UN—09JUL12
• Snap Ring Removal Tool¹ 1
• Snap Ring Installation Tool
• Press
IMPORTANT: Absolute cleanliness is essential
when working on hydraulic components.
Contamination can result in serious damage
or inadequate operation.
DO NOT use shop towels or rags to dry
cleaned parts. Lint will clog passages in the A—Drain Plugs (4 used) C—Hose
hydraulic/hydrostatic system and cause damage. B—Oil Filter

Disassemble Axle Shaft Housing

2. Remove four drain plugs (A) and drain all oil from
1. Separate hydrostatic assembly from differential hydrostatic unit.
assembly. (See Separate and Install Hydrostatic
Assembly and Differential Assembly—2 Speed.) 3. Remove oil filter (B) and hose (C).
1
1. For instructions on making tool, see Fabricated Tools. in this section.
Continued on next page OUMX258,0000AC3 -19-15SEP14-1/57

TM130419 (24FEB16) 40-40-59 PN=405

030916
 Power Train Repair—2 Speed

NOTE: This disassembly procedure is for the right axle

shaft housing. The procedure for the left side is
similar, but some parts are not interchangeable,
left to right for example. Do not mix parts
from the left or right sides.

4. Remove the nine cap screws (D) holding the right axle
shaft housing to the differential.
5. Remove the axle shaft housing using a hoist.

TCAL29613 —UN—09JUL12
D—Cap Screws (9 used)

OUMX258,0000AC3 -19-15SEP14-2/57

6. Note the location of the thrust washer (E) that fits in

the cam bearing bore in the axle case.

E—Thrust Washer

TCAL29614 —UN—09JUL12
Continued on next page OUMX258,0000AC3 -19-15SEP14-3/57

TM130419 (24FEB16) 40-40-60 030916

PN=406
 Power Train Repair—2 Speed

7. Remove snap ring (F).

F— Snap Ring

TCAL29615 —UN—09JUL12
OUMX258,0000AC3 -19-15SEP14-4/57

8. Remove the three brake disks (G) and three brake

separator plates (H). Note the “S” mark (I) on the
separator plates that designates the outside of the
plate.

G—Brake Disks (3 used) I— “S” Mark on Separator

H—Brake Separator Plates (3 Plates
used)

TCAL29616 —UN—09JUL12
OUMX258,0000AC3 -19-15SEP14-5/57

9. Remove snap ring (J) and flat washer (K) from brake
camshaft (L).
10. Remove brake camshaft (L).

J— Snap Ring L— Brake Camshaft

K—Flat Washer
TCAL29617 —UN—09JUL12

Continued on next page OUMX258,0000AC3 -19-15SEP14-6/57

TM130419 (24FEB16) 40-40-61 030916

PN=407
 Power Train Repair—2 Speed

11. Remove bushing (M).

M—Bushing

TCAL29618 —UN—09JUL12
OUMX258,0000AC3 -19-15SEP14-7/57

12. Turn axle shaft housing over and remove oil seal (N).

N—Oil Seal

TCAL29619 —UN—09JUL12
OUMX258,0000AC3 -19-15SEP14-8/57

13. The left axle housing has an extra support hanger (O)
for the camshaft arm with a bushing (P) and seals (Q).
If the bushing requires replacement, remove the seals
to access the bushing.
14. Remove oil seals (Q) and bushing (P).

TCAL29620 —UN—09JUL12
O—Support Hanger Q—Oil Seals
P—Bushing

Continued on next page OUMX258,0000AC3 -19-15SEP14-9/57

TM130419 (24FEB16) 40-40-62 030916

PN=408
 Power Train Repair—2 Speed

15. Remove four cap screws (R).

R—Cap Screws (4 used)

TCAL29621 —UN—09JUL12
OUMX258,0000AC3 -19-15SEP14-10/57

16. Drive the axle (S) out of the housing using a soft-faced
hammer.

S—Axle

TCAL29622 —UN—09JUL12
OUMX258,0000AC3 -19-15SEP14-11/57

17. Remove snap ring (T) and spacer (U).

T— Snap Ring U—Spacer

TCAL29623 —UN—09JUL12

Continued on next page OUMX258,0000AC3 -19-15SEP14-12/57

TM130419 (24FEB16) 40-40-63 030916

PN=409
 Power Train Repair—2 Speed

18. Remove bearing (V) from axle using a knife-edge

puller.

V—Bearing

TCAL29624 —UN—09JUL12
OUMX258,0000AC3 -19-15SEP14-13/57

19. Remove axle seal housing (W) from axle shaft.

W—Axle Seal Housing

TCAL29625 —UN—09JUL12
OUMX258,0000AC3 -19-15SEP14-14/57

20. Remove oil seal (X) and O-ring (Y).

X—Oil Seal Y—O-Ring

TCAL29626 —UN—09JUL12

Continued on next page OUMX258,0000AC3 -19-15SEP14-15/57

TM130419 (24FEB16) 40-40-64 030916

PN=410
 Power Train Repair—2 Speed

21. Inspect sleeve (Z) for wear or damage. Remove the

sleeve using a knife-edge puller if replacement is
required.
22. Inspect all parts for wear or damage. Replace parts
as needed.

TCAL29627 —UN—09JUL12
Z— Sleeve

OUMX258,0000AC3 -19-15SEP14-16/57

Axle Shaft Housing Assembly

1. Install new sleeve (A) on axle shaft (if needed). Press
sleeve into place using a length of pipe (B) with an
inside diameter of 50.8 mm (2 in.).

A—Sleeve B—Pipe with Inside Diameter

of 50.8 mm (2 in.)

TCAL29628 —UN—09JUL12
OUMX258,0000AC3 -19-15SEP14-17/57

2. Install new axle oil seal (C) and O-ring (D).

C—Axle Oil Seal D—O-Ring

TCAL29629 —UN—09JUL12

Continued on next page OUMX258,0000AC3 -19-15SEP14-18/57

TM130419 (24FEB16) 40-40-65 030916

PN=411
 Power Train Repair—2 Speed

3. Install axle seal housing (E) onto axle.

E—Axle Seal Housing

TCAL29630 —UN—09JUL12
OUMX258,0000AC3 -19-15SEP14-19/57

IMPORTANT: Press on inner race only to avoid

damaging bearing.

4. Install bearing (F) into axle. Press the bearing into

place using a length of pipe (G) with an inside diameter
of 50.8 mm (2 in.).

TCAL29631 —UN—09JUL12
F— Bearing G—Pipe

OUMX258,0000AC3 -19-15SEP14-20/57

5. Install spacer (H) and snap ring (I).

H—Spacer I— Snap Ring

TCAL29632 —UN—09JUL12

Continued on next page OUMX258,0000AC3 -19-15SEP14-21/57

TM130419 (24FEB16) 40-40-66 030916

PN=412
 Power Train Repair—2 Speed

6. Install axle into housing until bearing bottoms against

axle housing.
7. Install seal housing (J) into axle housing. Install four
cap screws (K). Tighten to specification.

J— Seal Housing K—Cap Screws (4 used)

TCAL29633 —UN—09JUL12
OUMX258,0000AC3 -19-15SEP14-22/57

8. Install new brake camshaft oil seal (L) using

appropriate seal driver.
NOTE: Note left axle shaft housing with extra cam
shaft support hanger is shown.

TCAL29634 —UN—09JUL12
9. If bushing and seals were removed from cam shaft
support hanger, install new bushing (M) and oil seals
(N).

L— Oil Seal N—Oil Seals

M—Bushing

OUMX258,0000AC3 -19-15SEP14-23/57

10. Install bushing (O) and flat washer (P).

O—Bushing P—Flat Washer

TCAL29635 —UN—09JUL12

Continued on next page OUMX258,0000AC3 -19-15SEP14-24/57

TM130419 (24FEB16) 40-40-67 030916

PN=413
 Power Train Repair—2 Speed

11. Install brake camshaft (Q) and snap ring (R).

Q—Brake Camshaft R—Snap Ring

TCAL29636 —UN—09JUL12
OUMX258,0000AC3 -19-15SEP14-25/57

12. Install three brake separator plates (S) and brake disks
(T). Note that the “S” marking (U) on the separator
plates should face out.

S—Brake Separator Plates U—“S” Marking on Separator

T— Brake Disks Plates

TCAL29637 —UN—09JUL12
OUMX258,0000AC3 -19-15SEP14-26/57

13. Install snap ring (V).

V—Snap Ring

TCAL29638 —UN—09JUL12

Continued on next page OUMX258,0000AC3 -19-15SEP14-27/57

TM130419 (24FEB16) 40-40-68 030916

PN=414
 Power Train Repair—2 Speed

14. Apply paper gasket between differential and axle

housing. Apply sufficient grease to hold the camshaft
thrust washer (W) in place and position it in the case
bore (X).

W—Camshaft Thrust Washer X—Case Bore

TCAL29639 —UN—09JUL12
OUMX258,0000AC3 -19-15SEP14-28/57

15. Using a hoist, position axle housing on differential.

Install two M10 x 60 cap screws (Y) and seven M10 x
45 cap screws (Z). Tighten to specification.

Y—M10 x 60 Cap Screws (2 Z— M10 x 45 Cap Screws (7

used) used)

TCAL29640 —UN—09JUL12
OUMX258,0000AC3 -19-15SEP14-29/57

Disassemble and Inspect Differential

1. Remove both axle shaft housings. (See Disassembly
of Axle Shaft Housing within this Group.)
2. Remove cap screws and washers (A).
TCAL29641 —UN—09JUL12

3. Remove brake actuator disk (B).

A—Cap Screws and Washers B—Brake Actuator Disk

Continued on next page OUMX258,0000AC3 -19-15SEP14-30/57

TM130419 (24FEB16) 40-40-69 030916

PN=415
 Power Train Repair—2 Speed

4. Remove six brake actuator balls (C).

5. Repeat steps 2-4 on opposite side.

C—Brake Actuator Balls (6

used)

TCAL29642 —UN—09JUL12
OUMX258,0000AC3 -19-15SEP14-31/57

6. Remove nine M8 x 35 cap screws (D).

7. Remove differential side cover (E).

D—M8 x 35 Cap Screws E—Differential Side Cover

TCAL29643 —UN—09JUL12
OUMX258,0000AC3 -19-15SEP14-32/57

8. Remove oil return tube (F), dipstick (G), and washer

(H).
9. Lift out idler gear shaft (I).
10. Lift out differential lock fork (J) and differential
assembly (K) as one assembly.

F— Oil Return Tube I— Idler Gear Shaft

G—Dipstick J— Differential Lock Fork
H—Washer K—Differential Assembly
TCAL29644 —UN—09JUL12

Continued on next page OUMX258,0000AC3 -19-15SEP14-33/57

TM130419 (24FEB16) 40-40-70 030916

PN=416
 Power Train Repair—2 Speed

11. Remove differential lock shaft seal (L).

L— Differential Lock Shaft Seal

TCAL29645 —UN—09JUL12
OUMX258,0000AC3 -19-15SEP14-34/57

12. Remove ten cap screws (M).

13. Remove ring gear (N).

M—Cap Screws (10 used) N—Ring Gear

TCAL29646 —UN—09JUL12
OUMX258,0000AC3 -19-15SEP14-35/57

14. Using a knife-edge puller, remove bearings (O).

15. Remove shift collar (P).

O—Bearing P—Shift Collar

TCAL29647 —UN—09JUL12

Continued on next page OUMX258,0000AC3 -19-15SEP14-36/57

TM130419 (24FEB16) 40-40-71 030916

PN=417
 Power Train Repair—2 Speed

16. Using a punch, drive spring pin (Q) from the pinion
cross shaft.

Q—Drive Spring Pin

TCAL29648 —UN—09JUL12
OUMX258,0000AC3 -19-15SEP14-37/57

17. Remove pinion cross shaft (R), bevel washers (S),

pinion gears (T), right side gear (U), left side gear (V),
and flat thrust washers (W) from differential housing
(X).
18. Inspect parts for wear or damage. Replace as needed.

R—Pinion Cross Shaft V—Left Side Gear

S—Bevel Washers W—Flat Thrust Washers
T— Pinion Gears X—Differential Housing
U—Right Side Gear

TCAL29649 —UN—09JUL12
OUMX258,0000AC3 -19-15SEP14-38/57

Disassemble and Assemble Differential Lock Lever

NOTE: The differential lock lever assembly does not
have to be disassembled unless repair is required.
Inspect components for wear or damage.

1. Compress spring (A) using snap ring removal tool (B).1 TCAL29650 —UN—09JUL12

2. Remove snap ring (C) from its groove while spring

is compressed.

A—Spring C—Snap Ring

B—Snap Ring Removal Tool

1
1. Snap ring removal tool is a fabricated tool. For instructions to
make tool, see Fabricated Tools in this section.
Continued on next page OUMX258,0000AC3 -19-15SEP14-39/57

TM130419 (24FEB16) 40-40-72 030916

PN=418
 Power Train Repair—2 Speed

3. Remove washer (D), spring (E), fork (F), and spring

pins (G) if replacement is required.

D—Washer F— Fork
E—Spring G—Spring Pins

TCAL29651 —UN—09JUL12
OUMX258,0000AC3 -19-15SEP14-40/57

4. Slide snap ring (H) on shaft.

5. Using snap ring installation tool (I), compress spring
(J) until snap ring locks in its groove.1

H—Snap Ring J— Spring

I— Snap Ring Installation Tool

TCAL29652 —UN—09JUL12
1
1. Snap ring installation tool is a fabricated tool. For instructions
to make tool, see Fabricated Tools in this section.
OUMX258,0000AC3 -19-15SEP14-41/57

Disassembl, Inspect Idler Shaft

1. Remove bearing (A) using a knife-edge puller.

A—Bearing

TCAL29653 —UN—09JUL12

Continued on next page OUMX258,0000AC3 -19-15SEP14-42/57

TM130419 (24FEB16) 40-40-73 030916

PN=419
 Power Train Repair—2 Speed

2. Remove bearing (B) using a knife-edge puller.

B—Bearing

TCAL29654 —UN—09JUL12
OUMX258,0000AC3 -19-15SEP14-43/57

3. Remove ring gear (C) from idler shaft (D).

C—Ring Gear D—Ider Shaft

TCAL29655 —UN—09JUL12
OUMX258,0000AC3 -19-15SEP14-44/57

Idler Shaft Assembly

1. Install ring gear (A) onto idler shaft (B).

A—Ring Gear B—Idler Shaft

TCAL29656 —UN—09JUL12

Continued on next page OUMX258,0000AC3 -19-15SEP14-45/57

TM130419 (24FEB16) 40-40-74 030916

PN=420
 Power Train Repair—2 Speed

IMPORTANT: Press on inner race only to avoid

damaging bearing.

2. Install bearing (C) using a press.

C—Bearing

TCAL29657 —UN—09JUL12
OUMX258,0000AC3 -19-15SEP14-46/57

IMPORTANT: Press on inner race only to avoid

damaging bearing.

3. Position a washer (D) to contact bearing inner race to

prevent bearing damage while applying pressure.
4. Install bearing (E) using a press.

TCAL29658 —UN—09JUL12
D—Washer E—Bearing

OUMX258,0000AC3 -19-15SEP14-47/57

Differential Assembly
1. Install side gears (G and E) with flat thrust washers (F)
inside housing (H).

E—Side Gear G—Side Gear

F— Flat Thrust Washers H—Differential Housing

TCAL29659 —UN—09JUL12

Continued on next page OUMX258,0000AC3 -19-15SEP14-48/57

TM130419 (24FEB16) 40-40-75 030916

PN=421
 Power Train Repair—2 Speed

2. Install pinion gears (I) between side gears.

3. Slide the bevel thrust washers (J) between pinion
gears and differential housing.

I— Pinion Gears J— Bevel Thrust Washers

TCAL29660 —UN—09JUL12
OUMX258,0000AC3 -19-15SEP14-49/57

4. Install pinion shaft (K) and secure it with spring pin (L).

K—Pinion Shaft L— Spring Pin

TCAL29661 —UN—09JUL12
OUMX258,0000AC3 -19-15SEP14-50/57

5. Clean threads of cap screws (M) and threads of gear

(N) with TY16285 Cure Primer.
6. Apply PM37477 Thread Lock and Sealer (Medium
Strength) to threads of cap screws.

TCAL29662 —UN—09JUL12
M—Cap Screws N—Threads of Gear

Continued on next page OUMX258,0000AC3 -19-15SEP14-51/57

TM130419 (24FEB16) 40-40-76 030916

PN=422
 Power Train Repair—2 Speed

7. Install gear with ridge side (O) facing differential

housing.
8. Install ten cap screws and tighten to specification.
Specification
Differential Ring

TCAL29663 —UN—09JUL12
Gear-to-Housing Cap
Screw—Torque............................................................................155 N·m
(114 lb.-ft.)

O—Gear (Ridge Side)

OUMX258,0000AC3 -19-15SEP14-52/57

9. Install differential lock shaft seal (P).

P—Differential Lock Shaft Seal

TCAL29664 —UN—09JUL12
OUMX258,0000AC3 -19-15SEP14-53/57

10. Install differential lock shaft (Q) and differential

assembly (R) into case as an assembly.
11. Install washer (S) on differential lock shaft.
12. Install idler shaft assembly (T).
13. Install oil return tube (U) and dipstick (V).

Q—Differential Lock Shaft T— Idler Shaft Assembly

R—Differential Assembly U—Oil Return Tube
S—Washer V—Dipstick
TCAL29665 —UN—09JUL12

Continued on next page OUMX258,0000AC3 -19-15SEP14-54/57

TM130419 (24FEB16) 40-40-77 030916

PN=423
 Power Train Repair—2 Speed

14. Apply PM38655 John Deere™ Form-In-Place Gasket

on side cover (W) and differential housing mating
surfaces.
15. Install side cover and nine M8 x 35 cap screws (X).
Tighten cap screws to specification.
Specification
Differential Side
Cover-to-Differential
Case Cap Screw (M8 x
35)—Torque...................................................................................26 N·m

TCAL29666 —UN—09JUL12
(19 lb.-ft.)

W—Differential Side Cover X—M8 x 35 Cap Screws

John Deere is a trademark of Deere & Company

OUMX258,0000AC3 -19-15SEP14-55/57

16. Install six brake actuator balls (Y).

Y—Brake Actuator Balls (6

used)

TCAL29667 —UN—09JUL12
Continued on next page OUMX258,0000AC3 -19-15SEP14-56/57

TM130419 (24FEB16) 40-40-78 030916

PN=424
 Power Train Repair—2 Speed

17. Install brake actuator disk (Z).

18. Install cap screws and washers (AA).
19. Repeat steps 16—18 on opposite side.
20. Install both axle housings. (See Axle Shaft Housing

TCAL29668 —UN—09JUL12
Assembly within this Group.)
21. Tighten all mounting hardware to specifications.
Specification
Axle Housing-to-
Differential Cap Screw
(M10 x 60)—Torque.......................................................................52 N·m
(38 lb.-ft.)
Axle Housing-to-
Differential Cap Screw Z— Brake Actuator Disk AA—Cap Screws and Washers
(M10 x 45)—Torque.......................................................................52 N·m
(38 lb.-ft.)
Axle Seal Housing-
to-Axle Housing Cap
Screw—Torque..............................................................................26 N·m
(19 lb.-ft.)
OUMX258,0000AC3 -19-15SEP14-57/57

Disassemble, Inspect, and Assemble PTO—2

Speed
Special or Required Tools

• Clutch Piston Compression Tool1

• M8 x 30 Cap Screw (2 used)
• Knife-Edge Puller

TCAL29669 —UN—09JUL12
Disassembly/Inspection
IMPORTANT: Absolute cleanliness is essential
when working on hydraulic components.
Contamination can result in serious damage
or inadequate operation.
DO NOT use shop towels or rags to dry
cleaned parts. Lint will clog passages in the
hydraulic/hydrostatic system and cause damage. A—PTO Drain Plug C—O-Ring
B—Solenoid Nut D—Solenoid Coil
NOTE: You do not need to remove transaxle to
repair PTO only. PTO can be removed without
disassembly of transaxle. 1. Drain PTO housing at drain plug (A).
Transaxle is shown removed for clarity. 2. Remove solenoid nut (B).
Use shop cloths or paper towels to immediately 3. Remove O-ring (C) and solenoid coil (D).
catch and clean up any spilled oil.
1
1. For instructions on making tool, see Fabricated Tools in this section.
Continued on next page OUMX258,0000AC4 -19-15SEP14-1/50

TM130419 (24FEB16) 40-40-79 030916

PN=425
 Power Train Repair—2 Speed

NOTE: PTO solenoid valve, relief valve, and

accumulator may be repaired without complete
disassembly of PTO.
All valves have small parts; take note of order
and direction of disassembly. Use caution not

TCAL29670 —UN—09JUL12
to drop or lose small parts.

4. Remove solenoid stud (E).

E—Solenoid Stud

OUMX258,0000AC4 -19-15SEP14-2/50

5. Remove solenoid valve parts (F-J).

6. Inspect parts for scoring or damage. Replace as
necessary.

TCAL29671 —UN—09JUL12
F—J— Solenoid Valve Parts

OUMX258,0000AC4 -19-15SEP14-3/50

NOTE: Valve adjustment shims may stick inside of valve

cap and fall out when removing cap. Remove
cap slowly to prevent loss of shims.

7. Remove relief valve cap (K).

K—Relief Valve Cap

TCAL29672 —UN—09JUL12

Continued on next page OUMX258,0000AC4 -19-15SEP14-4/50

TM130419 (24FEB16) 40-40-80 030916

PN=426
 Power Train Repair—2 Speed

8. Remove relief valve parts (L-O).

9. Inspect parts for scoring or damage. Replace as
necessary.

TCAL29673 —UN—09JUL12
L—O— Relief Valve Parts

OUMX258,0000AC4 -19-15SEP14-5/50

CAUTION: Accumulator spring is compressed.

Do not remove cover without properly
relieving spring pressure.

10. Remove one cap screw from accumulator cover (P).

NOTE: M8 x 30 cap screw will bottom in thread
hole. Do not overtighten.

TCAL29674 —UN—09JUL12
11. Install an M8 x 30 cap screw (Q) and tighten until snug.
12. Carefully remove remaining original cap screw (R) and
replace with an M8 x 30 cap screw. Tighten until snug.

P—Accumulator Cover R—Cap Screw

Q—M8 x 30 Cap Screw

OUMX258,0000AC4 -19-15SEP14-6/50

13. Slowly loosen both cap screws (S) evenly until spring
pressure is relieved. Remove cover (T).

S—Cap Screws T— Cover

TCAL29675 —UN—09JUL12

Continued on next page OUMX258,0000AC4 -19-15SEP14-7/50

TM130419 (24FEB16) 40-40-81 030916

PN=427
 Power Train Repair—2 Speed

14. Remove accumulator parts (U-W).

15. Inspect parts for scoring or damage. Replace as

TCAL29676 —UN—09JUL12
necessary.

U—W—Accumulator Parts
Shown

OUMX258,0000AC4 -19-15SEP14-8/50

16. Remove seven cap screws (X).

17. Remove PTO cover (Y).

X—Cap Screws (7 used) Y—PTO Cover

TCAL29677 —UN—09JUL12
OUMX258,0000AC4 -19-15SEP14-9/50

18. Remove PTO assembly (Z).

Z— PTO Assembly

TCAL29678 —UN—09JUL12

Continued on next page OUMX258,0000AC4 -19-15SEP14-10/50

TM130419 (24FEB16) 40-40-82 030916

PN=428
 Power Train Repair—2 Speed

19. Remove brake disk (AA).

20. Remove PTO oil supply tube (AB).

AA—Brake Disk AB—PTO Oil Supply Tube

TCAL29679 —UN—09JUL12
OUMX258,0000AC4 -19-15SEP14-11/50

21. Remove fiber seals (AC).

AC—Fiber Seals

TCAL29680 —UN—09JUL12
OUMX258,0000AC4 -19-15SEP14-12/50

22. Remove bearing (AD) using a knife-edge puller.

Remove spacer (AE).

AD—Bearing AE—Spacer

TCAL29681 —UN—09JUL12

Continued on next page OUMX258,0000AC4 -19-15SEP14-13/50

TM130419 (24FEB16) 40-40-83 030916

PN=429
 Power Train Repair—2 Speed

23. Remove clutch gear (AF).

AF—Clutch Gear

TCAL29682 —UN—09JUL12
OUMX258,0000AC4 -19-15SEP14-14/50

24. Inspect bearings (AG and AI) and snap ring (AH).
Remove and replace as necessary.

AG—Bearing AI— Bearing

AH—Snap Ring

TCAL29683 —UN—09JUL12
OUMX258,0000AC4 -19-15SEP14-15/50

25. Slide clutch assembly (AJ) partway off shaft and

remove three brake pins (AK). Remove clutch
assembly.
26. Remove key (AL).
27. Remove brake pack (AM).
TCAL29684 —UN—09JUL12
AJ—Clutch Assembly AL—Key
AK—Brake Pins (3 used) AM—Brake Pack

Continued on next page OUMX258,0000AC4 -19-15SEP14-16/50

TM130419 (24FEB16) 40-40-84 030916

PN=430
 Power Train Repair—2 Speed

28. Inspect bearing (AN) and shaft (AO). Use knife-edge

puller if bearing replacement is necessary.

AN—Bearing AO—Shaft

TCAL29685 —UN—09JUL12
OUMX258,0000AC4 -19-15SEP14-17/50

29. Holding all the clutch disks together, measure the

space between the bottom separator plate and
the PTO cylinder. If space measured exceeds
specification, replace all the clutch disks.

TCAL29686 —UN—09JUL12
OUMX258,0000AC4 -19-15SEP14-18/50

30. Disassemble clutch if required. Remove large snap

ring (AP). Lift top plate (AQ) off clutch assembly.
Measure thickness of the top plate. A minimum
thickness specification is required and the plate must
be flat; replace plate if necessary.
Specification
Clutch Top

TCAL29687 —UN—09JUL12
Plate—Thickness
(Minimum).................................................................................. 3.03 mm
(0.119 in.)

AP—Large Snap Ring AQ—Top Plate

Continued on next page OUMX258,0000AC4 -19-15SEP14-19/50

TM130419 (24FEB16) 40-40-85 030916

PN=431
 Power Train Repair—2 Speed

31. Remove seven clutch disks (AR) and seven separator

plates (AS). Measure clutch disks (seven used) and
separator plates (seven used) for minimum thickness
requirement. The separator plates must be flat;
replace plates if necessary. Check clutch basket
fingers (AT) for notching or other damage. Replace
clutch basket if necessary.
Specification
Clutch Disk—Thickness
(Minimum).................................................................................... 2.0 mm
(0.08 in.)

TCAL29688 —UN—09JUL12
Clutch Separator
Plate—Thickness
(Minimum).................................................................................... 1.0 mm
(0.04 in.)

AQ—Top Plate AS—Separator Plates (7 used)

AR—Clutch Disks (7 used) AT— Clutch Basket Fingers

OUMX258,0000AC4 -19-15SEP14-20/50

32. Disassemble clutch piston by placing piston and clutch

piston compression tool¹ (AU) in a vise.1
33. Tighten vise to compress spring (AV) and flat washer
(AW) to remove snap ring (AX).
34. Slowly back off on vise to remove spring (AV).

AU—Clutch Piston AW—Flat Washer

Compression Tool AX—Snap Ring

TCAL29689 —UN—09JUL12
AV—Spring

1
1. Clutch piston compression tool is a fabricated tool. For instructions
to make tool, see Fabricated Tools in this section.
Continued on next page OUMX258,0000AC4 -19-15SEP14-21/50

TM130419 (24FEB16) 40-40-86 030916

PN=432
 Power Train Repair—2 Speed

35. Remove piston (AY). Remove O-ring (AZ) and discard.

Piston must be free of nicks and scratches; if not,
replace it.
36. Check free length of piston return spring (BA). Replace
if required.
Specification
Piston Return
Spring—Free Length

TCAL29690 —UN—09JUL12
(Minimum)....................................................................... 75 mm (2.95 in.
(2.95 in.)
Piston Return
Spring—Length @ 499 N
(112 lb-force).............................................................................. 28.6 mm
(1.13 in.)

AY—Piston BA—Piston Return Spring

AZ—O-Ring

OUMX258,0000AC4 -19-15SEP14-22/50

37. Inspect brake pressure plate (BB). Plate must be flat

and not damaged.
38. The top plate (BC) must be flat; replace if necessary.

TCAL29691 —UN—09JUL12
39. Inspect brake disks (BD) (four used) and brake
separator plates (BE) (three used). The separator
plates must be flat; replace if necessary. If oil grooves
of brake disks are worn down, replace disks. If oil
grooves have disappeared, replace all plates and
disks.

BB—Pressure Plate BD—Brake Disks

BC—Top Plate BE—Brake Separator Plates

OUMX258,0000AC4 -19-15SEP14-23/50

40. Remove two cap screws (BF) and plate (BG).

BF—Cap Screws (2 used) BG—Plate

TCAL29692 —UN—09JUL12

Continued on next page OUMX258,0000AC4 -19-15SEP14-24/50

TM130419 (24FEB16) 40-40-87 030916

PN=433
 Power Train Repair—2 Speed

41. Remove shaft seal (BH).

BH—Shaft Seal

TCAL29693 —UN—09JUL12
OUMX258,0000AC4 -19-15SEP14-25/50

Assembly
NOTE: Clean, dry, and lubricate all parts with clean
hydrostatic fluid before assembly.

TCAL29694 —UN—09JUL12
1. Install new seal (A) flush with surface of housing.

A—Seal

OUMX258,0000AC4 -19-15SEP14-26/50

2. Install plate (B) and cap screws (C).

B—Plate C—Cap Screws

TCAL29695 —UN—09JUL12

Continued on next page OUMX258,0000AC4 -19-15SEP14-27/50

TM130419 (24FEB16) 40-40-88 030916

PN=434
 Power Train Repair—2 Speed

NOTE: Clutch piston must be positioned so that three

spokes cover three pin holes in drum. If improperly
installed, PTO brake will not work.

3. Replace O-ring (E) and install piston (D) into drum (G).
Three piston spokes (F) must cover three pin holes
(H) in drum.

D—Piston G—Drum

TCAL29696 —UN—09JUL12
E—O-Ring H—Three Pin Holes
F— Three Piston Spokes

OUMX258,0000AC4 -19-15SEP14-28/50

4. Install piston spring (I), washer (J), and snap ring (K)
using clutch piston compression tool (L).1

I— Piston Spring K—Snap Ring

J— Washer L— Clutch Piston Compression
Tool¹

TCAL29697 —UN—09JUL12
1
1. Clutch piston compression tool is a fabricated tool. For instructions
to make tool, see Fabricated Tools in this section.
Continued on next page OUMX258,0000AC4 -19-15SEP14-29/50

TM130419 (24FEB16) 40-40-89 030916

PN=435
 Power Train Repair—2 Speed

5. Install one separator plate (M) in clutch basket (O), then

one disk (N). Repeat until all seven separator plates
and seven disks are alternately installed in clutch.
6. Install top plate (P) in clutch basket.

M—Separator Plate O—Clutch Basket

N—Disk P—Top Plate

TCAL29698 —UN—09JUL12
OUMX258,0000AC4 -19-15SEP14-30/50

IMPORTANT: Position the snap ring (Q) so that

the open portion is against one of the
sides of the cylinder wall.

7. Install snap ring (Q) with open end facing drum wall.

Q—Snap Ring

TCAL29699 —UN—09JUL12
OUMX258,0000AC4 -19-15SEP14-31/50

8. Alternately install three brake separator plates (R) and

three brake disks (S).
9. Install brake top plate (U).
10. Install brake pressure plate (T).

R—Three Brake Separator T— Brake Pressure Plate

Plates U—Brake Top Plate
S—Three Brake Disks
TCAL29700 —UN—09JUL12

Continued on next page OUMX258,0000AC4 -19-15SEP14-32/50

TM130419 (24FEB16) 40-40-90 030916

PN=436
 Power Train Repair—2 Speed

11. Install key (V) into shaft.

12. Slide clutch (W) partially onto shaft.
13. Install three pins (X) into clutch.
14. Install clutch fully onto shaft.

V—Key X—Three Pins

W—Clutch

TCAL29701 —UN—09JUL12
OUMX258,0000AC4 -19-15SEP14-33/50

NOTE: Aligning clutch disks with a small O-ring pick and

rotating gear and hub will aid in installation.

15. Install PTO gear and hub (Y) to clutch.

Y—PTO Gear and Hub

TCAL29702 —UN—09JUL12
OUMX258,0000AC4 -19-15SEP14-34/50

16. Install spacer (Z) and bearing (AA) onto shaft.

Z— Spacer AA—Bearing

TCAL29703 —UN—09JUL12

Continued on next page OUMX258,0000AC4 -19-15SEP14-35/50

TM130419 (24FEB16) 40-40-91 030916

PN=437
 Power Train Repair—2 Speed

17. Install two fiber seals (AB).

AB—Fiber Seals

TCAL29704 —UN—09JUL12
OUMX258,0000AC4 -19-15SEP14-36/50

18. Install brake spacer ring (AD) and then brake disk
(AC) into housing.
19. Replace O-rings and install PTO supply tube (AE).

AC—Brake Disk AE—PTO Supply Tube

AD—Spacer Ring

TCAL29705 —UN—09JUL12
OUMX258,0000AC4 -19-15SEP14-37/50

20. Apply J-20D hydraulic fluid liberally to the brake disks

(AF). Align the brake disk tabs (AG).

AF—Brake Disks AG—Brake Disk Tabs

TCAL29706 —UN—09JUL12

Continued on next page OUMX258,0000AC4 -19-15SEP14-38/50

TM130419 (24FEB16) 40-40-92 030916

PN=438
 Power Train Repair—2 Speed

21. Check that brake disk tabs (AH) align with the cutouts
(AI) in the housing as you begin to insert the PTO
assembly.

AH—Brake Disk Tabs AI— Housing Cutouts

TCAL29707 —UN—09JUL12
OUMX258,0000AC4 -19-15SEP14-39/50

22. Align the PTO clutch gear (AJ) with the PTO gear
teeth (AK) as the unit is inserted in the housing.
23. Carefully guide PTO assembly into housing until clutch
gear and PTO gear faces are flush.
24. Install new PTO cover-to-PTO housing gasket to PTO
housing.

AJ—PTO Clutch Gear AK—PTO Gear Teeth

TCAL29708 —UN—09JUL12
Continued on next page OUMX258,0000AC4 -19-15SEP14-40/50

TM130419 (24FEB16) 40-40-93 030916

PN=439
 Power Train Repair—2 Speed

25. Install PTO cover (AL) using seven cap screws (AM).

AL—PTO Cover AM—Cap Screws

TCAL29709 —UN—09JUL12
OUMX258,0000AC4 -19-15SEP14-41/50

26. Install piston (AN), then sleeve (AO), and then spring

TCAL29710 —UN—09JUL12
(AP) into PTO cover.

AN—Piston AP—Spring
AO—Sleeve

OUMX258,0000AC4 -19-15SEP14-42/50

27. Install cover gasket (AQ) to cover (AR).

28. Install cover using two M8 x 30 cap screws (AS).
Tighten cap screws evenly until snug.

AQ—Gasket AS—M8 x 30 Cap Screws

AR—Cover

TCAL29711 —UN—09JUL12

Continued on next page OUMX258,0000AC4 -19-15SEP14-43/50

TM130419 (24FEB16) 40-40-94 030916

PN=440
 Power Train Repair—2 Speed

29. Remove one M8 x 30 cap screw (AT) and replace it

with an original cover cap screw. Tighten cap screw.
30. Repeat for other M8 x 30 cap screw.

AT— M8 x 30 Cap Screw

TCAL29712 —UN—09JUL12
OUMX258,0000AC4 -19-15SEP14-44/50

31. Install PTO relief valve (AU) and then spring (AV) into

TCAL29713 —UN—09JUL12
PTO cover.
32. Install shims (AW) and new seal (AX) into relief cap
(AY).

AU—PTO Relief Valve AX—Seal

AV—Spring AY—Relief Cap
AW—Shims

OUMX258,0000AC4 -19-15SEP14-45/50

33. Carefully install cap into threaded hole (AZ) in PTO

cover, taking care not to drop shims out of cap.

AZ—Threaded Hole

TCAL29714 —UN—09JUL12

Continued on next page OUMX258,0000AC4 -19-15SEP14-46/50

TM130419 (24FEB16) 40-40-95 030916

PN=441
 Power Train Repair—2 Speed

34. Install washer (BA) and then outer spool (BB), with
large boss (BC) up, into PTO cover.
35. Install spring (BD) and then inner spool (BE), with
fingers (BF) down, into PTO.

TCAL29715 —UN—09JUL12
BA—Washer BE—Inner Spool
BB—Outer Spool BF—Fingers
BC—Large Boss BG—Pin
BD—Spring

OUMX258,0000AC4 -19-15SEP14-47/50

36. Install pin (BG) into solenoid stud (BH).

37. Install new O-ring (BI).

BH—Solenoid Stud BI— O-Ring

TCAL29716 —UN—09JUL12
OUMX258,0000AC4 -19-15SEP14-48/50

38. Install new seal (BJ) and install solenoid stud (BH).
Tighten to specification.
Specification
Solenoid Stud—Torque.................................................................23 N·m
(203 lb.-in.)

TCAL29717 —UN—09JUL12
BH—Solenoid Stud BJ—Seal

Continued on next page OUMX258,0000AC4 -19-15SEP14-49/50

TM130419 (24FEB16) 40-40-96 030916

PN=442
 Power Train Repair—2 Speed

39. Install solenoid coil (BK) with wires toward threaded

end of solenoid stud, and then new O-ring (BL) and
nut (BM). Tighten nut to specification.
Specification
Solenoid Coil
Nut—Torque....................................................................................5 N·m
(44 lb.-in.)

40. Fill transaxle. (See Checking the Transaxle Oil Level

TCAL29718 —UN—09JUL12
in operator’s manual.)

BK—Solenoid Coil BM—Nut

BL—O-Ring

OUMX258,0000AC4 -19-15SEP14-50/50

TM130419 (24FEB16) 40-40-97 030916

PN=443
 Power Train Repair—2 Speed

Remove and Install 4WD Driveshaft—2 Speed

Special or Required Tools

TCAL29719 —UN—09JUL12
• Floor Jack
• Jackstand (2 used)
Remove
1. Park machine safely.
2. Stop engine.
3. Remove engine cover.
4. Disconnect battery (—) negative cable. A—Band Clamps C—Cap Screw and Washer
B—Universal Joint Boot
5. Block rear tires to prevent machine from rolling.

CAUTION: Support machine properly. 1. Slide rear universal joint of driveshaft onto 4WD axle
input shaft.
6. Raise front of machine using a floor jack and support
with jackstands. NOTE: Holes for cap screw and washer in front universal
joint and transaxle 4WD output shaft must be
7. Loosen band clamps (A) on front and rear universal aligned when installing driveshaft.
joint boots (B).
2. Align hole in front universal joint with hole in transaxle
8. Slide boots away from front and rear universal joints. 4WD output shaft.
9. Remove cap screw and washer (C) from front 3. Slide universal joint onto spline until the holes are
universal joint connection. aligned.
10. Slide driveshaft rearward to remove universal joint 4. Install washer and cap screw in front universal joint.
from transaxle output shaft. Tighten cap screw.
11. Lower and slide driveshaft forward to remove 5. Slide boots over front and rear universal joints.
driveshaft from 4WD axle input shaft.
6. Tighten band clamps.
12. Inspect the splines of the universal joints and
driveshafts for wear or damage. Replace parts as 7. Remove jackstands and lower machine.
needed.
8. Connect battery negative (—) cable.
Install
9. Install engine cover.
IMPORTANT: Always install new gaskets, O-rings, and
seals. Replace all damaged or rough moving
parts. Damaged or worn parts will leak.
OUMX258,0000AC5 -19-27MAR13-1/1

TM130419 (24FEB16) 40-40-98 030916

PN=444
 Power Train Repair—2 Speed

Remove and Install 4WD Axle—2 Speed

Special or Required Tools

• Floor Jack
• Jackstand (2 used)
• Hoist

TCAL29720 —UN—09JUL12
Removal

CAUTION: 4WD axle is heavy. An additional

person is required when removing 4WD
axle from machine.

IMPORTANT: Absolute cleanliness is essential

when working on hydraulic components.
Contamination can result in serious damage
A—Steering Cylinder
or inadequate operation. Clean all lines and
fittings prior to opening hydraulic system.

1. Park machine safely.

2. Stop engine.
3. Remove engine cover.
4. Disconnect battery negative (-) cable.
NOTE: Muffler and exhaust pipes must be removed
to remove and install 4WD axle.

5. Remove muffler and exhaust pipes. (See “Engine

Repair”.)
6. Block front wheels.

CAUTION: Support machine properly.

7. Raise rear of machine with floor jack and support

frame with jackstands.
8. Remove rear wheels.
9. Remove steering cylinder (A). (See Remove and
Install Steering Cylinder.)
OUMX258,0000AC6 -19-15SEP14-1/6

10. Support axle to relieve weight of axle on axle pin (B).

11. Remove two cap screws (C).
12. Remove axle pin.

B—Axle Pin C—Cap Screw (2 used)

TCAL29721 —UN—09JUL12

Continued on next page OUMX258,0000AC6 -19-15SEP14-2/6

TM130419 (24FEB16) 40-40-99 030916

PN=445
 Power Train Repair—2 Speed

13. Use a hoist and lift sling to raise right side of axle (D).
14. With an assistant, lift axle, rotate clockwise, and
remove axle out right side of machine.

D—Axle

TCAL29722 —UN—09JUL12
OUMX258,0000AC6 -19-15SEP14-3/6

Install

CAUTION: 4WD axle is heavy. An additional

person is required when installing 4WD
axle in machine.

IMPORTANT: Always install new gaskets, O-rings, and

TCAL29723 —UN—09JUL12
seals. Replace all damaged or rough moving
parts. Damaged or worn parts will leak.

1. Use a hoist and lift sling to lift the right side of 4WD
axle (A).
Specification
4WD Axle—Weight
(Approximate).................................................................................. 68 kg
(150 lb.)
A—Axle
2. With an assistant, install 4WD axle into right side of
machine.
3. Support axle in position. 4. Align axle pin pivot point with axle pin flange.
OUMX258,0000AC6 -19-15SEP14-4/6

5. Install 4WD axle pin (B).

6. Install and tighten two cap screws (C).
7. Remove support from axle.

B—Axle Pin C—Cap Screws (2 used)

TCAL29724 —UN—09JUL12

Continued on next page OUMX258,0000AC6 -19-15SEP14-5/6

TM130419 (24FEB16) 40-40-100 030916

PN=446
 Power Train Repair—2 Speed

8. Install steering cylinder (D). (See Remove and Install

Steering Cylinder.)
9. Install rear wheels. Tighten wheel bolts to specification.
Specification
Rear Wheels - 2
Speed—Torque...........................................................................122 N·m

TCAL29725 —UN—09JUL12
(90 lb.-ft.)

10. Remove jackstands and use floor jack to lower

machine.
11. Install muffler and exhaust pipes.
12. Connect battery negative (—) cable.
13. Install engine cover and remove wheel blocks.
D—Steering Cylinder

OUMX258,0000AC6 -19-15SEP14-6/6

Disassemble, Inspect, and Assemble 4WD

Axle—2 Speed
Special or Required Tools

• Floor Jack
• Jackstand (2 used)
• Hoist

TCAL29726 —UN—09JUL12
• Snap Ring Pliers Set
• Hydraulic Press
• Bushing, Bearing, and Seal Driver Set
• 3-Jaw Puller
• Knife-Edge Puller
IMPORTANT: Absolute cleanliness is essential
when working on hydraulic components.
Contamination can result in serious damage
or inadequate operation. A—Drain Plug

DO NOT use shop towels or rags to dry

cleaned parts. Lint will clog passages in the
hydraulic/hydrostatic system and cause damage.

Procedure
1. Remove axle from machine. (See Remove and Install
4WD Axle—2 Speed.)
2. Remove drain plug (A) at differential housing. Drain
oil into a properly marked container of sufficient size
to hold oil from axle.
Continued on next page OUMX258,0000AC7 -19-15SEP14-1/50

TM130419 (24FEB16) 40-40-101 030916

PN=447
 Power Train Repair—2 Speed

IMPORTANT: When removing tie rod, keep ball joints

clean. Dirt and contaminants can damage ball
joint seals and shorten service life.

3. Remove cotter pin and nut from each end of tie rod

TCAL29727 —UN—09JUL12
(B). Tie rod ends have a tapered joint. Remove tie rod.

B—Tie Rod

OUMX258,0000AC7 -19-15SEP14-2/50

DisassembleFinal Drive Hub

1. Remove drain plug (A) from lower gear case. Drain oil
into a properly marked container.
2. Remove eight cap screws and lock washers (B) from
lower gear case cover (C).

TCAL29728 —UN—09JUL12
3. Remove cover assembly. It may be necessary to tap
on cover with a soft-faced hammer to separate it from
the lower gear case (D).

A—Drain Plug C—Lower Gear Case Cover

B—Cap Screws and Lock D—Lower Gear Case
Washers (8 used)

OUMX258,0000AC7 -19-15SEP14-3/50

NOTE: Remove bearing (E) with a bearing puller only

if bearing requires replacement.

4. Inspect bearing (E) for wear, damage, or rough

movement. Replace bearing as needed.
5. Remove gasket (F) and clean gasket mating surfaces.

TCAL29729 —UN—09JUL12
6. Remove snap ring (G) to remove ring gear (H).
7. Inspect ring gear for wear or damage. Replace as
needed.

E—Bearing G—Snap Ring

F— Gasket H—Ring Gear

Continued on next page OUMX258,0000AC7 -19-15SEP14-4/50

TM130419 (24FEB16) 40-40-102 030916

PN=448
 Power Train Repair—2 Speed

8. Use a press to remove hub shaft (I) from cover.

I— Hub Shaft

TCAL29730 —UN—09JUL12
OUMX258,0000AC7 -19-15SEP14-5/50

9. Inspect oil seal wear sleeve (J) for wear or damage.

Replace as needed.

J— Oil Seal Wear Sleeve

TCAL29731 —UN—09JUL12
OUMX258,0000AC7 -19-15SEP14-6/50

10. Remove bearing (K). Inspect for wear, damage, or

rough movement. Replace as needed.
11. Remove oil seal (L).

K—Bearing L— Oil Seal

TCAL29732 —UN—09JUL12

Continued on next page OUMX258,0000AC7 -19-15SEP14-7/50

TM130419 (24FEB16) 40-40-103 030916

PN=449
 Power Train Repair—2 Speed

Disassemble Final Drive

1. Remove five axle housing-to-final drive cap screws
and lock washers (A).
2. Remove final drive assembly. It may be necessary to
tap on spindle gear case with a soft-faced hammer to

TCAL29733 —UN—09JUL12
separate final drive assembly from axle housing.

A—Cap Screws and Lock

Washers (5 used)

OUMX258,0000AC7 -19-15SEP14-8/50

3. Remove four cap screws and lock washers (B) to

remove steering arm. It may be necessary to use
a soft-faced hammer to separate steering arm from
spindle gear case.

TCAL29734 —UN—09JUL12
B—Cap Screws and Lock
Washers (4 used)

OUMX258,0000AC7 -19-15SEP14-9/50

4. Inspect oil seal wear sleeve (C) on steering arm for

wear or damage. Replace as needed.

C—Oil Seal Wear Sleeve

TCAL29735 —UN—09JUL12

Continued on next page OUMX258,0000AC7 -19-15SEP14-10/50

TM130419 (24FEB16) 40-40-104 030916

PN=450
 Power Train Repair—2 Speed

NOTE: When spindle and lower gear cases are separated,

a spacer, gear, and bearing from the spindle shaft
will be loose in the spindle gear case.

5. Put final drive assembly in a press. Press on spindle

shaft in spindle gear case to separate spindle and
lower gear cases. Support lower gear case so it does

TCAL29736 —UN—09JUL12
not fall and cause injury or damage.

OUMX258,0000AC7 -19-15SEP14-11/50

6. Remove spacer (G), bearing (H), and gear (I) from

spindle gear case.
7. Remove upper oil seal (D), bearing (E), and snap ring
(F) from top of spindle gear case.
8. Inspect parts for wear or damage. Inspect bearings for
wear, damage, or rough movement. Replace parts
as needed.

TCAL29737 —UN—09JUL12
D—Upper Oil Seal G—Spacer
E—Bearing H—Bearing
F— Snap Ring I— Gear

OUMX258,0000AC7 -19-15SEP14-12/50

9. Remove shim (L), lower oil seal (J), and bearing (K)
from lower gear case. Discard oil seal.
10. Inspect bearing for wear, damage, or rough movement.
Replace as needed.
11. Remove spindle shaft (M) from lower gear case.

TCAL29738 —UN—09JUL12
12. Inspect spindle shaft and splines on shaft for wear or
damage. Replace as needed.

J— Lower Oil Seal M—Spindle Shaft

K—Bearing N—Bearing
L— Shim

Continued on next page OUMX258,0000AC7 -19-15SEP14-13/50

TM130419 (24FEB16) 40-40-105 030916

PN=451
 Power Train Repair—2 Speed

13. Inspect bearing (O) on spindle shaft for wear,

damage, or rough movement. Replace as needed.
Remove bearing from spindle shaft only if it requires
replacement.

O—Bearing

TCAL29739 —UN—09JUL12
OUMX258,0000AC7 -19-15SEP14-14/50

Assemble Final Drive

TCAL29740 —UN—09JUL12
IMPORTANT: Always install new gaskets, O-rings, and
seals. Replace all damaged or rough moving
parts. Damaged or worn parts will leak.
Press on inner bearing race only to avoid
damaging bearing.

NOTE: Steps for assembly of left and right final

drives are the same.

1. Press on inner race of bearing (A) to install new

bearing on spindle shaft (B).

TCAL29741 —UN—09JUL12
A—Bearing B—Spindle Shaft

OUMX258,0000AC7 -19-15SEP14-15/50

2. Install spindle shaft (F) in lower gear case. It may be

necessary to tap shaft to seat bearing to bottom of
bore.
3. Install bearing (D) and seal (C). Install seal with spring
side into bore first and flush with mounting surface.
TCAL29742 —UN—09JUL12

4. Install shim (E).

C—Seal E—Shim
D—Bearing F— Shaft

Continued on next page OUMX258,0000AC7 -19-15SEP14-16/50

TM130419 (24FEB16) 40-40-106 030916

PN=452
 Power Train Repair—2 Speed

5. Install shim (I) on lower gear case.

6. If removed, press new sleeve (H) onto spindle gear
case (G).
7. Put spindle gear case (G) over spindle shaft. Do not
install into lower gear case at this time.

TCAL29743 —UN—09JUL12
G—Spindle Gear Case I— Shim
H—New Sleeve

OUMX258,0000AC7 -19-15SEP14-17/50

8. Install gear (J) on spindle shaft with gear teeth toward

lower gear case.

J— Gear

TCAL29744 —UN—09JUL12
OUMX258,0000AC7 -19-15SEP14-18/50

IMPORTANT: Push on inner race only to avoid

damaging bearing.

9. Install bearing (K) on spindle shaft. Tap on inner race

of bearing to install bearing onto spindle shaft.

K—Bearing

TCAL29745 —UN—09JUL12

Continued on next page OUMX258,0000AC7 -19-15SEP14-19/50

TM130419 (24FEB16) 40-40-107 030916

PN=453
 Power Train Repair—2 Speed

10. Install snap ring (L).

11. Install spacer (M) with stepped side against snap ring.
Keep spacer against snap ring while holding upper
gear case (N) and lower gear case (O) upright. Tap on
spindle gear case with a soft-face hammer to install
into lower gear case. Use care not to damage seal
in lower gear case.

L— Snap Ring N—Upper Gear Case

M—Spacer O—Lower Gear Case

TCAL29746 —UN—09JUL12
OUMX258,0000AC7 -19-15SEP14-20/50

12. Install bearing (P) in upper gear case tight against

snap ring. It may be necessary to tap on inner race to
install bearing.
13. Install new oil seal (Q) with spring side toward bearing.

P—Bearing Q—Oil Seal

TCAL29747 —UN—09JUL12
Continued on next page OUMX258,0000AC7 -19-15SEP14-21/50

TM130419 (24FEB16) 40-40-108 030916

PN=454
 Power Train Repair—2 Speed

14. Hold final drive assembly upright and install steering

arm (R). Tap on steering arm with a soft-faced hammer
to install steering arm on final drive assembly. Use
care not to damage seal.
15. Install and tighten four cap screws and washers (S).

TCAL29748 —UN—09JUL12
R—Steering Arm S—Cap Screws and Washers
(4 used)

OUMX258,0000AC7 -19-15SEP14-22/50

Assemble Final Drive Hub

IMPORTANT: Always install new gaskets, O-rings, and
seals. Replace all damaged or rough moving
parts. Damaged or worn parts will leak.

1. Install new hub shaft seal (A) with seal spring into
bore first. Push seal to the specified depth (B) below
top of bore.
Specification
Final Drive Hub Shaft
Seal—Installation Depth..................6.5 mm (0.25 in.) Below Top of Bore

A—Hub Shaft Seal B—Depth of Seal to Top of Bore

TCAL29749 —UN—09JUL12
OUMX258,0000AC7 -19-15SEP14-23/50

2. Carefully put lower gear case cover (C) over hub shaft
(D) so as not to damage seal.
IMPORTANT: Press on inner race only to avoid
damaging bearing.

3. Press on inner race of bearing to install bearing on

hub shaft in lower gear case cover. Push bearing tight
TCAL29750 —UN—09JUL12

against shoulder of hub shaft.

C—Lower Gear Case Cover D—Hub Shaft

Continued on next page OUMX258,0000AC7 -19-15SEP14-24/50

TM130419 (24FEB16) 40-40-109 030916

PN=455
 Power Train Repair—2 Speed

4. Install ring gear (E) and snap ring (F) on hub shaft.
5. Install new gasket (G).
6. Install bearing (H).

E—Ring Gear G—Gasket

TCAL29751 —UN—09JUL12
F— Snap Ring H—Bearing

OUMX258,0000AC7 -19-15SEP14-25/50

7. Install cover assembly on lower gear case. Install and

tighten eight cap screws and lock washers (I).
8. Install drain plug (J) in final drive and tighten to
specification.
Specification
4WD Axle Final Drive

TCAL29752 —UN—09JUL12
Drain Plug—Torque...............................................................39 ± 10 N·m
(29 ± 10 lb.-ft.)

I— Cap Screws and Lock J— Drain Plug

Washers (8 used)

OUMX258,0000AC7 -19-15SEP14-26/50

Disassemble Differential Input Shaft and Cover

1. Remove three cap screws and lock washers (A).
2. Remove differential input cover (B). Remove gasket
material from mating surfaces.

A—Cap Screws and Lock B—Differential Input Cover

TCAL29753 —UN—09JUL12
Washers

Continued on next page OUMX258,0000AC7 -19-15SEP14-27/50

TM130419 (24FEB16) 40-40-110 030916

PN=456
 Power Train Repair—2 Speed

3. Remove snap ring (C).

4. Remove input shaft assembly (D) from differential
housing.

C—Snap Ring D—Input Shaft Assembly

TCAL29754 —UN—09JUL12
OUMX258,0000AC7 -19-15SEP14-28/50

5. Inspect gear (E), inner and outer bearings (F), and

spline (G) of input shaft for wear, damage, or rough
movement. Replace parts as needed.

E—Gear G—Input Shaft Splines

F— Inner and Outer Bearings

TCAL29755 —UN—09JUL12
OUMX258,0000AC7 -19-15SEP14-29/50

6. Remove bearings from input shaft only if they require

replacement.

TCAL29756 —UN—09JUL12

Continued on next page OUMX258,0000AC7 -19-15SEP14-30/50

TM130419 (24FEB16) 40-40-111 030916

PN=457
 Power Train Repair—2 Speed

7. Remove and discard oil seal (H) from input housing

cover.

H—Oil Seal

TCAL29757 —UN—09JUL12
OUMX258,0000AC7 -19-15SEP14-31/50

Disassemble, Inspect Differential and 4WD

Axle Housing
1. Remove left and right final drive assemblies from axle.
(See Disassembly of Final Drive in this Group.)

TCAL29758 —UN—09JUL12
Continued on next page OUMX258,0000AC7 -19-15SEP14-32/50

TM130419 (24FEB16) 40-40-112 030916

PN=458
 Power Train Repair—2 Speed

2. Remove seven cap screws (A) to separate right

axle/differential case (B) and left axle case (C).

A—Cap Screws (7 used) C—Left Axle Case

B—Right Axle/Differential Case

TCAL29759 —UN—09JUL12
TCAL29760 —UN—09JUL12
OUMX258,0000AC7 -19-15SEP14-33/50

3. Remove pinion shaft with pinion gears (D), axle inner

gear (E) and ring gear (F). Inspect for wear or damage.
Replace parts as needed.
4. Remove left axle shaft (J) from axle case.

TCAL29761 —UN—09JUL12
NOTE: Remove bearing (G) with a bearing puller only
if bearing needs to be replaced.

5. Inspect inner bearing (G) for wear, damage, or rough

movement. Replace bearing as needed.
6. Inspect bearing (I) for wear, damage, or rough
movement. Replace bearing as needed.
7. Remove axle outer gear (H) from left axle. Inspect
splines in gear and axle. Replace gear or axle as D—Pinion Gears H—Axle Outer Gear
needed. E—Axle Inner Gear I— Bearing
F— Ring Gear J— Left Axle Shaft
G—Inner Bearing

Continued on next page OUMX258,0000AC7 -19-15SEP14-34/50

TM130419 (24FEB16) 40-40-113 030916

PN=459
 Power Train Repair—2 Speed

8. Check outer bearing (K) on left axle for wear, damage,

or rough movement. Replace bearing if necessary,
using a press.

K—Outer Bearing

TCAL29762 —UN—09JUL12
OUMX258,0000AC7 -19-15SEP14-35/50

9. Remove large (M) and small (L) O-rings, axle gear (N),
and bearing (O). Inspect gear and splines of gear for
wear or damage. Inspect bearing for wear, damage,
or rough movement. Replace parts as needed.
10. Remove right axle shaft (P) from axle case.
11. Remove axle outer gear (Q) on right axle. Inspect

TCAL29763 —UN—09JUL12
gear and splines of gear for wear or damage. Replace
gear or axle as needed.

L— Small O-Ring O—Bearing

M—Large O-Ring P—Right Axle Shaft
N—Axle Gear Q—Axle Outer Gear

TCAL29764 —UN—09JUL12

Continued on next page OUMX258,0000AC7 -19-15SEP14-36/50

TM130419 (24FEB16) 40-40-114 030916

PN=460
 Power Train Repair—2 Speed

12. Inspect outer bearing (R) on right axle for wear,

damage, or rough movement. Replace bearing if
necessary, using a press.

R—Outer Bearing

TCAL29765 —UN—09JUL12
OUMX258,0000AC7 -19-15SEP14-37/50

Assemble Right Axle Housing

IMPORTANT: Always install new gaskets, O-rings, and
seals. Replace all damaged or rough moving
parts. Damaged or worn parts will leak.
Push on inner race only to avoid
damaging bearing.

TCAL29766 —UN—09JUL12
1. Install new outer bearing (A) on right axle (B) if
removed. Support inner race of bearing and press
axle into bearing until tight against shoulder.

A—Outer Bearing B—Right Axle

OUMX258,0000AC7 -19-15SEP14-38/50

2. Install bearing (H), axle gear (I), small (C) and large
(D) O-rings on right axle case (E).
3. Install outer axle gear (F) on axle assembly (G).
4. Install axle assembly in axle case.

C—Small O-Ring G—Axle Assembly

TCAL29767 —UN—09JUL12
D—Large O-Ring H—Bearing
E—Right Axle Case I— Axle Gear
F— Outer Axle Gear

Continued on next page OUMX258,0000AC7 -19-15SEP14-39/50

TM130419 (24FEB16) 40-40-115 030916

PN=461
 Power Train Repair—2 Speed

IMPORTANT: Push on inner race only to avoid

damaging bearing.

5. Stand axle case on end and install bearing (J). It may

be necessary to tap on inner race of bearing to install
tight against bottom of bore in case.
6. Install axle gear on axle shaft.

TCAL29768 —UN—09JUL12
J— Bearing

OUMX258,0000AC7 -19-15SEP14-40/50

Assemble Left Axle and Differential Housing

IMPORTANT: Always install new gaskets, O-rings, and
seals. Replace all damaged or rough moving
parts. Damaged or worn parts will leak.
Push on inner race only to avoid
damaging bearing.

TCAL29769 —UN—09JUL12
1. Install new outer bearing (A) on left axle, if removed.
Support inner race of bearing and press axle into
bearing until tight against axle shoulder.

A—Outer Bearing

OUMX258,0000AC7 -19-15SEP14-41/50

2. Install axle outer gear (G).

3. Install bearing (F) and ring gear (E) in axle housing.
4. Install left axle assembly (H) in housing.
5. Install axle inner gear (D), pinion gears (C) and pinion
shaft (B).

TCAL29770 —UN—09JUL12
B—Pinion Shaft F— Bearing
C—Pinion Gears G—Axle Outer Gear
D—Axle Inner Gear H—Left Axle Assembly
E—Ring Gear

Continued on next page OUMX258,0000AC7 -19-15SEP14-42/50

TM130419 (24FEB16) 40-40-116 030916

PN=462
 Power Train Repair—2 Speed

Assembe Differential and 4WD Axle Housing

1. Be sure O-ring (A) is on axle housing.

A—O-Ring

TCAL29771 —UN—09JUL12
OUMX258,0000AC7 -19-15SEP14-43/50

2. Align gears and housings. Put housings together.

Install cap screws and lock washers between axle
housings. Be sure to install two longer cap screws (B)
in holes adjacent to input shaft. Tighten all cap screws.
3. Be sure O-ring is on end of axle housing.
4. Align final drive with axle housing.

TCAL29772 —UN—09JUL12
5. Install five cap screws and lock washers (C) to housing
between final drive assembly and axle housing.
Tighten cap screws to specification.
Specification
Axle Housing-to-Final
Drive Assembly Cap
Screw—Torque..............................................................................68 N·m
(39 lb.-ft.)
B—Long Cap Screws C—Cap Screws and Washers
6. Repeat steps 3—5 for opposite end of axle housing. (5 used)

OUMX258,0000AC7 -19-15SEP14-44/50

Assemble Differential Input Shaft and Cover

IMPORTANT: Always install new gaskets, O-rings, and
seals. Replace all damaged or rough moving
parts. Damaged or worn parts will leak.

1. Install new seal (A) in input shaft cover. Install seal TCAL29773 —UN—09JUL12

with seal spring toward inside of cover. Push seal to

bottom of bore.

A—Seal

Continued on next page OUMX258,0000AC7 -19-15SEP14-45/50

TM130419 (24FEB16) 40-40-117 030916

PN=463
 Power Train Repair—2 Speed

IMPORTANT: Push on inner race only to avoid

damaging bearing.

2. Install new bearings on input shaft by pressing on

inner race of bearing. Install inner bearing first, then
outer bearing. Push bearings tight against shoulder
of shaft.

TCAL29774 —UN—09JUL12
OUMX258,0000AC7 -19-15SEP14-46/50

3. Install input shaft in differential case.

4. Install snap ring (B).

B—Snap Ring

TCAL29775 —UN—09JUL12
OUMX258,0000AC7 -19-15SEP14-47/50

5. Ensure the mating surfaces between the differential

input cover (D) and housing are clean.
6. Clean the differential input cover cap screws (C) with
PM37509 John Deere™ Cure Primer.
7. Apply PM38655 John Deere™ Form-In-Place Gasket
to mating surface of cover.

TCAL29776 —UN—09JUL12
8. Install differential input shaft cover. Install and tighten
three cap screws.

C—Cap Screws D—Differential Input Cover

John Deere is a trademark of Deere & Company

Continued on next page OUMX258,0000AC7 -19-15SEP14-48/50

TM130419 (24FEB16) 40-40-118 030916

PN=464
 Power Train Repair—2 Speed

Final Assembly
1. Install tie rod (A). Install and tighten tie rod castellated
nuts to specification. Continue to turn nut clockwise to

TCAL29777 —UN—09JUL12
align with drilled hole and install cotter pin.
Specification
Tie Rod Castellated
Nut—Torque..................................................................................53 N·m
(39 lb.-ft.)

A—Tie Rod

OUMX258,0000AC7 -19-15SEP14-49/50

2. Install differential housing drain plug (B) and tighten

to specification.
Specification
4WD Axle Drain
Plugs—Torque.......................................................................39 ± 10 N·m
(29 ± 10 lb.-ft.)

TCAL29778 —UN—09JUL12
3. Remove oil filler cap and fill 4WD axle with oil to
proper level.
Specification
4WD Axle—Oil Capacity
(Approximate)................................................................................... 2.1 L
(2.25 qt.)

4. Install filler cap.

5. Install 4WD axle assembly in machine. (See Remove B—Differential Housing Drain
and Install 4WD Axle—2 Speed.) Plug

OUMX258,0000AC7 -19-15SEP14-50/50

TM130419 (24FEB16) 40-40-119 030916

PN=465
 Power Train Repair—2 Speed

TM130419 (24FEB16) 40-40-120 030916

PN=466
 Section 50
Hydraulics Repair
Contents

Page

Group 10—Component Location

Summary of References................................ 50-10-1
Hydraulic System Component
Location ..................................................... 50-10-1
Auxiliary Hydraulic Kit Component
Location ..................................................... 50-10-2
Steering System Hydraulic Hose
Routing ...................................................... 50-10-3
Weight Transfer System
Component Location ................................. 50-10-4
Lift System Hydraulic Hose
Routing ...................................................... 50-10-5

Group 20—Repair
Summary of References................................ 50-20-1
Remove and Install Oil Cooler....................... 50-20-1
Inspect Oil Cooler .......................................... 50-20-1
Remove and Install Lift Lever ........................ 50-20-2
Remove and Install Implement Lift
Valve .......................................................... 50-20-3
Disassemble and Assemble
Implement Lift Valve .................................. 50-20-4
Remove and Install Lift Cylinder.................... 50-20-4
Remove and Install Auxiliary
Hydraulic Valve .......................................... 50-20-6
Disassemble, Inspect, and
Assemble Auxiliary Hydraulic
Valve .......................................................... 50-20-7
Remove and Install Hydraulic
Pump ......................................................... 50-20-7
Disassemble and Assemble
Hydraulic Pump ....................................... 50-20-10

TM130419 (24FEB16) 50-1 030916

PN=1
 Contents

TM130419 (24FEB16) 50-2 030916

PN=2
 Group 10
Component Location
Summary of References • Steering System Hydraulic Hose Routing
• Hydraulic System Component Location • Weight Transfer System Component Location
• Lift System Hydraulic Hose Routing
• Auxiliary Hydraulic Kit Component Location
CB12260,00001ED -19-15SEP14-1/1

Hydraulic System Component Location

TCAL29779 —UN—02JUL12
A—Steering Valve F— Hydro Pump K—Hydraulic Hose, Hydraulic
B—Implement Lift Valve G—Charge Pump Pump to Steering
C—Oil Cooler H—Hydraulic Pump L— Tube and Hydraulic Hose,
D—Hydraulic Hose, Oil Cooler to I— Transaxle Implement Lift Valve to Oil
Hydro Pump J— Hydraulic Hose, Steering Cooler
E—Hydraulic Hose, Steering and Cylinder to Oil Cooler M—Hydraulic Hose, Steering
Implement Lift Valve to Oil Valve to Implement Lift Valve
Cooler

OUMX258,0000AFA -19-22MAR13-1/1

TM130419 (24FEB16) 50-10-1 030916

PN=469
 Component Location

Auxiliary Hydraulic Kit Component Location

TCAL29780 —UN—02JUL12

A—Auxiliary Control Lever (2 C—Auxiliary Lift Valve (single or E—Hydraulic Hose (2 used for G—Quick Couplers (4 used for
used with double-spool valve) double spool) double-spool valve) double-spool valve)
B—Auxiliary Control Cable (2 D—Hydraulic Hose, Auxiliary Lift F— Hydraulic Hose (2 used for H—Implement Lift Valve
used with double-spool valve) Valve to Oil Cooler double-spool valve)
OUMX258,0000AFB -19-22MAR13-1/1

TM130419 (24FEB16) 50-10-2 030916

PN=470
 Component Location

Steering System Hydraulic Hose Routing

TCAL29781 —UN—02JUL12
A—Steering Valve C—Left Turn Steering Hose D—Right Turn Steering Hose
B—Steering Cylinder
OUMX258,0000AFC -19-22MAR13-1/1

TM130419 (24FEB16) 50-10-3 030916

PN=471
 Component Location

Weight Transfer System Component Location

A—Implement Lift Valve D—Tube, Implement Lift Valve
B—Weight Transfer Valve to Tee
C—Tee, Implement Lift Valve E—Tube, Weight Transfer Valve
and Weight Transfer Valve to Implement Lift Valve
to Lift Cylinders

TCAL29782 —UN—02JUL12
OUMX258,0000AFD -19-22MAR13-1/1

TM130419 (24FEB16) 50-10-4 030916

PN=472
 Component Location

Lift System Hydraulic Hose Routing

TCAL29783 —UN—02JUL12
A—Right Lift Cylinder E—Hydraulic Hose, Implement G—Hydraulic Hose, Implement J— Left Lift Cylinder
B—Right Hydraulic Hose (retract) Lift Valve to Oil Cooler Lift Valve and Lift Cylinders
C—Right Hydraulic Hose (extend) F— Tee Fitting, Lift Cylinder to Oil Cooler
D—Tee Fitting, Implement Lift Hoses to Oil Cooler Hose H—Left Hydraulic Hose (extend)
Valve to Lift Cylinder Hoses I— Left Hydraulic Hose (retract)
OUMX258,0000AFE -19-22MAR13-1/1

TM130419 (24FEB16) 50-10-5 030916

PN=473
 Component Location

TM130419 (24FEB16) 50-10-6 030916

PN=474
 Group 20
Repair
Summary of References • Remove and Install Lift Cylinder
• Remove and Install Oil Cooler • Remove and Install Auxiliary Hydraulic Valve
• Disassemble, Inspect, and Assemble Auxiliary
• Inspect Oil Cooler Hydraulic Valve
• Remove and Install Lift Lever • Remove and Install Hydraulic Pump
• Remove and Install Implement Lift Valve • Disassemble and Assemble Hydraulic Pump
• Disassemble and Assemble Implement Lift Valve
OUMX258,0000AF8 -19-25FEB14-1/1

Remove and Install Oil Cooler

CAUTION: Escaping fluid under pressure can
penetrate the skin causing serious injury.
Avoid the hazard by relieving pressure before
disconnecting hydraulic or other lines. Tighten
all connections before applying pressure. Search

TCAL29827 —UN—02JUL12
for leaks with a piece of cardboard. Protect hands
and body from high-pressure fluids.
If an accident occurs, see a doctor immediately.
Any fluid injected into the skin must be surgically
removed within a few hours or gangrene may
result. Doctors unfamiliar with this type of
injury should reference a knowledgeable medical
source. Such information is available from Deere
& Company Medical Department in Moline, Illinois, A—Hydraulic Hoses C—Flange Lock Nut
U.S.A. Information may be obtained in the United B—Thumb Screw D—Cap Screw
States and Canada only by calling 1-800-822-8262.

IMPORTANT: Absolute cleanliness is essential 5. Remove thumb screw (B).

when working on hydraulic components.
Contamination can result in serious damage 6. Remove flange lock nut (C) and cap screw (D).
or inadequate operation. Clean all lines and
fittings prior to opening hydraulic system. 7. Remove oil cooler.
Install
Remove
Installation is done in reverse order of removal.
1. Park machine safely.
2. Turn key switch to OFF position and allow machine
• Fill transaxle to correct oil level.
to cool.
• Check all connections for leaks.Repair or replace as
needed.
3. Open engine cover. • Bleed hydraulic system. (See Hydraulic System
Bleeding Procedure.)
NOTE: Mark hose connections to ensure correct
installation.

4. Disconnect and cap hydraulic hoses (A).

OUMX258,0000AED -19-22MAR13-1/1

Inspect Oil Cooler as this could result in damage. Direct the

spray parallel to the fins.
CAUTION: Reduce compressed air to less
than 210 kPa (30 psi) when using for cleaning Inspection
purposes. Clear area of bystanders, guard 1. Check oil cooler for debris lodged in fins. Clean oil
against flying chips, and wear personal protection cooler using compressed air or pressure washer.
equipment including eye protection.
2. Inspect oil cooler for bent fins, cracks and damaged
IMPORTANT: Do not apply high-pressure spray seams. Repair or replace oil cooler if necessary.
directly at fins when cleaning the oil cooler,
OUMX258,0000AEE -19-22MAR13-1/1

TM130419 (24FEB16) 50-20-1 030916

PN=475
 Repair

Remove and Install Lift Lever

IMPORTANT: Absolute cleanliness is essential
when working on hydraulic components.
Contamination can result in serious damage
or inadequate operation. Clean all lines and
fittings prior to opening hydraulic system.

Remove

TCAL29828 —UN—02JUL12
1. Park machine safely.
2. Turn key switch to OFF position.
3. Remove plastic cap, nut and knob from levers (A and
B).
4. Loosen right side console.
5. Remove screw from inner side of control console cover.
A—Lift Lever B—Lift Lever
6. Lift right side control console cover and disconnect
PTO switch connector. Remove cover.
OUMX258,0000AEF -19-22MAR13-1/2

7. Remove flange lock nut and flat washer (C), pivot and
washer and carriage bolt (D) securing lever to bracket.
8. Remove cotter pin and washer (E) securing link (F)
to lever.

TCAL29829 —UN—02JUL12
9. Remove lever (G).
10. Remove cotter pin (H) on link end. Turn link and valve
control to remove pin (I).
11. Remove link.
12. Inspect parts for wear or damage. Replace as needed.
Install
C—Flat Washer G—Lever
• Installation is done in the reverse order of removal. D—Pivot, Washer, and Carriage
Bolt
H—Cotter Pin
I— Pin
• Lift lever and link should move freely. E—Cotter Pin and Washer
F— Link

OUMX258,0000AEF -19-22MAR13-2/2

TM130419 (24FEB16) 50-20-2 030916

PN=476
 Repair

Remove and Install Implement Lift Valve

CAUTION: Escaping fluid under pressure

can penetrate skin causing serious injury.
Avoid the hazard by relieving pressure before
disconnecting hydraulic or other lines. Tighten

TCAL29830 —UN—02JUL12
all connections before applying pressure. Search
for leaks with a piece of cardboard. Protect hands
and body from high pressure fluids.
If an accident occurs, see a doctor immediately.
Any fluid injected into the skin must be surgically
removed within a few hours or gangrene may
result. Doctors unfamiliar with this type of Implement Lift Valve Without Optional Weight Transfer Valve
injury should reference a knowledgeable medical
source. Such information is available from Deere
& Company Medical Department in Moline, Illinois, A—Linkage D—Hydraulic Line
U.S.A. Information may be obtained in the United B—Hydraulic Line E—Hydraulic Line
C—Hydraulic Line F— Cap Screws and Flange
States and Canada only by calling 1-800-822-8262. Nuts

IMPORTANT: Absolute cleanliness is essential

when working on hydraulic components.
Contamination can result in serious damage 6. Inspect valve for leakage, wear, and damage.
or inadequate operation. Clean all lines and
Install
fittings prior to opening hydraulic system.
1. Lubricate O-rings on fittings and adapters before
NOTE: This procedure is for machines without optional installing.
weight transfer valve. If the optional weight transfer
valve is installed, removal and installation procedure 2. Install implement lift valve to machine with cap screws
is similar. Remove the control cable from weight and flange nuts (F).
control valve shaft and disconnect hydraulic lines.
3. Connect lines (B, C, D, and E). Tighten fittings to
specifications.
Remove
Specification
1. Disconnect battery negative (—) cable. Implement Lift Valve
Fittings—Torque............................................................................47 N·m
2. Remove right side console panel.
(35 lb.-ft.)
NOTE: Mark all hydraulic lines and connection points
before removing to ensure correct installation. 4. Connect linkage (A) from lift lever.
5. Install right side console panel.
3. Disconnect linkage (A) from lift lever.
6. Connect battery cable.
4. Disconnect lines (B, C, D, and E). Close all openings
using caps and plugs. Wipe up spills immediately. 7. Bleed hydraulic system. (See Hydraulic System
Bleeding Procedure.)
5. Remove cap screws and flange nuts (F). Remove
implement lift valve from machine. 8. Check hydraulic oil level. Add oil if necessary.
OUMX258,0000AF0 -19-15SEP14-1/1

TM130419 (24FEB16) 50-20-3 PN=477

030916
 Repair

Disassemble and Assemble Implement Lift

Valve
IMPORTANT: Absolute cleanliness is essential
when working on hydraulic components.
Contamination can result in serious damage

TCAL29831 —UN—02JUL12
or inadequate operation.
DO NOT use shop towels or rags to dry
cleaned parts. Lint will clog passages in the
hydraulic/hydrostatic system and cause damage.

Disassemble
1. Remove parts (A-L).
2. Inspect parts for wear and damage. A—Screw with Washer (2 used) G—Spring
B—Cap H—Spacer
Assemble C—Detent Plug (2 used) I— Washer
D—Spring (2 used) J— O-Ring
• Lubricate and install new O-rings and seals. E—Ball (2 used) K—O-Ring
• Apply grease to all springs. F— Detent Screw L— Plug
• Apply thread lock and sealer to threads of all plugs and
screws.
• Tighten all plugs and screws to specifications. Lift Valve Plug—Torque.................................................................24 N·m
(215 lb.-in.)
Specification
Lift Valve Detent
Plug—Torque................................................................................3.5 N·m
(30 lb.-in.)
OUMX258,0000AF1 -19-15SEP14-1/1

Remove and Install Lift Cylinder

CAUTION: Escaping fluid under pressure can

penetrate the skin causing serious injury.
Avoid the hazard by relieving pressure before

TCAL29832 —UN—02JUL12
disconnecting hydraulic or other lines. Tighten
all connections before applying pressure. Search
for leaks using a piece of cardboard. Protect
hands and body from high-pressure fluids.
If an accident occurs, see a doctor immediately.
Any fluid injected into the skin must be surgically
removed within a few hours or gangrene may
result. Doctors unfamiliar with this type of
injury should reference a knowledgeable medical
A—Cylinder Hoses E—Pin
source. Such information is available from Deere B—Cylinder Hoses F— Lift Cylinder Ball Joint
& Company Medical Department in Moline, Illinois, C—Lift Cylinder G—Lift Arm
U.S.A. Information may be obtained in the United D—Cotter Pin
States and Canada only by calling 1-800-822-8262.

IMPORTANT: Absolute cleanliness is essential

when working on hydraulic components.
Contamination can result in serious damage
or inadequate operation. Clean all lines and
fittings prior to opening hydraulic system.

NOTE: Lift cylinders are not serviceable. A new

cylinder must be installed.
Continued on next page OUMX258,0000AF2 -19-22MAR13-1/2

TM130419 (24FEB16) 50-20-4 PN=478

030916
 Repair

Remove
1. Park machine safely.
2. Turn key to OFF position.
3. Remove attachment.

TCAL29833 —UN—02JUL12
NOTE: Removing drive wheel provides better
access to lift cylinder.

4. Disconnect lift cylinder hoses (A and B) from lift

cylinder (C). Close all openings using caps or plugs.

CAUTION: Injury to hands and feet can occur

when lift arm is released from lift cylinder ball
joint. Avoid the hazard by supporting lift arm H—Cotter Pin J— Lift Cylinder Base
I— Pin
before releasing lift cylinder ball joint from lift arm.

5. Remove cotter pin (D) and pin (E) to separate lift

cylinder ball joint (F) from lift arm (G). • Installation is done in the reverse order of removal.
• Lubricate O-rings on fittings and adapters before
6. Remove cotter pin (H) and pin (I) securing lift cylinder installing.
base (J) to frame. • Bleed hydraulic system. (See Hydraulic System
7. Remove lift cylinder from machine. Bleeding Procedure.)
• Check hydraulic oil level. Add oil if needed.
8. Inspect lift cylinder for leakage, wear or damage.
9. Replace lift cylinder as needed.
Install
NOTE: Raise and support lift arm before installing
lift cylinder ball joint.
OUMX258,0000AF2 -19-22MAR13-2/2

TM130419 (24FEB16) 50-20-5 030916

PN=479
 Repair

Remove and Install Auxiliary Hydraulic Valve

CAUTION: Escaping fluid under pressure

can penetrate skin causing serious injury.
Avoid the hazard by relieving pressure before
disconnecting hydraulic or other lines. Tighten

TCAL29834 —UN—02JUL12
all connections before applying pressure. Search
for leaks with a piece of cardboard. Protect hands
and body from high pressure fluids.
If an accident occurs, see a doctor immediately.
Any fluid injected into the skin must be surgically
removed within a few hours or gangrene may
result. Doctors unfamiliar with this type of
injury should reference a knowledgeable medical
source. Such information is available from Deere A—Hydraulic Hose Connection F— Cotter Pin and Pin
& Company Medical Department in Moline, Illinois, B—Hydraulic Hose Connection G—Bolts and Flange Nuts
U.S.A. Information may be obtained in the United C—Hydraulic Hose Connection H—Auxiliary Control Valve
D—Hydraulic Hose Connection I— Mounting Bracket
States and Canada only by calling 1-800-822-8262. E—Hydraulic Hose Connection

IMPORTANT: Absolute cleanliness is essential

when working on hydraulic components.
Contamination can result in serious damage 4. Remove bolts and flange nuts (G).
or inadequate operation. Clean all lines and
5. Remove auxiliary hydraulic valve (H) from mounting
fittings prior to opening hydraulic system.
bracket (I).
NOTE: Auxiliary hydraulic spool valves and housings are Install
matched and must be replaced as a unit.
Medium strength thread lock and sealer has been
• Lubricate and install new O-rings on fittings and
adapters.
applied to threads of spool end screws. • Apply thread lock and sealer to threads of all screws
and plugs.
Remove • Tighten all plugs and screws to specifications.
1. Disconnect battery negative (—) cable. • Install auxiliary lift valve onto mounting bracket.
• Connect all hoses and tighten fittings.
NOTE: Optional double-spool auxiliary hydraulic valve has • Connect lift lever link(s).
two valve controls and four auxiliary inlet/outlet ports. • Connect battery negative (—) cable.
• Bleed hydraulic system. (See Hydraulic System
2. Disconnect hydraulic hose connections (A-E). Close Bleeding Procedure.)
all openings using caps and plugs. Wipe up any spills • Check hydraulic oil level. Add oil if necessary.
immediately.
3. Remove cotter pin and pin from valve control (F).
OUMX258,0000AF3 -19-22MAR13-1/1

TM130419 (24FEB16) 50-20-6 030916

PN=480
 Repair

Disassemble, Inspect, and Assemble

Auxiliary Hydraulic Valve
IMPORTANT: Absolute cleanliness is essential
when working on hydraulic components.
Contamination can result in serious damage
or inadequate operation.
DO NOT use shop towels or rags to dry
cleaned parts. Lint will clog passages in the
hydraulic/hydrostatic system and cause damage.

1. Remove parts (A-P).

2. Inspect parts for wear or damage.

TCAL29835 —UN—02JUL12
• If screw (C), bushing (D), spring (E) and washer (F)
are worn or damaged, replace as necessary.
3. Inspect threads in ports for damage or wear.
• If port threads are worn or damaged, install new
optional auxiliary valve assembly.

A—Screw with Washer (2 used) I— Spacer

B—Cap J— Washer
C—Screw K—O-Ring
D—Bushing L— Poppet
E—Spring M—Spring
F— Washer N—Spacer
G—Spool O—O-Ring
H—Spring P—Plug

OUMX258,0000AF4 -19-22MAR13-1/1

Remove and Install Hydraulic Pump

Remove
IMPORTANT: Absolute cleanliness is essential
when working on hydraulic components.
Contamination can result in serious damage
or inadequate operation. Clean all lines and
fittings prior to opening hydraulic system.

NOTE: It is not necessary to remove transaxle to repair

hydraulic pump only. Hydraulic pump can be

TCAL29837 —UN—02JUL12
removed without disassembly of transaxle.
Transaxle is shown removed for clarity.
Use shop cloths or paper towels to immediately
catch and clean up any spilled oil. Close all
ports and lines using caps or plugs.

1. If transaxle is in unit, drain transaxle. (See Changing

the Transaxle Oil and Filter in the operator’s manual.) A—Hose Clamp (4 used) C—Bolt
B—Hoses (2 used)
NOTE: Power steering hose will rotate at power
steering valve.

2. Loosen the four hose clamps (A) and remove the two 3. Remove the bolt (C) holding the hydraulic line support
hoses (B) from the intake manifold. bracket.
Continued on next page OUMX258,0000AF6 -19-22MAR13-1/7

TM130419 (24FEB16) 50-20-7 030916

PN=481
 Repair

4. Remove the three hex head screws (D) holding the

intake manifold to the top of the hydraulic pump.
Remove the manifold assembly.

D—Hex Head Screws (3 used)

TCAL29838 —UN—02JUL12
OUMX258,0000AF6 -19-22MAR13-2/7

5. Remove the hydraulic line and pressure fitting (E) from

the bottom of the hydraulic pump by removing the
three cap screws (F).

E—Hydraulic Line and F— Cap Screws (3 used)

Pressure Fitting

TCAL29839 —UN—02JUL12
OUMX258,0000AF6 -19-22MAR13-3/7

6. Mark cover and pump (arrows) for reassembly.

Remove the four cap screws (G) marked in the photo
and remove the hydraulic pump. Do not remove the
remaining four cap screws at this time, as the pump
components could separate during removal.

TCAL29840 —UN—02JUL12
G—Cap Screws (4 used)

Continued on next page OUMX258,0000AF6 -19-22MAR13-4/7

TM130419 (24FEB16) 50-20-8 030916

PN=482
 Repair

Install
1. Install a new gasket on the hydraulic pump.
2. Align the pump drive gear shaft internal splines with
the splined shaft (H) on the transaxle and install the
hydraulic pump with the remaining four cap screws.

H—Splined Shaft

TCAL29841 —UN—02JUL12
OUMX258,0000AF6 -19-22MAR13-5/7

3. Install the hydraulic line (I) and pressure fitting (J) to the
bottom of the hydraulic pump with three cap screws.

I— Hydraulic Line J— Pressure Fitting

TCAL29842 —UN—02JUL12
OUMX258,0000AF6 -19-22MAR13-6/7

4. Install the intake manifold (K) to the top of the pump

with three hex head screws. Install the bolt (L) that
holds the hydraulic line support bracket and the two
rubber hoses (M). Secure hoses with screw clamps.
5. If the transaxle is mounted in the unit, refill it with oil.
(See operator’s manual.)

K—Intake Manifold M—Hoses (2 used)

L— Bolt TCAL29843 —UN—02JUL12

OUMX258,0000AF6 -19-22MAR13-7/7

TM130419 (24FEB16) 50-20-9 030916

PN=483
 Repair

Disassemble and Assemble Hydraulic Pump

IMPORTANT: Absolute cleanliness is essential
when working on hydraulic components.
Contamination can result in serious damage
or inadequate operation.

TCAL29844 —UN—02JUL12
DO NOT use shop towels or rags to dry
cleaned parts. Lint will clog passages in the
hydraulic/hydrostatic system and cause damage.

Disassemble
1. Remove the four remaining pump body cap screws
and separate the cover (A) from the body of the pump.

A—Pump Body Cover

OUMX258,0000AF7 -19-15SEP14-1/11

2. Remove the front thrust plate (B) from the gears.

Check the brass side (inside) for signs of damage
such as gouging, scoring or pitting. Replace pump if
damage or wear is evident.

B—Front Thrust Plate

TCAL29845 —UN—02JUL12
Continued on next page OUMX258,0000AF7 -19-15SEP14-2/11

TM130419 (24FEB16) 50-20-10 030916

PN=484
 Repair

3. Remove the pump drive gear (C) and idler gear (D)
assemblies from the pump body, noting the location
of the gears.
4. Inspect gear faces (E) for wear such as chipping,
pitting or spalling of the gear faces. Replace pump
as required.
5. Inspect internal shaft splines on the drive gear.
Replace pump if gear is worn or damaged.
6. Measure the bearing surfaces on both the idler gear
and drive gear. Replace pump if gears are worn below

TCAL29846 —UN—02JUL12
minimum specification.

C—Pump Drive Gear E—Gear Faces

D—Idler Gear

OUMX258,0000AF7 -19-15SEP14-3/11

7. Remove the rear thrust plate (F) from the pump body.
Check the brass side for wear or damage. Replace
pump as required.
8. Inspect the bushing surfaces (G) in the pump body
for wear or damage. Inspect the pump body internal
surfaces for scoring, scratching or excessive wear.
Replace pump if damaged.

F— Rear Thrust Plate G—Bushing Surfaces

TCAL29847 —UN—02JUL12
Continued on next page OUMX258,0000AF7 -19-15SEP14-4/11

TM130419 (24FEB16) 50-20-11 030916

PN=485
 Repair

9. Remove the internal snap ring (H) and the seal (I)
from the pump body.

H—Snap Ring I— Seal

TCAL29848 —UN—02JUL12
OUMX258,0000AF7 -19-15SEP14-5/11

Assemble
1. Install a new seal (J) in the pump body and secure
with internal snap ring (K).

J— Seal K—Snap Ring

TCAL29849 —UN—02JUL12
Continued on next page OUMX258,0000AF7 -19-15SEP14-6/11

TM130419 (24FEB16) 50-20-12 030916

PN=486
 Repair

2. Install the rear thrust plate in the pump body with the
brass side facing out (toward gear). Note that the
lubrication groove (L) goes toward the top (intake
side) of pump.

L— Lubrication Groove

TCAL29850 —UN—02JUL12
OUMX258,0000AF7 -19-15SEP14-7/11

3. Install the pump drive gear (M) and idler gear (N) in
the pump body.

M—Pump Drive Gear N—Idler Gear

TCAL29851 —UN—02JUL12
Idler gear (N) is symmetrical and can be placed in body either end first.

Continued on next page OUMX258,0000AF7 -19-15SEP14-8/11

TM130419 (24FEB16) 50-20-13 030916

PN=487
 Repair

4. Place front thrust plate (O) over shaft ends with the
brass surface to the inside. Thrust plate should be
flush with pump body gasket surface (P) when all
components are installed correctly.

O—Front Thrust Plate P—Pump Body Gasket Surface

TCAL29852 —UN—02JUL12
OUMX258,0000AF7 -19-15SEP14-9/11

5. If removed, clean and install formed O-ring gasket (Q)

in the grooves on the front cover.

Q—O-Ring Gasket

TCAL29853 —UN—02JUL12
OUMX258,0000AF7 -19-15SEP14-10/11

6. Install the front cover using four cap screws (R). Note
that the cover has an out (S) marking that must be
oriented on the bottom (outlet side) of pump. Tighten
cap screws to specifications.
Specification
Hydraulic Pump
Front Cover Cap
Screws—Torque............................................................................15 N·m TCAL29854 —UN—02JUL12
(113 lb.-in.)

R—Cap Screws (4 used) S—Out Marking

OUMX258,0000AF7 -19-15SEP14-11/11

TM130419 (24FEB16) 50-20-14 030916

PN=488
 Section 60
Steering and Brakes Repair
Contents

Page

Group 10—Component Location

Summary of References................................ 60-10-1
Steering System Component
Location ..................................................... 60-10-1

Group 20—Steering Repair

Summary of References................................ 60-20-1
Specifications ................................................ 60-20-1
Remove and Install Steering
Column Repair Kit ..................................... 60-20-1
Remove and Install Steering
Cylinder ..................................................... 60-20-2

Group 30—Brakes Repair

Summary of References................................ 60-30-1
Remove and Install Brake
Linkage ...................................................... 60-30-2
Remove and Install Turn Brake
Pedals........................................................ 60-30-4
Remove and Install Master Brake
Pedal ......................................................... 60-30-6
Remove and Install Park Brake
Lock Lever Assembly ................................ 60-30-8

TM130419 (24FEB16) 60-1 030916

PN=1
 Contents

TM130419 (24FEB16) 60-2 030916

PN=2
 Group 10
Component Location
Summary of References
• Steering System Component Location
CB12260,00001EE -19-15SEP14-1/1

Steering System Component Location

A—Steering Valve E—Hydraulic Hose, Steering
B—Hydraulic Hose, Steering Valve to Steering Cylinder
Valve to Lift Valve (right turn)
C—Charge Pump F— Hydraulic Hose, Steering
D—Steering Cylinder Valve to Steering Cylinder
(left turn)
G—Hydraulic Hose, Steering
Valve to Reservoir
H—Hydraulic Hose, Charge
Pump to Steering Valve

TCAL29855 —UN—12JUN12
OUMX258,0000B13 -19-22MAR13-1/1

TM130419 (24FEB16) 60-10-1 030916

PN=491
 Component Location

TM130419 (24FEB16) 60-10-2 030916

PN=492
 Group 20
Steering Repair
Summary of References • Remove and Install Steering Cylinder
• Remove and Install Steering Column Repair Kit
OUMX258,0000B2F -19-25MAR13-1/1

Specifications
Item Measurement Specification
Wheel Bolts
Rear Wheels - 2WD Torque 82 N·m
(60 lb.-ft.)
All Other Wheels Torque 122 N·m
(90 lb.-ft.)
OUMX258,000019D -19-30DEC13-1/1

Remove and Install Steering Column Repair

Kit
1. Remove steering valve.
2. Place steering valve in bench vice.
3. Remove push nuts (A).
4. Remove column assembly (B) and gasket (C).
Install
Installation is done in the reverse order of removal.

A—Push Nuts C—Gasket

B—Column Assembly

TCAL29872 —UN—12JUN12

OUMX258,0000B14 -19-27FEB14-1/1

TM130419 (24FEB16) 60-20-1 030916

PN=493
 Steering Repair

Remove and Install Steering Cylinder

Remove

CAUTION: Escaping fluid under pressure can

penetrate the skin causing serious injury.
Avoid the hazard by relieving pressure before
disconnecting hydraulic or other lines. Tighten
all connections before applying pressure. Search

TCAL29873 —UN—12JUN12
for leaks with a piece of cardboard. Protect hands
and body from high-pressure fluids.
If an accident occurs, see a doctor immediately.
Any fluid injected into the skin must be surgically
removed within a few hours or gangrene may
result. Doctors unfamiliar with this type of
injury should reference a knowledgeable medical
source. Such information is available from Deere
& Company Medical Department in Moline, Illinois, A—Hydraulic Hose D—Castle Nut
U.S.A. Information may be obtained in the United B—Hydraulic Hose E—Cotter Pin
States and Canada only by calling 1-800-822-8262. C—Steering Cylinder

IMPORTANT: IMPORTANT: Absolute cleanliness

is essential when working on hydraulic 6. Remove steering cylinder.
components. Contamination can result in
serious damage or inadequate operation. Install
Clean all lines and fittings prior to opening
hydraulic system. Installation is done in the reverse order of removal.

1. Park machine safely and turn key switch to stop

• Tighten castle nuts to specification before installing
cotter pins.
position.
Specification
2. Turn wheel back and forth several times to relieve Steering Cylinder Castle
hydraulic pressure from system. Nut—Torque..................................................................................75 N·m
(55 lb.-ft.)
NOTE: Mark hoses before removing to ensure
correct installation. • Fill hydraulic reservoir (transaxle) to correct level with
oil meeting specifications.
3. Disconnect and plug hydraulic hoses (A and B). • Bleed air from hydraulic system.
4. Remove cotter pin (E) and castle nut (D) from both
• Check all connections for leaks. Repair as needed.
sides of steering cylinder (C).
5. Separate steering cylinder from mounting using a
wedge-fork driver.
OUMX258,0000B15 -19-25FEB14-1/1

TM130419 (24FEB16) 60-20-2 PN=494

030916
 Group 30
Brakes Repair
Summary of References • Remove and Install Master Brake Pedal
• Remove and Install Brake Linkage • Remove and Install Park Brake Lock Lever Assembly
• Remove and Install Turn Brake Pedals
OUMX258,0000B30 -19-25MAR13-1/1

TM130419 (24FEB16) 60-30-1 030916

PN=495
 Brakes Repair

Remove and Install Brake Linkage

TCAL29883 —UN—11JUN12

A—Left Turn Brake Arm E—Right Master Brake Arm J— Turnbuckle (2 used) N—Left Brake Cam Arm
B—Right Turn Brake Arm F— Support (2 used) K—Lower Brake Link Assembly O—Left Master Brake Arm
C—Center Support G—Pedal Shaft (2 used)
D—Master Brake Pedal Support H—Bushing (2 used) L— Right Brake Cam Arm
I— Upper Brake Link Assembly M—Brake Return Spring (2 used)
(2 used)

Remove 4. Remove cotter pin and clevis pin holding upper left
1. Park machine on level ground. brake link assembly (I) to left master brake arm (O)
and left turn brake arm (A).
2. Raise machine and remove front wheels.
5. Remove cotter pin and clevis pin holding left lower
3. Remove left brake return spring (M) from latch hook. brake link assembly (K) to left brake cam arm (N) and
remove assembly (I, J, and K).
Continued on next page OUMX258,0000B16 -19-30DEC13-1/2

TM130419 (24FEB16) 60-30-2 030916

PN=496
 Brakes Repair

6. Remove right brake return spring (M) from latch hook. NOTE: The lower right side clevis pin should be installed
with its head facing outward. Place a washer
7. Remove cotter pin and clevis pin holding upper right between the clevis and rue pin.
brake link assembly (I) to right master brake arm (E)
and right turn brake arm (B). 2. Install brake link assembly on machine starting with
8. Remove cotter pin and clevis pin holding right lower lower clevis first, then upper clevis.
brake link assembly (K) to right brake cam arm (L) and 3. Install the brake return springs.
remove assembly (I, J, and K).
4. Check the left and right turn pedal free play and adjust
9. Inspect brake link assemblies and turnbuckles for turn brake linkage. (See Check and Adjust Turn
wear and damage. Replace as necessary. Brake.)
Install
1. Install locknuts on upper and lower brake link rods and
connect with turnbuckle. Adjust assembled linkage to
preset length according to specifications.
OUMX258,0000B16 -19-30DEC13-2/2

TM130419 (24FEB16) 60-30-3 030916

PN=497
 Brakes Repair

Remove and Install Turn Brake Pedals

TCAL29884 —UN—11JUN12

Continued on next page OUMX258,0000B17 -19-19DEC13-1/3

TM130419 (24FEB16) 60-30-4 030916

PN=498
 Brakes Repair

A—Right Turn Brake Arm H—Jam Nut, M8 (2 used) O—Support X—Left Master Brake Arm
B—Pedal Shaft I— Brake Return Spring Clip (2 P—Pivot Bushing Y—Screw, M8 x 30 (2 used)
C—Clevis Pin (2 used) used) Q—Washer Z— Right Turn Brake Pedal
D—Clevis (2 used) J— Clevis Pin (2 used) R—Locknut, M8 (2 used) AA—Right Turn Brake Pedal Pad
E—Cotter Pin (2 used) K—Left Turn Brake Pedal Pad S—Left Turn Brake Pedal AB—Locknut, M8 (2 used)
F— Jam Nut, M8 (Left-Hand L— Cotter Pin (2 used) T— Lubrication Fitting
Thread) (2 used) M—Locknut, M8 (2 used) U—Left Turn Brake Arm
G—Turnbuckle (2 used) N—Screw, M8 x 25 (2 used) V—Screw, M8 x 30 (2 used)
W—Spring Pin Set
OUMX258,0000B17 -19-19DEC13-2/3

Remove
1. Park machine on level ground.
2. Lower lift arms or attachment.
3. Open service hatch on operator’s platform.
4. Remove brake return spring from brake return spring
clip (I).
5. Remove screws (V) and locknuts (R) securing left turn

TCAL29885 —UN—19JUL12
brake pedal (S) to left turn brake arm (U).
6. Remove left turn brake pedal.
NOTE: Lower left turn brake arm to gain access and
remove screws on right turn brake pedal.

7. Remove screws (Y) and locknuts (X) securing right

turn brake pedal (Z) and right master brake arm (A).
8. Remove right turn brake pedal. A—Right Master Brake Arm V—Screw, M8
P—Lubrication Fitting X—Locknuts
9. Inspect all parts for wear or damage. Replace as R—Locknut Y—Screw, M8
necessary. S—Left Turn Brake Pedal Z— Right Turn Brake Pedal
U—Left Turn Brake Arm
Install
Installation is done in the reverse order of removal. • Check turn brake pedal free play and adjust. (See
Check and Adjust Turn Brake.)
• Make sure slots of inner and outer spring pins for spring
pin set (W) are 180° apart.
• Lubricate left turn brake arm and pedal shaft using
lubrication fitting (T).
OUMX258,0000B17 -19-19DEC13-3/3

TM130419 (24FEB16) 60-30-5 030916

PN=499
 Brakes Repair

Remove and Install Master Brake Pedal

TCAL29886 —UN—11JUN12

A—Pad G—Neutral Safety Arm K—Right Master Brake Arm P—Spring Pins
B—Master Brake Pedal H—Neutral Safety Link L— Locknut, M8 (2 used)
C—Pawl I— Right Turn Brake Arm M—Bracket
D—Arm J— Lubrication Fitting N—Support
E—Spring O—Screw, M10 x 40 (2 used)
F— Spring (Master Brake Pedal)
Continued on next page OUMX258,0000B18 -19-19DEC13-1/2

TM130419 (24FEB16) 60-30-6 030916

PN=500
 Brakes Repair

Remove
1. Park machine on level ground.
2. Unlock park brake.
3. Disconnect spring (F) from bracket (M) to release
support (N).

TCAL29887 —UN—11JUN12
NOTE: Lift up on forward motion pedal to remove
rear screw on master brake pedal.

4. Remove locknut (L) and screw (O).

5. Remove master brake pedal (B) and bracket.
6. Inspect master brake pedal and pad (A) for wear or
damage. Replace as necessary.
Install B—Master Brake pedal L— Locknut
C—Pawl M—Bracket
Installation is done in the reverse order of removal. D—Park Brake Arm N—Support
F— Spring O—Screw
• Make sure slots of inner and outer spring pins for spring
pin sets (P) are 180° apart.
• Apply grease to lubrication fitting (J) to lubricate right Adjust if necessary. (See Remove and Install Park
turn brake arm (I), right master brake arm (K), and Brake Lock Lever Assembly.)
pedal shaft. • Check neutral safety arm (G) and neutral safety link for
• Check master brake pedal free play and adjust. (See proper operation, and adjust if necessary. (See Adjust
Check and Adjust Turn Brake.) F-N-R Linkage, or Adjust F-N-R Linkage—2 Speed.)
• Move park brake lever to lock position. Park brake • Check brake switch for proper operation and adjust.
arm (D) should activate pawl (C), and lock the support. (See Adjust Brake Switch.)
OUMX258,0000B18 -19-19DEC13-2/2

TM130419 (24FEB16) 60-30-7 030916

PN=501
 Brakes Repair

Remove and Install Park Brake Lock Lever Assembly

TCAL29888 —UN—11JUN12

A—Plate D—Cap Screw H—Bushing (2 used) L— Locknut

B—Screw E—Spring I— Bracket
C—Park Brake Lock Lever F— Arm J— Pawl
Assembly G—Snap Ring K—Flange Nut
Continued on next page OUMX258,0000B19 -19-19DEC13-1/2

TM130419 (24FEB16) 60-30-8 030916

PN=502
 Brakes Repair

Remove
1. Park machine on level surface.
2. Unlock park brake.
3. Remove spring (E) from arm (F).
4. Remove cap screw (D) and nut (K) to disconnect park

TCAL29889 —UN—11JUN12
brake cable from bracket (I).
5. Remove screws (B) securing park brake lock lever
assembly (C) to steering column cover.
6. Remove park brake lock lever assembly and cable
from steering column cover.
7. Inspect park brake lock lever assembly and cable for
wear or damage. Replace as necessary.
E—Spring M—Support
Install F— Arm

Installation is done in the reverse order of removal.

• Move park brake lock lever to lock position. - Result: Park brake must hold the machine stationary.
• Depress master brake pedal. Pawl (J) should mesh (ANSI standards permit movement of no more than
with tooth on master brake pedal support (M) and lock 61 cm [24 in.] in one hour.) If machine moves more
master brake pedal. than that, brakes need to be adjusted.
• Test park brake: • Adjust brakes if necessary. (See Check and Adjust
- Stop machine on 17° slope (30% grade). Stop the Turn Brake.)
engine and lock park brake.
OUMX258,0000B19 -19-19DEC13-2/2

TM130419 (24FEB16) 60-30-9 030916

PN=503
 Brakes Repair

TM130419 (24FEB16) 60-30-10 030916

PN=504
 Section 70
Attachments Repair
Contents

Page
Page
Group 10—Repair, Cutting Units
Summary of References................................ 70-10-1 Install Snowblower Rotor and Fan................ 70-20-11
Rotate 60, 62, and 72-Inch (Side Replacing Fan or Coupler............................ 70-20-13
Discharge) Mower Deck ............................ 70-10-1 Install Rotor Assembly................................. 70-20-14
Rotate 72-Inch (Rear Discharge) Replace Rotor Bearing ................................ 70-20-15
Mower Deck............................................... 70-10-4
Remove and Install 60, 62 and Group 30—Repair, GLC System
72-Inch (Side Discharge) Mower Summary of References................................ 70-30-1
Deck Belt Shields ...................................... 70-10-6 Remove Collection System ........................... 70-30-1
Remove and Install 72-Inch Rear Install Collection System ............................... 70-30-6
Discharge Mower Deck Belt Install Hydraulic Pump to Deck...................... 70-30-9
Shield......................................................... 70-10-6 Replacing Blower Fan Drive Belt................. 70-30-11
Rotate V-Flex Mower Deck............................ 70-10-7 Install Suction Port....................................... 70-30-12
Remove 60, 72-Inch (Side Install Blower Hose...................................... 70-30-13
Discharge) and 62-Inch (Rear
Discharge) Mower Deck Drive
Belt ............................................................ 70-10-9
Install 60, 72-Inch (Side Discharge)
and 62-Inch (Rear Discharge)
Mower Deck Drive Belt ............................ 70-10-10
Remove 72-Inch (Rear Discharge)
Mower Deck Drive Belt ............................ 70-10-11
Install 72-Inch (Rear Discharge)
Mower Deck Drive Belt ............................ 70-10-12
Remove and Install V-Flex Mower
Deck Belt Shields .................................... 70-10-13
Remove and Install V-Flex Mower
Deck Drive Belts ...................................... 70-10-14
Align Vertical Belt Drive ............................... 70-10-16
Remove and Install Mower Deck
Blade ....................................................... 70-10-19
Sharpen and Balance Blades ...................... 70-10-20
Remove and Install Mower Deck
Spindle..................................................... 70-10-21
Disassemble and Inspect Mower
Deck Spindle ........................................... 70-10-26
Remove and Install Mower Deck
Drive Shaft............................................... 70-10-33
Mower Deck Drive Shaft Repair .................. 70-10-34
Remove and Install Mower Deck
Gearbox................................................... 70-10-35
Mower Deck Gearbox Repair ...................... 70-10-38
Caster Wheels, Yoke, and
Bearings .................................................. 70-10-39

Group 20—Repair, Snowblowers

Summary of References................................ 70-20-1
60-Inch Snowblower Gear Case
Inspection .................................................. 70-20-1
Snowblower Gear Assembly ......................... 70-20-1
Snowblower Main Case
Inspection .................................................. 70-20-7
Snowblower Main Case
Assembly ................................................... 70-20-7

TM130419 (24FEB16) 70-1 030916

PN=1
 Contents

TM130419 (24FEB16) 70-2 030916

PN=2
 Group 10
Repair, Cutting Units
Summary of References • Remove 72-Inch (Rear Discharge) Mower Deck Drive
Belt
• Rotate 60, 62, and 72-Inch (Side Discharge) Mower • Install 72-Inch (Rear Discharge) Mower Deck Drive Belt
Deck
• Remove and Install V-Flex Mower Deck Belt Shields
• Rotate 72-Inch (Rear Discharge) Mower Deck • Remove and Install V-Flex Mower Deck Drive Belts
• Remove and Install 60, 62 and 72-Inch (Side Discharge) • Align Vertical Belt Drive
Mower Deck Belt Shields
• Remove and Install Mower Deck Blade
• Remove and Install 72-Inch Rear Discharge Mower • Sharpen and Balance Blades
Deck Belt Shield
• Remove and Install Mower Deck Spindle
• Remove and Install 72-Inch Rear Discharge Mower • Disassemble and Inspect Mower Deck Spindle
Deck Belt Shield
• Remove and Install Mower Deck Drive Shaft
• Rotate V-Flex Mower Deck • Mower Deck Drive Shaft Repair
• Remove 60, 72-Inch (Side Discharge) and 62-Inch • Remove and Install Mower Deck Gearbox
(Rear Discharge) Mower Deck Drive Belt
• Install 60, 72-Inch (Side Discharge) and 62-Inch (Rear • Mower Deck Gearbox Repair
Discharge) Mower Deck Drive Belt
• Caster Wheels, Yoke, and Bearings
OUMX258,0000B62 -19-11SEP14-1/1

Rotate 60, 62, and 72-Inch (Side Discharge)

Mower Deck
Rotate Mower Deck for Service
1. Park machine on level surface.

TCAL29953 —UN—03JUL12
2. Move mower deck to fully raised position.

CAUTION: Failure to engage service latches

can result in mower deck dropping to ground
if hydraulic system pressure is lost.

3. Engage the service latches (A) on left and right hand

lift arms.
A—Service Latches

OUMX258,0000B3B -19-26FEB14-1/7

4. Side discharge decks only: Remove spring pin (B)

from drilled pin (C) holding anti-scalp wheel bracket
(D) onto left side of mower deck. Remove anti-scalp
wheel from mower deck.

B—Spring Pin D—Bracket

C—Drilled Pin
TCAL29954 —UN—03JUL12

Continued on next page OUMX258,0000B3B -19-26FEB14-2/7

TM130419 (24FEB16) 70-10-1 030916

PN=507
 Repair, Cutting Units

5. Unlock and open service hatch (E) on machine.

6. Pull forward on coupler ring (F) of PTO driveshaft (G).
Pull PTO driveshaft off of the PTO output shaft (H).

E—Service Hatch G—PTO Driveshaft

TCAL29955 —UN—03JUL12
F— Coupler Ring H—PTO Output Shaft

OUMX258,0000B3B -19-26FEB14-3/7

7. Remove retaining ring (I) from hanger pin (J).

NOTE: To return the mower deck to its original cutting
height, mark the hole location where the hanger
pin was installed before removing the pin.

8. Carefully remove hanger pin from adjustment plate (K).

Deck will drop. Repeat for other side of mower deck.

I— Retaining Ring K—Adjustment Plate

J— Hanger Pin

TCT007171 —UN—10APR13
OUMX258,0000B3B -19-26FEB14-4/7

9. Lower rear of mower deck to the ground. PTO

driveshaft (L) will drop clear of front axle.

L— PTO Driveshaft

TCAL29957 —UN—03JUL12

Continued on next page OUMX258,0000B3B -19-26FEB14-5/7

TM130419 (24FEB16) 70-10-2 030916

PN=508
 Repair, Cutting Units

10. Pull service lock handle (M) out and rotate back until
spring is compressed and pin (N) is locked into slot.
11. Continue to rotate the mower deck back until hole (O)
in deck bracket is aligned with service lock (P).

M—Service Lock Handle O—Hole

N—Pin P—Service Lock

TCAL29958 —UN—03JUL12
OUMX258,0000B3B -19-26FEB14-6/7

12. Rotate service lock handle forward to extend pin (Q)

into deck bracket.
Rotate Mower Deck for Operation
1. Pull mower deck service lock out of mower deck

TCAL29959 —UN—03JUL12
bracket.
2. Rotate deck forward while keeping PTO shaft from
wedging into ground or machine.
3. Connect PTO driveshaft to PTO output shaft of
transaxle.
4. Rotate mower deck to level position. Install rear
hanger pins into holes marked or to desired cutting
height holes on rear adjustment plates. Q—Pin
5. Install retaining rings on left and right side hanger pins.
6. Side discharge decks only: Install anti-scalp wheel 8. Lower mower deck to the ground.
on mower deck.
7. Unlock service latches.
OUMX258,0000B3B -19-26FEB14-7/7

TM130419 (24FEB16) 70-10-3 030916

PN=509
 Repair, Cutting Units

Rotate 72-Inch (Rear Discharge) Mower Deck

Rotate Mower Deck for Service
1. Raise the mower deck completely.
2. Park machine on a level surface.
3. Lock the park brake.

TCAL29960 —UN—03JUL12
4. Stop the engine and remove the key.
5. Wait for all moving parts to stop before you leave the
operator’s seat.
6. Engage the service latches.
7. Unlock and open service hatch (A) on machine.
8. Pull forward on the coupler ring (B) located on the
mower deck PTO driveshaft (C). Pull the driveshaft off A—Service Hatch C—PTO Driveshaft
of machine PTO output shaft (D). B—Coupler Ring D—PTO Output Shaft

OUMX258,0000B3C -19-17APR13-1/4

9. Remove the retaining ring (E) from the hanger pin (F).
NOTE: To return the mower deck to its original cutting
height, note the hole location that the hanger pin
was installed in before removing the hanger pin.

10. Remove hanger pin from hole in adjustment plate (G).

11. Repeat for the other side of mower deck.

E—Retaining Ring G—Adjustment Plate

F— Hanger Pin

TCT007172 —UN—10APR13
Continued on next page OUMX258,0000B3C -19-17APR13-2/4

TM130419 (24FEB16) 70-10-4 030916

PN=510
 Repair, Cutting Units

12. Lift deck until hole (I) lines up with pin. Lock pin (H)
into hole (I).

H—Service Lock Handle I— Hole

TCT007173 —UN—10APR13
OUMX258,0000B3C -19-17APR13-3/4

13. Rotate deck by pulling the deck backwards and lock

with pin (K).
Rotate Mower Deck for Operation
1. Pull mower deck service lock pin out of lift arm bracket.

TCT007174 —UN—13MAY13
2. Rotate deck forward, keeping mower deck driveshaft
from digging into ground.
3. Route mower deck driveshaft up on top of machine
front axle, and connect to machine PTO output shaft
on transaxle.
4. Continue to rotate mower deck to level position, and
install rear hanger pins into holes in rear adjustment
plates that correspond to desired cutting height.
J— Lift Arms K—Pins
5. Install retaining rings on left and right side hanger pins.
6. Lower lift arms (J) and secure with pins.
7. Unlock service latches. 8. Lower mower deck to ground.
OUMX258,0000B3C -19-17APR13-4/4

TM130419 (24FEB16) 70-10-5 030916

PN=511
 Repair, Cutting Units

Remove and Install 60, 62 and 72-Inch (Side

Discharge) Mower Deck Belt Shields
Removal

CAUTION: To avoid personal injury, make sure

TCT007176 —UN—10APR13
engine is off and mower deck PTO and drive belt
have stopped before removing belt shields.

1. Park machine on level surface.

2. Rotate mower deck for service, or remove mower deck
from machine. (See Rotate 60, 62, and 72-Inch (Side
Discharge) Mower Deck.)
72-inch mower deck shown
NOTE: The belt shield for the 60-inch mower deck consists
of two pieces. The belt shields for the 62-inch and A—Retaining Rings (6 used) B—Belt Shield
72-inch mower decks consist of one piece.

3. Remove six retaining rings (A) securing belt shield (B)

to mower deck. 2. Install six retaining rings (A) securing belt shield (B)
to mower deck.
4. Lift belt shield up off of the attaching bolts.
3. Rotate mower deck for operation.
5. Inspect belt shield for cracks, wear or damage.
Replace if necessary.
Installation
1. Install belt shield on the attaching bolts.
OUMX258,0000B3D -19-26FEB14-1/1

Remove and Install 72-Inch Rear Discharge

Mower Deck Belt Shield
CAUTION: Fingers and loose clothing can get
caught in rotating parts. Do not operate machine

TCT007177 —UN—10APR13
without all mower deck belt shields installed.

1. Lower deck to the ground or remove mower deck from

machine.
2. Remove wing nuts (A) and remove service tool (B).
3. Remove retaining nuts securing belt shields (C) to
mower deck.
4. Lift belt shields up off of the attaching bolts. A—Wing Nuts C—Belt Shields
B—Service Tool
Installation
1. Install belt shields (C)on to the attaching bolts.
2. Install retaining nuts securing belt shields (C) to mower 3. Install service tool (B) and wing nuts (A).
deck.
OUMX258,0000B3E -19-23APR13-1/1

TM130419 (24FEB16) 70-10-6 030916

PN=512
 Repair, Cutting Units

Rotate V-Flex Mower Deck

Rotate Mower Deck for Service
1. Park machine on level surface.
2. Unlock and open service hatch (A) on machine.

TCAL29975 —UN—03JUL12
3. Pull forward on the coupler ring (B) located on the
mower deck PTO driveshaft (C). Pull the driveshaft off
of machine PTO output shaft (D).

A—Service Hatch C—PTO Driveshaft

B—Coupler Ring D—PTO Output Shaft

OUMX258,0000B3F -19-19APR13-1/5

4. Pull out, turn and release the retaining ring (E) to

release the hanger pin (F) so the pin rides on the deck
bracket.
5. Remove quick pull pin from drilled pin (G) and remove
float chain (H).

E—Retaining Ring G—Drilled Pin

F— Hanger Pin H—Float Chain

TCT007178 —UN—10APR13
OUMX258,0000B3F -19-19APR13-2/5

NOTE: A second person may be needed to help lift

wing while latching wing chain.

6. Lift wing deck (J) and latch chain (I).

I— Latch Chain J— Wing Deck

TCAL29977 —UN—03JUL12

Continued on next page OUMX258,0000B3F -19-19APR13-3/5

TM130419 (24FEB16) 70-10-7 030916

PN=513
 Repair, Cutting Units

7. Start machine and raise mower deck to top of travel.

Stop engine. Mower deck should rotate.
8. Lift up on the front of deck until hanger pins snap into
holes of deck bracket.

TCAL29978 —UN—03JUL12
OUMX258,0000B3F -19-19APR13-4/5

CAUTION: Failure to engage service latches

can result in mower deck dropping to ground
if hydraulic system pressure is lost.

9. Lock service chain to latch brackets (K) on left and

TCAL29979 —UN—03JUL12
right side mower deck lift arms.
Rotating Mower Deck for Operation
1. Start machine and raise mower deck to top of travel
and stop engine.
2. Remove service chain latches.
3. While one person lifts up on front of deck, a second
person pulls mower deck service lock out of deck K—Latch Brackets
bracket.
4. Allow deck to rotate forward carefully.
8. Lift up on deck wings and release chains.
5. Latch service latch in retracted position.
9. Install chain safety pins.
6. Install pin and service chain.
10. Install driveshaft.
7. Lower mower deck to ground.
OUMX258,0000B3F -19-19APR13-5/5

TM130419 (24FEB16) 70-10-8 030916

PN=514
 Repair, Cutting Units

Remove 60, 72-Inch (Side Discharge) and

62-Inch (Rear Discharge) Mower Deck Drive
Belt
Procedure

TCT007179 —UN—10APR13
1. Park machine on level surface.
2. Lower attachment.
3. Remove belt shield. (See Remove and Install 60,
62 and 72-Inch (Side Discharge) Mower Deck Belt
Shields or Remove and Install 72-Inch Rear Discharge
Mower Deck Belt Shield.)
72-inch deck shown.
4. Loosen locknuts (A and B).
5. Remove nut (C), and remove tension spring and rod A—Locknut C—Nut
(D) from mower deck. B—Locknut D—Rod
6. Remove nuts and washers from locknuts (A and B).
OUMX258,0000B40 -19-23APR13-1/3

7. Remove drive belt (E) from belt tensioning sheave (F).

E—Drive Belt F— Sheave

TCT007180 —UN—10APR13
72-inch deck shown.

OUMX258,0000B40 -19-23APR13-2/3

8. Remove four cap screws (G) holding mower deck PTO

gearbox (H) to frame.
• 72-inch deck only: Remove support bushing (I).
9. Slide gearbox out from mounting brackets, and
remove drive belt (J) from sheave.
TCAL29982 —UN—03JUL12

10. Inspect drive belt for cracks, wear or damage. Replace

if necessary.

G—Cap Screws (4 used) I— Support Bushing

H—PTO Gearbox J— Drive Belt

72-inch deck shown.

OUMX258,0000B40 -19-23APR13-3/3

TM130419 (24FEB16) 70-10-9 030916

PN=515
 Repair, Cutting Units

Install 60, 72-Inch (Side Discharge) and

62-Inch (Rear Discharge) Mower Deck Drive
Belt

TCAL29983 —UN—03JUL12
CAUTION: BE CAREFUL when removing
drive belt from sheaves; your fingers may be
pinched and injury may result.

NOTE: For correct drive belt routing, refer to drive

belt routing diagram or drive belt tension
label on mower deck.
60-inch drive belt routing shown (from rear of deck).
1. Route drive belt (B) around mower deck as shown on
drive belt tension label on mower deck. A—Pulley B—Drive Belt

• 60-inch deck only: Loosen pulley (A).

OUMX258,0000B41 -19-15SEP14-1/4

2. Wrap the drive belt around the PTO gearbox drive

sheave (C) and install PTO gearbox onto mower deck
frame. Secure PTO gearbox with cap screws and
washers (D). Tighten cap screws to specification.
Specification
PTO Gearbox to Frame

TCAL29984 —UN—03JUL12
Cap Screw—Torque......................................................................99 N·m
(73 lb.-ft.)

3. 72-inch mower deck only: Install the support bushing

(E), cap screw and nut (F).

C—PTO Gearbox Drive Sheave E—Support Bushing

D—Cap Screws and Washers F— Nut 72-inch deck shown.

OUMX258,0000B41 -19-15SEP14-2/4

4. Install the drive belt (G) onto tensioning sheave (H).

G—Drive Belt H—Tensioning Sheave

TCT007181 —UN—10APR13

72-inch deck shown

Continued on next page OUMX258,0000B41 -19-15SEP14-3/4

TM130419 (24FEB16) 70-10-10 030916

PN=516
 Repair, Cutting Units

5. Install the tensioning bracket (I) to the mower deck

using two carriage head cap screws and nylock nuts
(J), and a flat washer (K). Do not tighten hardware at
this time.
6. Install tension spring and rod (L), and secure nut (M).

TCT007182 —UN—10APR13
7. Adjust spring tension for mower deck drive belt to
specification. Tighten tension bracket mounting cap
screws.
Specification
60 and 72-Inch Side and
Rear Discharge Mower
Deck Drive Belt Tension
Spring—Length........................................................................... 13.8 cm 72-inch deck shown
(5.44 in.)
60-Inch Gen II Mower I— Tensioning Bracket L— Rod
Deck Drive Belt Tension J— Nylock Nuts M—Nut
Spring—Length........................................................................... 12.7 cm K—Flat Washer
(5 in.)

8. Install belt shield.

OUMX258,0000B41 -19-15SEP14-4/4

Remove 72-Inch (Rear Discharge) Mower

Deck Drive Belt
1. Park machine safely.
2. Remove belt shields.
3. Loosen nuts (A).

TCAL29987 —UN—03JUL12
4. Remove nut (B). Remove tensioning spring and rod
(C) from deck.

A—Nuts C—Tensioning Spring and Rod

B — Nut

OUMX258,0000B42 -19-23APR13-1/3

5. Remove four locknuts and cap screws (D) holding

mower deck gearbox bracket to frame.

D—Locknuts and Cap Screws

TCAL29988 —UN—03JUL12

Continued on next page OUMX258,0000B42 -19-23APR13-2/3

TM130419 (24FEB16) 70-10-11 030916

PN=517
 Repair, Cutting Units

6. Remove belt (F) from sheave and remove bracket (E)

from mower deck.

E—Bracket F— Belt

TCAL29989 —UN—03JUL12
OUMX258,0000B42 -19-23APR13-3/3

Install 72-Inch (Rear Discharge) Mower Deck

Drive Belt

TCAL29990 —UN—03JUL12
1. Remove belt tensioner sheave and mower deck
gearbox as shown in (See Remove 72-Inch (Rear
Discharge) Mower Deck Drive Belt also (See Remove
and Install Mower Deck Gearbox.
NOTE: A belt routing decal is affixed to mower deck.

2. Route drive belt (A) around mower deck sheaves as

shown. A—Drive Belt

OUMX258,0000B43 -19-23APR13-1/4

3. Wrap the drive belt (B) around the drive sheave (C)
and lower gearbox bracket onto mower deck.

B—Drive Belt C—Drive Sheave

TCAL29991 —UN—03JUL12

Continued on next page OUMX258,0000B43 -19-23APR13-2/4

TM130419 (24FEB16) 70-10-12 030916

PN=518
 Repair, Cutting Units

4. Ensure that belt is routed correctly around all sheaves.

Install and tighten hardware (D).

D—Hardware

TCAL29992 —UN—03JUL12
OUMX258,0000B43 -19-23APR13-3/4

5. Install tension spring and rod (E) and secure with nut
(F).
6. Adjust tension for mower deck drive belt, and tighten
tensioner bracket mounting cap screws (G).
7. Install belt shields.

E—Tension Spring and Rod G—Cap Screws

F— Nut

TCAL29993 —UN—03JUL12
OUMX258,0000B43 -19-23APR13-4/4

Remove and Install V-Flex Mower Deck Belt

Shields
CAUTION: Fingers and loose clothing can get
caught in rotating parts. Do not operate machine
without all mower deck belt shields installed.

1. Remove knobs securing belt shields (A) to mower

deck.
TCAL29994 —UN—03JUL12

2. Lift belt shields up off of the attaching bolts.

3. Installation is done in the reverse order of removal.

A—Belt Shields

OUMX258,0000B44 -19-25MAR13-1/1

TM130419 (24FEB16) 70-10-13 030916

PN=519
 Repair, Cutting Units

Remove and Install V-Flex Mower Deck Drive

Belts
Remove Gearbox Belt

CAUTION: To avoid injury to hands or fingers

because of pinch areas, use care when
removing belt from sheave.

TCAL29995 —UN—03JUL12
1. Park machine on level surface.
2. Remove the mower deck belt shield.
3. Loosen nuts (A).

CAUTION: Spring is under tension and can cause

Parts removed for clarity.
injury. Use care when pulling back on spring
off idler arm. Use eye protection.
A—Nuts C—Tension Spring and Rod
4. Remove nut (B), and tension spring and rod (C) from B—Nut
mower deck.
OUMX258,0000B45 -19-19APR13-1/7

IMPORTANT: Do not clean mower belts using a

parts cleaning solvent or belt dressing. They
soften belts and shorten belt life.

5. Remove drive belts (D) from drive sheave (E).

TCAL29996 —UN—03JUL12
D—Drive Belts E—Drive Sheave

OUMX258,0000B45 -19-19APR13-2/7

Remove Vertical Drive Belt

1. Remove belt shields.

CAUTION: Spring is under tension and can cause

injury. Use care when pulling back on spring
off idler arm. Use eye protection.

2. Remove left belt.

• Loosen nut (A) on idler pivot, using a 15 mm wrench,
TCAL29997 —UN—03JUL12

and rotate idler and remove belt (B) by hand.

A—Nut B—Belt

Continued on next page OUMX258,0000B45 -19-19APR13-3/7

TM130419 (24FEB16) 70-10-14 030916

PN=520
 Repair, Cutting Units

3. Remove left center belt.

a. Partially remove left belt (B) by loosening nut from
previous steps.
b. Loosen nut (C) from left center idler pivot to rotate
idler using a 15 mm wrench, and remove belt (D)
by hand.

TCAL29998 —UN—03JUL12
B—Left Belt D—Belt
C—Nut

OUMX258,0000B45 -19-19APR13-4/7

4. Remove right center belt.

a. Partially remove left center belt (D) by loosening
nut from previous steps.
b. Loosen nut (E) from right center idler pivot to rotate

TCAL29999 —UN—03JUL12
idler using a 15 mm wrench, and remove belt (F)
by hand.

D—Left Center Belt F— Belt

E—Nut

OUMX258,0000B45 -19-19APR13-5/7

5. Remove right belt.

a. Partially remove right center belt (F) by loosening
nut from previous steps.
b. Loosen nut (G) from right idler pivot to rotate idler
using a 15 mm wrench, and remove belt (H) by hand.

F— Right Center Belt H—Belt

G—Nut
TCT007183 —UN—10APR13

Continued on next page OUMX258,0000B45 -19-19APR13-6/7

TM130419 (24FEB16) 70-10-15 030916

PN=521
 Repair, Cutting Units

Install Belt
NOTE: Belt routing diagram is affixed to mower deck
belt shield and to the deck.

TCAL30001 —UN—03JUL12
1. Route drive belt (A) around mower deck sheaves as
shown. (Shown from rear of deck.)
2. Install belt shields.

A—Drive Belt

TCAL30002 —UN—03JUL12
OUMX258,0000B45 -19-19APR13-7/7

Align Vertical Belt Drive

1. Loosen jam nuts and set screws (A) to adjust center
pulley on gearbox to specification. Tighten hardware.
Specification
Vertical Belt Drive Center
Pulley—Distance (B).........................................4 mm (0.16 in.) from end

TCAL30003 —UN—03JUL12
A—Set Screws B—Distance

Some parts removed for clarity.

Continued on next page OUMX258,0000B46 -19-15SEP14-1/9

TM130419 (24FEB16) 70-10-16 030916

PN=522
 Repair, Cutting Units

2. Use a straightedge on front of center pulley (C) to

locate pulley (D) on right side gearbox. If pulley is
located off shaft, go to step 1 and adjust center pulley
to specification.
Specification

TCAL30004 —UN—03JUL12
Vertical Belt Drive Center
Pulley—Distance...............................................4 mm (0.16 in.) from end

3. Use straightedge on right side gearbox back to center

pulley to verify right side pulley and gearbox location.
Rotate gearbox to get alignment. Work between steps
2 and 3 to get alignment within specification.
Specification
Vertical Belt Drive Pulley
Alignment—Distance....................................................................... 2 mm C—Center Pulley D—Pulley (Right Side Gearbox)
(0.08 in.)

OUMX258,0000B46 -19-15SEP14-2/9

4. Use straightedge on rear of center pulley (C) to locate

pulley (E) of left side gearbox. If pulley interferes with
gearbox, go back to step 1 and adjust specification
accordingly.
Specification

TCAL30005 —UN—03JUL12
Vertical Belt Drive Center
Pulley—Distance...............................................4 mm (0.16 in.) from end

5. Use straightedge on left side gearbox back to center

pulley to verify left side pulley and gearbox location.
Rotate gearbox to get alignment. Work between steps
4 and 5 to get alignment within specification.
Specification
Vertical Belt Drive Pulley
Alignment—Distance....................................................................... 2 mm C—Center Pulley E—Pulley (Left Side Gearbox)
(0.08 in.)

OUMX258,0000B46 -19-15SEP14-3/9

6. Assemble jam nut to set screws (A) (if not already

done).
7. Apply thread lock to set screws of each of the gearbox
pulleys and tighten to specifications.
Specification
TCAL30006 —UN—03JUL12

Gearbox Pulley Set

Screw—Torque..........................................................................8 ± 2 N·m
(65 ± 12 lb.-in.)

A—Set Screws

Continued on next page OUMX258,0000B46 -19-15SEP14-4/9

TM130419 (24FEB16) 70-10-17 030916

PN=523
 Repair, Cutting Units

8. Use straightedge between front of center pulley (C) to

right side pulley (D).

C—Center Pulley D—Right Side Pulley

TCAL30007 —UN—03JUL12
OUMX258,0000B46 -19-15SEP14-5/9

9. Remove belts (E) and center pivot pin and spacers (F).

E—Belts F— Center Pivot Pin and

Spacers

TCT007184 —UN—10APR13
OUMX258,0000B46 -19-15SEP14-6/9

10. Rotate right arm assembly (G) down to deck and

locate front of transfer pulley to straightedge.

G—Right Arm Assembly

TCAL30009 —UN—03JUL12

Continued on next page OUMX258,0000B46 -19-15SEP14-7/9

TM130419 (24FEB16) 70-10-18 030916

PN=524
 Repair, Cutting Units

11. Adjust three mounting bolts by loosening the three

nuts (H) near outer gearbox to locate pulley.
12. Rotate arm up and install center pin.
13. Repeat steps 10 through 12 on other side, except with

TCAL30010 —UN—03JUL12
straightedge on the back of center pulley.

H—Nuts

OUMX258,0000B46 -19-15SEP14-8/9

14. Remove center pin (I) and install spacers (J) between
brackets and drive arms to limit movement of arm to
specification.
Specification
Vertical Belt Drive Right
Arm Assembly Movement
(maximum)—Distance..................................................................... 2 mm
(0.08 in.)

15. Install drive belts.

TCAL30011 —UN—03JUL12
I— Center Pin J— Spacers

OUMX258,0000B46 -19-15SEP14-9/9

Remove and Install Mower Deck Blade

Removal
1. Rotate mower deck for service.

CAUTION: Mower blades are sharp. Wear heavy TCAL30012 —UN—03JUL12

gloves or wrap the ends of the blades with a rag.

2. Place a wooden block (A) between end of blade and

edge of mower deck to prevent blade from turning
when removing the attaching hardware.
3. Remove bolt (B), small and large washers (C)
and blade (D) from spindle by turning the bolt
counterclockwise until removed. Repeat for all blades
requiring service. A—Wooden Block C—Small and Large Washers
B—Bolt D—Blade
4. Inspect blades for damage. Replace damaged blades.
5. Clean the blades, spindles, and mounting hardware.
6. Sharpen and balance the blades.
Continued on next page OUMX258,0000B47 -19-15SEP14-1/2

TM130419 (24FEB16) 70-10-19 030916

PN=525
 Repair, Cutting Units

Installation
1. Make sure deflector cup (A) is seated firmly on mower
deck spindle.

CAUTION: Mower blades are sharp. Wear heavy

gloves or wrap the ends of the blades with a rag.

2. Install blade (B) onto spindle with wings of blade facing

TCAL30013 —UN—03JUL12
up toward deck shell. Make sure blade is firmly seated
against deflector cup.
3. Install large washer (C) with concave side toward
blade, then small washer (D) and cap screw (E).
Tighten cap screw to specification.
Specification
Blade Cap
Screw—Torque............................................................................122 N·m
(90 lb.-ft.) A—Deflector Cup D—Small Washer
B—Blade E—Cap Screw
4. Rotate mower deck to operating position. Lower C—Large Washer
mower to ground.
OUMX258,0000B47 -19-15SEP14-2/2

MXT001831 —UN—03JAN12
Sharpen and Balance Blades

CAUTION: Wear gloves when handling blade.

1. Clean blade.
2. Sharpen blade using grinder, file or power sharpener.
3. Do not alter original bevel (A). Blade should have
0.40 mm (0.016 in.) cutting edge (B) rather than a
razor-type edge. A—Bevel B—Cutting Edge

OUMX258,00002C6 -19-04JUN12-1/2

4. Put blade on nail in a vise or vertical wall stud.

5. Turn blade to horizontal position. If the blade is not
balanced, the heavy end will drop.
6. Grind bevel of heavy end. Do not change blade bevel
angle. MXT001832 —UN—19DEC11

OUMX258,00002C6 -19-04JUN12-2/2

TM130419 (24FEB16) 70-10-20 030916

PN=526
 Repair, Cutting Units

Remove and Install Mower Deck Spindle

Removal: 60-Inch Side Discharge and 62-Inch
Rear Discharge Mower Decks

CAUTION: To help prevent personal injury,

wear heavy gloves or wrap the end of
the blade with a rag.

1. Remove drive belt (See Remove 60, 72-Inch (Side

Discharge) and 62-Inch (Rear Discharge) Mower Deck
Drive Belt.)
2. Remove blade cap screw (A), flat washer (B), blade
washer (C), blade (D) and deflector (E).
3. Remove mounting locknuts (G).
4. Remove spindle assembly (F) from mower deck.
5. Inspect spindle assembly for wear or damage.
Replace components as necessary.
Installation: 60-Inch and 72-Inch Side Discharge and
62-Inch and 72-Inch Rear Discharge Mower Decks
1. Install spindle assembly (F) to mower deck.

TCT007186 —UN—10APR13
2. Install mounting locknuts (G).
• Tighten spindle mounting locknuts to specifications.
Specification
Spindle Mounting
Locknut—Torque.....................................................................24 ± 4 N·m
(18 ± 4 lb.-ft.)

3. Install deflector (E), blade (D), blade washer (C), flat

A—Cap Screw E—Deflector
washer (B), and blade cap screw (A). B—Flat Washer F— Spindle Assembly
C—Blade Washer G—Locknuts
IMPORTANT: Install blade with bent tips up. Install D—Blade
blade washer with concave side to blade.

• Install blade and tighten blade cap screw to • Install drive belt.
(See Install 60, 72-Inch (Side
specifications. Discharge) and 62-Inch (Rear Discharge) Mower Deck
Specification Drive Belt.)
Blade Cap
Screw—Torque............................................................................122 N·m
(90 lb.-ft.)
Continued on next page OUMX258,0000B4A -19-15SEP14-1/8

TM130419 (24FEB16) 70-10-21 030916

PN=527
 Repair, Cutting Units

Removal: 72-Inch Side and Rear Discharge

Mower Deck

CAUTION: To help prevent personal injury,

wear heavy gloves or wrap the end of
the blade with a rag.

1. Remove drive belt. (See Remove 60, 72-Inch (Side

Discharge) and 62-Inch (Rear Discharge) Mower
Deck Drive Belt or Remove 72-Inch (Rear Discharge)
Mower Deck Drive Belt.)
2. Remove blade cap screw (A), flat washer (B), blade

TCAL30017 —UN—03JUL12
washer (C), blade (D) and deflector (E).

A—Blade Cap Screw D—Blade

B—Flat Washer E—Deflector
C—Blade Washer

OUMX258,0000B4A -19-15SEP14-2/8

3. Remove four sheave-to-hub locknuts and bolts (F)

on spindle.

F— Sheave-to-Hub Locknuts
and Bolts (4 used)

TCAL30018 —UN—03JUL12
OUMX258,0000B4A -19-15SEP14-3/8

4. Remove six mounting locknuts (G) securing spindle

housing to mower deck.
5. Remove spindle from mower deck.
6. Inspect spindle assembly for wear or damage.
Replace components as necessary.

G—Locknuts
TCAL30019 —UN—03JUL12

Continued on next page OUMX258,0000B4A -19-15SEP14-4/8

TM130419 (24FEB16) 70-10-22 030916

PN=528
 Repair, Cutting Units

Installation: 72-Inch Side and Rear Discharge

Mower Deck
1. Install spindle to mower deck.
2. Install six mounting locknuts (G) securing spindle
housing to mower deck.

G—Locknuts

TCAL30019 —UN—03JUL12
OUMX258,0000B4A -19-15SEP14-5/8

3. Install four sheave-to-hub locknuts and bolts (F) on

spindle.

F— Sheave-to-Hub Locknuts
and Bolts (4 used)

TCAL30018 —UN—03JUL12
Continued on next page OUMX258,0000B4A -19-15SEP14-6/8

TM130419 (24FEB16) 70-10-23 030916

PN=529
 Repair, Cutting Units

4. Install deflector (E), blade (D), blade washer (C), flat

washer (B), and blade cap screw (A).
• Tighten spindle mounting locknuts to specifications.
Specification
Spindle Mounting
Locknut—Torque.....................................................................24 ± 4 N·m
(18 ± 4 lb.-ft.)

• Tighten sheave-to-hub locknuts to specifications.

Specification
Sheave Lock-
nut—Torque.............................................................................24 ± 4 N·m

TCAL30017 —UN—03JUL12
(18 ± 4 lb.-ft.)

IMPORTANT: Install blade with bent tips up. Install

blade washer with concave side to blade.

• Install blade and tighten cap screw to specifications.

Specification
Blade Cap
Screw—Torque............................................................................122 N·m
(90 lb.-ft.) A—Blade Cap Screw D—Blade
B—Flat Washer E—Deflector
• Install drive belt. (See Install 60, 72-Inch (Side C—Blade Washer
Discharge) and 62-Inch (Rear Discharge) Mower Deck
Drive Belt or Install 72-Inch (Rear Discharge) Mower
Deck Drive Belt.) 1. Remove drive belt. (See Remove and Install V-Flex
Removal: 7-Iron V-Flex Side Discharge Mower Decks Mower Deck Drive Belts.)

CAUTION: To help prevent personal injury,

wear heavy gloves or wrap the end of
the blade with a rag.
Continued on next page OUMX258,0000B4A -19-15SEP14-7/8

TM130419 (24FEB16) 70-10-24 030916

PN=530
 Repair, Cutting Units

2. Remove blade cap screw (A), blade washer (B), blade

(C) and deflector (D).
3. Remove mounting locknuts (E) and bolts (H).
4. Remove bracket (F).
5. Remove gearbox (G).
6. Inspect spindle assembly for wear or damage.
Replace components as necessary.
Installation: 7-Iron V-Flex Side Discharge
Mower Decks
1. Install gearbox (G).
2. Install bracket (F).
3. Install mounting locknuts (E) and bolts (H).

TCT007187 —UN—10APR13
4. Install deflector (D), blade (C), blade washer (B), and
blade cap screw (A).
5. Install drive belt. (See Remove and Install V-Flex
Mower Deck Drive Belts.)
6. Tighten spindle mounting locknuts to specifications.
Specification
Spindle Mounting
Locknut—Torque.....................................................................24 ± 4 N·m A—Blade Cap Screw F— Bracket
B—Blade Washer G—Gearbox
(18 ± 4 lb.-ft.) C—Blade H—Bolt
D—Deflector I— Pulley
IMPORTANT: Install blade with bent tips up. Install E—Locknuts
blade washer with concave side to blade.

7. Install blade and tighten blade cap screw to

specifications.
Specification
Blade Cap
Screw—Torque............................................................................122 N·m
(90 lb.-ft.)
OUMX258,0000B4A -19-15SEP14-8/8

TM130419 (24FEB16) 70-10-25 030916

PN=531
 Repair, Cutting Units

Disassemble and Inspect Mower Deck

Spindle
Disassembly and Inspection: 60-Inch Side
Discharge Mower Decks and 62-Inch Rear
Discharge Mower Decks
IMPORTANT: Always install new bearings and
seals when servicing spindles.

1. Install blade (R), blade washer (S), washer (T), and

cap screw (U) on spindle shaft (P). Tighten to 320 N·m
(236 lb.-ft.).
2. Place blade in a soft-jawed vise.
3. Remove flange nut (B).
4. Remove nuts (C), sheave (D), deflector (E) hub (F),
and deflector (G).
5. Remove cap screw (U), washer (T), blade washer (S),
and blade (R).
6. Remove spindle shaft (P) from housing (L).
7. Remove lower seal ring (M) and lower seal (O).
NOTE: Remove upper bearing (I) and lower bearing
(N) only if replacement is necessary.

8. Upper and lower bearings are seated against spindle

hub shoulder and cannot be removed with a press.
Remove upper seal (H) and bearings using a punch.
9. Remove spacer (J).
10. Inspect all parts for wear or damage. Replace parts
as needed.

A—Lubrication Fitting (apply L— Housing

grease) M—Lower Seal Ring
B—Flange Nut N—Lower Bearing
C—Nut O—Lower Seal

TCT007188 —UN—10APR13
D—Sheave P—Spindle Shaft
E—Upper Deflector Q—Lower Deflector
F— Hub R—Blade
G—Deflector S—Blade Washer
H—Upper Seal T— Washer
I— Upper Bearing U—Cap Screw
J— Spacer
K—Nut

Continued on next page OUMX258,0000B4B -19-07APR15-1/10

TM130419 (24FEB16) 70-10-26 030916

PN=532
 Repair, Cutting Units

Assembly: 60-Inch Side Discharge Mower Decks

and 62-Inch Rear Discharge Mower Decks
1. Using a press and disk driver large enough to contact
the bearing outer race, install lower bearing (A) until it
is seated against the shoulder in the housing (B).

TCAL30022 —UN—03JUL12
2. Turn the housing over.
3. Install spacer (C). Center the spacer over the lower
bearing.
IMPORTANT: Using disk drivers, support both
the inner and outer races of the upper and
lower bearings when installing the upper
bearing. Do not support the housing by
allowing it to rest on its end.
A—Lower Bearing C—Spacer
B—Housing D—Upper Bearing
4. Using a press and disk driver, install upper bearing (D)
until it rests against the bottom of the housing shoulder.
OUMX258,0000B4B -19-07APR15-2/10

NOTE: The inner diameter chamfer of the seal ring

is away from the bearing.

5. Using a press and disk, install lower seal (E) with open

TCAL30023 —UN—03JUL12
side toward bearing until the face of the seal is at the
specified height (F) from the lower end of the housing.
Specification
Seal Face Distance
from Lower End of
Housing—Distance..................................................................... 2.57 mm
(0.10 in.)

6. Install lower seal ring (G) with the outer diameter E—Lower Seal G—Lower Seal Ring
chamfered edge toward bearing. F— Height

Continued on next page OUMX258,0000B4B -19-07APR15-3/10

TM130419 (24FEB16) 70-10-27 030916

PN=533
 Repair, Cutting Units

7. Using a press, install seal (O) with open side toward

bearing until face of seal is flush with end of housing
(R).
8. Install spindle shaft (S) into housing (R).
9. Install hub (M), upper deflector (L), sheave (K), and
bushing (N).
10. Install flange nut (I).
IMPORTANT: Blade (U) must be properly seated
on the spindle, and concave side of blade
washer (V) MUST face toward blade.

11. Install lower deflector (T), blade (U), washers (V and

W), and cap screw (X).
12. Tighten blade cap screw to 320 N·m (236 lb.-ft.).
13. Place blade in a soft-jawed vise.
14. Tighten flange nut to specifications.
Specification
Spindle Flange
Nut—Torque................................................................................255 N·m
(188 lb.-ft.)

15. Loosen blade cap screw and retighten to specifications.

Specification
Blade Cap
Screw—Torque............................................................................122 N·m
(90 lb.-ft.)

16. Apply specified grease to lubrication fitting (H).

H—Lubrication Fitting Q—Nut

I— Nut R—Housing
J— Nut S—Spindle Shaft
K—Sheave T— Lower Deflector
L— Upper Deflector U—Blade
M—Hub V—Washer
N—Bracket W—Washer
O—Seal X—Bolt
P—Bearing

TCT007189 —UN—18APR13

Continued on next page OUMX258,0000B4B -19-07APR15-4/10

TM130419 (24FEB16) 70-10-28 030916

PN=534
 Repair, Cutting Units

Disassembly and Inspection: 72-Inch Side and

Rear Discharge Mower Decks
IMPORTANT: Do not install hexagon end of spindle
shaft in a vise to remove spindle sheave nut.
The hexagon end of the spindle shaft will be
damaged, resulting in improper blade operation.

1. Install blade (Q), blade washer (R), washer (S), and

cap screw (T) on spindle shaft (N). Tighten cap screw
to 320 N·m (236 lb.-ft.).
2. Place blade in a soft-jawed vise.
3. Remove flange nut (F).
NOTE: Remove bolts (C) from hub (D) only if replacement
of parts is necessary. If required, press bolts from
hub to remove upper deflector (E).

4. Remove hub, upper deflector, and bolts as an

assembly.
5. Remove cap screw, washer, blade washer, and blade.
6. Remove spindle shaft (O) from housing (I).
7. Remove lower seal ring (N) and lower seal (M).
NOTE: Remove upper bearing (G) and lower bearing
(K) only if replacement is necessary.

8. The upper bearing and lower bearing are seated

against the spindle hub shoulders and cannot be
removed with a press. Remove upper seal (L) and

TCT007185 —UN—11JUN14
bearings using a punch.
9. Remove spacer (K).
10. Inspect all parts for wear or damage. Replace parts
as needed.

A—Lubrication Fitting (apply K—Spacer

grease) L— Bearing
B—Flange Nut M—Washer
C—Pulley N—Seal
D—Hub O—Spindle
E—Deflector P—Lower Deflector
F— Screw Q—Blade
G—Seal, Upper R—Washer
H—Bearing S—Washer
I— Housing T— Cap Screw
J— Screw

Continued on next page OUMX258,0000B4B -19-07APR15-5/10

TM130419 (24FEB16) 70-10-29 030916

PN=535
 Repair, Cutting Units

Assembly: 72-Inch Side and Rear Discharge

Mower Decks
1. Using a press and disk driver large enough to contact
the bearing outer race, install lower bearing (A) until it
is seated against the shoulder in the housing (B).
2. Turn housing over.

TCAL30026 —UN—03JUL12
3. Install spacer (C). Center the spacer over the lower
bearing.
IMPORTANT: Using disk drivers, support both
the inner and outer races of the upper and
lower bearings when installing the upper
bearing. Do not support the housing by
allowing it to rest on its end.
A—Lower Bearing C—Spacer
4. Using a press and disk driver, install upper bearing (D) B—Housing D—Upper Bearing
until it rests against the bottom of the housing shoulder.
OUMX258,0000B4B -19-07APR15-6/10

NOTE: The inner diameter chamfer of the seal ring

is away from the bearing.

TCAL30027 —UN—03JUL12
5. Using a press and disk, install lower seal (E) with
open side toward bearing until the face of the seal is
the specified distance (F) from the lower end of the
housing.
Specification
Spindle Lower Seal Install
Depth—Distance............................................................... 2.57 mm (0.10
in.) From Lower End of Housing
E—Lower Seal G—Lower Seal Ring
6. Install lower seal ring (G) with the outer diameter F— Distance
chamfered edge toward bearing.
Continued on next page OUMX258,0000B4B -19-07APR15-7/10

TM130419 (24FEB16) 70-10-30 030916

PN=536
 Repair, Cutting Units

7. Using a press and disk, install upper seal (H) with

open side toward bearing until the face of the seal is
flush with the end of the housing (I).
8. Install spindle shaft (J) into housing.
9. If disassembled, assemble the upper deflector (K),
hub (L), and new bolts (M). Align holes of deflector and
hub. Press bolts into hub until tight against deflector.
10. Install upper deflector, hub, and bolts as an assembly.
11. Install flange nut (N).
IMPORTANT: Blade (P) must be properly seated
on the spindle, and concave side of blade

TCAL30028 —UN—03JUL12
washer (Q) must face toward blade.

12. Install lower deflector (O), blade, blade washer,

washer (R), and cap screw (S). Tighten blade cap
screw to 320 N·m (236 lb.-ft.).
13. Place blade in a soft-jawed vise.
14. Tighten flange nut to specifications.
Specification
H—Upper Seal O—Lower Deflector
Spindle Flange I— Housing P—Blade
Nut—Torque................................................................................255 N·m J— Spindle Shaft Q—Blade Washer
(188 lb.-ft.) K—Upper Deflector R—Washer
L— Hub S—Cap Screw
15. Loosen blade cap screw and retighten to specifications. M—Bolts T— Lubrication Fitting
N—Flange Nut
Specification
Blade Cap
Screw—Torque............................................................................122 N·m
(90 lb.-ft.)
16. Apply specified grease to lubrication fitting (T).
Continued on next page OUMX258,0000B4B -19-07APR15-8/10

TM130419 (24FEB16) 70-10-31 030916

PN=537
 Repair, Cutting Units

Disassembly and Inspection: V-Flex Deck

1. Remove bolts (H) and nuts (E).
2. Remove gearbox (G).
3. Inspect all parts for wear or damage. Replace parts
as needed.

A—Bolt F— Bracket
B—Washer G—Gearbox
C—Blade H—Bolt
D—Deflector I— Sheave
E—Nut

TCT007187 —UN—10APR13
OUMX258,0000B4B -19-07APR15-9/10

Assembly: V-Flex Deck

IMPORTANT: Blade (P) must be properly seated
on the spindle, and concave side of blade
washer (Q) must face toward blade.

1. Install lower deflector (D), blade (C), washer (B), and

cap screw (A).
2. Tighten blade cap screw (A) to specification.
Specification
Blade Cap
Screw—Torque............................................................................320 N·m
(240 lb.-ft.)

3. Apply multi-purpose lithium complex grease to

lubrication fitting.

A—Bolt F— Bracket TCT007187 —UN—10APR13

B—Washer G—Gearbox
C—Blade H—Bolt
D—Deflector I— Sheave
E—Nut

OUMX258,0000B4B -19-07APR15-10/10

TM130419 (24FEB16) 70-10-32 030916

PN=538
 Repair, Cutting Units

Remove and Install Mower Deck Drive Shaft

Removal
IMPORTANT: Use of incorrect greases can result in
premature wear of parts and component failures.

1. Lift up PTO drive shaft cover to gain access to the

front PTO drive shaft universal joint.

TCAL30035 —UN—03JUL12
2. Remove flanged head cap screw (A) to remove drive
shaft from PTO gearbox input shaft (B).

A—Cap Screw B—PTO Gearbox Input Shaft

OUMX258,0000B4C -19-15SEP14-1/3

3. Using care not to misplace shaft key (C), wrap a piece

of tape around shaft key and PTO gearbox input shaft.

C—Shaft Key

TCAL30036 —UN—03JUL12
OUMX258,0000B4C -19-15SEP14-2/3

4. Inspect the universal joint (D) and lubrication fitting (E)

for wear or damage. Replace as necessary.
Installation

• Remove tape from PTO gearbox input shaft, using care

TCAL30037 —UN—03JUL12
not to misplace shaft key.
• Apply a light coat of Multi-Purpose Grease to splines of
drive shaft.
• Install drive shaft onto PTO gearbox input shaft. Tighten
flange head cap screw to specifications.
Specification
Drive Shaft Flanged Head
Cap Screw—Torque......................................................................81 N·m
(60 lb.-ft.)
D—Universal Joint E—Lubrication Fitting
• Apply multi-purpose lithium complex grease to
lubrication fitting on universal joint.
OUMX258,0000B4C -19-15SEP14-3/3

TM130419 (24FEB16) 70-10-33 030916

PN=539
 Repair, Cutting Units

Mower Deck Drive Shaft Repair

TCAL30038 —UN—03JUL12
A—Lubrication Fitting H—Shaft M—Snap Ring S—Universal Joint Yoke
B—Yoke, with Tube I— Snap Ring N—Snap Ring T— Lubrication Fitting
C—Yoke J— Universal Joint Yoke O—Locking Collar U—Universal Joint
D—Snap Ring K—Universal Joint P—Compression Spring V—Snap Ring
E—Bearing L— Lubrication Fitting Q—Ball
F— Guard R—Snap Ring
G—Collar

• Inspect all parts for wear or damage. Replace parts • Apply a light coat of Multi-Purpose Lithium Complex
as needed. Grease to splines of drive shaft.
OUMX258,0000B4D -19-15SEP14-1/1

TM130419 (24FEB16) 70-10-34 030916

PN=540
 Repair, Cutting Units

Remove and Install Mower Deck Gearbox

Removal
1. Lower attachment to the ground.
2. Open hatch and pull collar (A) forward to remove drive

TCAL30039 —UN—03JUL12
shaft from PTO output shaft (B).

A—Collar B—PTO Output Shaft

OUMX258,0000B4E -19-15SEP14-1/7

3. Remove two cap screws (C) to remove bracket (D)

and rubber shield (E).

C—Cap Screws (2 used) E—Rubber Shield

D—Bracket

TCAL30040 —UN—03JUL12
OUMX258,0000B4E -19-15SEP14-2/7

4. Remove cap screw (F) to remove drive shaft from

PTO gearbox input shaft (G).

F— Cap Screw G—PTO Gearbox Input Shaft

TCAL30041 —UN—03JUL12

Continued on next page OUMX258,0000B4E -19-15SEP14-3/7

TM130419 (24FEB16) 70-10-35 030916

PN=541
 Repair, Cutting Units

5. Using care not to misplace shaft key (H), wrap a piece

of tape around shaft key and input shaft.
6. Remove the belt shield.

H—Shaft Key

TCAL30042 —UN—03JUL12
OUMX258,0000B4E -19-15SEP14-4/7

7. Loosen nuts (I) and (J) on belt tensioning bracket.

8. Remove nut (K), tension spring and rod (L).

I— Nut K—Nut
J— Nut L— Tension Spring and Rod

TCAL30043 —UN—03JUL12
72-Inch Side Discharge Deck Shown

OUMX258,0000B4E -19-15SEP14-5/7

9. Remove four cap screws (M) holding mower deck

gearbox (N) to frame.
• 72-inch deck only: Remove support bushing (O).
10. Slide gearbox out from mounting brackets and remove
drive belt (P) from gearbox sheave.

M—Cap Screws (4 used) O—Support Bushing TCAL30044 —UN—03JUL12

N—Mower Deck Gearbox P—Drive Belt

Continued on next page OUMX258,0000B4E -19-15SEP14-6/7

TM130419 (24FEB16) 70-10-36 030916

PN=542
 Repair, Cutting Units

NOTE: Gearbox sheave-to-shaft is a tapered joint

and may require a puller.

11. Remove cap screw (R) to remove drive sheave (Q)

from gearbox.
12. Inspect drive sheave for wear or damage. Replace if
necessary.
Installation

• Installation is done in the reverse order of removal.

• Install drive sheave to gearbox and tighten cap screw
to specifications.

TCAL30045 —UN—03JUL12
Specification
Drive Sheave Cap
Screw—Torque...................................................................129 ± 9.5 N·m
(95 ± 9.5 lb.-ft.)

• Wrap belt around drive sheave and install gearbox onto

mower deck frame. Tighten cap screws to specifications.
Specification
PTO Gearbox to Frame
Q—Drive Sheave R—Cap Screw
Cap Screw—Torque......................................................................99 N·m
(73 lb.-ft.)

• 72-inch deck only: Install the support bushing, cap • Install drive shaft onto gearbox input shaft and tighten
screw and nut. cap screw to specifications.
• Install tension spring, rod and adjusting nut. Adjust belt
Specification
tension to specifications. (See Remove 60, 72-Inch
Drive Shaft Cap
(Side Discharge) and 62-Inch (Rear Discharge) Mower
Screw—Torque..............................................................................81 N·m
Deck Drive Belt or Install 72-Inch (Rear Discharge)
(60 lb.-ft.)
Mower Deck Drive Belt.)
• Install belt shield. • Install drive shaft onto PTO output shaft. (See Remove
• Remove tape from gearbox input shaft, using care not and Install Mower Deck Drive Shaft.)
to misplace shaft key.
• Apply a light coat of MPG-2 Multi-Purpose Grease to
gearbox input shaft.
OUMX258,0000B4E -19-15SEP14-7/7

TM130419 (24FEB16) 70-10-37 PN=543

030916
 Repair, Cutting Units

Mower Deck Gearbox Repair

TCAL30046 —UN—03JUL12
A—Plug E—Bearing Cup N—Bearing X—Keyway
B—Output Shaft with Gear (26 F— Plug O—Shim Y—Gear (23 teeth - 60-inch
teeth - 60-inch and 72-inch G—Snap Ring P—Snap Ring and 72-inch deck, 24 teeth -
deck, 24 teeth - 62-inch deck) H—Shim Q—Shaft Seal 62-inch deck)
C—Shim I— Bearing Cup R—Shaft Seal Z— Housing
D—Bearing J— Bearing S—Snap Ring
K—Pipe Plug (2 used) T— Shim
L— Snap Ring U—Bearing Cup
M—Bearing Cup V—Bearing
W—Input Shaft

• Inspect all parts for wear or damage.Replace seals • Fill gearbox to proper level with approved gear oil. (See
or plugs as needed. If gears are worn or damaged, Hydrostatic Transaxle Oil.)
replace gearbox assembly.
Specification
IMPORTANT: Do not overfill the gearbox with oil. PTO Gearbox—Capac-
Damage to internal gearbox seal will result. ity...................................................................................................... 0.4 L
(13.5 oz.)
NOTE: Gearbox oil capacity is approximately
0.4 L (13.5 oz).
OUMX258,0000B4F -19-15SEP14-1/1

TM130419 (24FEB16) 70-10-38 PN=544

030916
 Repair, Cutting Units

Caster Wheels, Yoke, and Bearings

Repair

A—Quick-Lock Pin K—Yoke

B—Pin Guard L— Nut
C—Spacer (6 used) M—Tire
D—Bushing N—Cap
E—Nut (2 used) O—Bearing
F— Bushing P—Wheel
G—Bolt (2 Used) Q—Bushing
H—Pivot R—Spacer
I— Spacer S—Bolt
J— Washer

TCT007300 —UN—19APR13
60-Inch, 62-Inch and 72-Inch side and rear discharge decks

OUMX258,0000B50 -19-07APR15-1/2

• Inspect all parts for wear or damage. Replace parts

as needed.
• Apply multi-purpose HD lithium complex grease to
lubrication fittings.
• Tighten caster wheel axles to specifications.
Specification
Caster Wheel
Axle—Torque.................................................................................80 N·m
(60 lb.-ft.)

NOTE: Deck caster tires are not semi-pneumatic and

cannot be separated from the wheel.

• If tire is replaced, inflate tire to specified inflation

pressure.
Specification
Caster Tire—Pressure................................................................. 152 kPa
(22 psi)
TCT007301 —UN—19APR13

A—Quick-Lock Pin H—Cap

B—Pin Guard I— Tire
C—Spacer J— Wheel
D—Bushing K—Spacer
E—Washer L— Bolt
F— Yoke M—Cap
G—Nut N—Lubrication Fitting

72-Inch flex decks

OUMX258,0000B50 -19-07APR15-2/2

TM130419 (24FEB16) 70-10-39 030916

PN=545
 Repair, Cutting Units

TM130419 (24FEB16) 70-10-40 030916

PN=546
 Group 20
Repair, Snowblowers
Summary of References • Install Snowblower Rotor and Fan
• 60-Inch Snowblower Gear Case Inspection • Replacing Fan or Coupler
• Install Rotor Assembly
• Snowblower Gear Assembly • Replace Rotor Bearing
• Snowblower Main Case Inspection
• Snowblower Main Case Assembly
OUMX258,0000B63 -19-25MAR13-1/1

60-Inch Snowblower Gear Case Inspection

TCAL30049 —UN—03JUL12
A—Housing C—Gears E—Bearing Caps
B—Bearings D—Shafts F— End Caps

1. Inspect housing (A) for cracks. 5. Inspect bearing caps (E) for wear and galling.
2. Inspect bearings (B) for wear. 6. Inspect end caps (F) for cracks or distortion.
3. Inspect gears (C) for chipped, worn or broken teeth. 7. Replace parts as required when assembling gear case.
4. Inspect shafts (D) for wear and straightness.
OUMX258,0000B51 -19-25MAR13-1/1

Snowblower Gear Assembly

1. Install snap rings (A).

A—Snap Rings
TCAL30050 —UN—03JUL12

Continued on next page OUMX258,0000B52 -19-16SEP14-1/16

TM130419 (24FEB16) 70-20-1 030916

PN=547
 Repair, Snowblowers

2. Press bearing cups into case until they bottom out

against snap rings.

TCAL30051 —UN—03JUL12
OUMX258,0000B52 -19-16SEP14-2/16

3. Press oil seals into case until they are flush with flat
surface of case.

TCAL30052 —UN—03JUL12
OUMX258,0000B52 -19-16SEP14-3/16

4. Place key in input shaft. Align slot in worm gear with

key and tap into place with soft faced hammer.

TCAL30053 —UN—03JUL12

Continued on next page OUMX258,0000B52 -19-16SEP14-4/16

TM130419 (24FEB16) 70-20-2 030916

PN=548
 Repair, Snowblowers

5. Install retaining ring with D05327ST retaining ring

pliers.

TCAL30054 —UN—03JUL12
OUMX258,0000B52 -19-16SEP14-5/16

IMPORTANT: Do not press on bearing cage.

6. Press bearing (B) on plain end of input shaft until

bottomed on retaining ring.
7. Clean burrs off shaft and install bearing.

TCAL30055 —UN—03JUL12
B—Bearing

OUMX258,0000B52 -19-16SEP14-6/16

8. Put bearing cup (C) over bearing (plain end).

C—Bearing Cup

Continued on next page TCAL30056 —UN—03JUL12

OUMX258,0000B52 -19-16SEP14-7/16

TM130419 (24FEB16) 70-20-3 030916

PN=549
 Repair, Snowblowers

9. Press bearing cup into case until press plate bottoms

against input shaft. Remove press plate and use thin
wall pipe with large enough diameter to clear bearing.
Press bearing cup until below snap ring groove.

TCAL30057 —UN—03JUL12
OUMX258,0000B52 -19-16SEP14-8/16

10. Install snap ring (D) with snap ring pliers.

11. Turn input shaft to seat bearings in cups. Push
and pull input shaft to check for excessive end play.
Use a dial indicator to measure end play. Compare
measurement to specification.

TCAL30058 —UN—03JUL12
Specification
Snowblower Gearcase
Shaft—End Play
(Maximum)............................................................................... 0.076 mm
(0.003 in.)

If end play exceeds this specification, remove snap

ring and install shim under snap rings.

D—Snap Ring

OUMX258,0000B52 -19-16SEP14-9/16

12. Press cap in case until flush with surface.

TCAL30059 —UN—03JUL12

Continued on next page OUMX258,0000B52 -19-16SEP14-10/16

TM130419 (24FEB16) 70-20-4 030916

PN=550
 Repair, Snowblowers

13. Put bearing cup (E) in case.

E—Bearing Cup

TCAL30060 —UN—03JUL12
OUMX258,0000B52 -19-16SEP14-11/16

TCAL30061 —UN—03JUL12
14. Install retaining ring in groove on output shaft (F) with
JDT-1 retaining ring pliers.
15. Put key in shaft and slide gear over key.
16. Grease an oil seal and insert shaft through case and
oil seal.

F— Output Shaft

OUMX258,0000B52 -19-16SEP14-12/16

17. Turn input shaft (G) and set gear teeth in worm gear.
18. Press bearing cup into cover far enough to install
retaining ring.

TCAL30062 —UN—03JUL12
G—Input Shaft

OUMX258,0000B52 -19-16SEP14-13/16

19. Install snap ring (H).

20. Press new seal into cover until flush with end cap.

H—Snap Ring
TCAL30063 —UN—03JUL12

Continued on next page OUMX258,0000B52 -19-16SEP14-14/16

TM130419 (24FEB16) 70-20-5 030916

PN=551
 Repair, Snowblowers

21. Install bearing (I) on shaft.

22. Install new gasket (J).
23. Slip cover over shaft.

TCAL30064 —UN—03JUL12
I— Bearing J— Gasket

OUMX258,0000B52 -19-16SEP14-15/16

24. Secure cover with four cap screws (K). Tighten to

specification.
Specification
Snowblower
Gearcase Cover Cap

TCAL30065 —UN—03JUL12
Screw—Torque...................................................................... 20—24 N·m
(180—216 lb.-in.)

25. Add John Deere™ GL-5® Gear Oil-SAE 80W-90 to

specification.
Specification
Snowblower
Gearcase—Capacity........................................................................ 0.4 L
(13.5 oz.)
K—Cap Screws L— Pipe Plugs
26. Apply Loctite® 592 pipe sealant with TEFLON® to
pipe plugs (L). Tighten pipe plugs to specification.
Specification
Snowblower Gearcase
Pipe Plug—Torque........................................................................18 N·m
(160 lb.-in.)

John Deere is a trademark of Deere & Company

Loctite is a trademark of Henkel Corporation
TEFLON is a trademark of Du Pont Co.
OUMX258,0000B52 -19-16SEP14-16/16

TM130419 (24FEB16) 70-20-6 030916

PN=552
 Repair, Snowblowers

Snowblower Main Case Inspection

TCAL30066 —UN—03JUL12
A—Housing C—Gear E—Bearing Caps
B—Bearings D—Shaft F— End Caps

1. Inspect housing (A) for cracks. 5. Inspect bearing caps (E) for wear or galling.
2. Inspect bearings (B) for wear. 6. Inspect end caps (F) for cracks or distortion.
3. Inspect gear (C) for chipped, worn or broken teeth. 7. Replace parts as required when assembling gear case.
4. Inspect shaft (D) for wear and straightness.
OUMX258,0000B53 -19-25MAR13-1/1

Snowblower Main Case Assembly

1. Clean sealing adhesive off both gear case halves
before assembly. Wash parts in cleaning solvent and
dry them.

TCAL30067 —UN—03JUL12
2. Press bearing cups far enough into each case half so
snap rings can be installed.

Continued on next page OUMX258,0000B54 -19-15SEP14-1/9

TM130419 (24FEB16) 70-20-7 030916

PN=553
 Repair, Snowblowers

NOTE: Some gear cases may have a shim under snap

ring. If a shim was removed on disassembly,
install it to maintain correct end play.

3. Install snap rings in slot behind cups in each case half.

Invert case half and press bearing cup tight against

TCAL30068 —UN—03JUL12
snap ring.
4. Press oil seals into each case half.
5. Apply RTV sealant around outside edge of each cap.
Press cap into each case half.

OUMX258,0000B54 -19-15SEP14-2/9

6. Press bearing (A) on short end of small gear input

shaft until bearing bottoms against gear shoulder. Do
not press against bearing cage.

A—Bearing

TCAL30069 —UN—03JUL12
OUMX258,0000B54 -19-15SEP14-3/9

7. Press bearing (B) on long end of small gear (C) input

shaft.

B—Bearing C—Small Gear

TCAL30070 —UN—03JUL12

Continued on next page OUMX258,0000B54 -19-15SEP14-4/9

TM130419 (24FEB16) 70-20-8 030916

PN=554
 Repair, Snowblowers

8. Press bearing (D) on short end of large gear shaft until

bottomed against gear (E).
9. Press bearing on long end of large gear shaft until
bottomed against gear.

TCAL30071 —UN—03JUL12
10. Put gear shaft and bearing assemblies in case half.

D—Bearing E—Large Gear

OUMX258,0000B54 -19-15SEP14-5/9

11. Apply RTV sealant (F) evenly around sealing surface

of each case half.

F— RTV Sealant

TCAL30072 —UN—03JUL12
OUMX258,0000B54 -19-15SEP14-6/9

12. Put gear case halves together and install two socket
head screws (G) and cap screws (H). Tighten socket
head screws to specifications.
Specification
Snowblower Gear
Case Socket Head

TCAL30073 —UN—03JUL12
Screw—Torque..............................................................................26 N·m
(228 lb.-in.)

Tighten cap screws to specifications.

Specification
Snowblower Gear Case
Cap Screw—Torque......................................................................41 N·m
(34 lb.-ft.)

G—Socket Head Screws H—Cap Screws

Continued on next page OUMX258,0000B54 -19-15SEP14-7/9

TM130419 (24FEB16) 70-20-9 030916

PN=555
 Repair, Snowblowers

13. Check input and output shaft end play. End play
should be within specifications.
Specification
Snowblower Input and
Output Shaft—End Play.................................................0.025—0.15 mm

TCAL30074 —UN—03JUL12
(0.001—0.006 in.)
Snowblower Main Case
Shaft—Rolling Drag
Torque............................................................................. 0.19—0.98 N·m
(1.736—8.680 lb.-in.)
Snowblower Main Case
Shaft—Backlash.................................................................0.15—0.4 mm
(0.006—0.016 in.)

OUMX258,0000B54 -19-15SEP14-8/9

IMPORTANT: Adjust backlash to specifications.

Backlash is adjusted by added or
removing shims.

14. If necessary disassemble gear case and add or

remove shims to get correct end play.

TCAL30075 —UN—03JUL12
15. When end play and backlash are within limits, fill gear
case to specifications with John Deere™ GL-5®Gear
Oil.
Specification
Snowblower
Gearcase—Capacity........................................................................ 0.4 L
(13.5 oz.)

16. Apply Loctite® 592 pipe sealant with TEFLON® to 18. Tighten main gear case to snowblower housing bolts
pipe plugs. Torque pipe plugs to specifications. to specifications.
Specification Specification
Snowblower Gearcase Main Gear Case-to-
Pipe Plug—Torque........................................................................18 N·m Snowblower Housing
(160 lb.-in.) Cap Screw—Torque...................................................................47.5 N·m
(35 lb.-ft.)
17. Reinstall gear case and power shaft (make sure key
is installed in gear case shaft). Install cap screw and
elastic locknut (no specified torque).
John Deere is a trademark of Deere & Company
Loctite is a trademark of Henkel Corporation
TEFLON is a trademark of Du Pont Co.
OUMX258,0000B54 -19-15SEP14-9/9

TM130419 (24FEB16) 70-20-10 PN=556

030916
 Repair, Snowblowers

Install Snowblower Rotor and Fan

TCAL30076 —UN—03JUL12
1. Remove rotor assembly.
OUMX258,0000B55 -19-25MAR13-1/7

2. Remove cap screws and lock washers (A) securing

support to worm gear case.

A—Cap Screws and Lock

Washers

TCAL30077 —UN—03JUL12

Continued on next page OUMX258,0000B55 -19-25MAR13-2/7

TM130419 (24FEB16) 70-20-11 030916

PN=557
 Repair, Snowblowers

3. Remove three flange bolts (B) securing rotor to each

side of housing.
4. Remove rotor by pulling and lifting it forward out of
housing.

TCAL30078 —UN—03JUL12
5. Remove bearings, shear coupling and flighting.

B—Flange Bolts

OUMX258,0000B55 -19-25MAR13-3/7

6. Loosen locking collar set screw. Loosen locking collar

(C) from bearing by tapping it counterclockwise with
a punch and hammer. Remove bearing and flange
assembly and locking collar.
7. Remove cotter pin (D) and drilled pin.

TCAL30079 —UN—03JUL12
8. Remove shear bolt (E) and coupling.

C—Locking Collar E—Shear Bolt

D—Cotter Pin

OUMX258,0000B55 -19-25MAR13-4/7

9. Slide or pull flighting (F) off drive shaft.

10. Replace fan or coupling plate and reinstall assembly.
11. Tighten nut on cap screw securing fan coupling to
gear case shaft.

TCAL30080 —UN—03JUL12
12. Replace flighting bearings.

F— Flighting

Continued on next page OUMX258,0000B55 -19-25MAR13-5/7

TM130419 (24FEB16) 70-20-12 030916

PN=558
 Repair, Snowblowers

13. Remove bearing with a slide hammer puller on each

end of flighting.

TCAL30081 —UN—03JUL12
OUMX258,0000B55 -19-25MAR13-6/7

14. Press new bearing (G) flush to end of flighting shaft.

G—Bearing

TCAL30082 —UN—03JUL12
OUMX258,0000B55 -19-25MAR13-7/7

Replacing Fan or Coupler

1. Remove rotor from housing.
2. Remove cap screw (A) and pull fan assembly off gear
case shaft. Be careful not to lose key in shaft.

A—Cap Screw

TCAL30083 —UN—03JUL12

Continued on next page OUMX258,0000B56 -19-25MAR13-1/2

TM130419 (24FEB16) 70-20-13 030916

PN=559
 Repair, Snowblowers

3. Remove three cap screws (B) and lock washers

securing fan to coupling plate. Remove fan from
coupling plate.

B—Cap Screws (3 used)

TCAL30084 —UN—03JUL12
OUMX258,0000B56 -19-25MAR13-2/2

Install Rotor Assembly

1. Install shear coupling and shear bolt (A). Tighten nut
on shear bolt only enough to draw couplings together.
Do not overtighten nut.
2. Install drilled pin and cotter pin (B). Spread ends of

TCAL30085 —UN—03JUL12
cotter pin.
3. Install locking collar (C) and bearing and flange
assembly.

A—Shear Bolt C—Locking Collar

B—Cotter Pin

OUMX258,0000B57 -19-25MAR13-1/3

4. Install rotor assembly in support slot. Install cap

screws and lock washers (D). Leave cap screws loose
until final assembly.

D—Cap Screws and Lock

Washers

TCAL30086 —UN—03JUL12

Continued on next page OUMX258,0000B57 -19-25MAR13-2/3

TM130419 (24FEB16) 70-20-14 030916

PN=560
 Repair, Snowblowers

5. Install spacer (E) between housing and flange

assembly.
6. Install three carriage bolts, lock washers and nuts (F).
Leave nuts loose on bolts on one end of rotor until
other assembly is installed on other end of rotor. Then

TCAL30087 —UN—03JUL12
tighten nuts on bolts on both assemblies.
7. Tighten locking collar (G) onto bearing. Then tighten
set screw in locking collar.
8. Tighten cap screws installed in Step 4.

E—Spacer G—Locking Collar

F— Lock Washers and Nuts

OUMX258,0000B57 -19-25MAR13-3/3

Replace Rotor Bearing

1. Remove rotor from housing.
2. Loosen set screw (A) in locking collar. Loosen locking
collar by tapping it counterclockwise with a punch and

TCAL30088 —UN—03JUL12
hammer.
3. Remove old bearing (B) from shaft with flanges.
Separate flanges and install new bearing. Slide
bearing and flange assembly back on shaft. Reinstall
rotor assembly in housing.
4. Turn locking collar on bearing. Tighten locking collar
by tapping it clockwise with a hammer and punch.
5. Tighten set screw in locking collar. A—Set Screw B—Bearing

OUMX258,0000B58 -19-25MAR13-1/1

TM130419 (24FEB16) 70-20-15 030916

PN=561
 Repair, Snowblowers

TM130419 (24FEB16) 70-20-16 030916

PN=562
 Group 30
Repair, GLC System
Summary of References • Replacing Blower Fan Drive Belt
• Remove Collection System • Install Suction Port
• Install Blower Hose
• Install Collection System
• Install Hydraulic Pump to Deck
BS62576,000178B -19-15APR14-1/1

Remove Collection System

1. Park machine safely. (See Parking Safely in the
Safety section.)
2. Empty and close the hopper.

TCT009262 —UN—06NOV13
3. Remove suction hose from the blower end cap.
4. Remove stop nut (A). Pull out port connector (B) and
remove suction port (C).

BS62576,000177D -19-16SEP14-1/11

5. Remove two bolts (D) and protective cover (E).

TCT009263 —UN—06NOV13
Continued on next page BS62576,000177D -19-16SEP14-2/11

TM130419 (24FEB16) 70-30-1 030916

PN=563
 Repair, GLC System

6. Remove four bolts (F).

NOTE: The ring gear of the Rotex coupling is bolted
onto the shaft of the pump and remains
mounted on the pump side.

NOTE: The hydraulic hoses remain mounted on the pump.

The hydraulic hoses must not be dismounted.

TCT009264 —UN—18FEB14
7. Uncouple the Rotex coupling. Remove the pump (G)
and bracket (H).
8. Clean the shaft and coupler on the gear box drive shaft.

BS62576,000177D -19-16SEP14-3/11

9. Rotate cover (I) 90° and install to mower deck with

two bolts (J).
10. Thread the pump hoses out of the hose holder.

TCT009265 —UN—06NOV13
BS62576,000177D -19-16SEP14-4/11

11. If desired, loosen bolt (K) and remove hose holder (L).

CAUTION: Avoid injury! Prevent injury from

crushing by locking the hydraulic cylinder if the
GLC is raised for service or cleaning.

12. Raise the hopper to its highest position and install lift
cylinder safety channel. (See Using the Lift Cylinder
Safety Channel in the Safety section.)
TCT009266 —UN—02FEB14

13. Screw the star handle onto the threaded rod to keep
it from getting lost.

Continued on next page BS62576,000177D -19-16SEP14-5/11

TM130419 (24FEB16) 70-30-2 030916

PN=564
 Repair, GLC System

14. Open the upper locking mechanism (M) on the engine

cover.

TCT009267 —UN—06NOV13
BS62576,000177D -19-16SEP14-6/11

15. Remove spring locking pin (N) from rod (O). Remove
engine cover

TCT009268 —UN—06NOV13
BS62576,000177D -19-16SEP14-7/11

16. Disconnect the wiring harness from the collection

system to the GLC harness (P) on the left side of the
vehicle.

TCT009269 —UN—06NOV13

Continued on next page BS62576,000177D -19-16SEP14-8/11

TM130419 (24FEB16) 70-30-3 030916

PN=565
 Repair, GLC System

17. Parking stands are required for removing the collection

system:
a. Loosen the clamp bolts (Q) on the left side of the
collection system.
b. Install left side parking stand (R) and tighten clamp
bolts.

TCT009273 —UN—02JAN14
c. Loosen the clamp bolt (S) on the right side of the
collection system.
d. Install right side parking stand (T) and tighten clamp
bolt.
18. Crank up the parking stand until it is firmly seated on
the ground. Do not remove the hardware and do not
roll the collection system back at this time. Left parking stand.

TCT009274 —UN—02JAN14
Right parking stand.

Continued on next page BS62576,000177D -19-16SEP14-9/11

TM130419 (24FEB16) 70-30-4 030916

PN=566
 Repair, GLC System

19. Loosen the top (U) and bottom (V) hardware securing
the collection system to the vehicle. Do not remove
the nuts at this time.
20. Remove the lift cylinder safety channel and lower the
collection system.

TCT009271 —UN—02JAN14
Top Mounting Hardware

TCT009275 —UN—02JAN14
Bottom Mounting Hardware

BS62576,000177D -19-16SEP14-10/11

21. Disconnect the hydraulic hoses from collection system

to rear auxiliary ports.
a. Lift and lower function (W).
b. Open and close function (X).
22. Hang the hydraulic lines going to deck over the GLC
lift structure.
23. If using a homologation kit, remove the lower GLC
attaching brackets. Install the homologation rear light
bracket and connect the harness.
24. Install rear bumper weight if vehicle is equipped with
a cab.
TCT009272 —UN—02JAN14

25. Remove wheel weights if installed.

26. Refer to attachment OM to determine if additional rear
ballast is needed.

BS62576,000177D -19-16SEP14-11/11

TM130419 (24FEB16) 70-30-5 030916

PN=567
 Repair, GLC System

Install Collection System

CAUTION: Avoid injury! To install attachment,

machine must be parked on a level surface.

NOTE: Hydraulic kits must be installed before

installing the collection system.

TCT009138 —UN—19OCT13
1. Park machine safely. (See Parking Safely in the
Safety section.)
IMPORTANT: Avoid damage! The upper and lower
holders of the grass collection device must be
mounted on the vehicle. The grass collection
device must be mounted on the parking stands.

2. Install upper and rear mounting brackets (if removed).

3. Remove rear bumper weight (if installed).
4. Remove homologation rear light bar (if installed).
5. Open the upper locking mechanism (A) on the engine
cover.
BS62576,000177B -19-16SEP14-1/8

6. Remove spring locking pin (B) from rod (C). Remove

engine cover.
NOTE: Parking stands are recommended for
storage and installation.

NOTE: Leave hardware loose during installation.

7. Carefully back machine up to the collection system.

TCT009139 —UN—19OCT13
8. Remove the hydraulic pump with mounted hoses
off the tower of the lift-out mechanism of the grass
collection device. Set hydraulic pump and hoses down
next to the vehicle.
9. Position the collection system in place at the rear of
the vehicle. The park stands can be cranked up and
down to position the GLC to the machine.
Continued on next page BS62576,000177B -19-16SEP14-2/8

TM130419 (24FEB16) 70-30-6 030916

PN=568
 Repair, GLC System

NOTE: The upper ROPS mounted brackets can be

twisted and must first be aligned before the
fastening bolts are installed.

10. Align the upper holder (D) on the collection system

with the upper mounting brackets (E).
11. Install two M20 x 120 mm bolts, four D21 washers, two

TCT009142 —UN—02JAN14
D22.5 lockwashers, and two M20 nuts (F) to secure
collection system to the upper mounting brackets. Do
not tighten at this time.
12. Install two M16 x 45 mm bolts, four D17 washers, and
two M16 locknuts (G) to secure the bottom of the
collection system (H) to the rear support brackets (I).
Do not tighten at this time.
13. Tighten the upper mounting bolts (F and J) to
specification.
ROPS Mounting Bracket Bolts—Specification
M20x120 mm
Bolts—Torque..............................................................................350 N·m
(258 lb.-ft.)

TCT009143 —UN—02JAN14
M18x110 mm
Bolts—Torque..............................................................................240 N·m
(177 lb.-ft.)

14. Tighten the lower mounting bolts (G) to specification.

Rear Support Bracket Bolts—Specification
M16x45 mm
Bolts—Torque..............................................................................175 N·m
(129 lb.-ft.)
M12x40 mm
15. Loosen the clamp bolts and remove the parking
Bolts—Torque................................................................................70 N·m
stands. Tighten clamp bolts.
(52 lb.-ft.)
BS62576,000177B -19-16SEP14-3/8

IMPORTANT: Avoid damage! Check to make sure that

all hydraulic hoses are routed away from moving
parts and pinch points. Use tie straps to secure
hoses to the machine to prevent damage.

16. Connect hydraulic hoses from collection system to

rear auxiliary ports.
a. Lift and lower function (K).
b. Open and close function (L).
TCT009144 —UN—02JAN14

Continued on next page BS62576,000177B -19-16SEP14-4/8

TM130419 (24FEB16) 70-30-7 030916

PN=569
 Repair, GLC System

17. Check function of hydraulic levers.

a. Lever (M)—lift and lower.
b. Lever (N)—open and close.
NOTE: If the hopper does not raise, check the
hydraulic connections.

18. Start the vehicle and raise the hopper to the highest

TCT009145 —UN—02JAN14
position.

BS62576,000177B -19-16SEP14-5/8

CAUTION: Avoid injury! Install safety channel

before standing under hopper.

19. Remove the safety channel (O) from the left side of the
collection system. Install channel on the lift cylinder
and secure with the lock pin.

TCT009146 —UN—02JAN14
BS62576,000177B -19-16SEP14-6/8

20. Connect wiring harness from collection system to GLC

harness (P) on the vehicle.
21. Install the engine cover.
22. Lower the hopper to the lowest position.
23. Make sure that all the covers are firmly bolted on.
24. Check the oil level.
TCT009147 —UN—02JAN14

Left rear of vehicle shown.

Continued on next page BS62576,000177B -19-16SEP14-7/8

TM130419 (24FEB16) 70-30-8 030916

PN=570
 Repair, GLC System

25. 1585 Models Only:

a. For 1585 with 600L hopper and 60 in. or 72 in.
deck, install one 25 kg (55 lb.) wheel weight.
b. For 1585 with 900L hopper and 60 in. or 72 in.

TCT010976 —UN—29MAR14
deck, install two 25 kg (55 lb.) wheel weights.

Picture Note: Two wheel weights shown.

BS62576,000177B -19-16SEP14-8/8

Install Hydraulic Pump to Deck

1. Remove two bolts (A) and cover (B) from mower deck
gearbox.
2. Clean the shaft and coupler on the pump.

TCT009149 —UN—20OCT13
BS62576,000177C -19-16SEP14-1/3

3. Install shaft key (C) onto gearbox shaft (D).

4. Slide coupler (E) onto gearbox shaft. Do not tighten
set screw at this time.
5. Install pump (G), aligning coupler and spider (H) with
coupler on gearbox shaft.
6. Secure pump to mower deck with four bolts (I) and
plate (J).
7. Slide coupler on gearbox toward pump until it stops TCT009150 —UN—06NOV13

against the pump coupler. Tighten set screw to

specification.
Specification
Pump Coupler Set
Screw—Torque..............................................................................10 N·m
(90 lb.-in.)

Continued on next page BS62576,000177C -19-16SEP14-2/3

TM130419 (24FEB16) 70-30-9 030916

PN=571
 Repair, GLC System

8. Rotate cover (K) 90° and install to mower deck with

two bolts (L).

TCT009151 —UN—06NOV13
BS62576,000177C -19-16SEP14-3/3

TM130419 (24FEB16) 70-30-10 030916

PN=572
 Repair, GLC System

Replacing Blower Fan Drive Belt

CAUTION: Avoid injury! Prevent injury from

crushing by locking the hydraulic cylinder if the
GLC is raised for service or cleaning.

1. Park machine safely. (See Parking Safely in the

SAFETY section.)

TCT009755 —UN—03JAN14
2. Raise the hopper to its highest position and install lift
cylinder safety channel. (See Using the Lift Cylinder
Safety Channel in the Safety section.)
3. Remove hood.
4. Remove the hardware (A) in two places securing the
belt guard (B) to the frame.
BS62576,000178A -19-15APR14-1/2

5. Loosen motor mounting hardware (C).

6. Loosen locknut (D) on belt tension adjustment screw.
7. Turn belt tension adjustment screw (E) clockwise.
Slide motor to release tension on belts (F).
8. Remove belts.
NOTE: Always replace belts as a pair.

TCT009756 —UN—03JAN14
9. Install new belts.
10. Tension belts. (See Checking and Adjusting Blower
Fan Drive Belt.)

BS62576,000178A -19-15APR14-2/2

TM130419 (24FEB16) 70-30-11 030916

PN=573
 Repair, GLC System

Install Suction Port

1. Raise discharge chute on mower deck.
2. Clean grass and dirt from mower deck opening.
3. Lay the blower hose out to the right side of the vehicle.
NOTE: Adapter plate (A) must be installed on the

TCT009191 —UN—27OCT13
underside of the mower deck.

4. Using existing holes in the mower deck, install adapter

plate (A) using two M8 locknuts (B) and two M8 x 20
mm carriage bolts.

152.4 cm (60 in.) chute adapter plate shown. Deck

chute guard removed for clarity.

TCT009192 —UN—27OCT13
183 cm (72 in.) chute adapter plate shown. Deck chute
guard removed for clarity.

BS62576,000177E -19-11APR14-1/2

5. Attach suction port (C) to deck with port connector (D)

and secure with stop nut (E).
6. Attach blower hose adapter to suction port:
• 152.4 cm (60 in.) suction port—200 mm (7.9 in.)
• 183 cm (72 in.) suction port—220 mm (8.7 in.)
TCT009159 —UN—27OCT13

152.4 cm (60 in.) chute adapter shown, 183 cm (72 in.) is the same.

BS62576,000177E -19-11APR14-2/2

TM130419 (24FEB16) 70-30-12 030916

PN=574
 Repair, GLC System

Install Blower Hose

1. Attach the front of the blower hose (A) to the suction
port with hose clamp (B). Tighten clamp.

TCT009160 —UN—02JAN14
BS62576,000177F -19-11APR14-1/2

2. Install blower end cap (C) onto blower using hardware

(D and E). Hose inlet must be oriented down and
forward as shown.
IMPORTANT: Avoid damage! To prevent damage
to the hose, the hose must not contact the
ground or interfere with the front wheel.
Shorten the hose, if necessary.

NOTE: Hose length must be adjusted so the hose

does not dip toward the ground, and makes a
smooth curve up to the blower.

3. Attach the blower hose at the rear to the blower end

cap. Slide the hose end on completely. Tighten hose
clamp (F).

TCT009161 —UN—02JAN14
BS62576,000177F -19-11APR14-2/2

TM130419 (24FEB16) 70-30-13 030916

PN=575
 Repair, GLC System

TM130419 (24FEB16) 70-30-14 030916

PN=576
 Section 80
Cab Repair
Contents

Page

Group 10—Repair
Summary of References................................ 80-10-1
Headliner Remove and Install ....................... 80-10-1
Outer Roof Remove and Install ..................... 80-10-2
Cleaning Cab Air Filter .................................. 80-10-4
Remove and Install Cab Door ....................... 80-10-5
Cab Removal and Installation........................ 80-10-6

TM130419 (24FEB16) 80-1 030916

PN=1
 Contents

TM130419 (24FEB16) 80-2 030916

PN=2
 Group 10
Repair
Summary of References • Cleaning Cab Air Filter
• Headliner Remove and Install • Remove and Install Cab Door
• Cab Removal and Installation
• Outer Roof Remove and Install
OUMX258,0000A78 -19-17JUN14-1/1

Headliner Remove and Install

Remove:
1. Remove radio housing cover (A) and radio from

LVAL13698 —UN—08NOV10
tractor, if equipped.

A—Radio Housing Cover

OUMX258,0000A79 -19-21MAR13-1/5

2. Remove three screws (B) and sun visor assembly (C).

B—Screw (3 used) C—Sun Visor Assembly

LVAL13699 —UN—08NOV10
OUMX258,0000A79 -19-21MAR13-2/5

NOTE: There is a slot in front of dome light lens that a flat

screwdriver will fit into to ease lens removal.

3. Remove dome light lens (D) and two screws

underneath. Disconnect dome light wiring connector.

LVAL13700 —UN—08NOV10
D—Dome Light Lens

Continued on next page OUMX258,0000A79 -19-21MAR13-3/5

TM130419 (24FEB16) 80-10-1 030916

PN=579
 Repair

4. Pull off three knobs (E) and air conditioner switch (F).
5. Remove air conditioner controls cover (G) by removing
two screws (H).

E—Knobs G—Cover

LVAL13701 —UN—08NOV10
F— Air Conditioner Switch H—Screw (2 used)

OUMX258,0000A79 -19-21MAR13-4/5

6. Remove the recirculation filter covers (I) at the rear of

cab by removing four screws (J).
7. Remove head liner by pulling in outer edges at four
corners. Head liner is secured by hanging on copper
weld studs of cab frame in four places.

LVAL13702 —UN—08NOV10
8. Repair or replace headliner as necessary.
Install:
Installation is the reverse of removal.

I— Recirculation Filter Covers J— Screw (4 used)

OUMX258,0000A79 -19-21MAR13-5/5

Outer Roof Remove and Install

Remove:
1. Remove two wing nuts (A), washers, and rear filter
housing (B).

LVAL13703 —UN—08NOV10
A—Wing Nut (2 used) B—Rear Filter Housing

Continued on next page OUMX258,0000A7A -19-21MAR13-1/3

TM130419 (24FEB16) 80-10-2 030916

PN=580
 Repair

2. Remove two screws (C) and remove rear amber lights,

rear covers and/or rear work lights on each side.

C—Screw (2 used)

LVAL13704 —UN—08NOV10
OUMX258,0000A7A -19-21MAR13-2/3

3. Remove thirteen nuts (D) around outside of cab and

lift off top outer cab roof (E).
4. Repair or replace outer roof as necessary.
Install:

LVAL13705 —UN—08NOV10
Installation is the reverse of removal.

D—Nut (13 used) E—Top Outer Cab Roof

LVAL13706 —UN—08NOV10
OUMX258,0000A7A -19-21MAR13-3/3

TM130419 (24FEB16) 80-10-3 030916

PN=581
 Repair

Cleaning Cab Air Filter

1. Remove two wing bolts (A), washers, and filter base
(B).
2. Remove filter (C) from filter base, and clean with
compressed air. Inspect filter for damage. Replace if

LVAL13682 —UN—08NOV10
necessary.
3. Install filter back into filter base.

A—Wing Bolt (2 used) C—Filter

B—Filter Base

LVAL13683 —UN—08NOV10
OUMX258,0000A7B -19-21MAR13-1/2

IMPORTANT: Avoid Damage! Be sure the six

tabs (D) on the roof panel fit into the
slots (E) on filter base.

4. Install filter base, making sure six tabs (D) on roof

panel are installed into slots (E) in filter base. Secure
base assembly back into roof panel with two washers
and wing bolts.

LVAL13684 —UN—08NOV10
D—Tabs E—Slots

OUMX258,0000A7B -19-21MAR13-2/2

TM130419 (24FEB16) 80-10-4 030916

PN=582
 Repair

Remove and Install Cab Door

Removal
1. Park machine safely. See the “Safety Section”
2. Left side door: Unscrew the special bolt (A) from the
door frame (B).

A—Bolt B—Frame

TCT011481 —UN—25JUN14
BS62576,000164D -19-20JUN14-1/3

3. Right side door: Twist the cable (C) 90° and remove
the cable from the door frame.
4. Close and latch the door.

C—Cable

TCT010660 —UN—21FEB14
Picture Note: Right Door. Travel limit cable shown partially removed.

BS62576,000164D -19-20JUN14-2/3

5. Remove the push lock washer (D) from each hinge pin
and remove the hinge pins (E).
6. Unlatch the door and carefully lift the door off the
machine.
7. Make repairs as necessary.
Installation:
Installation is the reverse of removal.
TCT010661 —UN—21FEB14

D—Lock Washer E—Hinge Pin

BS62576,000164D -19-20JUN14-3/3

TM130419 (24FEB16) 80-10-5 030916

PN=583
 Repair

Cab Removal and Installation

Cab Removal:
1. Park machine safely. Block wheels.
2. Disconnect negative (-) battery cable.
NOTE: Close all openings using caps and plugs to prevent
contamination. Tag or label all cooling and HVAC
system hoses and lines to aid during installation.

3. Recover/recycle air conditioning refrigerant. (See

Recover/Recycle Refrigerant) Disconnect and cap
refrigerant lines at (A) and (B).

CAUTION: Avoid Injury! Hot fluid from

pressurized cooling system can cause serious
burns. Shut off engine. Only remove radiator
cap when cool enough to touch with bare
hands. Slowly loosen cap to first stop to relieve
pressure before removing completely.

TCT011482 —UN—25JUN14
4. Drain coolant from radiator and cooling system.
5. Disconnect heater hoses.
6. Remove cab doors. (See Remove and Install Cab
Door).

A—High Pressure Line B—Low Pressure Line

OUO2003,0000080 -19-17SEP14-1/5

7. Disconnect cab harness connector (C).

C—Cab Electrical Harness

Connector

TCT011477 —UN—25JUN14

Continued on next page OUO2003,0000080 -19-17SEP14-2/5

TM130419 (24FEB16) 80-10-6 030916

PN=584
 Repair

8. Install JDG1580 lift bar (D) and JDG2069 brackets (E)

attached to a suitable hoist to cab frame above door.

D—Lift Bar E—Brackets

TCT011478 —UN—25JUN14
OUO2003,0000080 -19-17SEP14-3/5

9. Remove two cap screws, nuts, and spacers (F) and

cap screw and nut (G) on each side of cab securing
cab to machine frame.

F— Cap Screws, Nuts with G—Cap Screw and Nut

Spacers

TCT011479 —UN—25JUN14
Continued on next page OUO2003,0000080 -19-17SEP14-4/5

TM130419 (24FEB16) 80-10-7 030916

PN=585
 Repair

10. Remove two pins (H) securing rear of cab to machine

frame.
11. Carefully hoist cab and check for and disconnect any
remaining connections to machine.
Installation:
Installation is done in the reverse order of removal using
the following special instructions:
• Tighten mounting cap screws to specification.

TCT011480 —UN—25JUN14
Specification
Cab Mounting cap
screws—Torque.............................................................................80 N·m
(60 lb.-ft.)

• Use new O-rings on AC fittings.

• Fill engine with approved coolant and bleed air from
system.
• Charge air conditioning system with refrigerant. (See
H—Pins
Recover/Recycle Refrigerant).
OUO2003,0000080 -19-17SEP14-5/5

TM130419 (24FEB16) 80-10-8 030916

PN=586
 Section 90
Miscellaneous Repair
Contents

Page

Group 10—Repair
Summary of References................................ 90-10-1
Remove and Install Right Side
Panel ......................................................... 90-10-1
Remove and Install Fuel Tank ....................... 90-10-4

TM130419 (24FEB16) 90-1 030916

PN=1
 Contents

TM130419 (24FEB16) 90-2 030916

PN=2
 Group 10
Repair
Summary of References • Remove and Install Fuel Tank
• Remove and Install Right Side Panel
OUMX258,0000B66 -19-15NOV13-1/1

Remove and Install Right Side Panel

1. Park machine safely.
2. Remove wing nuts (A) on front and back of battery
cover (B) and remove cover.
3. Disconnect — negative battery cable.
4. Loosen clamp and disconnect air cleaner hose from
side cover.

TCT008087 —UN—19NOV13
A—Wing Nut B—Cover

BS62576,000158C -19-27MAY14-1/6

5. Remove bolt (C) from front of side panel.

C—Bolt

Continued on next page TCT008088 —UN—19NOV13

BS62576,000158C -19-27MAY14-2/6

TM130419 (24FEB16) 90-10-1 030916

PN=589
 Repair

6. Remove bolt (D) from rear of side panel and remove

panel.

D—Bolt

TCT008089 —UN—19NOV13
BS62576,000158C -19-27MAY14-3/6

Installation
1. Install bolt and washer (A) and nut (B) to rear side
cover mount.

A—Bolt B—Nut

TCT009356 —UN—19NOV13
Continued on next page BS62576,000158C -19-27MAY14-4/6

TM130419 (24FEB16) 90-10-2 030916

PN=590
 Repair

2. Install bolt and washer (C) into front side cover mount.
3. Connect negative battery cable.

C—Bolt

TCT008088 —UN—19NOV13
BS62576,000158C -19-27MAY14-5/6

4. Install battery cover (D) and secure on each end with

wing nut (E).

D—Cover E—Wing Nut

TCT009357 —UN—19NOV13
BS62576,000158C -19-27MAY14-6/6

TM130419 (24FEB16) 90-10-3 030916

PN=591
 Repair

Remove and Install Fuel Tank

NOTE: It is preferable to perform procedure when
fuel tank is almost empty.

1. Park machine safely.

2. Disconnect negative — battery cable.
3. Mark and disconnect fuel hoses (A) and (B). Plug hose
ends and tank fittings.

TCT008090 —UN—19NOV13
A—Suction Line B—Return Line

BS62576,000158D -19-06APR15-1/6

4. Remove bolt and nut (C) and bolt (D) from front tank
mounts.

C—Bolt D—Bolt

TCT008091 —UN—19NOV13
Continued on next page BS62576,000158D -19-06APR15-2/6

TM130419 (24FEB16) 90-10-4 030916

PN=592
 Repair

5. Remove bolt and nut (E) from rear tank mount.

6. If necessary, have an assistant help lift tank from
machine.

E—Bolt

TCT009352 —UN—19NOV13
BS62576,000158D -19-06APR15-3/6

Installation
1. Install bolts and flat washers (A) and (B) to front fuel
tank mounts. Do not tighten.

A—Bolt B—Bolt and Nut

TCT009354 —UN—19NOV13
Continued on next page BS62576,000158D -19-06APR15-4/6

TM130419 (24FEB16) 90-10-5 030916

PN=593
 Repair

2. Install bolt and flat washer (C) up through tank mount

and frame. Install nut (D) and tighten.
3. Tighten bolt (A) on front tank mount and then tighten
bolt (B).

C—Bolt and Flat Washer D—Nut

TCT009355 —UN—19NOV13
BS62576,000158D -19-06APR15-5/6

4. Install fuel hoses (E) and (F) and secure with clamps.

E—Hose to Fuel Pump F— Hose to Cooler

TCT009353 —UN—19NOV13
BS62576,000158D -19-06APR15-6/6

TM130419 (24FEB16) 90-10-6 030916

PN=594
 Section 220
Engine Operation, Tests, and Adjustments
Contents

Page
Page
Group 10—Theory of Operation
Summary of References.............................. 220-10-1 Engine Runs Rough - Uneven
Engine Information ...................................... 220-10-1 Combustion Sound................................220-20-17
Cooling System Operation - Diagnose Engine Runs Rough - Surges
Diesel....................................................... 220-10-1 During Idle.............................................220-20-18
Lubrication System Operation - Engine Runs Rough - Surges During
Diesel....................................................... 220-10-2 Idle ........................................................220-20-18
Fuel and Air System Operation - Diagnose Engine Runs Rough - Surges
Diesel....................................................... 220-10-2 Under Load ...........................................220-20-19
Engine Runs Rough - Surges Under
Group 20—Diagnosis—3TNV80 Load ......................................................220-20-19
Diagnose Engine Will Not Start ...................220-20-1 Diagnose Engine Runs Rough -
Diagnose Engine Will Not Start ...................220-20-1 Excessive Vibration ...............................220-20-19
Diagnose Engine Starts But Does Not Engine Runs Rough - Excessive
Continue Running - No Exhaust Vibration ................................................220-20-20
Smoke .....................................................220-20-3 Diagnose Excessive Fuel
Diagnose Engine Starts But Does Not Consumption .........................................220-20-20
Continue Running - No Exhaust Excessive Fuel Consumption ....................220-20-20
Smoke .....................................................220-20-3 Diagnose Excessive Oil
Diagnose Engine Starts But Does Consumption .........................................220-20-21
Not Continue Running - Excessive Excessive Oil Consumption.......................220-20-21
Exhaust Smoke .......................................220-20-4 Diagnose Fuel Oil in Crankcase ................220-20-22
Diagnose Engine Starts But Does Fuel Oil in Crankcase ................................220-20-22
Not Continue Running - Excessive Diagnose Coolant in Crankcase ................220-20-23
Exhaust Smoke .......................................220-20-4 Coolant in Crankcase ................................220-20-23
Diagnose Low Engine Output - Normal Diagnose Low Oil Pressure .......................220-20-24
Exhaust Color..........................................220-20-6 Low Oil Pressure .......................................220-20-24
Diagnose Low Engine Output - Normal Diagnose Engine Overheating...................220-20-25
Exhaust Color..........................................220-20-6 Engine Overheating...................................220-20-25
Diagnose Low Engine Output - White Diagnose Low Engine Coolant
Exhaust Color..........................................220-20-7 Temperature ..........................................220-20-26
Low Engine Output - White Exhaust Low Engine Coolant Tempera-
Color........................................................220-20-7 ture ........................................................220-20-26
Diagnose Low Engine Output - Black Diagnose Low Compression......................220-20-26
Exhaust Color..........................................220-20-8 Low Compression......................................220-20-26
Low Engine Output - Black Exhaust Diagnose Starter Motor Does Not
Color........................................................220-20-9 Rotate....................................................220-20-27
Diagnose Exhaust Color White Under Starter Motor Does Not Rotate ..................220-20-27
Load ......................................................220-20-10 Diagnose Starter Rotates Slowly...............220-20-28
Exhaust Color White Under Load ..............220-20-10 Starter Rotates Slowly ...............................220-20-28
Diagnose Exhaust Color Black Under Diagnose Starter Rotates But Does
Load ......................................................220-20-12 Not Crank ..............................................220-20-29
Exhaust Color Black Under Load ..............220-20-12 Starter Rotates But Does Not
Diagnose High Exhaust Crank.....................................................220-20-29
Temperature ..........................................220-20-13
High Exhaust Temperature ........................220-20-13 Group 30—Diagnosis—3TNV82A, 3TNV88
Diagnose Engine Runs Rough - Engine Will Not Start ...................................220-30-1
Misfiring.................................................220-20-15 Procedure ....................................................220-30-1
Engine Runs Rough - Misfiring..................220-20-15
Diagnose Engine Runs Rough - Group 40—Tests and Adjustments—3TNV80F
Uneven Combustion Sound ..................220-20-16 Summary of References.............................. 220-40-1

Continued on next page

TM130419 (24FEB16) 220-1 030916

PN=1
 Contents

Page Page

Check and Adjust Alternator Drive Test Oil Pressure—3TNV82A,

Belt Tension—3TNV80F .......................... 220-40-1 3TNV88 ................................................. 220-45-17
Adjust Valve Clear- Test Fuel Pump Pres-
ance—3TNV80F...................................... 220-40-2 sure—3TNV82A, 3TNV88 ..................... 220-45-18
Check Valve Lift—3TNV80F........................ 220-40-4 Test Fuel Transfer Pump
Test Cylinder Compres- Flow—3TNV82A, 3TNV88..................... 220-45-18
sion—3TNV80F ....................................... 220-40-5 Test Fuel System
Test Engine Oil Pres- Leakage—3TNV82A, 3TNV88 .............. 220-45-19
sure—3TNV80F....................................... 220-40-6 Prime Fuel System—3TNV82A,
Leak Test Fuel Sys- 3TNV88 ................................................. 220-45-19
tem—3TNV80F........................................ 220-40-7
Priming Diesel Fuel
System—3TNV80F.................................. 220-40-7
Adjust Slow Idle
Speed—3TNV80F ................................... 220-40-8
Adjust Throttle Cable—3TNV80F ................ 220-40-9
Test Fuel Injection
System—3TNV80F................................ 220-40-10
Test Fuel Injection
Nozzle—3TNV80F................................. 220-40-11
Injection Pump Static Timing Check
and Adjust—3TNV80F........................... 220-40-13
Pressure Test Cooling
System—3TNV80F................................ 220-40-15
Pressure Test Radiator
Cap—3TNV80F ..................................... 220-40-16
Test Thermostat—3TNV80F...................... 220-40-16
Test Cylinder Leak-
down—3TNV80F ................................... 220-40-17
Fuel Transfer Pump Pressure
Test—3TNV80F ..................................... 220-40-17
Fuel Transfer Pump Flow
Test—3TNV80F ..................................... 220-40-18

Group 45—Tests and Adjust-

ments—3TNV82A, 3TNV88
Summary of References.............................. 220-45-1
Adjust Fan and Alternator Drive
Belt—3TNV82A, 3TNV88 ........................ 220-45-1
Test Cylinder Compres-
sion—3TNV82A, 3TNV88........................ 220-45-2
Adjust Slow Idle—3TNV82A,
3TNV88 ................................................... 220-45-3
Adjust Throttle Cable—3TNV82A,
3TNV88 ................................................... 220-45-4
Injection Pump Static
Timing—3TNV82A, 3TNV88.................... 220-45-5
Adjust Valve Clear-
ance—3TNV82A, 3TNV88 .................... 220-45-10
Test Fuel Injection
Nozzle—3TNV82A, 3TNV88 ................. 220-45-12
Test Thermostat Open-
ing—3TNV82A, 3TNV88 ....................... 220-45-14
Test Cylinder Pressure
Leakage—3TNV82A, 3TNV88 .............. 220-45-15
Pressure Test Cooling
System—3TNV82A, 3TNV88 ................ 220-45-15
Test Radiator Pressure
Cap—3TNV82A, 3TNV88...................... 220-45-16

TM130419 (24FEB16) 220-2 030916

PN=2
 Group 10
Theory of Operation
Summary of References • Lubrication System Operation - Diesel
• Engine Information • Fuel and Air System Operation - Diesel
• Cooling System Operation - Diesel
CB12260,00001EC -19-15SEP14-1/1

Engine Information
This vehicle specific technical manual has only engine
information which is specific to the vehicle. Most of
the engine information is found in the relevant engine
component technical manual. Use this manual in
conjunction with the relevant component technical manual
(CTM) for engine information.

M44215 —UN—07SEP88
• 3TNV88C Yanmar Diesel Engines.

BS62576,0001589 -19-16FEB16-1/1

Cooling System Operation - Diesel block. Here it circulates through the block and around
the cylinders.
Function
From the block, coolant is then directed through the
The coolant pump circulates coolant through the cooling cylinder head and into thermostat housing. With the
system, drawing hot coolant from the engine block and thermostat open, 85°C (185°F), warm engine coolant
circulating it through the radiator for cooling. passes through the housing into the top of the radiator,
Theory of Operation where it is circulated to dissipate heat.

The pressurized cooling system includes the radiator, When coolant system pressure exceeds 90 kPa (13 psi),
water pump, fan and thermostat. a valve in the radiator cap opens to allow coolant to
discharge into the coolant recovery tank.
During the warm-up period, the thermostat remains closed
and the impeller type coolant pump draws coolant from When temperature is reduced, a vacuum is produced in
the bypass tube. Coolant from the pump flows to the the radiator and coolant is drawn back out of the coolant
cylinder block water jacket and up through the cylinder recovery tank through a valve in the radiator cap.
head, providing a fast warm-up period. A coolant temperature sensor informs the operator of
Once the engine has reached operating temperature, the the engine coolant temperature and warns of a high
thermostat opens and coolant is pumped from the bottom temperature condition by lighting a lamp.
of the radiator via the lower radiator hose into the cylinder
OUMX258,0000B6A -19-25MAR13-1/1

TM130419 (24FEB16) 220-10-1 030916

PN=597
 Theory of Operation

Lubrication System Operation - Diesel From the main oil galley, oil is forwarded under pressure
Function to the crankshaft main bearing journals and the idler
gear shaft. Also, an oil passage from the main oil galley,
A full pressure system lubricates engine parts with clean through an external oil line, routes lubricating oil to the
oil. fuel injection pump.
Theory of Operation Drilled cross-passages in the crankshaft distribute the oil
from the main bearings to connecting rod bearings. Lube
The pressure lubrication system consists of an oil
oil holes in main bearing oil grooves are provided to direct
strainer, positive-displacement crankshaft-driven pump,
oil to the camshaft bearings.
oil pressure regulating valve, full flow oil filter, and an
electrical pressure warning switch. A drilled passage from the rear camshaft bearing through
the cylinder block and cylinder head supplies lubricating
The pump draws lubrication oil from the oil pan through a
oil to the rocker arm shaft. The hollow shaft distributes oil
strainer and a suction tube. The oil pressure regulating
to the rocker arms, tappets and valves.
valve maintains pressure at a specified level that prevents
over-pressurization of the system. The oil is then pumped The oil pressure switch activates an indicator light to alert
through an oil passage to the oil filter, then to the engine the operator to shut down the engine if oil pressure drops
block main oil galley. below specification.
OUMX258,0000B6B -19-25MAR13-1/1

Fuel and Air System Operation - Diesel The injection pump meters fuel as determined by the
Function governor and delivers it at high pressure to the injection
nozzles.
The fuel system supplies fuel to injection nozzles.
The injection nozzle prevents flow until high pressure is
The air intake system filters air needed for combustion. reached, opening the valve and spraying atomized fuel
into the combustion chamber. Injection lines have trapped
Fuel System
fuel whenever injection is not taking place.
An electric fuel transfer pump provides pressurized fuel
A small amount of fuel leaks past the nozzle valve to
to the injection pump. The fuel transfer pump draws fuel
lubricate the fuel injection nozzle. This leakage combines
from a vented fuel tank and then sends it to an in-line
with excess fuel from the injection pump and is returned to
filter. Low pressure fuel from the fuel transfer pump flows
the tank. Any air in the fuel system is bled out with return
through the fuel filter to the fuel gallery of the injection
fuel to the fuel tank.
pump. After the injection pump galley is full, excess fuel is
returned, along with leak-off fuel from the nozzles, through Air System
the return line to the fuel tank.
Air enters the air filter through the inlet hose. The primary
If the machine ever runs out of fuel, there are two air bleed and secondary elements filter the air before entering the
lines that allow air to escape from the top of the filter and intake manifold.
the injection pump. These two lines allow the system to
be self-bleeding. An air filter restriction indicator has a button that exposes
a red indicator when the air filter needs servicing. The
The engine speed is controlled by the throttle lever and air filter restriction indicator is exposed when the vacuum
cable. The cable is connected to the injection pump reaches a specified level. A small amount of vacuum is
governor control lever. The fuel shutoff solenoid controls always present due to some restriction of air movement
the injection pump shutoff shaft. When the solenoid is through the filter elements. The unloading valve is like a
retracted (ignition ON), the engine can be started. When one-way valve. It ejects heavy dirt particles from the air
the ignition is turned off, return springs on the shutoff stream during engine operation, but does not let air into
shaft extend the solenoid, moving the shutoff linkage to the air filter housing. The operator can squeeze the valve
the shutoff position. to let the large particles out.
OUMX258,0000B6C -19-25MAR13-1/1

TM130419 (24FEB16) 220-10-2 030916

PN=598
 Group 20
Diagnosis—3TNV80
Diagnose Engine Will Not Start
Engine Will Not Start, 3TNV80
OUMX258,0000B6D -19-30DEC13-1/19

Diagnose Engine Will Not Start

OUMX258,0000B6D -19-30DEC13-2/19

•1 Test Procedure Starting procedure being used is correct for conditions? YES: Go to next step.

NO: Use correct procedure

for conditions. See the
Operator’s Manual.

OUMX258,0000B6D -19-30DEC13-3/19

•2 (Continued) Battery 12.7 VDC or higher? YES: Go to next step.

NO: Charge and check

battery.

OUMX258,0000B6D -19-30DEC13-4/19

•3 (Continued) No open circuits in wiring? YES: Go to next step.

NO: Repair or replace as

needed.

OUMX258,0000B6D -19-30DEC13-5/19

•4 (Continued) Starting motor functioning properly? YES: Go to next step.

NO: Repair or replace

starting motor.

OUMX258,0000B6D -19-30DEC13-6/19

•5 (Continued) Correct type of fuel being used? YES: Go to next step.

NO: Drain and replace fuel.

OUMX258,0000B6D -19-30DEC13-7/19

•6 (Continued) Engine oil of correct viscosity and type? YES: Go to next step.

NO: Replace engine oil

with oil of proper viscosity
and type. Replace oil filter.

Continued on next page OUMX258,0000B6D -19-30DEC13-8/19

TM130419 (24FEB16) 220-20-1 PN=599

030916
 Diagnosis—3TNV80

•7 (Continued) No water in fuel? YES: Go to next step.

NO: Drain and replace fuel.

OUMX258,0000B6D -19-30DEC13-9/19

•8 (Continued) Fuel filter not clogged? YES: Go to next step.

NO: Replace fuel filter.

OUMX258,0000B6D -19-30DEC13-10/19

•9 (Continued) No air leak in fuel system? YES: Go to next step.

NO: Repair fuel system.

OUMX258,0000B6D -19-30DEC13-11/19

•10 (Continued) Fuel lines not plugged, pinched or cracked? YES: Go to next step.

NO: Repair or replace fuel

lines as needed.

OUMX258,0000B6D -19-30DEC13-12/19

•11 (Continued) Correct volume of fuel supplied to injection pump? YES: Go to next step.

NO: Replace fuel pump.

OUMX258,0000B6D -19-30DEC13-13/19

•12 (Continued) Intake and/or exhaust valve clearance correct? YES: Go to next step.

NO: Adjust valve

clearance.

OUMX258,0000B6D -19-30DEC13-14/19

•13 (Continued) Intake and/or exhaust valve not seized? YES: Go to next step.

NO: Replace valve

and check valve guide.
(See Remove and
Install Cylinder Head
and Valves—3TNV80F
and Disassemble and
Assemble Cylinder Head
and Valves—3TNV80F.)

Continued on next page OUMX258,0000B6D -19-30DEC13-15/19

TM130419 (24FEB16) 220-20-2 PN=600

030916
 Diagnosis—3TNV80

•14 (Continued) Piston rings not broken or seized? YES: Go to next step.

NO: Replace rings. Check

piston and cylinder. (See
Remove and Install
Piston and Connecting
Rod—3TNV80F.)
OUMX258,0000B6D -19-30DEC13-16/19

•15 (Continued) Piston rings, piston or cylinder not worn? YES: Go to next step.

NO: Replace piston and/or

rings; bore or hone cylinder.
(See Remove and Install
Piston and Connecting
Rod—3TNV80F.)
OUMX258,0000B6D -19-30DEC13-17/19

•16 (Continued) Crankshaft pin or bearing not seized? YES: Go to next step.

NO: Regrind crankshaft

and replace bearings. (See
Inspect Crankshaft and
Main Bearings—3TNV80F.)
OUMX258,0000B6D -19-30DEC13-18/19

•17 (Continued) Is injection pump timing correct? NO: (See Injection Pump
Static Timing Check and
Adjust—3TNV80F.)

OUMX258,0000B6D -19-30DEC13-19/19

Diagnose Engine Starts But Does Not

Continue Running - No Exhaust Smoke Engine Starts But Does Not Continue Running -
No Exhaust Smoke, 3TNV80
OUMX258,0000B6E -19-30DEC13-1/10

Diagnose Engine Starts But Does Not Continue Running - No Exhaust Smoke
OUMX258,0000B6E -19-30DEC13-2/10

•1 Test Procedure Correct type of fuel being used? YES: Go to next step.

NO: Drain and replace fuel.

OUMX258,0000B6E -19-30DEC13-3/10

•2 (Continued) Engine oil of proper viscosity and type? YES: Go to next step.

NO: Replace engine oil

and filter with oil of proper
viscosity and type.

Continued on next page OUMX258,0000B6E -19-30DEC13-4/10

TM130419 (24FEB16) 220-20-3 PN=601

030916
 Diagnosis—3TNV80

•3 (Continued) Fuel filter not clogged? YES: Go to next step.

NO: Replace fuel filter.

OUMX258,0000B6E -19-30DEC13-5/10

•4 (Continued) No air leak in fuel system? YES: Go to next step.

NO: Repair fuel system.

OUMX258,0000B6E -19-30DEC13-6/10

•5 (Continued) Fuel lines not plugged, pinched or cracked? YES: Go to next step.

NO: Repair or replace fuel

lines as needed.
OUMX258,0000B6E -19-30DEC13-7/10

•6 (Continued) Correct volume of fuel supplied to injection pump? YES: Go to next step.

NO: Replace fuel pump.

OUMX258,0000B6E -19-30DEC13-8/10

•7 (Continued) Correct volume of fuel supplied to injection pump? YES: Go to next step.

NO: Replace fuel pump.

OUMX258,0000B6E -19-30DEC13-9/10

•8 (Continued) Valve clearance correct? NO: Adjust valve clear-

ance. (See Adjust Valve
Clearance—3TNV80F.0

OUMX258,0000B6E -19-30DEC13-10/10

Diagnose Engine Starts But Does Not

Continue Running - Excessive Exhaust Engine Starts But Does Not Continue Running -
Smoke Excessive Exhaust Smoke, 3TNV80
OUMX258,0000B6F -19-30DEC13-1/9

Diagnose Engine Starts But Does Not Continue Running - Excessive Exhaust Smoke
OUMX258,0000B6F -19-30DEC13-2/9

•1 Diagnostic Procedure Correct type of fuel being used? YES: Go to next step.

NO: Drain and replace fuel.

Continued on next page OUMX258,0000B6F -19-30DEC13-3/9

TM130419 (24FEB16) 220-20-4 PN=602

030916
 Diagnosis—3TNV80

•2 (Continued) No water in fuel? YES: Go to next step.

NO: Drain and replace fuel.

OUMX258,0000B6F -19-30DEC13-4/9

•3 (Continued) Fuel filter not clogged? YES: Go to next step.

NO: Replace fuel filter.

OUMX258,0000B6F -19-30DEC13-5/9

•4 (Continued) Air filter not clogged? YES: Go to next step.

NO: Replace air filter(s).

OUMX258,0000B6F -19-30DEC13-6/9

•5 (Continued) Intake and/or exhaust valve not seized? YES: Go to next step.

NO: Repair as necessary.

(See Remove and
Install Cylinder Head
and Valves—3TNV80F
and Disassemble and
Assemble Cylinder Head
and Valves—3TNV80F.)

OUMX258,0000B6F -19-30DEC13-7/9

•6 (Continued) Piston rings not broken or seized? YES: Go to next step.

NO: Replace rings. Check

piston and cylinder. (See
Remove and Install
Piston and Connecting
Rod—3TNV80F, Inspect
Piston and Connecting
Rod—3TNV80F,
and Inspect Cylinder
Bore—3TNV80F.)

OUMX258,0000B6F -19-30DEC13-8/9

•7 (Continued) Piston rings, piston or cylinder not worn? YES: Go to next step.

NO: Replace piston

and/or rings, bore or hone
cylinder. (See Inspect
Cylinder Bore Taper and
Out-of-Round—3TNV80F.)

OUMX258,0000B6F -19-30DEC13-9/9

TM130419 (24FEB16) 220-20-5 PN=603

030916
 Diagnosis—3TNV80

Diagnose Low Engine Output - Normal

Exhaust Color Low Engine Output - Normal Exhaust Color, 3TNV80
OUMX258,0000B70 -19-25MAR13-1/11

Diagnose Low Engine Output - Normal Exhaust Color

OUMX258,0000B70 -19-25MAR13-2/11

•1 Procedure Correct type of fuel being used? YES: Go to next step.

NO: Drain and replace fuel.

OUMX258,0000B70 -19-25MAR13-3/11

•2 (Continued) Fuel filter not clogged? YES: Go to next step.

NO: Replace fuel filter.

OUMX258,0000B70 -19-25MAR13-4/11

•3 (Continued) Fuel lines not clogged, cracked or pinched? YES: Go to next step.

NO: Clean or replace fuel

lines.

OUMX258,0000B70 -19-25MAR13-5/11

•4 (Continued) No air leakage into fuel system? YES: Go to next step.

NO: Repair fuel supply

system.

OUMX258,0000B70 -19-25MAR13-6/11

•5 (Continued) Proper volume of fuel to injection pump? YES: Go to next step.

NO: Check or replace fuel

pump.

OUMX258,0000B70 -19-25MAR13-7/11

•6 (Continued) Intake and exhaust valve clearance correct? YES: Go to next step.

NO: Adjust valve clear-

ance. (See Adjust Valve
Clearance—3TNV80F.)

Continued on next page OUMX258,0000B70 -19-25MAR13-8/11

TM130419 (24FEB16) 220-20-6 PN=604

030916
 Diagnosis—3TNV80

•7 (Continued) Intake or exhaust valves not leaking compression? YES: Go to next step.

NO: Grind valves and

seats. (See Remove
and Install Cylinder Head
and Valves—3TNV80F,
Disassemble and
Assemble Cylinder Head
and Valves—3TNV80F
and Grind Valve
Seats—3TNV80F.)
OUMX258,0000B70 -19-25MAR13-9/11

•8 (Continued) Intake or exhaust valves not seized? YES: Go to next step.

NO: Replace valve and

check valve guide.
OUMX258,0000B70 -19-25MAR13-10/11

•9 (Continued) Cylinder head gasket not leaking compression? NO: Replace head
gasket. (See Remove and
Install Cylinder Head and
Valves—3TNV80F .)
OUMX258,0000B70 -19-25MAR13-11/11

Diagnose Low Engine Output - White

Exhaust Color Low Engine Output - White Exhaust Color, 3TNV80
OUMX258,0000B71 -19-30DEC13-1/11

Low Engine Output - White Exhaust Color

OUMX258,0000B71 -19-30DEC13-2/11

•1 Test Procedure Correct type of fuel? YES: Go to next step.

NO: Drain and replace fuel.

OUMX258,0000B71 -19-30DEC13-3/11

•2 (Continued) No water in fuel? YES: Go to next step.

NO: Drain and replace fuel.

OUMX258,0000B71 -19-30DEC13-4/11

•3 (Continued) Even volume of fuel being injected? YES: Go to next step.

NO: Repair or replace

fuel injection pump or fuel
injectors.

Continued on next page OUMX258,0000B71 -19-30DEC13-5/11

TM130419 (24FEB16) 220-20-7 PN=605

030916
 Diagnosis—3TNV80

•4 (Continued) Proper spray pattern from injectors? YES: Go to next step.

NO: Clean or replace fuel

injection nozzles.
OUMX258,0000B71 -19-30DEC13-6/11

•5 (Continued) Intake or exhaust valve stems not worn? YES: Go to next step.

NO: Replace valve guides

and valves. (See Remove
and Install Cylinder Head
and Valves—3TNV80F
and Disassemble and
Assemble Cylinder Head
and Valves—3TNV80F.)
OUMX258,0000B71 -19-30DEC13-7/11

•6 (Continued) Is injection pump timing correct? YES: Go to next step.

NO: Time injection pump.

OUMX258,0000B71 -19-30DEC13-8/11

•7 (Continued) Piston rings installed correctly and staggered? YES: Go to next step.

NO: Install piston

rings correctly. (See
Disassemble and Assemble
Piston and Connecting
Rod—3TNV80F.)

OUMX258,0000B71 -19-30DEC13-9/11

•8 (Continued) Piston, rings, or cylinder not worn? YES: Go to next step.

NO: Replace pistons

and rings; bore or hone
cylinders.

OUMX258,0000B71 -19-30DEC13-10/11

•9 (Continued) Piston rings not broken or seized? NO: Replace rings.

Replace pistons if damaged.
Bore cylinder if damaged.
(See Inspect Cylinder
Bore—3TNV80F.)

OUMX258,0000B71 -19-30DEC13-11/11

Diagnose Low Engine Output - Black

Exhaust Color Low Engine Output - Black Exhaust Color, 3TNV80
Continued on next page OUMX258,0000B72 -19-30DEC13-1/13

TM130419 (24FEB16) 220-20-8 030916

PN=606
 Diagnosis—3TNV80

Low Engine Output - Black Exhaust Color

OUMX258,0000B72 -19-30DEC13-2/13

•1 Test Procedure Is engine NOT being run under high-altitude or high-temperature conditions? YES: Go to next step.

NO: Reduce load.

OUMX258,0000B72 -19-30DEC13-3/13

•2 (Continued) Correct type of fuel? YES: Go to next step.

NO: Drain and replace fuel.

OUMX258,0000B72 -19-30DEC13-4/13

•3 (Continued) Air filter elements not clogged? YES: Go to next step.

NO: Clean or replace air

filter elements.

OUMX258,0000B72 -19-30DEC13-5/13

•4 (Continued) Exhaust pipe not clogged? YES: Go to next step.

NO: Clean exhaust pipe.

OUMX258,0000B72 -19-30DEC13-6/13

•5 (Continued) Engine running cool enough? YES: Go to next step.

NO: Adjust fan belt

tension. (See Check and
Adjust Alternator Drive Belt
Tension—3TNV80F.)

OUMX258,0000B72 -19-30DEC13-7/13

•6 (Continued) Cooling system filled to correct level? YES: Go to next step.

NO: Check for leaks and

fill system to correct level.

OUMX258,0000B72 -19-30DEC13-8/13

•7 (Continued) Correct volume of fuel being injected? YES: Go to next step.

NO: Replace faulty fuel

injection pump or fuel
injectors.

Continued on next page OUMX258,0000B72 -19-30DEC13-9/13

TM130419 (24FEB16) 220-20-9 PN=607

030916
 Diagnosis—3TNV80

•8 (Continued) Correct pattern from fuel injectors? YES: Go to next step.

NO: Clean or replace

fuel injection nozzles.
(See Remove, Inspect,
and Install Fuel Injection
Nozzle—3TNV80F.)
OUMX258,0000B72 -19-30DEC13-10/13

•9 (Continued) Is injection pump timing correct? YES: Go to next step.

NO: Time injection pump.

(See Injection Pump
Static Timing Check and
Adjust—3TNV80F.)
OUMX258,0000B72 -19-30DEC13-11/13

•10 (Continued) Intake or exhaust valves not leaking compression? YES: Go to next step.

NO: Grind valves and

seats. (See Remove
and Install Cylinder Head
and Valves—3TNV80F
and Disassemble and
Assemble Cylinder Head
and Valves—3TNV80F.)
OUMX258,0000B72 -19-30DEC13-12/13

•11 (Continued) Intake or exhaust valve not seized? NO: Replace valve and
check valve guide.

OUMX258,0000B72 -19-30DEC13-13/13

Diagnose Exhaust Color White Under Load

Exhaust Color White Under Load, 3TNV80
OUMX258,0000B73 -19-30DEC13-1/11

Exhaust Color White Under Load

OUMX258,0000B73 -19-30DEC13-2/11

•1 Test Procedure Correct type of fuel? YES: Go to next step.

NO: Drain and replace fuel.

OUMX258,0000B73 -19-30DEC13-3/11

•2 (Continued) No water in fuel? YES: Go to next step.

NO: Drain and replace fuel.

Continued on next page OUMX258,0000B73 -19-30DEC13-4/11

TM130419 (24FEB16) 220-20-10 PN=608

030916
 Diagnosis—3TNV80

•3 (Continued) Engine not running too cool? YES: Go to next step.

NO: Check thermostat.

OUMX258,0000B73 -19-30DEC13-5/11

•4 (Continued) Correct volume of fuel being injected? YES: Go to next step.

NO: Replace faulty fuel

injection pump.
OUMX258,0000B73 -19-30DEC13-6/11

•5 (Continued) Correct pattern from fuel injectors? YES: Go to next step.

NO: Clean or replace

fuel injection nozzles.
(See Remove, Inspect,
and Install Fuel Injection
Nozzle—3TNV80F.)
OUMX258,0000B73 -19-30DEC13-7/11

•6 (Continued) Is injection pump timing correct? YES: Go to next step.

NO: Time injection pump.

(See Injection Pump
Static Timing Check and
Adjust—3TNV80F.)

OUMX258,0000B73 -19-30DEC13-8/11

•7 (Continued) Piston rings installed correctly? YES: Go to next step.

NO: Install piston

rings correctly. (See
Disassemble and Assemble
Piston and Connecting
Rod—3TNV80F.)

OUMX258,0000B73 -19-30DEC13-9/11

•8 (Continued) Pistons, rings or cylinders not worn? YES: Go to next step.

NO: Replace pistons

and rings; bore or hone
cylinders.

OUMX258,0000B73 -19-30DEC13-10/11

•9 (Continued) Piston rings not broken or seized? NO: Replace rings.

Replace pistons if damaged.
Bore cylinder if damaged.

OUMX258,0000B73 -19-30DEC13-11/11

TM130419 (24FEB16) 220-20-11 PN=609

030916
 Diagnosis—3TNV80

Diagnose Exhaust Color Black Under Load

Exhaust Color Black Under Load, 3TNV80
OUMX258,0000B74 -19-28MAR13-1/12

Exhaust Color Black Under Load

OUMX258,0000B74 -19-28MAR13-2/12

•1 Test Procedure Is engine NOT being run under high-altitude or high-temperature conditions? YES: Go to next step.

NO: Reduce load.

OUMX258,0000B74 -19-28MAR13-3/12

•2 (Continued) Correct type of fuel? YES: Go to next step.

NO: Drain and replace fuel.

OUMX258,0000B74 -19-28MAR13-4/12

•3 (Continued) Air filter elements not clogged? YES: Go to next step.

NO: Clean or replace air

filter elements.

OUMX258,0000B74 -19-28MAR13-5/12

•4 (Continued) Exhaust pipe not clogged? YES: Go to next step.

NO: Clean exhaust pipe.

OUMX258,0000B74 -19-28MAR13-6/12

•5 (Continued) Even volume of fuel being injected? YES: Go to next step.

NO: Replace faulty fuel

injection pump or fuel
injectors.

OUMX258,0000B74 -19-28MAR13-7/12

•6 (Continued) Correct volume of fuel being injected? YES: Go to next step.

NO: Replace faulty fuel

injection pump or fuel
injectors.

Continued on next page OUMX258,0000B74 -19-28MAR13-8/12

TM130419 (24FEB16) 220-20-12 PN=610

030916
 Diagnosis—3TNV80

•7 (Continued) Proper spray pattern from injectors? YES: Go to next step.

NO: Clean or replace

fuel injection nozzles.
(See Remove, Inspect,
and Install Fuel Injection
Nozzle—3TNV80F.)
OUMX258,0000B74 -19-28MAR13-9/12

•8 (Continued) Is injection pump timing correct? YES: Go to next step.

NO: Time injection pump.

(See Injection Pump
Static Timing Check and
Adjust—3TNV80F.)
OUMX258,0000B74 -19-28MAR13-10/12

•9 (Continued) Intake or exhaust valves not leaking compression? YES: Go to next step.

NO: Grind valves and

seats. (See Remove
and Install Cylinder Head
and Valves—3TNV80F,
Disassemble and
Assemble Cylinder Head
and Valves—3TNV80F
and Grind Valve
Seats—3TNV80F.)
OUMX258,0000B74 -19-28MAR13-11/12

•10 (Continued) Intake or exhaust valves not seized? NO: Replace valve
and check valve guide.
(See Remove and
Install Cylinder Head
and Valves—3TNV80F
and Disassemble and
Assemble Cylinder Head
and Valves—3TNV80F.)

OUMX258,0000B74 -19-28MAR13-12/12

Diagnose High Exhaust Temperature

High Exhaust Temperature, 3TNV80
OUMX258,0000B75 -19-30DEC13-1/10

High Exhaust Temperature

OUMX258,0000B75 -19-30DEC13-2/10

•1 Test Procedure Cooling system filled to correct level? YES: Go to next step.

NO: Check for leaks and

fill system to correct level.

Continued on next page OUMX258,0000B75 -19-30DEC13-3/10

TM130419 (24FEB16) 220-20-13 PN=611

030916
 Diagnosis—3TNV80

•2 (Continued) Engine running cool enough? YES: Go to next step.

NO: Adjust fan belt

tension. (See Check and
Adjust Alternator Drive Belt
Tension—3TNV80F.)
OUMX258,0000B75 -19-30DEC13-4/10

•3 (Continued) Exhaust pipe not clogged? YES: Go to next step.

NO: Clean exhaust pipe.

OUMX258,0000B75 -19-30DEC13-5/10

•4 (Continued) Correct volume of fuel being injected? YES: Go to next step.

NO: Replace faulty fuel

injection pump or fuel
injectors.
OUMX258,0000B75 -19-30DEC13-6/10

•5 (Continued) Intake or exhaust valve clearance correct? YES: Go to next step.

NO: Adjust valve clear-

ance. (See Adjust Valve
Clearance—3TNV80F.)

OUMX258,0000B75 -19-30DEC13-7/10

•6 (Continued) Intake or exhaust valve clearance correct? YES: Go to next step.

NO: Adjust valve

clearance.

OUMX258,0000B75 -19-30DEC13-8/10

•7 (Continued) Intake or exhaust valves not leaking compression? YES: Go to next step.

NO: Grind valves and

seats. (See Remove
and Install Cylinder Head
and Valves—3TNV80F,
Disassemble and
Assemble Cylinder Head
and Valves—3TNV80F
and Grind Valve
Seats—3TNV80F.)

Continued on next page OUMX258,0000B75 -19-30DEC13-9/10

TM130419 (24FEB16) 220-20-14 PN=612

030916
 Diagnosis—3TNV80

•8 (Continued) Piston rings not broken or seized? NO: Replace rings.

Replace pistons if
damaged. Bore cylinder
if damaged. (See Inspect
Cylinder Bore—3TNV80F
and Inspect Cylinder
Bore Taper and
Out-of-Round—3TNV80F.)
OUMX258,0000B75 -19-30DEC13-10/10

Diagnose Engine Runs Rough - Misfiring

Engine Runs Rough - Misfiring, 3TNV80
OUMX258,0000B76 -19-30DEC13-1/11

Engine Runs Rough - Misfiring

OUMX258,0000B76 -19-30DEC13-2/11

•1 Test Procedure No water in fuel? YES: Go to next step.

NO: Drain and replace fuel.

OUMX258,0000B76 -19-30DEC13-3/11

•2 (Continued) Intake or exhaust valve clearance correct? YES: Go to next step.

NO: Adjust valve clear-

ance. (See Adjust Valve
Clearance—3TNV80F.)

OUMX258,0000B76 -19-30DEC13-4/11

•3 (Continued) Correct volume of fuel being injected? YES: Go to next step.

NO: Replace faulty fuel

injection pump or fuel
injectors.

OUMX258,0000B76 -19-30DEC13-5/11

•4 (Continued) Is injection pump timing correct? YES: Go to next step.

NO: Time injection pump.

(See Injection Pump
Static Timing Check and
Adjust—3TNV80F.)

Continued on next page OUMX258,0000B76 -19-30DEC13-6/11

TM130419 (24FEB16) 220-20-15 PN=613

030916
 Diagnosis—3TNV80

•5 (Continued) Backlash of timing gear not excessive? YES: Go to next step.

NO: Replace gears as

needed. (See Remove
and Install Timing Gear
Cover—3TNV80F and
Remove and Install Idler
Gear—3TNV80F.)
OUMX258,0000B76 -19-30DEC13-7/11

•6 (Continued) Combustion chambers clean of foreign matter? YES: Go to next step.

NO: Clean combustion

chambers. (See
Remove and Install
Piston and Connecting
Rod—3TNV80F.)
OUMX258,0000B76 -19-30DEC13-8/11

•7 (Continued) Intake or exhaust valves not leaking compression? YES: Go to next step.

NO: Grind valves and

seats. (See Remove
and Install Cylinder Head
and Valves—3TNV80F,
Disassemble and
Assemble Cylinder Head
and Valves—3TNV80F
and Grind Valve
Seats—3TNV80F.)
OUMX258,0000B76 -19-30DEC13-9/11

•8 (Continued) Intake or exhaust valves not seized? YES: Go to next step.

NO: Replace valve

and check valve guide.
(See Remove and
Install Cylinder Head
and Valves—3TNV80F,
and Disassemble and
Assemble Cylinder Head
and Valves—3TNV80F.)

OUMX258,0000B76 -19-30DEC13-10/11

•9 (Continued) Piston rings not broken or seized? NO: Replace rings.

Replace pistons if damaged.
Bore cylinder if damaged.

OUMX258,0000B76 -19-30DEC13-11/11

Diagnose Engine Runs Rough - Uneven

Combustion Sound Engine Runs Rough - Uneven Combustion
Sound, 3TNV80
Continued on next page OUMX258,0000B77 -19-25MAR13-1/9

TM130419 (24FEB16) 220-20-16 PN=614

030916
 Diagnosis—3TNV80

Engine Runs Rough - Uneven Combustion Sound

OUMX258,0000B77 -19-25MAR13-2/9

•1 Test Procedure Correct type of fuel being used? YES: Go to next step.

NO: Drain and replace fuel.

OUMX258,0000B77 -19-25MAR13-3/9

•2 (Continued) No water in fuel? YES: Go to next step.

NO: Drain and replace

fuel. Check fuel filter.
OUMX258,0000B77 -19-25MAR13-4/9

•3 (Continued) Intake and exhaust valve clearance correct? YES: Go to next step.

NO: Adjust valve clear-

ance. (See Adjust Valve
Clearance—3TNV80F.)

OUMX258,0000B77 -19-25MAR13-5/9

•4 (Continued) Even volume of fuel being injected? YES: Go to next step.

NO: Replace faulty fuel

injection pump or fuel
injectors.

OUMX258,0000B77 -19-25MAR13-6/9

•5 (Continued) Proper spray pattern from injectors? YES: Go to next step.

NO: Clean or replace

fuel injection nozzles.
(See Remove, Inspect,
and Install Fuel Injection
Nozzle—3TNV80F.)

OUMX258,0000B77 -19-25MAR13-7/9

•6 (Continued) Air filter elements not clogged? YES: Go to next step.

NO: Clean or replace air

filter elements.

OUMX258,0000B77 -19-25MAR13-8/9

•7 (Continued) Exhaust pipe not clogged? NO: Clean exhaust pipe.

OUMX258,0000B77 -19-25MAR13-9/9

TM130419 (24FEB16) 220-20-17 PN=615

030916
 Diagnosis—3TNV80

Diagnose Engine Runs Rough - Surges

During Idle Engine Runs Rough - Surges During Idle, 3TNV80
OUMX258,0000B78 -19-30DEC13-1/8

Engine Runs Rough - Surges During Idle

OUMX258,0000B78 -19-30DEC13-2/8

•1 Test Procedure No water in fuel? YES: Go to next step.

NO: Drain and replace

fuel. Check fuel filter.
OUMX258,0000B78 -19-30DEC13-3/8

•2 (Continued) Even volume of fuel injected? YES: Go to next step.

NO: Replace faulty fuel

injection pump or fuel
injectors.

OUMX258,0000B78 -19-30DEC13-4/8

•3 (Continued) Intake and exhaust valve clearance correct? YES: Go to next step.

NO: Adjust valve clear-

ance. (See Adjust Valve
Clearance—3TNV80F.)

OUMX258,0000B78 -19-30DEC13-5/8

•4 (Continued) Proper spray pattern from injectors? YES: Go to next step.

NO: Clean or replace

fuel injection nozzles.
(See Remove, Inspect,
and Install Fuel Injection
Nozzle—3TNV80F.)

OUMX258,0000B78 -19-30DEC13-6/8

•5 (Continued) Intake or exhaust valves not seized? YES: Go to next step.

NO: Replace valve

and check valve guide.
(See Remove and
Install Cylinder Head
and Valves—3TNV80F
and Disassemble and
Assemble Cylinder Head
and Valves—3TNV80F .)

Continued on next page OUMX258,0000B78 -19-30DEC13-7/8

TM130419 (24FEB16) 220-20-18 030916

PN=616
 Diagnosis—3TNV80

•6 (Continued) Piston rings not broken or seized? NO: Replace rings.

Replace pistons if
damaged. Bore cylinder
if damaged. (See Inspect
Cylinder Bore—3TNV80F
and Inspect Cylinder
Bore Taper and
Out-of-Round—3TNV80F.)
OUMX258,0000B78 -19-30DEC13-8/8

Diagnose Engine Runs Rough - Surges

Under Load Engine Runs Rough - Surges Under Load, 3TNV80
OUMX258,0000B79 -19-30DEC13-1/6

Engine Runs Rough - Surges Under Load

OUMX258,0000B79 -19-30DEC13-2/6

•1 Test Procedure No water in fuel? YES: Go to next step.

NO: Drain and replace

fuel. Check fuel filters.

OUMX258,0000B79 -19-30DEC13-3/6

•2 (Continued) Even volume of fuel injected? YES: Go to next step.

NO: Replace faulty fuel

injection pump or fuel
injectors.

OUMX258,0000B79 -19-30DEC13-4/6

•3 (Continued) Proper spray pattern from injectors? YES: Go to next step.

NO: Clean or replace

fuel injection nozzles.
(See Remove, Inspect,
and Install Fuel Injection
Nozzle—3TNV80F.)

OUMX258,0000B79 -19-30DEC13-5/6

•4 (Continued) Piston rings not broken or seized? NO: Replace rings.

Replace pistons if
damaged. Bore cylinder
if damaged. (See Inspect
Cylinder Bore—3TNV80F
and Inspect Cylinder
Bore Taper and
Out-of-Round—3TNV80F.)

OUMX258,0000B79 -19-30DEC13-6/6

Diagnose Engine Runs Rough - Excessive

Vibration Engine Runs Rough - Excessive Vibration, 3TNV80
Continued on next page OUMX258,0000B7A -19-16SEP14-1/7

TM130419 (24FEB16) 220-20-19 030916

PN=617
 Diagnosis—3TNV80

Engine Runs Rough - Excessive Vibration

OUMX258,0000B7A -19-16SEP14-2/7

•1 Test Procedure Even volume of fuel injected? YES: Go to next step.

NO: Replace faulty fuel

injection pump or fuel
injectors.
OUMX258,0000B7A -19-16SEP14-3/7

•2 (Continued) Proper spray pattern from injectors? YES: Go to next step.

NO: Clean or replace

fuel injection nozzles.
(See Remove, Inspect,
and Install Fuel Injection
Nozzle—3TNV80F.)
OUMX258,0000B7A -19-16SEP14-4/7

•3 (Continued) Piston rings not broken or seized? YES: Go to next step.

NO: Replace rings.

Replace pistons if
damaged. Bore cylinder
if damaged. (See Inspect
Cylinder Bore—3TNV80F
and Inspect Cylinder
Bore Taper and
Out-of-Round—3TNV80F.)

OUMX258,0000B7A -19-16SEP14-5/7

•4 (Continued) Crankshaft pin or bearing not worn or seized? YES: Go to next step.

NO: Regrind crankshaft

and replace bearings.

OUMX258,0000B7A -19-16SEP14-6/7

•5 (Continued) Connecting rod bolts torqued properly? NO: Replace damaged

components.

OUMX258,0000B7A -19-16SEP14-7/7

Diagnose Excessive Fuel Consumption

Excessive Fuel Consumption, 3TNV80
OUMX258,0000B7B -19-25MAR13-1/6

Excessive Fuel Consumption

Continued on next page OUMX258,0000B7B -19-25MAR13-2/6

TM130419 (24FEB16) 220-20-20 030916

PN=618
 Diagnosis—3TNV80

•1 Test Procedure Engine not running too cool? YES: Go to next step.

NO: Check thermo-

stat. (See Test Thermo-
stat—3TNV80F.)
OUMX258,0000B7B -19-25MAR13-3/6

•2 (Continued) Correct volume of fuel being injected? YES: Go to next step.

NO: Replace faulty fuel

injection pump or fuel
injectors.
OUMX258,0000B7B -19-25MAR13-4/6

•3 (Continued) Correct pattern from fuel injectors? YES: Go to next step.

NO: Clean or replace

fuel injection nozzles.
(See Remove, Inspect,
and Install Fuel Injection
Nozzle—3TNV80F.)
OUMX258,0000B7B -19-25MAR13-5/6

•4 (Continued) Intake or exhaust valves not leaking compression? NO: Grind valves and
seats.

OUMX258,0000B7B -19-25MAR13-6/6

Diagnose Excessive Oil Consumption

Excessive Oil Consumption, 3TNV80
OUMX258,0000B7C -19-30DEC13-1/8

Excessive Oil Consumption

OUMX258,0000B7C -19-30DEC13-2/8

•1 Test Procedure Engine oil of correct viscosity and type? YES: Go to next step.

NO: Replace engine oil

with oil of proper viscosity
and type. Replace oil filter.

OUMX258,0000B7C -19-30DEC13-3/8

•2 (Continued) No external or internal oil leak? YES: Go to next step.

NO: Repair as needed.

Continued on next page OUMX258,0000B7C -19-30DEC13-4/8

TM130419 (24FEB16) 220-20-21 PN=619

030916
 Diagnosis—3TNV80

•3 (Continued) Intake or exhaust valve stems not worn? YES: Go to next step.

NO: Replace valve guides

and valves. (See Remove
and Install Cylinder Head
and Valves—3TNV80F
and Disassemble and
Assemble Cylinder Head
and Valves—3TNV80F.)
OUMX258,0000B7C -19-30DEC13-5/8

•4 (Continued) Piston rings installed correctly and properly staggered? YES: Go to next step.

NO: Install piston

rings correctly. (See
Disassemble and Assemble
Piston and Connecting
Rod—3TNV80F.)
OUMX258,0000B7C -19-30DEC13-6/8

•5 (Continued) Piston rings not broken or seized? NO: Replace rings.

Check piston and
cylinder. (See Inspect
Piston and Connecting
Rod—3TNV80F.)
OUMX258,0000B7C -19-30DEC13-7/8

•6 (Continued) Pistons, rings or cylinders not worn? YES: Go to next step.

NO: Replace pistons

and rings; bore or hone
cylinders. (SSee Inspect
Cylinder Bore—3TNV80F
and Inspect Cylinder
Bore Taper and
Out-of-Round—3TNV80F.)

OUMX258,0000B7C -19-30DEC13-8/8

Diagnose Fuel Oil in Crankcase

Fuel Oil in Crankcase, 3TNV80
OUMX258,0000B7D -19-30DEC13-1/6

Fuel Oil in Crankcase

OUMX258,0000B7D -19-30DEC13-2/6

•1 Test Procedure Correct volume of fuel being injected? YES: Go to next step.

NO: Replace faulty fuel

injection pump or fuel
injectors.

Continued on next page OUMX258,0000B7D -19-30DEC13-3/6

TM130419 (24FEB16) 220-20-22 030916

PN=620
 Diagnosis—3TNV80

•2 (Continued) Intake or exhaust valve not seized or broken? YES: Go to next step.

NO: Replace valve

and check valve guide.
(See Remove and
Install Cylinder Head
and Valves—3TNV80F,
Disassemble and
Assemble Cylinder Head
and Valves—3TNV80F
and Grind Valve
Seats—3TNV80F.)
OUMX258,0000B7D -19-30DEC13-4/6

•3 (Continued) Piston rings not broken or seized? YES: Go to next step.

NO: Replace rings. Check

piston and cylinder. (See
Remove and Install
Piston and Connecting
Rod—3TNV80F, Inspect
Piston and Connecting
Rod—3TNV80F, and
Disassemble and Assemble
Piston and Connecting
Rod—3TNV80F.)
OUMX258,0000B7D -19-30DEC13-5/6

•4 (Continued) Pistons rings, piston or cylinders not worn? NO: Replace pistons
and rings; bore or hone
cylinders.
OUMX258,0000B7D -19-30DEC13-6/6

Diagnose Coolant in Crankcase

Coolant in Crankcase, 3TNV80
OUMX258,0000B7E -19-25MAR13-1/4

Coolant in Crankcase
OUMX258,0000B7E -19-25MAR13-2/4

•1 Test Procedure Cylinder head gasket not leaking? YES: Go to next step.

NO: Replace head gasket.

Resurface head and block
if necessary. (See Remove
and Install Cylinder Head
and Valves—3TNV80F.)

OUMX258,0000B7E -19-25MAR13-3/4

•2 (Continued) Is cylinder block not cracked? NO: Replace cylinder

block.

OUMX258,0000B7E -19-25MAR13-4/4

TM130419 (24FEB16) 220-20-23 030916

PN=621
 Diagnosis—3TNV80

Diagnose Low Oil Pressure

Low Oil Pressure, 3TNV80
OUMX258,0000B7F -19-30DEC13-1/9

Low Oil Pressure

OUMX258,0000B7F -19-30DEC13-2/9

•1 Test Procedure Oil at correct level? YES: Go to next step.

NO: Add oil.

OUMX258,0000B7F -19-30DEC13-3/9

•2 (Continued) Engine oil of correct viscosity and type? YES: Go to next step.

NO: Replace engine oil

with oil of proper viscosity
and type. Replace oil filter.

OUMX258,0000B7F -19-30DEC13-4/9

•3 (Continued) No external or internal oil leak? YES: Go to next step.

NO: Repair as needed.

OUMX258,0000B7F -19-30DEC13-5/9

•4 (Continued) Oil pressure regulator valve not worn or damaged? YES: Go to next step.

NO: Clean or replace

regulator valve. (See
Remove and Install
Oil Pump—3TNV80F
and Inspect Oil
Pump—3TNV80F.)

OUMX258,0000B7F -19-30DEC13-6/9

•5 (Continued) Crankshaft pin or bearing not worn? YES: Go to next step.

NO: Regrind crankshaft

and replace bearings.
(See Remove and Install
Crankshaft and Main
Bearings—3TNV80F and
Inspect Crankshaft and
Main Bearings—3TNV80F.)

Continued on next page OUMX258,0000B7F -19-30DEC13-7/9

TM130419 (24FEB16) 220-20-24 PN=622

030916
 Diagnosis—3TNV80

•6 (Continued) Connecting rod bolts torqued properly? YES: Go to next step.

NO: Replace damaged

components. Tighten to
correct specification.
OUMX258,0000B7F -19-30DEC13-8/9

•7 (Continued) Is engine not worn excessively? NO: Repair engine as

needed.

OUMX258,0000B7F -19-30DEC13-9/9

Diagnose Engine Overheating

Engine Overheating, 3TNV80
OUMX258,0000B80 -19-25MAR13-1/11

Engine Overheating
OUMX258,0000B80 -19-25MAR13-2/11

•1 Test Procedure Is engine NOT being run under high-altitude or high-temperature conditions? YES: Go to next step.

NO: Reduce load on

engine.

OUMX258,0000B80 -19-25MAR13-3/11

•2 (Continued) Cooling system filled to correct level? YES: Go to next step.

NO: Check for leaks and

fill system to correct level.

OUMX258,0000B80 -19-25MAR13-4/11

•3 (Continued) Is radiator clear of debris? YES: Go to next step.

NO: Clean radiator fins.

OUMX258,0000B80 -19-25MAR13-5/11

•4 (Continued) Is radiator core free from blockage? YES: Go to next step.

NO: Clean or replace

radiator.

OUMX258,0000B80 -19-25MAR13-6/11

•5 (Continued) Is fan operating correctly? YES: Go to next step.

NO: Adjust fan belt

tension. (See Check and
Adjust Alternator Drive Belt
Tension—3TNV80F.)

Continued on next page OUMX258,0000B80 -19-25MAR13-7/11

TM130419 (24FEB16) 220-20-25 PN=623

030916
 Diagnosis—3TNV80

•6 (Continued) Is thermostat operating correctly? YES: Go to next step.

NO: Check thermo-

stat. (See Test Thermo-
stat—3TNV80F.)
OUMX258,0000B80 -19-25MAR13-8/11

•7 (Continued) Is lower radiator hose not collapsed? YES: Go to next step.

NO: Replace lower radiator

hose.
OUMX258,0000B80 -19-25MAR13-9/11

•8 (Continued) Is cylinder head gasket not leaking? YES: Go to next step.

NO: Replace head gasket.

Resurface head and block
if necessary. (See Remove
and Install Cylinder Head
and Valves—3TNV80F.)
OUMX258,0000B80 -19-25MAR13-10/11

•9 (Continued) Is cylinder block not cracked? NO: Replace cylinder

block.

OUMX258,0000B80 -19-25MAR13-11/11

Diagnose Low Engine Coolant Temperature

Low Engine Coolant Temperature, 3TNV80
OUMX258,0000B81 -19-25MAR13-1/3

Low Engine Coolant Temperature

OUMX258,0000B81 -19-25MAR13-2/3

•1 Test Procedure Is thermostat operating correctly? NO: Check thermo-

stat. (See Test Thermo-
stat—3TNV80F.)

OUMX258,0000B81 -19-25MAR13-3/3

Diagnose Low Compression

Low Compression, 3TNV80
OUMX258,0000B82 -19-30DEC13-1/6

Low Compression
Continued on next page OUMX258,0000B82 -19-30DEC13-2/6

TM130419 (24FEB16) 220-20-26 030916

PN=624
 Diagnosis—3TNV80

•1 Test Procedure Intake or exhaust valves not leaking compression? YES: Go to next step.

NO: Grind valves and

seats. (See Remove
and Install Cylinder Head
and Valves—3TNV80F,
Disassemble and
Assemble Cylinder Head
and Valves—3TNV80F
and Grind Valve
Seats—3TNV80F.)
OUMX258,0000B82 -19-30DEC13-3/6

•2 (Continued) Intake or exhaust valve not seized? YES: Go to next step.

NO: Replace valve guides

and valves.
OUMX258,0000B82 -19-30DEC13-4/6

•3 (Continued) Piston rings installed correctly and properly staggered? NO: Install piston
rings correctly. (See
Remove and Install
Piston and Connecting
Rod—3TNV80F and
Disassemble and Assemble
Piston and Connecting
Rod—3TNV80F.)
OUMX258,0000B82 -19-30DEC13-5/6

•4 (Continued) Pistons, rings or cylinders not worn or seized? YES: Go to next step.

NO: Replace pistons

and rings; bore or hone
cylinders. (See Inspect
Piston and Connecting
Rod—3TNV80F, and
Disassemble and Assemble
Piston and Connecting
Rod—3TNV80F.)

OUMX258,0000B82 -19-30DEC13-6/6

Diagnose Starter Motor Does Not Rotate

Starter Motor Does Not Rotate, 3TNV80
OUMX258,0000B83 -19-30DEC13-1/7

Starter Motor Does Not Rotate

Continued on next page OUMX258,0000B83 -19-30DEC13-2/7

TM130419 (24FEB16) 220-20-27 030916

PN=625
 Diagnosis—3TNV80

•1 Test Procedure Is there a click sound from starter solenoid? YES: Go to next step.

NO: Check that all starting

conditions are met.
OUMX258,0000B83 -19-30DEC13-3/7

•2 (Continued) Are battery cables clean and tight? YES: Go to next step.

NO: Tighten or clean as

necessary.
OUMX258,0000B83 -19-30DEC13-4/7

•3 (Continued) Is battery fully charged? YES: Go to next step.

NO: Charge battery.

OUMX258,0000B83 -19-30DEC13-5/7

•4 (Continued) Does crankshaft rotate freely? YES: Go to next step.

NO: Repair engine as

needed.

OUMX258,0000B83 -19-30DEC13-6/7

•5 (Continued) Are starting circuit and key switch working correctly? NO: Repair as necessary.

OUMX258,0000B83 -19-30DEC13-7/7

Diagnose Starter Rotates Slowly

Starter Rotates Slowly, 3TNV80
OUMX258,0000B84 -19-30DEC13-1/6

Starter Rotates Slowly

OUMX258,0000B84 -19-30DEC13-2/6

•1 Test Procedure Are battery cables clean and tight? YES: Go to next step.

NO: Tighten or clean as

necessary.

OUMX258,0000B84 -19-30DEC13-3/6

•2 (Continued) Is battery fully charged? YES: Go to next step.

NO: Charge battery.

Continued on next page OUMX258,0000B84 -19-30DEC13-4/6

TM130419 (24FEB16) 220-20-28 PN=626

030916
 Diagnosis—3TNV80

•3 (Continued) Does crankshaft rotate freely? YES: Go to next step.

NO: Repair engine as

needed.
OUMX258,0000B84 -19-30DEC13-5/6

•4 (Continued) Are starting motor and solenoid functioning correctly? NO: Replace starting
motor.

OUMX258,0000B84 -19-30DEC13-6/6

Diagnose Starter Rotates But Does Not Crank

Starter Rotates But Does Not Crank, 3TNV80
OUMX258,0000B85 -19-30DEC13-1/3

Starter Rotates But Does Not Crank

OUMX258,0000B85 -19-30DEC13-2/3

•1 Test Procedure Does the pinion mesh with ring gear? NO: Faulty starter drive.
Replace.

NO: Check for worn pinion

or ring gear, and incorrect
starting motor alignment.

OUMX258,0000B85 -19-30DEC13-3/3

TM130419 (24FEB16) 220-20-29 PN=627

030916
 Diagnosis—3TNV80

TM130419 (24FEB16) 220-20-30 030916

PN=628
 Group 30
Diagnosis—3TNV82A, 3TNV88
Engine Will Not Start Coolant in the radiator is extremely hot
during operation.
Engine Will Not Start, 3TNV82A, 3TNV88

CAUTION: Avoid Injury! The engine may start

to rotate at any time. Keep hands away from
all moving parts when testing.
OUMX258,0000C2B -19-31DEC13-1/18

Procedure
OUMX258,0000C2B -19-31DEC13-2/18

Step 1 Proper starting procedure being used is correct for conditions? YES: Go to next step.
NO: Use correct procedure
for conditions. (See
Operator’s Manual.)

OUMX258,0000C2B -19-31DEC13-3/18

Step 2 Battery 12.7 VDC or higher? YES: Go to next step.

NO: Charge and check
battery.

OUMX258,0000C2B -19-31DEC13-4/18

Step 3 No open circuits in wiring? YES: Go to next step.

NO: Repair or replace as
needed.

OUMX258,0000C2B -19-31DEC13-5/18

Step 4 Starting motor functioning properly? YES: Go to next step.

NO: Repair or replace
starting motor.

OUMX258,0000C2B -19-31DEC13-6/18

Step 5 Engine oil of correct viscosity and type? YES: Go to next step.
NO: Replace engine oil
with oil of proper viscosity
and type. Replace oil filter.

OUMX258,0000C2B -19-31DEC13-7/18

Step 6 No water in fuel? YES: Go to next step.

NO: Drain and replace fuel.

OUMX258,0000C2B -19-31DEC13-8/18

Step 7 Fuel filter not clogged? YES: Go to next step.

NO: Replace fuel filter.

OUMX258,0000C2B -19-31DEC13-9/18

Step 8 No air leak in fuel system? YES: Go to next step.

NO: Repair fuel system.

Continued on next page OUMX258,0000C2B -19-31DEC13-10/18

TM130419 (24FEB16) 220-30-1 PN=629

030916
 Diagnosis—3TNV82A, 3TNV88

Step 9 Fuel lines not plugged, pinched, or cracked? YES: Go to next step.
NO: Repair or replace fuel
lines as needed.
OUMX258,0000C2B -19-31DEC13-11/18

Step 10 Correct volume of fuel supplied to injection pump? YES: Go to next step.
NO: Replace fuel transfer
pump.
OUMX258,0000C2B -19-31DEC13-12/18

Step 11 Intake and/or exhaust valve clearance correct? YES: Go to next step.
NO: Adjust valve clear-
ance. (See.Adjust Valve
Clearance—3TNV82A,
3TNV88)
OUMX258,0000C2B -19-31DEC13-13/18

Step 12 Injection pump timing correct? YES: Go to next step.

NO: Correctly time
injection pump.

OUMX258,0000C2B -19-31DEC13-14/18

Step 13 Intake and/or exhaust valve not seized? YES: Go to next step.
NO: Replace valve
and check valve guide.
(See Remove and
Install Cylinder Head
and Valves—3TNV82A,
3TNV88 and Disassemble
and Assemble
Cylinder Head and
Valves—3TNV82A,
3TNV88.)

OUMX258,0000C2B -19-31DEC13-15/18

Step 14 Piston rings not broken or seized? YES: Go to next step.

NO: Replace rings.
Check piston and cylinder.
(See Disassemble and
Assemble Cylinder Head
and Valves—3TNV82A,
3TNV88 and Cylinder
Bore—3TNV82A, 3TNV88.)

OUMX258,0000C2B -19-31DEC13-16/18

Step 15 Piston rings, piston, or cylinder not worn? YES: Go to next step.
NO: Replace piston and/or
rings; bore or hone cylinder.
(See Remove and Install
Piston and Connecting
Rod—3TNV82A,
3TNV88 and Inspect
Piston—3TNV82A,
3TNV88.)

Continued on next page OUMX258,0000C2B -19-31DEC13-17/18

TM130419 (24FEB16) 220-30-2 PN=630

030916
 Diagnosis—3TNV82A, 3TNV88

Step 16 Crankshaft pin or bearing not seized? NO: Regrind crankshaft

and replace bearings.
(See Remove and Install
Crankshaft and Main
Bearings—3TNV82A,
3TNV88.)
OUMX258,0000C2B -19-31DEC13-18/18

TM130419 (24FEB16) 220-30-3 030916

PN=631
 Diagnosis—3TNV82A, 3TNV88

TM130419 (24FEB16) 220-30-4 030916

PN=632
 Group 40
Tests and Adjustments—3TNV80F
Summary of References • Adjust Throttle Cable—3TNV80F
• Check and Adjust Alternator Drive Belt
• Test Fuel Injection System—3TNV80F
Tension—3TNV80F
• Test Fuel Injection Nozzle—3TNV80F
• Injection Pump Static Timing Check and
• Adjust Valve Clearance—3TNV80F Adjust—3TNV80F
• Check Valve Lift—3TNV80F
• Pressure Test Cooling System—3TNV80F
• Test Cylinder Compression—3TNV80F
• Pressure Test Radiator Cap—3TNV80F
• Test Engine Oil Pressure—3TNV80F • Test Thermostat—3TNV80F
• Leak Test Fuel System—3TNV80F
• Test Cylinder Leakdown—3TNV80F
• Priming Diesel Fuel System—3TNV80F
• Fuel Transfer Pump Pressure Test—3TNV80F
• Adjust Slow Idle Speed—3TNV80F
• Fuel Transfer Pump Flow Test—3TNV80F
OUMX258,0000BAB -19-26MAR13-1/1

Check and Adjust Alternator Drive Belt

Tension—3TNV80F
Reason
To maintain correct alternator drive belt tension.

TCAL28317 —UN—28JUN12
Special or Required Tools

• JDG529 or JDST28 Belt Tension Gage

• Straightedge
Check Procedure
1. Park machine safely.
2. Remove engine cover. A—Midpoint C—Alternator Pulley
B—Fan-to-Coolant Pump D—Belt Deflection
3. Disconnect negative (—) battery cable. Pulley
4. Apply approximately 98 N (22 lb-force) to the belt at
the midpoint (A) between the fan/coolant pump pulley
(B) and the alternator pulley (C). Check belt deflection Check Results
(D) using JDG529 or JDST28 Belt Tension Gage and
a straightedge and compare to specification. If deflection is not within specification, perform Adjustment
Specification
Procedure.
Alternator Drive Belt
—Deflection @ 98 N (22
lb-force)..................................................................................10—15 mm
(0.40—0.60 in.)

OUMX258,0000BAC -19-16SEP14-1/2

Adjustment Procedure
1. Loosen top cap screw (E), mounting bracket cap
screw (F), and lower nut (G).
2. Apply force to the alternator housing until tension is
correct.
3. Tighten cap screws and nut.
TCAL28318 —UN—28JUN12

E—Cap Screw G—Lower Nut

F— Mounting Bracket Cap
Screw

OUMX258,0000BAC -19-16SEP14-2/2

TM130419 (24FEB16) 220-40-1 030916

PN=633
 Tests and Adjustments—3TNV80F

Adjust Valve Clearance—3TNV80F

TCAL28319 —UN—28JUN12
Reason
To be sure that valves are fully opening at the correct
time, but not remaining open too long or wearing valve
train unnecessarily.
Special or Required Tools
E = Exhaust Valves, I = Intake Valves
• Feeler Gage
• 10 mm End Wrench 1— Cylinder Number One I— Intake Valves
• Flat Blade Screwdriver E—Exhaust Valves
• 17 mm Wrench
Procedure intake valve has closed (raised up), turn the crankshaft
1. Engine must be cool (room temperature) before valve an additional half turn.
clearance is checked.
2. Be sure that ignition is off and key is removed before
attempting to turn engine by hand.
3. Remove rocker arm cover. (See Remove and Install
Rocker Arm Cover—3TNV80F.)
NOTE: Top dead center (TDC) is where the piston is at
its highest point of travel during the compression
stroke. The valves (E and I) must be checked
with piston at or near TDC.
Cylinder number one (1) is located toward the
front of machine (flywheel side).

4. Using a 17 mm wrench, turn the crankshaft pulley

in the direction of engine rotation while watching the
rocker arms of the number one cylinder. When the
Continued on next page OUMX258,0000BAD -19-16SEP14-1/3

TM130419 (24FEB16) 220-40-2 030916

PN=634
 Tests and Adjustments—3TNV80F

5. Try to move rocker arms (A) and push rods (D) for
the cylinder to be adjusted. If both rocker arms and
push rods are loose, the piston is near TDC on the

TCAL28320 —UN—28JUN12
compression stroke and you may proceed to step 8.
6. Slide feeler gage of appropriate size between valve
cap (F) and rocker arm. There should be a slight
drag on the feeler gage when the clearance (G) is to
specification.
Specification
Valve Adjust-
ment—Clearance.............................................................0.15—0.25 mm
(0.006—0.010 in.)

7. To adjust a valve, loosen locknut (C) and turn adjusting

screw (B) until blade of feeler gage has a slight drag
when inserted between rocker arm and valve cap.
Hold adjusting screw while tightening locknut.

TCAL28321 —UN—28JUN12
8. Recheck valve clearance after tightening locknut.

A—Rocker Arm D—Push Rods

B—Adjusting Screw F— Valve Cap
C—Locknut G—Clearance

OUMX258,0000BAD -19-16SEP14-2/3

TCAL28322 —UN—28JUN12
9. Check that valve cap (H) on the end of the valve stem
remained seated on valve and inside valve spring
retainer.
10. Repeat steps 4 through 9 for cylinders 2 and 3.
11. Install rocker arm cover.
Picture Note: Left Valve Cap Shows Normal Position

H—Valve Cap

OUMX258,0000BAD -19-16SEP14-3/3

TM130419 (24FEB16) 220-40-3 030916

PN=635
 Tests and Adjustments—3TNV80F

Check Valve Lift—3TNV80F

Reason
To test for excessive wear on camshaft lobes, cam
followers, rocker arms, valve stems, and valve caps, and

TCAL28323 —UN—28JUN12
for worn or bent push rods.
Special or Required Tools

• Dial Indicator with Magnetic Base

Procedure
1. Remove rocker arm cover. (See Remove and Install
Rocker Arm Cover—3TNV80F.)
2. Check that valve clearance is within specification.
Results
Adjust if necessary. (See Adjust Valve
Clearance—3TNV80F.) The valve lift should be the same for all valves. If
one or more valves have less travel than the others,
3. Fasten dial indicator to engine and position indicator
remove and inspect the camshaft, followers, and
tip on valve retainer. Valve must be fully closed and
push rods. (SeeRemove and Install Rocker Arm
rocker arm must move freely.
Assembly—3TNV80F.) If camshaft, followers, and push
4. Set the dial indicator to zero. rods are within specifications, remove and inspect the
cylinder head. (See Remove and Install Cylinder Head
5. Rotate crankshaft while observing dial indicator as and Valves—3TNV80F.)
valve is moved to full open (down) position.
6. Repeat for each valve.
OUMX258,0000BAE -19-06JUN14-1/1

TM130419 (24FEB16) 220-40-4 030916

PN=636
 Tests and Adjustments—3TNV80F

Test Cylinder Compression—3TNV80F

Reason
To determine the condition of the pistons, rings, cylinder
walls, and valves.
Special or Required Tools

TCAL28324 —UN—28JUN12
• JT07043 Compression Gage Assembly
• JDG472 or JDG560 Adapter
Procedure
1. Run engine for five minutes to bring to operating
temperature. Shut off engine.
2. Remove injection nozzles.
A—Adapter B—Compression Gage
3. Install the heat protector from the end of the fuel
injector and install JDG472 or JDG560 Adapter (A).
4. Install JT07042 or JT07043 Pressure Gauge (B). Cylinder Compres-
sionx—Pressure Differ-
5. Disconnect the fuel control solenoid connector. ence Between Cylinders
IMPORTANT: Do not overheat the starting (Maximum)........................................................................ 197—294 kPa
motor during this test. (29—43 psi)
Results
6. Rotate the engine for five seconds with the starting
motor. Minimum cranking speed is 250 rpm. • If the pressure reading is below specification, squirt
clean engine oil into the cylinders through the fuel
7. Record the pressure reading for each cylinder. injector ports and repeat the test.
Compare the pressure readings with specifications. • If the pressure increases significantly, check piston,
Specification rings, and cylinder walls for wear or damage.
Cylinder Compres- • If the pressure does not increase significantly, check for
sion—Pressure.................................................................. 3432 ± 98 kPa leaking valves, valve seats, or cylinder head gasket.
(498 ± 14 psi)
OUMX258,0000BAF -19-04MAR15-1/1

TM130419 (24FEB16) 220-40-5 PN=637

030916
 Tests and Adjustments—3TNV80F

Test Engine Oil Pressure—3TNV80F

Reason
To determine if the engine bearings or the lubrication
system components are worn.
NOTE: The connector, hose assembly, and gage are
found in other SERVICEGARD™ test kits.

Special or Required Tools

• JT03349 Connector
• JT03017 Hose Assembly
• JT07034 0—700 kPa (0—100 psi) Gage
Procedure
1. Remove the oil pressure sender.
2. Install JT03349 Connector (C).

TCAL28325 —UN—28JUN12
3. Connect JT03017 Hose Assembly (B) and JT07034
Gage (A).
IMPORTANT: Do not run the engine if there is
insufficient oil pressure!

4. Start the engine. If the pressure reading is below 60

kPa (8.7 psi) at slow idle rpm, stop the engine.
5. If the oil pressure is at least 60 kPa (8.7 psi), run the A—JT07034 Gage C—JT03349 Connector
engine approximately five minutes to heat the oil. B—JT03017 Hose Assembly
Check the oil pressure at engine rated speed.
Specification
Engine Oil—Pressure at • If oil pump is within specification, the engine may have
Engine Rated Speed....................................................... 240—3450 kPa
parts worn beyond specification. (See Diagnostics for
(35—50 psi)
appropriate symptom to fix).

Results

• If oil pressure is not within specification, inspect the oil

pump.
SERVICEGARD is a trademark of Deere & Company
OUMX258,0000BB0 -19-16SEP14-1/1

TM130419 (24FEB16) 220-40-6 030916

PN=638
 Tests and Adjustments—3TNV80F

Leak Test Fuel System—3TNV80F

Reason
Tests the fuel system plumbing for external leakage. This
test also determines if air is entering the fuel system at
connections, allowing fuel to siphon back to tank.
Procedure
1. Park machine safely.

TCAL28329 —UN—28JUN12
2. Remove engine cover.
3. Disconnect the fuel supply line (A) and return line (B)
at the fuel tank.
4. Place the fuel return line into a suitable container to
catch drained fuel.

CAUTION: Do not apply more than the specified

A—Fuel Supply Line B—Fuel Return Line
air pressure to the fuel system. Damage to the
injection pump or personal injury may result.

5. Apply the specified air pressure to fuel supply hose Specification

until all fuel is drained from the system. Fuel System Leak
Specification Test—Air Pressure
Fuel System Leak (Maximum).................................................................................. 103 kPa
Test—Air Pressure................................................................ 34—69 kPa (15 psi)
(5—10 psi) 8. Apply liquid soap and water solution to all joints and
6. Plug the end of the fuel return hose. connections in the fuel system and inspect for leaks.

7. Apply air pressure within specification to the fuel Results

system at the fuel supply line. Do not exceed a
Find leaks and repair or replace parts as necessary.
maximum specified air pressure.
OUMX258,0000BB2 -19-16SEP14-1/1

Priming Diesel Fuel System—3TNV80F

Reason

TCAL28330 —UN—28JUN12
Any time the fuel system has been opened up for service
(lines disconnected, running out of fuel or changing the
fuel filter), it is necessary to prime the system.
1. Park machine safely.
2. Turn OFF PTO switch.
Electric boost pump is located under the seat on the left
3. Lower attachments to the ground. side of engine compartment.

4. Lock the parking brake.

A—Fuel Pump
5. Turn the key switch to the RUN position for 2 minutes
prior to starting the engine. The fuel pump (A) will
pressurize the fuel and remove any air in the system.
6. Start the engine. If the engine will not start, repeat the
previous step.
OUMX258,0000BB3 -19-27MAR13-1/1

TM130419 (24FEB16) 220-40-7 PN=639

030916
 Tests and Adjustments—3TNV80F

Adjust Slow Idle Speed—3TNV80F

IMPORTANT: The slow idle adjustment is the only
adjustment that can be made on this engine.
The fast idle and torque capsule adjustments
are preset by the engine manufacturer to
comply with strict EPA/CARB emissions
requirements, and are adjustable only by
authorized diesel service facilities.

Reason

TCAL28331 —UN—28JUN12
To achieve proper slow idle speed setting. Provides
adequate rpm to keep engine running smoothly without
stalling.
Special or Required Tools

• JT05719A Digital Tachometer

Procedure
A—Jam Nut C—Injection Pump Throttle
1. Park machine safely. B—Screw Lever
2. Start engine and run for five minutes to bring machine
to operating temperature.
Specification
3. Remove engine cover.
Slow Idle—Speed.............................................................. 1525 ± 25 rpm
4. Move throttle lever to slow idle position.
7. If slow idle speed does not meet specification, loosen
5. Use JT05719A Digital Tachometer to check engine jam nut (A) and turn screw (B). After adjustment,
speed at crankshaft pulley. tighten jam nut.
6. Visually check that the injection pump throttle lever (C) 8. After slow idle speed adjustment, adjust throttle cable.
is against the slow idle stop screw. Check slow idle (See Adjust Throttle Cable—3TNV80F.)
speed and compare to specification.
OUMX258,0000BB4 -19-15SEP14-1/1

TM130419 (24FEB16) 220-40-8 PN=640

030916
 Tests and Adjustments—3TNV80F

Adjust Throttle Cable—3TNV80F

Reason
To ensure that throttle linkage is adjusted correctly, and
to allow full fast idle and slow idle positions of governor
throttle lever.

TCAL28332 —UN—28JUN12
Procedure
1. Park machine on level surface with key switch off,
transmission in neutral, and park brake on.
2. Remove engine cover.
3. Place throttle control in slow idle position.
4. Loosen clamp screw (A), jam nut (C), and cap screw A—Clamp Screw C—Jam Nut
(D). B—Cable Housing D—Cap Screw

5. Move cable housing (B) to specification from edge of

clamp to end of cable housing
7. With throttle control at slow idle position, and injection
Specification
pump lever fully seated against slow idle stop, tighten
Cable Housing—Dis-
cap screw and jam nut.
tance from edge of clamp
to end of cable housing.............................................................. 13.0 mm 8. Move throttle control to fast idle position, making sure
(0.50 in.) injection pump lever is fully seated against fast idle
stop.
6. Tighten clamp screw.
OUMX258,0000BB5 -19-16SEP14-1/1

TM130419 (24FEB16) 220-40-9 030916

PN=641
 Tests and Adjustments—3TNV80F

Test Fuel Injection System—3TNV80F

CAUTION: Escaping fluid under pressure can

penetrate the skin causing serious injury.
Avoid the hazard by relieving pressure before
disconnecting hydraulic or other lines. Tighten
all connections before applying pressure. Search
for leaks with a piece of cardboard. Protect hands
and body from high-pressure fluids.

TCAL28333 —UN—28JUN12
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. Information may be obtained in the United
States and Canada only by calling 1-800-822-8262.
A—Nut
Reason
To stop fuel flow to the cylinders (one at a time), while
engine is running, to determine what effect that cylinder Results
has on overall engine performance.
When fuel flow is stopped to a cylinder, engine rpm should
Special or Required Tools drop, engine should begin to vibrate and run roughly, and
exhaust noise will be uneven until fuel flow is restored.
• 17-mm Open End Wrench (2 used)
If test produces the results described above but engine
Procedure
performance remains poor, test the following:
1. Park machine on level surface with park brake on and
transmission in neutral.
• Clogged air cleaner elements, leaking air filter outlet
hoses, or clamps.
• Restriction in exhaust system.
CAUTION: This test will cause diesel fuel to be • Presence of coolant or diesel fuel in crankcase oil.
released from fuel system. Injection pump is
capable of producing extremely high pressure. If defeating a single cylinder has no effect on overall
Eye protection must be worn. Do not open fuel engine performance, test the following:
injector connectors more than 1/8 of a turn.
Do not place hands near fuel injectors during • Fuel injection nozzle opening pressure, spray pattern,
and leakage for that cylinder. (See Test Fuel Injection
test. Do not allow any debris to enter intake
Nozzle—3TNV80F.)
manifold during test. Do not smoke.
• Cylinder compression or cylinder leakage. (See Test
Cylinder Compression—3TNV80F.)
2. Start engine and run at slow idle.
• Fuel supply pump pressure.
3. Using two 17-mm open end wrenches, loosen nut (A) Specification
on one high-pressure fuel injection line, either at the Fuel Pump—Pressure
fuel injector nozzle or at injection pump, while holding (Minimum)..................................................................................... 29 kPa
lower nut stationary with second wrench. Loosen nut (4.3 psi)
only 1/8 of a turn (45°).
• Fuel shutoff solenoid opening fully.
4. Listen for engine speed to drop and exhaust noise to • Fuel control and governor linkage flyweights allowing
change. full fuel flow to injection pump.
5. Tighten nut and allow engine to return to original • Injection pump timing correct.
speed before loosening next cylinder’s fuel line nut. If the above test results are within specifications, remove
injection pump and have tested at an Authorized Diesel
6. Compare sound and speed of each cylinder as it is
Service (ADS) Center.
disabled.
7. Tighten fuel line nuts and stop engine.
OUMX258,0000BB6 -19-16SEP14-1/1

TM130419 (24FEB16) 220-40-10 PN=642

030916
 Tests and Adjustments—3TNV80F

Test Fuel Injection Nozzle—3TNV80F

Reason
To determine opening pressure, leakage, and chatter and
spray patterns of fuel injection nozzle.
Special or Required Tools

• D01109AA Diesel Fuel Injection Nozzle Tester

• D01110AA Adapter Set
• 23622 Straight Adapter
• Container
Connections

TCAL28334 —UN—28JUN12
IMPORTANT: Use clean, filtered diesel fuel when
testing injection nozzles for best results.

Connect fuel injection nozzle to D01109AA Diesel Fuel

Injection Nozzle Tester using parts from D01110AA
Adapter Set and 23622 Straight Adapter.
Pressure Test Procedure
Test fuel injection nozzle opening pressure following the 3. Watch for leakage from nozzle spray orifice. Keep
nozzle tester manufacturer’s instructions. Compare to track of time elapsed before leakage begins. Compare
specification. to specification.
Specification
Specification
Fuel Injection
Fuel Injection
Nozzle—Pressure................................................... 12 300—13 300 kPa
Nozzle—Leakage at 11
(1784—1929 psi)
032 kPa (1600 psi)...................... No leakage for 10 seconds (minimum)
Pressure Test Results Leakage Test Results
If pressure reading does not meet specification, If leakage time does not meet specification, disassemble
disassemble injection nozzle and inspect nozzle assembly injection nozzle and inspect nozzle assembly for
for contamination or stuck valve. (See Remove, Inspect, contamination. Replace nozzle assembly if necessary.
and Install Fuel Injection Nozzle—3TNV80F.) If necessary, (See Remove, Inspect, and Install Fuel Injection
add or remove shims to change opening pressure. Nozzle—3TNV80F.)
Leakage Test Procedure Chatter and Spray Pattern Test Procedure
Test fuel injection nozzle leakage following the nozzle Test fuel injection nozzle chatter and spray pattern
tester manufacturer’s instructions. following the nozzle tester manufacturer’s instructions.
1. Dry nozzle completely using a lint-free cloth. 1. Pressurize nozzle until nozzle opening pressure is
2. Pressurize nozzle to specification. reached.
Specification 2. Listen for “chatter” sound and watch spray pattern.
Fuel Injection
Nozzle—Pressure.................................................................. 11 032 kPa
(1600 psi)
Continued on next page OUMX258,0000BB7 -19-16SEP14-1/3

TM130419 (24FEB16) 220-40-11 PN=643

030916
 Tests and Adjustments—3TNV80F

Chatter and Spray Pattern Test Results

TCAL28335 —UN—28JUN12
Correct Spray Pattern

OUMX258,0000BB7 -19-16SEP14-2/3

• If nozzle chatter or spray pattern does not meet

specifications, disassemble injection nozzle and inspect
nozzle assembly for contamination. Inspect valve

TCAL28336 —UN—28JUN12
seating surface. Replace nozzle assembly if necessary.
(See Remove, Inspect, and Install Fuel Injection
Nozzle—3TNV80F.)
Chatter and Spray Pattern at 11 800 ± 1000 kPa (1712
± 145 psi)—Specification
Slow Hand Lever
Movement—Leakage
at 11 032 kPa (1600 psi).....................................................Chatter sound Incorrect Spray Patterns
Slow Hand Lever
Movement—Leakage
at 11 032 kPa (1600 psi)..................... Fine stream, 5—10° spray pattern
starting/stopping of injection, disassemble injection
Fast Hand Lever
nozzle and inspect nozzle assembly for contamination.
Movement—Leakage
Replace nozzle assembly if necessary. (See Remove,
at 11 032 kPa (1600 psi)........ Fine atomized spray, 5—10° spray pattern
Inspect, and Install Fuel Injection Nozzle—3TNV80F.)

• If there is excessive difference in spray angle or

injection angle, incomplete atomizing, or sluggish
OUMX258,0000BB7 -19-16SEP14-3/3

TM130419 (24FEB16) 220-40-12 030916

PN=644
 Tests and Adjustments—3TNV80F

Injection Pump Static Timing Check and

Adjust—3TNV80F
Reason
To make sure that the injection pump timing is set to

TCAL28337 —UN—28JUN12
engine manufacturer’s specification.
Special or Required Tools

• Timing Tool (Made from High-Pressure Pipe, Nut, and a

Clear Plastic Straw)
Procedure
Injector Pump Timing Marks
IMPORTANT: The injection pump timing should
be correct. The timing is set at the factory,
and will not normally change during the life NOTE: Normal rotation, as viewed from the flywheel
of the engine. Check and adjust the timing end, is counterclockwise. The number one fuel
only as the last option, or if there is reason injection line is closet to the flywheel.
to believe the timing has been altered.
8. Clean areas around injectors and top of injection pump
Check the fuel, fuel supply system, injectors, and remove the fuel injection lines.
air intake system and cylinder compression
before continuing. 9. Cover openings on injectors and the number two and
three delivery valves on injection pump to keep dirt
1. Park machine on a level surface. from entering system.
2. Place mow-transport lever in TRANSPORT position.
3. Lower attachments to the ground.
4. Lock park brake.
5. Turn key to OFF position.
6. Remove air cleaner assembly.
7. If injection pump was removed, align the arrow or line
on the injection pump flange on the mark noted during
pump removal.
Continued on next page OUMX258,0000BB8 -19-15SEP14-1/4

TM130419 (24FEB16) 220-40-13 030916

PN=645
 Tests and Adjustments—3TNV80F

10. Install the timing tool (A) and clear straw (B) on the
number one delivery valve of injection pump.
B
A—Timing Tool B—Clear Straw

Drill Out
A (#45 Drill Bit)

30-50 mm
(1.2-2.0 in.)

TCAL28338 —UN—28JUN12
Injection
Pump

OUMX258,0000BB8 -19-15SEP14-2/4

11. Identify which set of timing marks is for number one

cylinder (C) and mark flywheel (D) accordingly.
12. Turn ignition switch to the on position and listen for
fuel shutoff solenoid to click on. (Fuel shutoff solenoid

TCAL28339 —UN—28JUN12
must be on and stay on during test).
13. Turn the flywheel counterclockwise (as viewed from
the flywheel end) until the timing tool straw shows fuel
movement.
14. Turn the flywheel clockwise (back) until the No. 1
cylinder top dead center (TDC) mark and pump timing
marks have gone past the mark on the flywheel
housing by at least 50 mm (2 in.).
C—Number One Cylinder D—Flywheel Mark
15. Snap the straw with your finger until the level of the Timing Mark
fuel, or a bubble, is set part way up the straw. This will
be the point to watch for fuel movement.
NOTE: If there is no fuel movement, engine may be on starts to move. Stop rotating the flywheel the instant
exhaust stroke. Rotate flywheel 360° and repeat test. the fuel begins to move.

16. Slowly turn the flywheel counterclockwise (as viewed

from the flywheel end) until the fuel in the straw just
Continued on next page OUMX258,0000BB8 -19-15SEP14-3/4

TM130419 (24FEB16) 220-40-14 030916

PN=646
 Tests and Adjustments—3TNV80F

17. Check the injection pump timing marks on the

flywheel. The 21° mark (E) or 17° mark (F) on the
flywheel must line up with the line (G) in the timing
hole of the flywheel housing.
Results

• If the timing is not within specifications, loosen the three

pump mounting nuts and turn the pump toward the
engine block to retard the timing or away from the block
to advance the timing. Recheck the timing.
Specification
Fuel Injection—Timing
(3TNV80).............................................................................................17°

TCT005861 —UN—19NOV12
• If the timing did not change, remove pump and have
tested by an authorized diesel injection service shop.
• If the timing is correct, remove timing tool, install injector
lines, install air cleaner assembly and hood.

E—21° Mark G—Line on Housing

F— 17° Mark (3TNV80)

OUMX258,0000BB8 -19-15SEP14-4/4

Pressure Test Cooling System—3TNV80F

Reason
Inspect the cooling system for leaks.
Special or Required Tools

TCAL28341 —UN—28JUN12
• D05104ST Cooling System Pressure Pump
• JDG692 Radiator Pressure Test Kit
Procedure
1. Remove the cap and attach the pressure pump (A)
to radiator.
2. Apply pressure according to minimum specification,
but not in excess of maximum specification.
A—Pressure Pump
Specification
Cooling System
—Pressure (Minimum
after 15 Sec).......................................................................... 88 ± 15 kPa Results
(12.8 ± 2.2 psi)
Cooling System—Pres- • Pressure should hold to minimum specification. If
sure (Maximum Applied)................................................................ 97 kPa
pressure decreases, check for leaks. Repair leaks or
(14 psi)
replace parts as necessary.
• If the pressure test still indicates leakage after all
3. Check for leaks throughout the cooling system. After external leaks have been stopped, a defective head
15 seconds, the pressure should be at or above gasket, cracked block, or cylinder head may be the
minimum specification. cause. (See Test Cylinder Leakdown—3TNV80F.)
OUMX258,0000BB9 -19-16SEP14-1/1

TM130419 (24FEB16) 220-40-15 030916

PN=647
 Tests and Adjustments—3TNV80F

Pressure Test Radiator Cap—3TNV80F

Reason

TCAL28342 —UN—28JUN12
Test the radiator cap for operating in the correct pressure
range.
• D05104ST Cooling System Pressure Pump
• JDG692 Radiator Pressure Test Kit (Adapters)
Procedure
1. Install the radiator cap (A) on the pressure pump.
A—Radiator Cap
2. Apply pressure. Pressure valve in the cap should
open at specification.
Specification
Radiator Cap Results
Valve—Opening
Pressure........................................................................................ 88 kPa
• If the cap leaks, retighten and test again. Replace the
cap if pressure is not within specification.
(12.8 psi)
OUMX258,0000BBA -19-16SEP14-1/1

Test Thermostat—3TNV80F
Reason
To determine opening temperature of thermostat.
Special or Required Tools

• Thermometer

TCAL28343 —UN—28JUN12
• Glass Container
• Heating Unit
Procedure

CAUTION: Do not allow thermostat or

thermometer to rest against the side or bottom
of glass container when heating water. Either
may rupture if overheated.
Thermostat—Lift Height
1. Suspend thermostat (A) and thermometer in a above 85° C (185° F)
container of water. (Minimum)....................................................................................... 8 mm
(0.315 in.)
2. Heat and stir the water. Observe opening action
of thermostat and compare temperatures with 3. Remove thermostat and observe its closing action
specifications. as it cools.
Specification Results
Thermostat—Begin to
Open Temperature.............................................................69.5—72.5° C • If thermostat does not open according to specifications,
(157—163° F) replace.
Thermostat—Fully-Open • If closing action is not smooth and slow, replace
Temperature.................................................................................... 85° C thermostat.
(185° F)
OUMX258,0000BBB -19-16SEP14-1/1

TM130419 (24FEB16) 220-40-16 PN=648

030916
 Tests and Adjustments—3TNV80F

Test Cylinder Leakdown—3TNV80F

c. Move piston to bottom of stroke with intake and
Reason exhaust valves closed.

To determine if compression pressure is leaking from the d. Connect hose from JT03502 Cylinder Leakdown
cylinder. Tester to adapter.

Special or Required Tools e. Apply specified air pressure into cylinder.

Specification
• JT03502 Cylinder Leakdown Tester Cylinder Leakdown
• JDG472 Adapter Test—Air Pressure
Procedure (Maximum)................................................................................ 2448 kPa
(355 psi)
1. Park machine safely.
f. Check for bubbles in recovery tank or air escaping
2. Remove engine cover. from muffler, air cleaner, or oil dipstick tube.
3. With coolant at proper level and radiator cap tight, 6. Repeat for each cylinder.
run engine for five minutes to bring to operating
temperature. Results

4. Remove cap from recovery tank. • If bubbles are present in the recovery tank, check for
cracks in cylinder head and block. Check for damaged
5. Check for bubbles coming from overflow hose at head gasket.
bottom of tank. If bubbles are present, isolate source • If air escapes from muffler, check for worn exhaust valve.
of compression leak. • If air escapes from air cleaner, check for worn intake
valve.
a. Remove fuel injection nozzles.
• If air escapes from engine oil dipstick tube, check for
b. Install JDG472 Adapter in injection port of cylinder worn piston rings.
to be tested.
OUMX258,0000BBC -19-16SEP14-1/1

Fuel Transfer Pump Pressure Test—3TNV80F

Reason
To determine fuel transfer pump operating pressure.
Special or Required Tools

• JDG356 Fuel Pump Pressure Test Kit

TCT006865 —UN—27MAR13
Procedure
1. Verify fuel is within 15—25° C (59—77° F).
2. Disconnect transfer pump hose (A) from outlet side
of pump.
3. Install the hose and gage to outlet side hose of pump.
4. Turn key switch to ON position for 15 seconds.
A—Transfer Pump Hose
5. Record fuel pressure reading on gage.
Specification
Fuel Transfer
Pump—Pressure............................................................. 21.5—37.3 kPa
Results
(3.1—5.4 psi)
• If the pressure is not within specification, replace the
fuel transfer pump.
OUMX258,0000BBD -19-15FEB16-1/1

TM130419 (24FEB16) 220-40-17 PN=649

030916
 Tests and Adjustments—3TNV80F

Fuel Transfer Pump Flow Test—3TNV80F

Reason
To determine fuel transfer pump flow.
Procedure
1. Verify fuel is within 15—25° C (59—77° F).
2. Disconnect fuel pump outlet hose (A) at fuel filter.

TCAL28534 —UN—29JUN12
3. Place hose in graduated container.
4. Turn key switch to ON position for 15 seconds.
5. Compare fuel amount to specification.
Results
If fuel flow is below specification, replace the fuel transfer
pump.
A—Fuel Pump Outlet Hose
Specification
Fuel Transfer
Pump.—Volume Flow
15 Sec (Minimum)........................................................................ 400 mL
(13.5 oz)

OUMX258,0000BBE -19-16SEP14-1/1

TM130419 (24FEB16) 220-40-18 030916

PN=650
 Group 45
Tests and Adjustments—3TNV82A, 3TNV88
Summary of References • Test Thermostat Opening—3TNV82A, 3TNV88
• Adjust Fan and Alternator Drive Belt—3TNV82A, • Test Cylinder Pressure Leakage—3TNV82A, 3TNV88
3TNV88
• Pressure Test Cooling System—3TNV82A, 3TNV88
• Test Radiator Pressure Cap—3TNV82A, 3TNV88
• Test Cylinder Compression—3TNV82A, 3TNV88 • Test Oil Pressure—3TNV82A, 3TNV88
• Adjust Slow Idle—3TNV82A, 3TNV88 • Test Fuel Pump Pressure—3TNV82A, 3TNV88
• Adjust Throttle Cable—3TNV82A, 3TNV88 • Test Fuel Transfer Pump Flow—3TNV82A, 3TNV88
• Injection Pump Static Timing—3TNV82A, 3TNV88 • Test Fuel System Leakage—3TNV82A, 3TNV88
• Adjust Valve Clearance—3TNV82A, 3TNV88 • Prime Fuel System—3TNV82A, 3TNV88
• Test Fuel Injection Nozzle—3TNV82A, 3TNV88
OUMX258,0000C0D -19-15APR13-1/1

Adjust Fan and Alternator Drive

Belt—3TNV82A, 3TNV88
Reason

TCAL28501 —UN—29JUN12
To keep proper tension on the belt to drive the water
pump and the alternator. To prevent shortened belt and
bearing life.
Special or Required Tools

• JDG529 or JDST28 Belt Tension Gage

Procedure
1. Park machine safely.
2. Remove engine cover.
3. Disconnect battery negative (-) cable.
4. Check the belt tension between the fan and alternator
using a belt tension gage and a straight edge.
OUMX258,0000BFD -19-11SEP14-1/2

Adjustment Procedure
1. Loosen top cap screw (A) and lower bolt (B).
2. Apply force to the alternator housing until tension is
correct.
3. Tighten cap screw and bolt.
Results

• If deflection is not within specifications, loosen both

alternator mounting cap screw and bolt. Apply force to
front alternator housing only (near the belt) until tension
TCT011766 —UN—11SEP14

is within specification. Tighten cap screw and bolt.

Specification
Alternator Drive
Belt—Deflection at 98
N (22 lb-force)........................................................................10—15 mm
(0.4—0.6 in.)

A—Cap Screw B—Bolt

OUMX258,0000BFD -19-11SEP14-2/2

TM130419 (24FEB16) 220-45-1 030916

PN=651
 Tests and Adjustments—3TNV82A, 3TNV88

Test Cylinder Compression—3TNV82A,

3TNV88
Reason
To determine the condition of the pistons, rings, cylinder

TCAL28502 —UN—29JUN12
walls and valves.
Special or Required Tools

• JT07043 Compression Gage Assembly

• JDG472 or JDG560 Adapter
Procedure
1. Remove the injection nozzles.
A—Adapter B—Compression Gauge
2. Install the heat protector from end of injector and Assembly
install JDG560 adapter (A).
3. Install JT07042 or JT07043 Pressure Gauge (B).
3TNV82A Cylinder
4. Disconnect the fuel control solenoid connector. Compression—Pressure
(Minimum)....................................................................... 2448 ± 103 kPa
IMPORTANT: Do not overheat starting motor
(355 ± 15 psi)
during test.
3TNV88 Cylinder Com-
pression—Pressure......................................................... 3427 ± 103 kPa
5. Crank the engine for five seconds with the starting
(497 ± 15 psi)
motor. Minimum cranking speed is 250 rpm.
3TNV88 Cylinder
6. Record the pressure reading for each cylinder. Compression—Pressure
(Minimum)....................................................................... 2751 ± 103 kPa
Results (399 ± 15 psi)
Difference Between
• If the pressure reading is below specification, perform Cylinders—Pressure
cylinder pressure leakage test to help determine (Maximum)........................................................................ 200—300 kPa
the cause of compression loss. (See Test Cylinder (29—44 psi)
Pressure Leakage—3TNV82A, 3TNV88.)
Specification
3TNV82A Cylinder Com-
pression—Pressure......................................................... 3158 ± 103 kPa
(458 ± 15 psi)
OUMX258,0000BFE -19-04MAR15-1/1

TM130419 (24FEB16) 220-45-2 PN=652

030916
 Tests and Adjustments—3TNV82A, 3TNV88

Adjust Slow Idle—3TNV82A, 3TNV88

IMPORTANT: The slow idle adjustment is the only
adjustment that can be made on this engine.
The fast idle and torque capsule adjustments
are pre-set by the engine manufacturer to
comply with strict EPA/CARB emissions
requirements, and are adjustable only by
authorized diesel service facilities.

TCAL28503 —UN—29JUN12
Reason
To achieve proper slow idle rpm setting. Provides
adequate rpm to keep the engine running smoothly
without stalling.
Special or Required Tools

• JT05719A Digital Tachometer

A—Jam Nut B—Slow Idle Stop Screw
Procedure
1. Place a small piece of reflective tape on the crankshaft
pulley.
2. Start the engine and run for 5 minutes to attain
operating temperature.
3. Move the throttle lever to slow idle position.
4. Use JT05719A Hand Held Digital Tachometer to check
engine speed at the crankshaft pulley.
5. Visually check that the injection pump throttle lever
is against slow idle stop screw. If not, adjust throttle
cable. (See Adjust Throttle Cable—3TNV82A,
3TNV88.)
6. Check if slow idle speed is set to specification.
Specification
3TNV82A Slow
Idle—Speed....................................................................... 1525 ± 50 rpm
3TNV88 Slow
Idle—Speed....................................................................... 1500 ± 50 rpm

Results

• If the slow idle rpm is not according to specifications,

loosen the jam nut (A) and turn the slow idle stop
screw (B) clockwise to increase the engine speed, or
counterclockwise to decrease the engine speed until the
slow idle speed is within specification. After adjustment,
tighten the jam nut.
OUMX258,0000BFF -19-15SEP14-1/1

TM130419 (24FEB16) 220-45-3 030916

PN=653
 Tests and Adjustments—3TNV82A, 3TNV88

Adjust Throttle Cable—3TNV82A, 3TNV88

Reason
To ensure that throttle linkage is adjusted correctly, and
allow full fast idle and slow idle positions of governor
throttle lever.
Procedure

TCAL28504 —UN—29JUN12
1. Park machine on level surface with key switch off,
transmission in neutral, and park brake locked.
2. Remove engine cover.
3. Place throttle control in slow idle position.
4. Cable housing should be specified distance (D) from
edge of clamp to end of cable housing. If necessary,
loosen clamp cap screw (A) and move cable housing
to specification. Retighten clamp bolt.
A—Clamp Cap Screw C—Cap Screw
Specification B—Jam Nut D—13.0—19.0 mm (0.50—0.75
Throttle Cable—Distance in.)
from edge of clamp to
end of cable housing........................................................13.0—19.0 mm
(0.50—0.75 in.) 7. Move throttle control to fast idle position, making sure
5. Loosen jam nut (B), and cap screw (C). injection pump lever is fully seated against fast idle
stop.
6. With throttle control at slow idle position, and injection
pump lever fully seated against slow idle stop, tighten
cap screw and jam nut.
OUMX258,0000C00 -19-16SEP14-1/1

TM130419 (24FEB16) 220-45-4 030916

PN=654
 Tests and Adjustments—3TNV82A, 3TNV88

Injection Pump Static Timing—3TNV82A,

3TNV88
Check Injection Pump Timing
NOTE: Locate and record the fuel injection pump timing
index number stamped into the boss on the engine
side of the fuel injection pump housing. Treat
this number as though there is a decimal point
between the two digits, i.e., 68 = 6.8.
Using the chart below, find the correct Fuel
Injection Reference (FIR) for the model that
you are working on.
FIR (Fuel Injection Reference

TCAL28505 —UN—29JUN12
Yanmar Engine Model Number)
3TNV82A-DJMA 4
3TNV88-DJMA 5

Insert the numbers you have recorded into the following

equation:
(Fuel Injection Pump Timing Index Number x 2) + FIR
Number = FIT° (Fuel Injection Timing in Degrees).
Record the calculated fuel injection timing in degrees. A—Return Hose

Special or Required Tools

• JDG10436 Yanmar TNV Diesel Engine Timing Tool Kit 3. Remove the forward fuel injection pump plunger plug
on top of the fuel injection pump.
NOTE: Some fuel may drain from the fuel injection
pump during the process. Make provisions
to contain any such spillage.

1. Turn off the fuel valve in the fuel supply hose and the
fuel return hose.
2. Clamp shut the fuel injection pump return hose (A)
leading to the fuel filter.
Continued on next page OUMX258,0000C01 -19-16SEP14-1/7

TM130419 (24FEB16) 220-45-5 030916

PN=655
 Tests and Adjustments—3TNV82A, 3TNV88

4. Install a dial adapter and clamp (B) from the diesel

engine timing tool kit into the pump plunger opening.

B—Dial Adapter and Clamp

TCAL28506 —UN—29JUN12
OUMX258,0000C01 -19-16SEP14-2/7

5. Install the dial indicator (C) with extension from the

Yanmar TNV Diesel Engine Timing Tool Kit into the
adapter. Secure the adapter clamp at approximately
the midpoint of its travel.

C—Dial Indicator

TCAL28507 —UN—29JUN12
Continued on next page OUMX258,0000C01 -19-16SEP14-3/7

TM130419 (24FEB16) 220-45-6 030916

PN=656
 Tests and Adjustments—3TNV82A, 3TNV88

NOTE: The following references to the direction of rotation

are facing the coolant pump end of the engine and
are adjusted by turning the crankshaft pulley.

6. Using a wrench on the crankshaft pulley bolt, rotate

the crankshaft in a clockwise direction while looking

TCAL28508 —UN—29JUN12
through the flywheel inspection port (D). Rotate the
crankshaft until the injection timing marks on the
flywheel are visible.

D—Inspection Port

OUMX258,0000C01 -19-16SEP14-4/7

7. Highlight the timing reference mark (E) on the flywheel

housing. Highlight the TDC mark (F) on the flywheel.

TCT006705 —UN—12APR13
A typical flywheel will have multiple timing grids, depending on the
number of cylinders. Any grid can be used to check fuel injection timing.

TCT006707 —UN—12APR13

Continued on next page OUMX258,0000C01 -19-16SEP14-5/7

TM130419 (24FEB16) 220-45-7 030916

PN=657
 Tests and Adjustments—3TNV82A, 3TNV88

8. Highlight the target timing mark (G) on the flywheel

as calculated earlier.
9. Rotate the crankshaft counterclockwise until the dial
indicator shows that the injection pump plunger is at
the bottom of its stroke. Rock the crankshaft back and
forth slightly to confirm a point where the dial indicator
shows no movement. Zero the dial indicator.

TCT006706 —UN—12APR13
10. Slowly rotate the crankshaft clockwise until the dial
indicator shows a pump plunger lift within specification.
Specification
Pump Plunger
Lift—Height................................................................................... 2.5 mm
(0.100 in.)

11. Check the position of the flywheel target timing mark

in relation to the timing reference mark on the flywheel
housing. If the two marks are aligned, the fuel injection G—Target Timing Mark
timing is correct. If the marks do not align, the fuel
injection timing must be adjusted.
12. If the injection timing is correct, remove the indicator Adjust Fuel Injection Timing
and adapter. Replace the pump plunger plug and its
copper gasket and tighten to specifications. Replace NOTE: If the timing marks did not align above, the
the flywheel inspection port cover. Open the fuel following steps need to be performed to properly
supply valve and remove the clamp from the fuel time the injection pump to the engine.
supply hose and the fuel return hose.
Specification Special or Required Tools
Pump Plunger—Torque.................................................................34 N·m
(25 lb.-ft.)
• JDG10436 Yanmar TNV Diesel Engine Timing Tool Kit
1. Leave the dial indicator installed in the fuel injection
13. Prime the fuel system. Operate the engine and check pump. Do not disturb the reading on the dial indicator.
for leaks.
Continued on next page OUMX258,0000C01 -19-16SEP14-6/7

TM130419 (24FEB16) 220-45-8 030916

PN=658
 Tests and Adjustments—3TNV82A, 3TNV88

2. Rotate the flywheel until the target timing mark (A) and
the timing reference mark on the flywheel housing or
backplate (B) are aligned.
3. Note the reading on the dial indicator. If the reading is
less than 2.5 mm the fuel injection timing is "retarded."
If the dial indicator reading is greater than 2.5 mm
(0.100 in.) the fuel injection timing is "advanced."

TCT006708 —UN—16APR13
4. Loosen the nuts fastening the fuel injection pump to
the gearcase or front plate. Loosen the rear bracket(s)
on the fuel injection pump.
NOTE: Some engine models may require the intake
manifold and fuel injection pump insulator be
removed to access the inner fuel injection
pump retaining nuts.
Loosening the high pressure injection line
nuts on the fuel injection pump may make A—Target Timing Mark B—Reference Mark
rotating the pump easier.

5. Rotate the fuel injection pump until the dial indicator specification. If removed, install the intake manifold
reads 2.5 mm (0.100 in.). To "advance" the injection and pump insulator. Tighten the high-pressure
timing, rotate the top of the fuel injection pump away injection line nuts to specification. Open the fuel return
from the engine. To "retard" the injection timing, rotate line and prime the fuel system. Operate the engine
the top of the fuel injection pump toward the engine. and check it for leaks.
6. When the dial indicator reads 2.5 mm (0.100 in.) of Specification
pump plunger lift, and the target timing mark on the Pump Plunger—Torque.................................................................34 N·m
flywheel aligns with the reference mark on the flywheel (25 lb.-ft.)
housing or engine back plate, the injection timing is High-Pressure Injection
correct. Line Nut—Torque..........................................................................32 N·m
(24 lb.-ft.)
7. Tighten the fuel injection pump mounting nuts and
rear bracket(s).
8. Remove the dial indicator and adapter. Replace the
plug in the pump plunger opening and tighten it to
OUMX258,0000C01 -19-16SEP14-7/7

TM130419 (24FEB16) 220-45-9 PN=659

030916
 Tests and Adjustments—3TNV82A, 3TNV88

Adjust Valve Clearance—3TNV82A, 3TNV88

Reason
To be sure that the valves are fully opening and closing
at the correct time, and not wearing the valve train
unnecessarily.
Special or Required Tools

• Feeler Gage

TCAL28514 —UN—29JUN12
• 10 mm End Wrench
• Flat Blade Screwdriver
• 17 mm Wrench
Procedure
1. The engine must be cool (room temperature) before
the valve clearance is checked.
2. Be sure that ignition key is off before attempting to
A—Flywheel Mark B—Bottom Edge Engine
turn engine by hand. Backplate
3. Remove the engine cover.
4. Remove the rocker arm cover. (See Remove and is rotated. If rocker arms are still moving when TDC
Install Rocker Arm Cover—3TNV82A, 3TNV88.) mark is approached, engine is on exhaust stroke.
5. Turn the crankshaft in the direction of engine rotation Rotate crankshaft one full revolution and try again.
(counterclockwise-looking at flywheel). Align number
one TDC mark on the flywheel (A) with bottom edge 6. Try to move rocker arms and/or push rods for No. 1
of engine back plate (B). cylinder:

NOTE: “Top dead center (TDC)” is when the piston is • If the rocker arms and push rods are loose, the piston
at its highest point of travel in the cylinder on is at TDC on the compression stroke. Go to step 7.
the compression stroke. Number one cylinder • If the rocker arms and push rods are not loose, rotate
is cylinder closest to flywheel. the flywheel one revolution (360°), and recheck the
rocker arms and push rods.
When top dead center is reached, the rocker arms
for that cylinder will be motionless as the crankshaft
Continued on next page OUMX258,0000C02 -19-06APR15-1/3

TM130419 (24FEB16) 220-45-10 030916

PN=660
 Tests and Adjustments—3TNV82A, 3TNV88

7. Slide a feeler gage between the valve cap (B) and

rocker arm to measure the clearance. Verify that the

TCAL28515 —UN—29JUN12
clearance is within specification
Specification
Valve Cap-to-Rocker
Arm—Clearance...............................................................0.15—0.25 mm
(0.006—0.010 in.)

8. To adjust the valves, loosen the locknut (D) and turn the
adjusting screw (C) until the blade of the feeler gage
can be inserted between the rocker arm and valve cap.
Hold the adjusting screw while tightening the locknut.
9. Recheck the valve clearance after tightening the
locknut.

TCAL28516 —UN—29JUN12
B—Valve Cap D—Locknut
C—Adjusting Screw

OUMX258,0000C02 -19-06APR15-2/3

TCAL28517 —UN—29JUN12
10. Check that the valve cap on the valve stem remained
seated on the valve and inside the valve spring retainer.
11. Repeat steps 5—10 for number two and three
cylinders using the appropriate cylinder number timing
mark on the flywheel.
12. Reinstall the rocker arm cover, air cleaner bracket,
and housing.
13. Replace the engine cover.
OUMX258,0000C02 -19-06APR15-3/3

TM130419 (24FEB16) 220-45-11 030916

PN=661
 Tests and Adjustments—3TNV82A, 3TNV88

Test Fuel Injection Nozzle—3TNV82A,

3TNV88
CAUTION: Escaping fluid under pressure can
penetrate the skin causing serious injury.
Avoid the hazard by relieving pressure before
disconnecting hydraulic or other lines. Tighten
all connections before applying pressure. Search
for leaks with a piece of cardboard. Protect hands
and body from high pressure fluids.
If an accident occurs, see a doctor immediately.
Any fluid injected into the skin must be surgically
removed within a few hours or gangrene
may result. Doctors unfamiliar with this type

TCAL28527 —UN—29JUN12
of injury should reference a knowledgeable
source. Such information is available from
the Deere & Company Medical Department
in Moline, Illinois, U.S.A.

Reason
To determine opening pressure, leakage, chatter and
spray pattern of the fuel injection nozzle.
A—Diesel Fuel Injection Nozzle D—23621
Special or Required Tools Tester E—23622 Straight Adapter
B—36352 F— Fuel Injection Nozzle
• D01109AA Diesel Fuel Injection Nozzle Tester C—23617
• D01110AA Adapter Set
• 23622 Straight Adapter
• Container
1. Dry the nozzle completely using a lint-free cloth.
Connections
2. Pressurize the nozzle to 11 032 kPa (1600 psi) for
Connect the fuel injection nozzle (F) to D01109AA Diesel 10 seconds.
Fuel Injection Nozzle Tester (A) using parts 36352 (B),
23617 (C), 23621 (D) from D01110AA Adapter Set, and 3. Watch for leakage from nozzle spray orifice.
23622 straight adapter (E).
Results
IMPORTANT: Use clean filtered diesel fuel when
testing injection nozzles to get best test results. • Fuel should not leak from the nozzle when the nozzle
is pressurized.
Procedure 1 • If the injection nozzle leaks fuel, disassemble and
inspect the nozzle assembly for contamination. Inspect
Test the fuel injection nozzle opening pressure following the valve seating surface. Replace the nozzle assembly
the Nozzle Tester manufacturer's instructions. if necessary.
The opening pressure must be to specification. Procedure 3
Results Test the fuel injection nozzle chatter and spray pattern
following the nozzle tester manufacturer's instructions.
• If the pressure reading does not meet specification,
disassemble the injection nozzle and inspect for 1. Pressurize nozzle to 21 600 kPa (3133 psi).1
contamination or a stuck valve. If necessary, add or
2. With slow hand lever movement there should be a
remove shims to change opening pressure.
“chatter” sound.
Procedure 2
Test fuel injection nozzle leakage following the nozzle
tester manufacturer's instructions.
1
Values are for used fuel injectors. Add 3447 kPa (500 psi)
when testing new injectors.
Continued on next page OUMX258,0000C03 -19-16SEP14-1/2

TM130419 (24FEB16) 220-45-12 030916

PN=662
 Tests and Adjustments—3TNV82A, 3TNV88

3. With fast hand lever movement the nozzle should

exhibit an even, fine atomized spray pattern (G).
4. Place a sheet of white paper 30 cm (12 in.) below
the nozzle. The injection spray should form a perfect
circle on the paper.
Results

• If nozzle chatter or the spray pattern does not meet

specifications, disassemble the injection nozzle and
inspect the nozzle assembly for contamination. Inspect
the valve seating surface. Replace the nozzle assembly
if necessary.
Specification
Fuel Injection
Nozzle—Opening
Pressure.................................................................. 21 600—22 600 kPa
(3133—3278 psi)

• If there is excessive difference in the spray angle

TCAL28528 —UN—29JUN12
or injection angle, incomplete atomizing or sluggish
starting/stopping of injection (H), disassemble the
injection nozzle and inspect the nozzle assembly
for contamination. Replace the nozzle assembly if
necessary.

G—Spray Pattern H—Injection

OUMX258,0000C03 -19-16SEP14-2/2

TM130419 (24FEB16) 220-45-13 030916

PN=663
 Tests and Adjustments—3TNV82A, 3TNV88

Test Thermostat Opening—3TNV82A,

3TNV88
Reason
To determine opening temperature of thermostat.
Special or Required Tools

• Thermometer
• Glass Container

TCAL28529 —UN—29JUN12
• Heating Unit
Procedure

CAUTION: DO NOT allow thermostat or

thermometer to rest against the side or bottom
of glass container when heating water. Either
may rupture if overheated.
A—Thermostat B—Thermometer
1. Suspend the thermostat (A) and a thermometer (B) in
a container of water.
2. Heat and stir the water. Observe opening action 4. Remove the thermostat and observe the closing action
of the thermostat and compare temperatures with as it cools.
specifications.
Specification Results
Thermostat—Tempera-
ture—Begins to Open.........................................................69.5—72.5° C
• The thermostat should begin opening at specification.
(157—163° F)
• The thermostat should be fully open at specification.
Thermostat—Tempera-
• Replace the thermostat if the lift height is less than
specification, or if the closing action is not smooth and
ture—Fully Open ............................................................................ 85° C
slow.
(185° F)

3. Measure opening height.

Specification
Thermostat—Full
Opening Height
(Minimum)....................................................................................... 8 mm
(0.32 in.)
OUMX258,0000C04 -19-16SEP14-1/1

TM130419 (24FEB16) 220-45-14 030916

PN=664
 Tests and Adjustments—3TNV82A, 3TNV88

Test Cylinder Pressure Leakage—3TNV82A, c. Move the piston to the bottom of the stroke with
3TNV88 intake and exhaust valves closed.
Reason d. Connect the hose from the compressed air source
to adapter.
To determine if compression pressure is leaking from
cylinder. e. Apply shop air pressure into the cylinder.
Special or Required Tools f. Check for bubbles in the recovery tank or air
escaping from the muffler, air cleaner or oil fill
• JDG560 Adapter opening.
Procedure 5. Repeat for each cylinder.
1. Raise hood and remove cap from coolant surge tank. Results
2. With the coolant at the proper level and the radiator • If bubbles are present in the surge tank, check for
cap tight, run the engine for 5 minutes to bring it to cracks in the cylinder head and the block. Check for
operating temperature. a damaged head gasket.
3. Look into the surge tank and check for bubbles coming • If air escapes from the muffler, check for a worn exhaust
from the overflow hose at the bottom of the tank. valve.
• If air escapes from air cleaner, check for a worn intake
4. If bubbles are present, isolate the source of valve.
compression leak: • If air escapes from engine oil fill, check for worn piston
rings.
a. Remove the injection nozzles.
b. Install JDG560 Adapter in the injection port of the
cylinder to be tested.
OUMX258,0000C05 -19-15APR13-1/1

Pressure Test Cooling System—3TNV82A,

3TNV88
Reason
Inspect the cooling system for leaks.

TCAL28530 —UN—29JUN12
Special or Required Tools

• D05104ST Cooling System Pressure Pump

• JDG692 Radiator Pressure Test Kit (Adapters)
Procedure
1. Remove the cap and attach the pressure pump to
radiator.
2. Apply pressure according to specifications, not to
exceed maximum specification. Specification
Specification Cooling System—Pres-
Cooling System— sure (Minimum after 15
Maximum Applied Sec)....................................................................................... 88 ± 15 kPa
Pressure........................................................................................ 97 kPa (12.8 ± 2.2 psi)
(14 psi) Results
3. Check for leaks throughout the cooling system. After • Pressure should hold at specification. If pressure
15 seconds, the pressure should be at or above decreases, check for leaks. Repair leaks or replace
minimum specification. parts as necessary.
• If the pressure test still indicates leakage after all external
leaks have been stopped, a defective head gasket,
cracked block, or cylinder head may be the cause. (See
Test Cylinder Pressure Leakage—3TNV82A, 3TNV88.)
OUMX258,0000C06 -19-16SEP14-1/1

TM130419 (24FEB16) 220-45-15 PN=665

030916
 Tests and Adjustments—3TNV82A, 3TNV88

Test Radiator Pressure Cap—3TNV82A,

3TNV88

TCAL28531 —UN—29JUN12
Reason
Test the radiator cap for operating in the correct pressure
range.
Special or Required Tools

• D05104ST Cooling System Pressure Pump

• JDG692 Radiator Pressure Test Kit (Adapters) A—Radiator Cap
Procedure
1. Install the radiator cap (A) on the pressure pump.
Results
2. Apply pressure. Pressure valve in the cap should
open at specification. • If the cap leaks, retighten and test again. Replace the
cap if pressure is not within specification.
Specification
Radiator Cap
Valve—Opening
Pressure........................................................................................ 88 kPa
(12.8 psi)
OUMX258,0000C07 -19-16SEP14-1/1

TM130419 (24FEB16) 220-45-16 030916

PN=666
 Tests and Adjustments—3TNV82A, 3TNV88

Test Oil Pressure—3TNV82A, 3TNV88

Reason
To determine if the engine bearings or the lubrication
system components are worn.
Special or Required Tools

• JT03349 Connector
• JT03017 Hose Assembly
• JT07034 0—700 kPa (0—100 psi) Gage
Procedure
1. Remove the oil pressure sender.
2. Install JT03349 Connector (C).
3. Connect JT03017 Hose Assembly (B) and JT07034
Pressure Gage (A).

TCAL28532 —UN—29JUN12
IMPORTANT: Do not run the engine if there is
insufficient oil pressure!

4. Start the engine. If the pressure reading is below 60

kPa (8.7 psi) at slow idle rpm, stop the engine.
5. If the oil pressure is at least 60 kPa (8.7 psi), run the
engine approximately five minutes to heat the oil.
Check the oil pressure at engine rated speed.
Results A—Pressure Gauge C—Connector
B—Hose Assembly
• If the oil pressure is not within specifications, inspect
the oil pump. If the relief valve is suspected, the spring
can be replaced. 3TNV88 Oil—Pressure..................................................... 335 ± 0.50 kPa
(49 ± 7.2 psi)
Specification
3TNV82A • If the oil pump is within specifications, the engine may
Oil—Pressure...................................................................... 320 ± 10 kPa have parts worn beyond specifications.
(46 ± 1.4 psi)
OUMX258,0000C08 -19-16SEP14-1/1

TM130419 (24FEB16) 220-45-17 PN=667

030916
 Tests and Adjustments—3TNV82A, 3TNV88

Test Fuel Pump Pressure—3TNV82A, 3TNV88

Reason
To determine fuel transfer pump operating pressure.
Special or Required Tools

TCAL28533 —UN—29JUN12
• JDG356 Fuel Pump Pressure Test Kit
Procedure
1. Verify fuel is within 15—25° C (59—77° F).
2. Disconnect transfer pump hose (A) from outlet side
of pump at fuel filter.
3. Install the hose and gage to outlet side hose of pump.
4. Turn key switch to ON position for 15 seconds. A—Transfer Pump Hose

5. Record fuel pressure reading on gage.

Specification Results
Fuel Transfer
Pump—Pressure............................................................. 21.5—37.3 kPa • If the pressure is not within specification, replace the
(3.1—5.4 psi) fuel transfer pump.
OUMX258,0000BB1 -19-15FEB16-1/1

Test Fuel Transfer Pump Flow—3TNV82A,

3TNV88
Reason
To determine fuel transfer pump flow.
Procedure
1. Verify fuel is within 15—25° C (59—77° F).

TCAL28534 —UN—29JUN12
2. Disconnect fuel pump outlet hose (A) at fuel filter.
3. Place hose in graduated container.
4. Turn key switch to ON position for 15 seconds.
5. Compare fuel amount to specification.
Results
If fuel flow is below specification, replace the fuel transfer A—Fuel Pump Outlet Hose
pump.
Specification
Fuel Transfer
Pump.—Volume Flow
15 Sec (Minimum)........................................................................ 400 mL
(13.5 oz)

OUMX258,0000C0A -19-16SEP14-1/1

TM130419 (24FEB16) 220-45-18 030916

PN=668
 Tests and Adjustments—3TNV82A, 3TNV88

Test Fuel System Leakage—3TNV82A, 3. Apply 34—69 kPa (5—10 psi) air pressure to fuel
3TNV88 supply hose until all fuel is drained from the system.

Reason 4. Plug the end of the fuel return hose.

Tests the fuel system plumbing for external leakage. This 5. Apply 34—69 kPa (5—10 psi) air pressure to the
test also determines if air is entering the fuel system at fuel system at the fuel supply line. Do not exceed a
connections, allowing fuel to siphon back to tank. maximum pressure of 103 kPa (15 psi).

Procedure 6. Apply liquid soap and water solution to all joints and
connections in the fuel system, and inspect for leaks.
1. Disconnect the fuel supply line and return line at the
fuel tank. Results

2. Place the fuel return line into a suitable container to • Find leaks and repair or replace parts as necessary.
catch drained fuel.

CAUTION: Do not apply more than 103 kPa (15

psi) air pressure to the fuel system. Damage to
the injection pump or personal injury may result.
OUMX258,0000C0B -19-15APR13-1/1

Prime Fuel System—3TNV82A, 3TNV88

Reason
Any time the fuel system has been opened up for service
(lines disconnected, running out of fuel or changing the
fuel filter), it is necessary to prime the system.

TCAL28535 —UN—29JUN12
1. Park machine safely.
2. Turn OFF PTO switch.
3. Lower attachments to the ground.
4. Lock the parking brake.
5. Turn the key switch to the RUN position for 2 minutes Electric boost pump is located under the seat on the left
prior to starting the engine. The fuel pump (A) will side of engine compartment.
pressurize the fuel and remove any air in the system.
A—Fuel Pump
6. Start the engine. If the engine will not start, repeat the
previous step.
OUMX258,0000C0C -19-15APR13-1/1

TM130419 (24FEB16) 220-45-19 030916

PN=669
 Tests and Adjustments—3TNV82A, 3TNV88

TM130419 (24FEB16) 220-45-20 030916

PN=670
 Section 230
Electrical Operation, Tests, and Adjustments
Contents

Page
Page
Group 10—Theory of Operation, Non-T4
Summary of References.............................. 230-10-1 Electrical Components, T4 .......................... 230-20-6
Unswitched Power Circuit Main Schematic, T4..................................... 230-20-7
Operation, Non-T4................................... 230-10-2 Engine Connector X5057
Switched Power Circuit Operation, Schematic.............................................. 230-20-16
Non-T4..................................................... 230-10-3 Engine Connector X5058
Cranking Circuit Operation, Schematic.............................................. 230-20-17
Non-T4..................................................... 230-10-6 Engine Connector X5059
Charging Circuit Operation, Schematic.............................................. 230-20-18
Non-T4..................................................... 230-10-8 Engine Connector X5060
Operator Presence and PTO Schematic.............................................. 230-20-19
Interlock Circuit Operation, Engine Controls and Sensors
Non-T4..................................................... 230-10-9 Schematic.............................................. 230-20-20
Engine Oil Pressure Light and Cab Schematic, Lower .............................. 230-20-21
Buzzer Circuit Operation, Cab Schematic, Upper .............................. 230-20-23
Non-T4................................................... 230-10-14 GLC Schematic ......................................... 230-20-27
Engine Coolant Temperature Light Electrical Components,
and Buzzer Circuit Operation, Homologation ........................................ 230-20-29
Non-T4................................................... 230-10-16 Homologation Wiring Schematic ............... 230-20-30
Hydraulic Oil Temperature Light Front Work Light Wiring
Circuit Operation, Non-T4...................... 230-10-18 Schematic.............................................. 230-20-33
Cold Start Operation, Non-T4.................... 230-10-20 Backup Alarm Wiring Schematic ............... 230-20-34
Fuel Shutoff Solenoid Circuit Beacon Light Wiring Schematic................. 230-20-35
Operation, Non-T4................................. 230-10-22
Cruise Control Circuit Operation, Group 30—Diagnosis
Non-T4................................................... 230-10-24 Power Circuit Diagnosis, Non-T4 ................230-30-1
Unswitched Power Circuit............................230-30-1
Group 15—Theory of Operation, Tier 4 Switched Power Circuit (Lights
Summary of References.............................. 230-15-1 Only)........................................................230-30-2
Unswitched Power Circuit Switched Power...........................................230-30-2
Operation, T4........................................... 230-15-2
Switched Power Circuit Operation, Group 40—Tests and Adjustments
T4 ............................................................ 230-15-6 Summary of References.............................. 230-40-1
Cranking Circuit Operation, T4 .................. 230-15-10 Battery Test.................................................. 230-40-2
Charging Circuit Operation, T4.................. 230-15-13 Battery Load Test......................................... 230-40-3
Operator Presence and PTO Battery Charge ............................................ 230-40-4
Interlock Circuit Operation, T4............... 230-15-16 Regulated Voltage Output Test.................... 230-40-4
Engine Oil Pressure Circuit Key Switch Test ........................................... 230-40-5
Operation, T4......................................... 230-15-18 Beacon Light Switch Test ............................ 230-40-6
Engine Coolant Temperature Relay Test.................................................... 230-40-7
Circuit Operation, T4 ............................. 230-15-19 Relay Test, Cab Power ................................ 230-40-7
Hydraulic Oil Temperature Circuit Glow Plug Test............................................. 230-40-8
Operation, T4......................................... 230-15-21 Air Preheater Test........................................ 230-40-8
Cold Start Circuit Operation, T4 ................ 230-15-23 Diode Pack AMT386 Test ............................ 230-40-8
Cruise Control Circuit Operation, Diode Pack AMT477 Test .......................... 230-40-10
T4 .......................................................... 230-15-24 Headlight Switch Test (Single)................... 230-40-10
CAN Bus.................................................... 230-15-25 Turn Signal Switch Test ............................. 230-40-11
Rotary Light Switch Test ............................ 230-40-11
Group 20—Schematics Rotary Blower Switch Test......................... 230-40-12
Summary of References.............................. 230-20-1 Cruise Control Switch Test ........................ 230-40-12
Electrical Components, Non-T4................... 230-20-1 Cruise Brake Switch Test, Non-T4.............. 230-40-13
Main Schematic, Non-T4 ............................. 230-20-2 Wiper Switch Test ...................................... 230-40-13

Continued on next page

TM130419 (24FEB16) 230-1 030916

PN=1
 Contents

Page Page

Diode Test.................................................. 230-40-14 Light Switch Connector................................ 230-50-9

Fuse Test ................................................... 230-40-14 Headlights Connector ................................ 230-50-10
A/C (HVAC) Switch Test ............................ 230-40-15 PTO Switch Connector, Non-T4 ................ 230-50-10
A/C Temperature Control Switch PTO Switch Connector, T4 ........................ 230-50-10
Test ........................................................ 230-40-15 PTO Solenoid Connector........................... 230-50-10
Dome Light Switch Test ............................. 230-40-16 Air Heater Relay Connector....................... 230-50-11
Door Switch Test........................................ 230-40-16 Cab Power Relay Connector ..................... 230-50-11
PTO Switch Test, Non-T4 .......................... 230-40-17 Cruise Control Relay Connector................ 230-50-11
PTO Switch Test, T4.................................. 230-40-17 Fuel Pull-In Relay Connector..................... 230-50-11
PTO Solenoid Test..................................... 230-40-18 PTO Shutdown Relay Connector .............. 230-50-12
Hydraulic Temperature Switch Cruise Control Switch Connector .............. 230-50-12
Test ........................................................ 230-40-18 Cruise Control Brake Switch
Engine Oil Pressure Switch Test ............... 230-40-19 Connector .............................................. 230-50-12
Coolant Temperature Switch Test.............. 230-40-20 Cruise Control Magnet Connector.............. 230-50-12
Fuel Pump Test.......................................... 230-40-20 Flasher Relay Connector........................... 230-50-13
Fuel Shutoff Solenoid Test, Diode Pack Connector............................... 230-50-13
Non-T4................................................... 230-40-21 Cab Power Connector ............................... 230-50-13
Cruise Control Magnet Test ....................... 230-40-22 Wiper Switch Connector ............................ 230-50-14
Seat Switch Test ........................................ 230-40-22 Fan Speed Switch Connector.................... 230-50-14
Park Brake Switch Test.............................. 230-40-23 Beacon Switch Connector ......................... 230-50-14
Warning Alarm Test ................................... 230-40-23 Homologation Harness
DPF Differential Pressure Sensor Connector .............................................. 230-50-15
Test, T4.................................................. 230-40-23
DPF Inlet Temperature Sensor,
T4 .......................................................... 230-40-23
DPF Mid Temperature Sensor, T4.............. 230-40-24
Accelerator Sensor Test, T4 ...................... 230-40-24

Group 50—Connectors
Summary of References.............................. 230-50-1
Accelerator Sensor Connector .................... 230-50-1
Alarm Buzzer Connector, Non-T4................ 230-50-1
Alarm Buzzer Connector, T4 ....................... 230-50-2
Alternator Connector, Non-T4...................... 230-50-2
Alternator Connector, T4 ............................. 230-50-2
Power Outlet Connector .............................. 230-50-2
Auxiliary Cab Power Connector................... 230-50-3
Control Module Connector, 8 Pin................. 230-50-3
Control Module Connector, 6 Pin................. 230-50-3
Engine Preheat Timer Module
Connector ................................................ 230-50-4
Engine Control Module (ECU)
Connector, 94 Pin .................................... 230-50-5
Engine Control Module (ECU)
Connector, 60 Pin .................................... 230-50-6
Fuel Shutoff Solenoid Connector................. 230-50-7
Fuel Transfer Pump Connector,
Non-T4..................................................... 230-50-7
Fuel Transfer Pump Connector,
T4 ............................................................ 230-50-7
Hydraulic Oil Temperature Switch
Connector, Non-T4 .................................. 230-50-8
Hydraulic Oil Temperature Switch
Connector, T4 .......................................... 230-50-8
Instrument Cluster Connector,
Non-T4..................................................... 230-50-8
Display Unit Connector, T4.......................... 230-50-8
Key Switch Connector ................................. 230-50-9
Brake Switch Connector .............................. 230-50-9
Seat Switch Connector ................................ 230-50-9

TM130419 (24FEB16) 230-2 030916

PN=2
 Group 10
Theory of Operation, Non-T4
Summary of References • Engine Coolant Temperature Light and Buzzer Circuit
Operation, Non-T4
• Unswitched Power Circuit Operation, Non-T4 • Hydraulic Oil Temperature Light Circuit Operation,
• Switched Power Circuit Operation, Non-T4 Non-T4
• Cranking Circuit Operation, Non-T4 • Cold Start Operation, Non-T4
• Charging Circuit Operation, Non-T4 • Fuel Shutoff Solenoid Circuit Operation, Non-T4
• Operator Presence and PTO Interlock Circuit Operation, • Cruise Control Circuit Operation, Non-T4
Non-T4
• Engine Oil Pressure Light and Buzzer Circuit Operation,
Non-T4
OUMX258,0000C0F -19-04JUN14-1/1

TM130419 (24FEB16) 230-10-1 030916

PN=673
 Theory of Operation, Non-T4

Unswitched Power Circuit Operation, Non-T4 The positive (+) battery cable connects the battery to the
Function: starting motor battery terminal B. This connection is used
as a tie point for the rest of the electrical system.
Provides unswitched power to the primary components
whenever the battery is connected. The battery cables and the starting motor connections
must be in good condition for the electrical system to
Operating Conditions: function properly.

• Battery connected. The ground cable connects from the negative (—)
• Key switch in OFF position. battery terminal to the engine ground (W1). The ground
connection is equally important as the positive (+)
Theory of Operation cable. The starting motor depends on these cables
and connections to carry the high current necessary for
Voltage must be present at the following components with operation.
the key switch in the STOP position:
The components are all protected by the EF-1 80 amp
• Battery (G1) positive (+) terminal. fuse.
• Battery terminal B of starting motor (M1).
• Fuse Holder (EF1) The auxiliary outlet (X-2) is protected by fuse (F1).
• G-2B terminal of Alternator (G2) Voltage is available from the fuse, through 492 Yel wire
• Fuel Shutoff Solenoid Relay (K5). to the auxiliary outlet (X-2).
• Cab Power Relay (K8) The EF-1 80 amp fuse holder provides power to the key
• Air Heater Relay (K6). switch (S1), the fuel pull-in relay (K5), the air heater relay
• Fuse Holder (F1) (K6), and the cab power relay (K8).
• Auxiliary Outlet (X-2)
• Battery terminal B of key switch (S1). Power Circuit Schematic
85 86 K8
243 Red 30 87 Cab Power
Relay
2
242 Red 1 Sp-1 1
2 X-1
250 Red 3
4 Cab
S1 5
240 Red

6 Power
Key Switch
85 86 K5
S2 S1
210 Red 30 87 Fuel Pull-In
B A 2 225 Red
Relay
Sp-8 1
M
85 86 K6
G
Air Heater
230 Red

Sp-9 30 87
EF-1 225 Red
1 2
220 Red
Start
Fuse Relay
Run
Off M-1C
Holder
M-1A
80A
200 Red B A
241 Red

F1
Fuse
290 Red Holder
G-2B 102 Blk GT-1A X-2 Power
G GT-1 GT-2 10A 492 Yel A
A
B

A B B
TCT007270 —UN—27DEC13

G2 GT-2A M
Alternator
G1 Battery
M1 Starter Motor

EF-1— Fuse Holder K5—Fuel Pull-In Relay M1—Starter Motor

F1— Fuse Holder K6—Air Heater Relay S1— Key Switch
G1—Battery K8—Cab Power Relay X-2— Auxiliary Power Outlet
G2—Alternator
OUMX258,0000C10 -19-04JUN14-1/1

TM130419 (24FEB16) 230-10-2 PN=674

030916
 Theory of Operation, Non-T4

Switched Power Circuit Operation, Non-T4 • Control module connector (A1B) terminal 1.
Function:
• 15 amp fuse (F3).
• Control module connector (A1B) terminal 3.
Provides power to the primary components when the key • 402 Yel wire.
switch is in the RUN position. • 412 Yel wire.
• Ground wires 107, 114, 112, 110 and 100 Blk.
Operating Conditions:
With the key switch (S1) in the RUN position, current also
• Battery Connected flows to fuel pump (M2), causing the fuel pump to come
• Key switch in RUN position ON. Current flows through the following components to
fuel pump (M2):
Theory of Operation:
• Key switch (S1) terminals (B and A).
Voltage must be present at the following components with • 400 Yel wire.
the key switch in the RUN position: • Control module connector (A1B) terminal 1.
• 15 amp fuse (F3).
• Key switch (S1) terminal A. • Control module connector (A1B) terminal 3.
• Control module connector (A1B) terminal 1. • 402 Yel wire.
• Fuse (F3). • 456 Yel wire.
• Fuse (F4). • Fuel pump (Y4).
• Start relay (K1). • Ground wires 126, 124, and 100 Blk.
• Hold-in relay (K2).
• Control module connector (A1B) terminal 4. If optional cab power relay (K8) is installed, current also
• Light switch (S8). flows from the key switch (S1) in the RUN position to cab
• Control module connector (A1B) terminal 3. power relay (K8), energizing the relay. Current flows
• Buzzer (H7). through the following components to energize cab power
• Alternator connector (G-2B). relay (K8):
• Instrument cluster (A100). • Key switch (S1) terminals (B and A).
• Diesel engine preheat timer (A2). • 400 Yel wire.
• Fuel pull-in relay (K5). • Control module connector (A1B) terminal 1.
• Air heater relay (K6). • 15 amp fuse (F3).
• PTO switch (S3). • Control module connector (A1B) terminal 3.
• Seat switch (S2). • 402 Yel wire.
• PTO shutdown relay (K4). • 480 Yel wire.
• Optional cab power relay (K8). • Cab power relay (K8) terminals (86 and 85).
With the key switch (S1) in the RUN position, current flows • Ground wires 155, 124, and 100 Blk.
to instrument cluster (A100), causing the hour meter to
With cab power relay energized voltage is available to cab
operate. Current flows through the following components
power connector (X-1) from cab power relay (K8) terminal
to instrument cluster (A100):
87 through the 490 Yel wire, and then the 491, 493, and
• Key switch (S1) terminals (B and A). 494 Yel wires.
• 400 Yel wire.

Continued on next page OUMX258,0000C11 -19-04JUN14-1/3

TM130419 (24FEB16) 230-10-3 030916

PN=675
 Theory of Operation, Non-T4

Switched Power Circuit Schematic (1 of 2)

S1 402 Yel
Key Switch
S2 S1
A1
B A
Control Module A1A
242 Red 400 Yel
A
M G F4 B
A1B 15A C
Start
400 Yel A 1 F3 D
E
Run 15A
B H2 F
Off 3
402 Yel C
4
G
450 Yel D PTO H
E 5 (Grn)
F 6 K1
S8
K2 K3
Light Switch Start
1
2
Relay

H1 Hold-In PTO
Hold-In Relay Relay
(Red)

K8
Cab Power
85 86 491 Yel
155 Blk 480 Yel 1
30 87
Sp-13 493 Yel 2 X-1
490 Yel
12
3
4
Cab
494 Yel 5
6
Power
242 Red

243 Red

2
503 Yel A X-4
Sp-1 B 404 Yel
1 Cab Power
240 Red

K5
Fuel Pull-In
85 86
210 Red 407 Yel
30 87
2 225 Red
Sp-8 1
Sp-9
220 Red
230 Red

225 Red
1 2
EF-1
Fuse R101
Holder 611 Brn A B
408 Yel
M-1A 470
80A
200 Red B A

G-2B G-2A 155 Blk

200 Red
G
A
B

241 Red

290 Red 3 F1
102 Blk GT-1A
GT-1 GT-2
Fuse
Holder
G2
TCT007271 —UN—27DEC13

Alternator 10A 492 Yel

M A B

G1 Battery GT-2A
M1
Starter Motor

EF-1— Fuse Holder and Fuse G2—Alternator M1—Starter Motor X-4— Cab Power Connector
F1— Fuse K5—Fuel Pull-In Relay S1— Key Switch
G1—Battery K8—Cab Power Relay X-1— Cab Power Connector
Continued on next page OUMX258,0000C11 -19-04JUN14-2/3

TM130419 (24FEB16) 230-10-4 030916

PN=676
 Theory of Operation, Non-T4

Switched Power Circuit Schematic (2 of 2)

402 Yel A100
Instrument Cluster
412 Yel A 12V-16V DC
B Service
C Preheater
D Ground
E Engine Oil Pressure
F Engine Temperature S3
G Battery Discharge
H Hydraulic Temperature PTO Switch
C100
3
410 Yel 9
K4 411 Yel

410 Yel
412 Yel
PTO Shutdown 1 4

411 Yel
402 Yel
7
85 86
S2 On
430 Yel Off
30 87
Seat Switch
87a H7
Off Seat 1 Sp-2 Buzzer

456 Yel
On Seat 2

A 403 Yel A

430 Yel
480 Yel
407 Yel
404 Yel
409 Yel
406 Yel
405 Yel
403 Yel
B B

480 Yel

405 Yel A H2
B Homologation Kit

407 Yel
406 Yel
404 Yel

Power

Control Fuel
A 406 Yel
B
Logic C
Gnd
K6 Pre-heat
D
Wait Light
E
Air Heater Hold In Signal
F

85 86
409 Yel A2
30 87
220 Red Engine Preheat Timer
Y4
Fuel Transfer Pump
Red 456 Yel
M A
Blk B 126 Blk
1 Sp-12
2
155 Blk

X-2 Power
TCT007272 —UN—27DEC13

A
B
Sp-5
100 Blk 124 Blk
12
T-35
W2

A2—Engine Preheat Timer H7—Buzzer M1—Starter Motor Y4— Fuel Transfer Pump
Module K4—PTO Shutdown Relay S2— Seat Switch
A100— Instrument Cluster K6—Air Heater Relay S3— PTO Switch
H2—Homologation Kit Connector K8—Cab Power Relay X-2— Auxiliary Power Outlet
OUMX258,0000C11 -19-04JUN14-3/3

TM130419 (24FEB16) 230-10-5 030916

PN=677
 Theory of Operation, Non-T4

Cranking Circuit Operation, Non-T4 position, switched power flows from the key switch to
the control module (A1) through 400 Yel wire. Within the
Function: control module power flows to the contacts of the start
relay (K1) and fuse (F3). From fuse (F3), power flows
Provide power to the starting motor (M1) to crank the
out of the control module through 402 and 410 Yel wires
engine.
to the PTO switch (S3). With the PTO switch in the Off
Operating Conditions: position, power flows through the PTO switch and through
752 Pur wire to brake switch (S4). With the brake switch
To crank the engine, the following conditions must be met: in the On position, power flows through the brake switch
and through the 743 Pur wire to the control module and
• Key switch in start position. then to the coil of start relay (K1).
• PTO switch (S3) must be in the DISENGAGED (Off)
position. When the key switch (S1) is in the start position, ground
• Brake switch (S4) must be in the BRAKES LOCKED is supplied to the coil of start relay (K1) and the relay is
(On) position (master brake pedal depressed). energized. With the relay energized, power flows from the
relay contacts, out of the control module (A1) and through
Theory of Operation: 747 Pur wire to the starting motor (M1) solenoid to engage
The power circuit provides power to the starting motor the starting motor and crank the engine.
solenoid and key switch. With the key switch in the start

Continued on next page OUMX258,0000C12 -19-04JUN14-1/2

TM130419 (24FEB16) 230-10-6 030916

PN=678
 Theory of Operation, Non-T4

Cranking Circuit Schematic

S1 A1
Key Switch Control Module A1A
S2 S1 A 743 Pur
195 Blk F4 B
A1B 15A C
242 Red
B A
400 Yel A 1 F3 D
E 195 Blk
15A
B H2 F
3
M G 402 Yel C
4
G
190 Blk
D PTO H
E 5 (Grn)
Start
747 Pur F 6 K1
Run
Off K2 K3
Start
2
Relay
1
Sp-6
H1 Hold-In PTO
Hold-In Relay Relay
110 Blk

(Red)

2
1
Sp-5
242 Red

S3
402 Yel
100 Blk

PTO Switch
3
1 410 Yel 9
Sp-1 752 Pur
1 Sp-2
1 4
7
T-35
On
240 Red

Off S4
W-2 Brake Switch
A
743 Pur C
2
752 Pur
1 Sp-8 B D

Off
EF-1 On
Fuse
747 Pur

Holder
M-1A
230 Red 80A
B A

290 Red
102 Blk GT-1A M-1B

TCT007268 —UN—27DEC13
GT-1 GT-2
GT-2A
M1
M Starter Motor
G1 Battery

A1—Control Module G1—Battery S3— PTO Switch

EF-1— Fuse Holder and Fuse M1—Starter Motor S4— Brake Switch
S1— Key Switch
OUMX258,0000C12 -19-04JUN14-2/2

TM130419 (24FEB16) 230-10-7 030916

PN=679
 Theory of Operation, Non-T4

Charging Circuit Operation, Non-T4 output is determined by the intensity of magnetism at

the field coil. As the battery voltage drops, the regulator
Function: adjusts the voltage at the field coil, which in turn intensifies
To maintain battery voltage between 12.2 and 14.7 volts the magnetic field at the field coil to increase alternator
DC. output.

Operating Conditions: The alternator produces alternating current (AC) which is

then rectified to direct current (DC) by an internal rectifier.
• Key switch in RUN position.
• Engine RUNNING. Charging current flows from the alternator through 200
Red wire to the battery terminal on starting motor (M1)
Theory of Operation: and then to the battery positive (+) terminal through the
positive (+) red battery cable.
The power circuit provides switched power to the
instrument cluster through the 402 and 412 Yel wires and When the alternator has no output or low output, the
to the alternator (G2) through 404 Yel wire. instrument cluster discharge light is turned on by providing
ground through 610 Brn wire. The alternator provides the
The alternator has an internal voltage regulator that ground internally.
monitors battery voltage and increases alternator output
to maintain proper voltage and battery charge. Alternator
S2 S1 A
F4 B
A1B 15A C
242 Red
B A
400 Yel A 1 F3 D
E
15A
B H2 F
3
M G 402 Yel C
4
G
D PTO H
E 5 (Grn)
Start F 6 K1
Run
Off K2 K3
Start A1
S1 Relay Control Module
Key Switch
H1 Hold-In PTO
Relay Relay
242 Red

Hold-In
402 Yel

(Red)

A100
1 Sp-1 Instrument Cluster
412 Yel A 12V-16V DC
B Service
240 Red

C Preheater
1 Sp-2 112 Blk D Ground
2 404 Yel E Engine Oil Pressure
F Engine Temperature
610 Brn G Battery Discharge
H Hydraulic Temperature
2
Sp-8 C100
1 EF-1 2
Sp-6
1
Fuse
R101
Holder 611 Brn 408 Yel
110 Blk

A B
230 Red
M-1A 470
80A
200 Red B A

G-2B G-2A
200 Red 2
G Sp-5
A
B

290 Red 1
3
102 Blk GT-1A
GT-1 GT-2
100 Blk

TCT007269 —UN—27DEC13

G2
Alternator
GT-2A M
M1 T-35
G1 Starter Motor W2
Battery

A1—Control Module G1—Battery EF-1— Fuse Holder S4— Brake Switch

A100— Instrument Cluster G2—Alternator S1— Key Switch
M1—Starter Motor S3— PTO Switch
OUMX258,0000C13 -19-04JUN14-1/1

TM130419 (24FEB16) 230-10-8 030916

PN=680
 Theory of Operation, Non-T4

Operator Presence and PTO Interlock Circuit (A1). From connector (A-1A), the current flows to the coil
Operation, Non-T4 of hold-in relay (K2), energizing the relay and charges
the capacitor of control module (A1). The energy stored
Function: in the capacitor will keep the hold-in relay (K2) energized
for approximately one second if the operator leaves the
The purpose of the “operator presence” portion of this seat, as on rough terrain. The current will also cause
circuit is to automatically stop the engine whenever the hold-in LED (H1), located on control module (A1), to
operator rises from the seat for more than one second come on providing visual proof that the hold-in relay coil
when PTO is ENGAGED and/or park brake is UNLOCKED. is energized to aid in troubleshooting.
The purpose of the “PTO interlock” portion of the circuit If the operator is not on the seat, the hold-in relay can
is to provide the following: still be energized by putting PTO switch (S3) in the
• Require the operator to be sitting on the seat and park DISENGAGED (Off) position and brake switch (S4) in the
brake UNLOCKED before the PTO can be ENGAGED. BRAKES LOCKED (On) position. When this happens,
• Automatically disengages the PTO whenever any of current is allowed to flow through 752 Pur wire, across
the following occurs: the brake switch contacts, then through 743 Pur wire, to
- park brake lock is engaged terminal A of connector (A-1A) of control module (A1).
- engine coolant temperature exceeds 110° C (230° F) From connector (A-1A), current flows to the coil of hold-in
- engine oil pressure drops below safe operating relay (K2), energizing the relay. The current will also
pressure cause hold-in LED (H1) to come on.
- hydraulic oil temperature exceeds safe operating Hold-in Power (Engine Run) Circuit
temperature
- key switch is placed in the START position When the hold-in relay is energized, current from fuse
• Provide a means for the engine to continue operating (F3) is allowed to flow across the contacts of the hold-in
when the operator is not on the seat. relay, then through 640 Grn wire, to splice 3.
Operating Conditions: From splice 3, current flows to the following components:

• Key switch in ON position. • Fuel solenoid (650 Grn wire).

• Diesel engine control module (630 Grn wire).
Theory of Operation:
PTO Interlock Circuit
Unswitched and Switched Power Circuits
NOTE: For safety reasons, the PTO interlock circuit
Protection for operator presence and PTO interlock circuit contains a latching circuit. Because of this, the
is provided by fuse (EF-1) and 15 amp switched power PTO switch must be at the DISENGAGED position
fuse (F3) located on control module (A1). before the PTO can be ENGAGED.
Turning key switch (S1) to the ON or start position allows When PTO switch is in the DISENGAGED position,
current from the positive (+) terminal of battery (G1) to current from fuse (F3) is allowed to flow through 748 Pur
flow through fuse (EF1), 230, 240 and 242 Red wires, wire, to terminal D of connector (A-1A) on control module
then to terminal B of the key switch. The current flows (A1). From connector (A-1A), current flows to the coil of
out terminal A of the key switch, through 400 Yel wire, to PTO relay (K3), energizing the relay. The current will also
switched power fuse (F3). From fuse (F3), current flows cause PTO LED (H2), located on control module (A1), to
through 402 Yel wire to splice 2. come on providing visual proof that the PTO relay coil is
From splice 2, current flows to the following components: energized to aid in troubleshooting.

• Seat switch (S2) (411 Yel wire). With the PTO relay energized, current is allowed to flow
• PTO switch (S3) (410 Yel wire). across the relay contacts, out terminal E of connector
• Coil of PTO shutdown relay (K4) (430 Yel wire). (A-1B), then through 750 and 760 Pur wires, to PTO
shutdown relay (K4). The current flows across the
Operator Present and Not Present Circuits normally closed contacts of the relay, then through 700
Pur wire, to brake switch (S4). If the brake switch is at
For the engine to operate, one of the following must occur: the OFF position (park brake UNLOCKED), the current
• Operator must be on the seat when the PTO is will flow across the switch contacts, then through 788 Pur
ENGAGED and/or park brake UNLOCKED. wire, to terminal F of connector (A-1A) on control module
• When operator is not on the seat, the PTO must be (A1). From connector (A-1A), the current flows to the coil
DISENGAGED and park brake LOCKED. of PTO relay (K3), thus latching the PTO relay. At this
point, the PTO can be ENGAGED by moving the PTO
When the operator is sitting on the seat, current flows switch to the ENGAGED position.
across the seat switch contacts, through 831 and 830 Pnk
wires, to terminal B of connector (A-1A) on control module PTO Solenoid Circuit

Continued on next page OUMX258,0000C14 -19-04JUN14-1/5

TM130419 (24FEB16) 230-10-9 030916

PN=681
 Theory of Operation, Non-T4

With the PTO circuit latched and the PTO switch at

• terminal F to the control module (A1) connector (A-1A),
terminal C through 320 Blu wire. Current continues
the ENGAGED position, current is now allowed to flow through the control module (A1) out connector (A-1A),
through 770 Pur wire, to PTO solenoid (Y1), energizing terminal E to key switch (S1) through 195 Blk wire.
the solenoid. When the key switch is in the START position, current
PTO Shutdown Relay Circuit continues to ground through 190, 110 and 100 Blk wires.

The coil of PTO shutdown relay (K4) is provided a ground When the path to ground for the coil of PTO shutdown
through 360 Org and 315 Grn wires to diode pack (V1), relay (K4) is completed as previously stated, the relay
terminal C. The diode pack allows current to continue out is energized. With the shutdown relay energized, the
to ground from any of the remaining terminals as follows: normally closed contacts of the relay are now open,
causing current to stop flowing to the coil of PTO relay
• terminal B to the engine oil pressure switch (B2) through (K3). This de-energizes the PTO relay, which stops current
626 and 625 Tan wires. When the engine oil pressure is flow to the PTO solenoid, thus stopping the PTO system.
below a safe operating pressure, the engine oil pressure
switch closes and completes the ground circuit. With diode pack terminal F grounded by the key switch
• terminal D to the hydraulic oil temperature switch to energize PTO shutdown relay (K4), current also flows
(B3A) through 526 and 525 Blu wires. When the from the Instrument Cluster (A100) to diode pack (V1):
hydraulic oil temperature rises above a safe operating
temperature, the hydraulic oil temperature switch closes
• Engine coolant temperature light - 311 Org wire.
and completes the ground circuit through 121, 124 and
• Engine oil pressure light - 626 Tan wire.
100 Blk wires.
• Hydraulic oil temperature light - 526 Blu wire.
• terminal E to the engine coolant temperature switch This provides an instrument cluster light check when the
(B1) through 311 and 310 Org wires. When the key switch is in the START position.
engine coolant temperature exceeds 110° C (230°
F), the engine coolant temperature switch closes and
completes the ground circuit.

Continued on next page OUMX258,0000C14 -19-04JUN14-2/5

TM130419 (24FEB16) 230-10-10 030916

PN=682
 Theory of Operation, Non-T4

Operator Presence and PTO Interlock

Schematic (1 of 3)

S1 A1
Key Switch Control Module A1A
A 743 Pur
195 Blk
S2 S1
190 Blk F4 B 830 Pnk
A1B 15A C 320 Blu
B A 1 F3 D 748 Pur
242 Red 400 Yel 400 Yel A 15A E 195 Blk
B
3 H2 F 788 Pur
M G 402 Yel C
4
G
D PTO H 640 Grn
5 (Grn)
750 Pur E
Start F 6 K1
Run
Off K2 K3
Start
Relay
1
1
Sp-1 Sp-3 2
125 Blk
H1 Hold-In PTO
A1C Hold-In Relay Relay
(Red)

650 Grn
630 Grn
240 Red

190 Blk
2
1 Sp-8 A2
Engine Preheat Timer
230 Red

EF1 Power
Fuse A
Control Fuel
Holder B
Logic C 630 Grn
Gnd
M-1A Pre-heat
D 109 Blk
80A E
Wait Light
B A
Hold In Signal
F

290 Red
102 Blk GT-1A
GT-1 GT-2
Y2
Hold
Fuel Pull-In
A 650 Grn
B
Gnd
GT-2A M Solenoid C 101 Blk

G1 Battery
M1
Starter Motor
125 Blk

1 5
112 Blk

101 Blk
2 6 109 Blk
100 Blk 1 2
124 Blk
TCT007273 —UN—03APR13

3 7
W2
4 8 122 Blk
Sp-5
Sp-6
110 Blk
1 2

A1—Control Module 1— Unswitched Power 4— PTO Shutdown Circuit 7— PTO

A2—Engine Preheat Timer 2— Switched Power 5— PTO Brake Circuit 8— Fuel Hold-In Circuit
S1— Key Switch 3— Operator Present Circuit 6— PTO Interlock Circuit
Y2— Fuel Solenoid
Continued on next page OUMX258,0000C14 -19-04JUN14-3/5

TM130419 (24FEB16) 230-10-11 030916

PN=683
 Theory of Operation, Non-T4

Operator Presence and PTO Interlock

Schematic (2 of 3)

402 Yel
750 Pur K4
PTO Shutdown
85 86
360 Org 430 Yel
30 87
760 Pur 87a
700 Pur
748 Pur

412 Yel
402 Yel
S3

411 Yel
410 Yel
PTO Switch
3
410 Yel 9 748 Pur
752 Pur
760 Pur 1 Sp-2
1 4 2
750 Pur 770 Pur

112 Blk
7
On

403 Yel
430 Yel
Off

S4
Brake Switch
A
743 Pur C
752 Pur
B D
788 Pur 700 Pur
Off 121 Blk
On
S2
Seat Switch
Off Seat
On Seat

411 Yel A
830 Pnk 831 Pnk B

112 Blk
320 Blu

Y1 S7
PTO Solenoid Cruise Control
771 Gry Brake
A 770 Pur
B 120 Blk A
121 Blk

831 Pnk B
830 Pnk
Off
Sp-12 1 On
124 Blk 2

1 5
V2 2 6
Diode Pack
TCT007274 —UN—03APR13

Sp-11
3 7
115 Blk A
122 Blk
1 2
111 Blk
116 Blk
B
C
4 8
D
771 Gry E
F

K4—PTO Shutdown Relay S7— Cruise Control Brake Switch 3— Operator Present Circuit 6— PTO Interlock Circuit
S2— Seat Switch V2— Diode Pack 4— PTO Shutdown Circuit 7— PTO
S3— PTO Switch Y1— PTO Solenoid 5— PTO Brake Circuit
S4— Brake Switch 2— Switched Power
Continued on next page OUMX258,0000C14 -19-04JUN14-4/5

TM130419 (24FEB16) 230-10-12 030916

PN=684
 Theory of Operation, Non-T4

Operator Presence and PTO Interlock

Schematic (3 of 3)
360 Org
A100
C100 Instrument Cluster
412 Yel 412 Yel A 12V-16V DC
B Service
C Preheater
112 Blk 112 Blk D Ground
625 Tan E Engine Oil Pressure
310 Org F Engine Temperature
G Battery Discharge
B2 525 Blu H Hydraulic Temperature
Engine Oil
Pressure Switch
H7
625 Tan Buzzer
626 Tan
P
403 Yel A
360 Org B
315 Grn

B3A
Hydraulic
Oil Temperature
T

B 121 Blk
A 525 Blu
526 Blu

403 Yel
121 Blk

B1 V1
Coolant Diode Pack
A
Temperature Switch 626 Tan B
315 Grn C
310 Org 526 Blu D
311 Org 311 Org E
T 320 Blu F

320 Blu

1 5
2 6 TCT007275 —UN—03APR13

3 7
4 8

A100— Instrument Cluster B2—Engine Oil Pressure Switch H7—Buzzer 7— PTO

B1—Coolant Temperature Switch B3A— Hydraulic Oil Temperature V1— Diode Pack
Switch 2— Switched Power
4— PTO Shutdown Circuit
OUMX258,0000C14 -19-04JUN14-5/5

TM130419 (24FEB16) 230-10-13 030916

PN=685
 Theory of Operation, Non-T4

Engine Oil Pressure Light and Buzzer Circuit fuse (F3), current flows through 402 and 412 Yel wires to
Operation, Non-T4 the instrument cluster (A100) engine oil pressure light.
The current flows through the engine oil pressure light,
Function: through 625 Tan wire then through the closed contacts of
engine oil pressure switch (B2) to ground, causing the
To warn the operator if the engine oil pressure drops engine oil pressure light to come on.
below the safe operating level.
Current from fuse (F3) also flows to buzzer (H7) through
Operating Conditions: 403 Yel wire. The current flows through the buzzer and
315 Grn wire to diode pack (V1) terminal C. From the
• Key switch in RUN position. diode pack, current flows through 626 Tan wire to the
• Engine RUNNING. engine oil pressure switch (B2), through the switch and
Theory of Operation: then to ground, activating the buzzer.

The engine oil pressure light and buzzer circuit is With engine oil pressure switch (B2) closed, current also
controlled by engine oil pressure switch (B2). When flows from diode pack (V1) terminal C through 315 Grn
engine oil pressure is below the safe operating level, the and 360 Org wires to PTO shutdown relay (K4) coil. This
engine oil pressure switch will provide a path to ground for prevents the PTO system from operating. (See Operator
the instrument cluster (A100) engine oil pressure light and Presence and PTO Interlock Circuit Operation, Non-T4.)
buzzer (H7). Protection for the engine oil pressure light When the engine oil pressure rises to a safe operating
circuit is provided by fuse (F3). level, such as when the engine is initially started, the
When key switch (S1) is in the RUN position and engine oil contacts of the engine oil pressure switch open, causing
pressure is low, current flows from the positive (+) terminal the engine oil pressure light to go off and the buzzer to
of battery (G1), through fuse (EF1), through 230, 240 and de-activate.
242 Red wires to terminal B of the key switch (S1).
The current flows out terminal A of key switch (S1),
through 400 Yel wire to the control module fuse (F3). From

Continued on next page OUMX258,0000C15 -19-04JUN14-1/2

TM130419 (24FEB16) 230-10-14 030916

PN=686
 Theory of Operation, Non-T4

Engine Oil Pressure Circuit Schematic

K4 A100
PTO Shutdown Instrument Cluster
85 86 412 Yel A 12V-16V DC
360 Org 430 Yel B Service
30 87 C Preheater
87a 112 Blk D Ground
625 Tan E Engine Oil Pressure
F Engine Temperature
G Battery Discharge
2 Sp-2 H Hydraulic Temperature
402 Yel
1
C100

S1
Key Switch A1
S2 S1
Control Module
A1B
B A
400 Yel A 1 F3
242 Red 15A
B
3
M G 402 Yel C
4
D
Start
E 5
6
H7
F
1
Sp-1 Run Buzzer
Off
403 Yel A
360 Org B
240 Red

315 Grn

B2
Engine Oil V1
2
1 Sp-8 Pressure Switch Diode Pack
625 Tan A
230 Red

EF-1 T-40
626 Tan 626 Tan B
P 315 Grn C
Fuse D
E
Holder F

M-1A
80A
B A
112 Blk

290 Red
102 Blk GT-1A
GT-1 GT-2
2
1 Sp-6

GT-2A M
110 Blk

G1 Battery

TCT007276 —UN—27DEC13
1
M1
Starter Motor 2
100 Blk 1 2 3
T-35
W2 Sp-5
4

A100— Instrument Cluster K4—PTO Shutdown Relay 2— Switched Power Circuit

B2—Engine Oil Pressure Switch S1— Key Switch 3— PTO Shutdown Circuit
H7—Buzzer V1— Diode Pack 4— Engine Oil Pressure Circuit
1— Unswitched Power Circuit
OUMX258,0000C15 -19-04JUN14-2/2

TM130419 (24FEB16) 230-10-15 030916

PN=687
 Theory of Operation, Non-T4

Engine Coolant Temperature Light and • Switched power fuse (F3)

Buzzer Circuit Operation, Non-T4 • Instrument cluster preheat wait light (412 Yel wire)
Function: • Instrument cluster engine coolant temperature light
(412 Yel wire)
To warn the operator if the engine coolant temperature • Buzzer (H7) (403 Yel wire)
exceeds the safe operating level. When the coolant temperature exceeds 110°C (230°F),
Operating Conditions: the engine coolant temperature switch (B1) closes and
completes the circuit to ground (310 Org wire), causing the
• Key switch in RUN position. coolant temperature light to come on. The engine coolant
• Engine RUNNING. temperature switch also completes the buzzer (H7) ground
• Engine coolant temperature greater than 110°C (230°F). circuit (310 Org wire), causing the buzzer to come on.
Diode pack (V1) is used to isolate the coolant temperature
Theory of Operation: light from other circuits that turn on the buzzer.
The engine coolant temperature light circuit is controlled With engine coolant temperature switch (B1) closed,
by engine coolant temperature switch (B1). The switch current also flows from diode pack (V1) terminal C through
is located in the base of the engine thermostat housing 315 Grn and 360 Org wires to PTO shutdown relay (K4)
where it senses the engine coolant temperature. coil. This prevents the PTO system from operating. (See
Operator Presence and PTO Interlock Circuit Operation,
Protection for the engine coolant temperature light circuit
Non-T4.)
is provided by fuse (EF-1) and 15 Amp switched power
fuse (F3).
When the key switch (S1) is in the RUN position voltage is
available from key switch terminal A through wire 400 Yel
to the following:

Continued on next page OUMX258,0000C16 -19-06APR15-1/2

TM130419 (24FEB16) 230-10-16 030916

PN=688
 Theory of Operation, Non-T4

Engine Coolant Circuit Schematic

K4 A100
PTO Shutdown Instrument Cluster
85 86 412 Yel A 12V-16V DC
360 Org 430 Yel B Service
30 87 C Preheater
87a 112 Blk D Ground
E Engine Oil Pressure
310 Org F Engine Temperature
G Battery Discharge
2 Sp-2 H Hydraulic Temperature
402 Yel
1
C100

S1
Key Switch A1
S2 S1
Control Module
A1B
B A
400 Yel A 1 F3
242 Red 15A
B
3
M G 402 Yel C
4
D
Start
E 5
6
H7
F
1
Sp-1 Run Buzzer
Off
403 Yel A
360 Org B
240 Red

315 Grn

2
B1 V1
1 Sp-8 Diode Pack
Coolant
A
230 Red

EF-1 Temperature Switch B

315 Grn C
Fuse 310 Org D
311 Org 311 Org E
Holder T T-39 F
M-1A
80A
B A
112 Blk

290 Red
102 Blk GT-1A
GT-1 GT-2
2
1 Sp-6

GT-2A M
110 Blk

G1 Battery

TCT007277 —UN—27DEC13
1
M1
Starter Motor 2
100 Blk 1 2 3
T-35
W2 Sp-5
4

A100— Instrument Cluster K4—PTO Shutdown Relay 2— Switched Power Circuit

B1—Coolant Temperature Switch S1— Key Switch 3— PTO Shutdown Circuit
H7—Buzzer V1— Diode Pack 4— Engine Coolant Temperature
1— Unswitched Power Circuit Circuit
OUMX258,0000C16 -19-06APR15-2/2

TM130419 (24FEB16) 230-10-17 030916

PN=689
 Theory of Operation, Non-T4

Hydraulic Oil Temperature Light Circuit • Switched power fuse (F3)

Operation, Non-T4 • Instrument cluster preheat wait light (412 Yel wire)
Function: • Instrument cluster hydraulic oil temperature light (412
Yel wire)
To warn the operator if the hydraulic oil temperature • Buzzer (H7) (403 Yel wire)
exceeds the safe operating level. With hydraulic oil temperature switch (B63A) closed,
Operating Conditions: current also flows from diode pack (V1) terminal C through
315 Grn and 360 Org wires to PTO shutdown relay (K4)
• Key switch in RUN position. coil. This prevents the PTO system from operating.
• Engine RUNNING. When the hydraulic oil temperature exceeds 101—108°
• Hydraulic oil temperature greater than 101—108° C C (214—226° F), the hydraulic oil temperature switch
(214—226° F).
(B3A) closes and completes the circuit to ground through
Theory of Operation: 525 Blu wire, causing the instrument cluster hydraulic oil
temperature light to come on.
The hydraulic oil temperature light circuit is controlled by
hydraulic oil temperature switch (B3A). Ground is provided to the hydraulic oil temperature switch
through 121, 124 and 100 Blk wires.
Protection for the hydraulic oil temperature light circuit
is provided by fuse (EF1) and 15 amp switched power The hydraulic oil temperature switch also completes the
fuse (F3). buzzer (H7) ground circuit (315 Grn, V1 diode pack, and
526 Blu wire), causing the buzzer to come on. Diode pack
When the key switch (S1) is in the RUN position voltage is (V1) is used to isolate the hydraulic oil temperature light
available from key switch terminal A through wire 400 Yel from other circuits that turn on the buzzer.
to the following:

Continued on next page OUMX258,0000C18 -19-04JUN14-1/2

TM130419 (24FEB16) 230-10-18 030916

PN=690
 Theory of Operation, Non-T4

Hydraulic Oil Temperature Circuit Schematic

K4 A100
PTO Shutdown Instrument Cluster
85 86 412 Yel A 12V-16V DC
360 Org 430 Yel B Service
30 87 C Preheater
87a 112 Blk D Ground
E Engine Oil Pressure
F Engine Temperature
G Battery Discharge
2 Sp-2 525 Blu H Hydraulic Temperature
402 Yel
1
C100

S1
Key Switch A1
S2 S1
Control Module
A1B
B A
400 Yel A 1 F3
242 Red 15A
B
3
M G 402 Yel C
4
D
Start
E 5
6
H7
F
1
Sp-1 Run Buzzer
Off
403 Yel A
360 Org B
240 Red

315 Grn

B3A
Hydraulic
2 Oil Temperature V1
1 Sp-8 T Diode Pack
A
230 Red

EF-1 B
A
121 Blk B
525 Blu 315 Grn C
Fuse 526 Blu 526 Blu D
E
Holder F

M-1A
121 Blk

80A
B A
112 Blk

290 Red
102 Blk GT-1A 1
GT-1 Sp-12 2
GT-2
2
1 Sp-6
124 Blk

GT-2A M
110 Blk

G1 Battery

TCT007278 —UN—27DEC13
1
M1
Starter Motor 2
100 Blk 1 2 3
T-35
W2 Sp-5 4

A100— Instrument Cluster H7—Buzzer 1— Unswitched Power Circuit 4— Hydraulic Oil Temperature
B3A— Hydraulic Oil Temperature K4—PTO Shutdown Relay 2— Switched Power Circuit Circuit
Switch S1— Key Switch 3— PTO Shutdown Circuit
V1— Diode Pack
OUMX258,0000C18 -19-04JUN14-2/2

TM130419 (24FEB16) 230-10-19 030916

PN=691
 Theory of Operation, Non-T4

Cold Start Operation, Non-T4 wire to terminal F of the preheat timer module. Initially,
the preheat timer module allows the current to flow to
Function: controlled ground, which causes the wait light to come
To preheat the air entering the engine combustion on.
chamber to allow for easier starting during cold weather. • 409 Yel wire to the coil of air heater relay (K6). The
current flows through the relay, through 350 Org
Also, to provide a means to let the operator know that the wire, to terminal E of the diesel engine preheat timer
cold start system is activated. module. Initially, the module allows the current to flow to
controlled ground, thus energizing the cold start relay.
Operating Conditions:
With the cold start relay energized, unswitched battery
• Key switch in RUN or START position. current from fuse (EF-1) is allowed to flow across the
relay contacts and the 900 Wht wire to the air heater or
Theory of Operation: glow plugs (R1).
When starting a diesel engine when the ambient At the same time, current from fuse (F3) flows to control
temperature is below 5° C (40° F), compression module hold-in relay (K2). When the operator presence or
temperature alone may not provide enough heat to ignite PTO interlock circuits energize the hold-in relay through
the air/fuel mixture. Because of this, an air heater or glow connector A1A, terminal A, current from fuse (F3) is
plugs are installed to provide added heat to the incoming allowed to flow across the contacts of the hold-in relay,
combustion air. through 640 Grn and 630 Grn wires, to terminal C of the
The cold start circuit is activated whenever the key is in preheat timer control module.
the START or RUN position. NOTE: For information on how the hold-in circuit
Protection for engine air preheat circuit is provided by fuse operates, see Operator Presence and PTO Interlock
(EF-1) and 15 amp switched power fuse (F3). Circuit Operation in this group.

NOTE: Fuse (F3) is located on control module (A1). Hold-in relay (K2) is located on control module (A1).

Turning key switch (S1) to the RUN or START position Current at terminal A of the diesel engine preheat timer
allows current from the positive (+) terminal of battery module (A2) enables a timer circuit within the module.
(G1) to flow through fuse (EF-1), 230, 240 and 242 Red After approximately 16 seconds has elapsed from the time
wire, to terminal B of the key switch. The current flows current began to flow to terminal A, the control module will
out terminal A of the key switch, through 400 Yel wire break the path to ground, causing the wait light to go off.
to switched power fuse (F3) in the control module (A1), The moment the wait light goes off indicates the minimum
connector A-1B, terminal A. amount of time has elapsed to allow the engine intake air
temperature to rise sufficiently for engine start.
From fuse (F3), current flows through the following:
After approximately 30 seconds has elapsed from the time
• 402 Yel wire to splice 2. current began to flow to terminal A, the control module will
• 406 Yel wire to terminal A of the diesel engine preheat break the cold start relay's path to ground, causing the
timer module (A2), to provide power for the module. relay to de-energize and stop current to the air heater or
• 412 Yel wire to instrument panel (A100) preheat light. glow plugs.
From the preheat light, current flows through 330 Grn

Continued on next page OUMX258,0000C19 -19-04JUN14-1/2

TM130419 (24FEB16) 230-10-20 030916

PN=692
 Theory of Operation, Non-T4

Cold Start Circuit Schematic

S1 A1
Key Switch Control Module A1A
S1
A 743 Pur
S2
B
C
B A
A1B F3 D
1
242 Red 400 Yel A 15A E
B F
3
M G 402 Yel C
4 K2 G
D
5
H 640 Grn
E
Start F 6
Run 1
Sp-3 2
Off
H1 Hold-In
Hold-In Relay
(Red)

630 Grn
A100
Instrument Cluster
412 Yel A 12V-16V DC
B Service
402 Yel 330 Grn C Preheater
112 Blk D Ground
1 Sp-2 E Engine Oil Pressure
2 F Engine Temperature
G Battery Discharge
H Hydraulic Temperature
242 Red

409 Yel
406 Yel

C100

330 Grn

406 Yel
1 Sp-1 350 Org
A2
Engine Preheat Timer
240 Red

K6
Air Heater Power

Control Fuel
A 406 Yel
85 86 B
350 Org 409 Yel Logic C 630 Grn
Sp-8 Sp-9 Gnd
D 109 Blk
2 30 87
225 Red 220 Red 900 Wht Pre-heat
E 350 Org
1 1 2 Wait Light
Hold In Signal
F 330 Grn

EF-1
Fuse R1
Glow Plugs
Holder 900 Wht
M-1A
230 Red 80A
B A
Sp-5
290 Red 100 Blk 109 Blk
102 Blk 12
GT-1A T-35 Sp-6
GT-1 GT-2
110 Blk 112 Blk

TCT007279 —UN—27DEC13
GT-2A 12
W2
M 1 4
2 5
G1 Battery
M1 Starter Motor 3

A1—Control Module G1—Battery R1—Glow Plugs 4— Wait Light Circuit

A2—Engine Preheat Timer H1—Hold-In Indicator LED (Red) S1— Key Switch 5— Hold-In Relay Control Circuit
Module K2—Hold-In Relay 1— Unswitched Power Circuit
A100— Instrument Cluster K6—Air Heater Relay 2— Switched Power Circuit
EF-1— Fuse Holder and Fuse M1—Starter Motor 3— Hold-In Signal Circuit
OUMX258,0000C19 -19-04JUN14-2/2

TM130419 (24FEB16) 230-10-21 030916

PN=693
 Theory of Operation, Non-T4

Fuel Shutoff Solenoid Circuit Operation, Both fuse (F3) and hold-in relay (K2) are
Non-T4 located on control module (A1).
Function:
At the same time, current from fuse (F3) also flows
To stop the engine by stopping fuel flow to the injection through 402 Yel and 407 Yel wires, to coil of fuel shutoff
pump. This is accomplished either manually using the key solenoid relay (K5). The current flows through the relay
switch or automatically when the operator rises from the coil, then through 751 Pur wire, to terminal B of diesel
seat for more than one second while PTO is ENGAGED engine preheat timer module (A2). The module allows the
or park brake is UNLOCKED. current to flow to ground, thus energizing the fuel shutoff
solenoid relay.
Operating Conditions:
With the fuel shutoff solenoid relay energized, unswitched
• Key switch in RUN or START position. battery current from fuse (EF1) is allowed to flow across
• Operator on seat, or park brake LOCKED and PTO the relay contacts to the pull-in windings of fuel shutoff
DISENGAGED. solenoid (Y2), thus energizing the pull-in windings. The
energized windings cause the solenoid armature and
Theory of Operation: linkage to move to the ON position.
Protection for the fuel shutoff solenoid circuit is provided After approximately one second, the diesel engine control
by fuse (EF-1) and 15amp switched power fuse (F3). module breaks the fuel shutoff solenoid relay coils path
to ground, de-energizing the relay. The relay contacts
Turning key switch (S1) to the RUN or START position
open, causing the current to stop flowing to the solenoid's
allows current from the positive (+) terminal of battery
pull-in windings.
(G1) to flow through fuse (EF1), 230, 240, and 242 Red
wires to terminal B of the key switch. The current flows Current from the hold-in circuit continues to flow to the
out terminal A of the key switch, through 400 Yel wire to solenoid's hold-in windings. The magnetic field produced
switched power fuse (F3). by this current is sufficient to hold the solenoid armature
in, thus keeping the fuel shutoff linkage at the ON position
As long as the hold-in relay (K2) is energized, current from
and allowing the engine to continue running.
fuse (F3) is allowed to flow through 640 Grn and 650 Grn
wires, to the hold-in windings of fuel shutoff solenoid (Y2), During machine operation, the operator presence circuit
thus energizing the hold-in windings. The magnetic field controls the hold-in power circuit. The operator presence
produced in the hold-in windings is not enough to move circuit contains a built-in capacitor delay (located on A1
the solenoid armature by itself. control module) so if the operator bounces on the seat
during machine operation, the engine will continue to run.
NOTE: For information on how the hold-in circuit
operates, (See Operator Presence and PTO
Interlock Circuit Operation, Non-T4.)

Continued on next page OUMX258,0000C1A -19-04JUN14-1/2

TM130419 (24FEB16) 230-10-22 030916

PN=694
 Theory of Operation, Non-T4

Fuel Shutoff Circuit Schematic

S1 A1
Key Switch Control Module A1A
S1
A 743 Pur
S2
B
C
B A
A1B F3 D
1
242 Red 400 Yel A 15A E
B F
3
M G 402 Yel C
4 K2 G
D
5
H 640 Grn
E
Start F 6
Run 1
Sp-3 2
Off
H1 Hold-In
Hold-In Relay
(Red)
Y2
242 Red

630 Grn
Fuel Shutoff
402 Yel Solenoid
1 Sp-2
2

Hold
409 Yel
406 Yel
1 Sp-1 Pull-In
A 650 Grn
Gnd
B 910 Wht
C 101 Blk
K5
Fuel Pull-In
240 Red

Relay
85 86
751 Pur 407 Yel 406 Yel
30 87
2 210 Red 210 Red 911 Wht 910 Wht
1 1 2
Sp-8 Sp-10

A2
Engine Preheat Timer
Power
EF-1 Control Fuel
A 406 Yel
Fuse B 751 Pur
Logic C 630 Grn
Gnd
Holder Pre-heat
D 109 Blk
Wait Light
E
M-1A F
230 Red 80A Hold In Signal
B A

290 Red 109 Blk

102 Blk GT-1A Sp-5
GT-1 GT-2 100 Blk 110 Blk
12

TCT007280 —UN—27DEC13
T-35
GT-2A
M 1 4
W2
2 5
G1 Battery 3
M1 Starter Motor

A1—Control Module H1—Hold-In Indicator LED (Red) S1— Key Switch 3— Hold-In Signal Circuit
A2—Engine Preheat Timer K2—Hold-In Relay Y2— Fuel Shutoff Solenoid 4— Pull-In Circuit
Module K5—Fuel Pull-In Relay 1— Unswitched Power Circuit 5— Hold-In Relay Control Circuit
EF-1— Fuse Holder and Fuse M1—Starter Motor 2— Switched Power Circuit
G1—Battery
OUMX258,0000C1A -19-04JUN14-2/2

TM130419 (24FEB16) 230-10-23 030916

PN=695
 Theory of Operation, Non-T4

Cruise Control Circuit Operation, Non-T4 current flows through 402 Yel and 411 Yel wires to seat
switch (S2).
Function:
From the seat switch, current flows through 831 Pnk wire,
To provide a means of keeping the speed of the machine across the contacts of cruise control brake switch (S7),
constant without the need of having the operator's foot on then through 832 Pnk wire to cruise control switch (S5).
the forward hydrostatic control pedal.
With the cruise control switch at the momentary engage
The circuit controls an electromagnet that when energized, position, current is allowed through the 837 and 836 Pnk
holds the forward hydrostatic control pedal at the desired wires, to cruise control electromagnet (Y3). The current
position as selected by the operator. flows through the electromagnet, then to ground through
135, 110, and 100 Blk wires, energizing the electromagnet.
Operating Conditions:
Current also flows through 835 Pnk wire to the coil of
• Key switch in RUN position. cruise control relay (K7) coil. The current flows through
• Operator on seat. the relay coil, then to ground through 130, 110, and 100
• Brakes UNLOCKED. Blk wires, energizing the relay.
• Cruise control switch in the ENGAGE or ON positions.
With the cruise control relay energized, the cruise control
Theory of Operation: switch can be released to the ON position. In this position,
NOTE: To engage the cruise control, the cruise current is allowed to flow from cruise control switch,
control switch must be first moved to the engage through 833 Pnk wire, and across the cruise control relay
position to latch the circuit. contacts. From the relay contacts current flows through
834 and 836 Pnk wires to the cruise control electromagnet.
Protection for cruise control circuit is provided by fuse Current also flows from the relay contacts through 835
(EF-1) and the 15 amp switched power fuse (F3) located Pnk wire to the cruise control relay coil completing the
on control module (A1). circuit latch, keeping the electromagnet energized.

When key switch (S1) is in the RUN position, operator on The cruise control will be de-activated should any of the
the seat, brakes UNLOCKED, and cruise control switch following occur:
(S5) moved to the ENGAGE position, current from the • Cruise control switch moved to the OFF position.
positive (+) terminal of battery (G1) is allowed to flow • Brakes are applied (cruise control brake switch moves
through fuse (EF-1), then through 230, 242, and 240 Red to the brakes OFF position).
wires to terminal B of the key switch. • Operator rises from the seat.
The current flows out terminal A of the key switch, through
400 Yel wire to switched power fuse (F3). From fuse (F3),

Continued on next page OUMX258,0000C1B -19-04JUN14-1/2

TM130419 (24FEB16) 230-10-24 030916

PN=696
 Theory of Operation, Non-T4

Cruise Control Circuit Schematic

S1 A1
Key Switch Control Module
A1B
K7
S2 S1
400 Yel A 1 F3 Cruise Control
15A
B
B A
402 Yel C 3 Relay
D 4
E 5 85 86
M G 6
F 835 Pnk 130 Blk
30 87
242 Red

Start 834 Pnk 833 Pnk

Run
Off S2
1 Seat Switch S7
Sp-2
Off Seat Cruise Control Sp-7
1
Sp-1 On Seat 834 Pnk
Brake Switch 840 Gry
1 2
837 Pnk
411 Yel A 836 Pnk
831 Pnk B A
240 Red

B D
831 Pnk 832 Pnk
Off S5
On
Cruise Control
Switch X5
Y3 A 832 Pnk
Cruise Control B
C
833 Pnk
837 Pnk
2
1 Sp-8 Magnet
836 Pnk Engage
835 Pnk A On
230 Red

135 Blk B Off

EF-1
Fuse 2
Sp-6
Holder 1
130 Blk
M-1A
80A
110 Blk

B A

V2
Diode Pack
290 Red Sp-5 Sp-11
2
102 Blk GT-1A 1 122 Blk 115 Blk A
1 2 B

GT-1 GT-2 C
840 Gry D
100 Blk

TCT007281 —UN—27DEC13
F

GT-2A M
T-35
1 4
G1 Battery
M1 2 5
Starter Motor W2 3

A1—Control Module S1— Key Switch 1— Unswitched Power Circuit 5— Cruise Control Circuit
EF-1— Fuse Holder and Fuse S2— Seat Switch 2— Switched Power Circuit
G1—Battery S5— Cruise Control Switch 3— Operator Presence Circuit
K7—Cruise Control Relay S7— Cruise Brake Switch 4— Cruise Control Latching
M1—Starter Motor Y3— Cruise Control Magnet Circuit
OUMX258,0000C1B -19-04JUN14-2/2

TM130419 (24FEB16) 230-10-25 030916

PN=697
 Theory of Operation, Non-T4

TM130419 (24FEB16) 230-10-26 030916

PN=698
 Group 15
Theory of Operation, Tier 4
Summary of References • Engine Oil Pressure Circuit Operation, T4
• Unswitched Power Circuit Operation, T4 • Engine Coolant Temperature Circuit Operation, T4
• Hydraulic Oil Temperature Circuit Operation, T4
• Switched Power Circuit Operation, T4 • Cold Start Circuit Operation, T4
• Cranking Circuit Operation, T4 • Cruise Control Circuit Operation, T4
• Charging Circuit Operation, T4 • CAN Bus
• Operator Presence and PTO Interlock Circuit Operation,
T4
CB12260,0000037 -19-24JUL14-1/1

TM130419 (24FEB16) 230-15-1 030916

PN=699
 Theory of Operation, Tier 4

Unswitched Power Circuit Operation, T4 • K3 Start relay pin 30

• K11 Cab power relay pin 30
Function: • C12 Cab power connector, pin 3
Provides unswitched power to the primary components • C15 Fuse holder pin 1 and 2, 3 and 4, 5 and 6, 7 and 8
whenever the battery is connected. • Splices Sp-1, Sp-2, and Sp-15
• ECU pins 1, 3, and 5
Operating Conditions: • C14 Power outlet connector
• C12 Cab power connector
• Battery connected. The battery cables and the starter motor connections
• Key switch in OFF position. must be in good condition for the electrical system to
Theory of Operation function properly.
Voltage must be present at the following components with The ground cable connects from the negative (—)
the key switch in the STOP position: battery terminal to the engine ground (W1). The ground
connection is equally important as the positive (+)
• Battery (G1) positive (+) terminal cable. The starter motor depends on these cables and
• Battery terminal GT-1A of starter motor connections to carry the high current necessary for
• Fuse holder (EF1) operation.
• G-2B of alternator (G2)
• VCU pin L1 The components are all protected by the EF1 80 Amp fuse.
• S23 key switch pin B NOTE: The 2xx series Red wires are dedicated to
• K1 Glow plug relay the unswitched power circuits.
• K2 EGR valve relay pin 30

Continued on next page CB12260,000062E -19-19MAR15-1/4

TM130419 (24FEB16) 230-15-2 030916

PN=700
 Theory of Operation, Tier 4

Engine Control
Unit (ECU) 37 550 Yel 550 Yel

Switched +12V 88 513 Yel

VB 1 213 Red
VB 3 214 Red
VB 5 215 Red

525 Yel
S2 S1
599 Yel
Sp-13
B A
242 Red 525 Yel
M G 500 Yel

Start
Run
Off
Vehicle Control
Unit (VCU) S23
Key Switch 220 Red
VBAT Unswitched L1 208 Red

+12V Switched M1 240 Red

514 Yel

212 Red
Sp-6

2 1
242 Red 20A 203 Red 230 Red
Keyswitch Sp-1
4 3
211 Red 25A 205 Red
C14 ECU

TCT009604 —UN—26DEC13
6 5
A 492 Red 10A 241 Red 225 Red
B Sp-3
Aux Power
8 7
208 Red 15A 209 Red
1 VCU
2

ECU—Engine Control Unit S23— Key Switch 2— Switched Power

VCU—Vehicle Control Unit 1— Unswitched Power
Continued on next page CB12260,000062E -19-19MAR15-2/4

TM130419 (24FEB16) 230-15-3 030916

PN=701
 Theory of Operation, Tier 4

Unswitched Power Schematic, T4 (2 of 3)

Headlights
501 Yel 1 +12V
2 Gnd 553 Yel
3 Backlight A20 A
B
4 J1939+ PDU S17
5 J1939- S37 C38
6 Output (SWG) Seat Switch Headlights Switch
Off Seat
C17 On Seat 4
5
510 Yel A 3
B 1
551 Yel
2
550 Yel
501 Yel
Sp-2 551 Yel
500 Yel 506 Yel
518 Yel 510 Yel
507 Yel 516 Yel 516 Yel
530 Yel Service
A
502 Yel B

C41 C
A D
C A E
B B F
C7
A
D C40 G
S7 B Off
H
J
Cruise Control C On

Switch S25 C24

Engage
On Park Brake Switch
Off
220 Red 220 Red

212 Red

240 Red 240 Red

C12
Cab Power G-2B G-2A
1 200 Red
212 Red 2
G
A
B

3 202 Red EF1 G2

3
4
T-8 Fuse Alternator
5
Sp-15 6 200 Red 80A
230 Red 201 Red B A
T-4

GT-1A M-1B
G1

TCT012427 —UN—19MAR15
225 Red M1
Battery
M Starter Motor
1
2

A20— PDU G1—Battery S17— Seat Switch 1— Unswitched Power

C12— Cab Power Connector G2—Alternator S25— Park Brake Switch 2— Switched Power
C24— Service Connector M1—Starter Motor S37— Headlights Switch
EF1— Fuse, 80A S7— Cruise Control Switch
Continued on next page CB12260,000062E -19-19MAR15-3/4

TM130419 (24FEB16) 230-15-4 030916

PN=702
 Theory of Operation, Tier 4

Unswitched Power Schematic, T4 (3 of 3)

S21
PTO Switch
7 9

3
2
516 Yel 1
5 6
4
8 10
On
Off K2 K3 K11
EGR Valve Relay Start Relay Cab Power Relay
85 86 85 86 85 86
30 87 30 87 30 87
87a 207 Red 87a
212 Red

K1

243 Red
Glow Plug Relay
85 86

220 Red 30 87
87a 207 Red Sp-4

212 Red

240 Red 240 Red

TCT009606 —UN—26DEC13
1
2

K1—Glow Plug Relay K3—Start Relay S21— PTO Switch 2— Switched Power
K2—EGR Valve Relay K11— Cab Power Relay 1— Unswitched Power
CB12260,000062E -19-19MAR15-4/4

TM130419 (24FEB16) 230-15-5 030916

PN=703
 Theory of Operation, Tier 4

Switched Power Circuit Operation, T4 • S23 key switch pins A and S2

Function: • S21 PTO switch
• Splices Sp-13, and Sp-2
Provides power to the primary components when the key • C7 cruise control switch connector
switch is in the RUN position. • VCU pin M1
• S25 brake switch
Operating Conditions: • S37 headlight switch
• Battery Connected • C40 and C41 connectors
• Key switch in RUN position • ECU connector ECU-1, pin 37
• ECU connector ECU-1, pin 88
Theory of Operation: • S17 seat switch
• G2 alternator, G-2A connector
NOTE: The 5xx series Yel wires are dedicated to • C24 Service connector
the switched power circuits.

Voltage must be present at the following components with

the key switch in the RUN position:

Continued on next page CB12260,000062F -19-19MAR15-1/4

TM130419 (24FEB16) 230-15-6 030916

PN=704
 Theory of Operation, Tier 4

Engine Control
Unit (ECU) 37 550 Yel 550 Yel

Switched +12V 88 513 Yel

VB 1 213 Red
VB 3 214 Red
VB 5 215 Red

525 Yel
S2 S1
599 Yel
Sp-13
B A
242 Red 525 Yel
M G 500 Yel

Start
Run
Off
Vehicle Control
Unit (VCU) S23
Key Switch 220 Red
VBAT Unswitched L1 208 Red

+12V Switched M1 240 Red

514 Yel

212 Red
Sp-6

2 1
242 Red 20A 203 Red 230 Red
Keyswitch Sp-1
4 3
211 Red 25A 205 Red
C14 ECU

TCT009604 —UN—26DEC13
6 5
A 492 Red 10A 241 Red 225 Red
B Sp-3
Aux Power
8 7
208 Red 15A 209 Red
1 VCU
2

ECU—Engine Control Unit S23— Key Switch 2— Switched Power

VCU—Vehicle Control Unit 1— Unswitched Power
Continued on next page CB12260,000062F -19-19MAR15-2/4

TM130419 (24FEB16) 230-15-7 030916

PN=705
 Theory of Operation, Tier 4

Switched Power Schematic, T4 (2 of 3)

Headlights
501 Yel 1 +12V
2 Gnd 553 Yel
3 Backlight A20 A
B
4 J1939+ PDU S17
5 J1939- S37 C38
6 Output (SWG) Seat Switch Headlights Switch
Off Seat
C17 On Seat 4
5
510 Yel A 3
B 1
551 Yel
2
550 Yel
501 Yel
Sp-2 551 Yel
500 Yel 506 Yel
518 Yel 510 Yel
507 Yel 516 Yel 516 Yel
530 Yel Service
A
502 Yel B

C41 C
A D
C A E
B B F
C7
A
D C40 G
S7 B Off
H
J
Cruise Control C On

Switch S25 C24

Engage
On Park Brake Switch
Off
220 Red 220 Red

212 Red

240 Red 240 Red

C12
Cab Power G-2B G-2A
1 200 Red
212 Red 2
G
A
B

3 202 Red EF1 G2

3
4
T-8 Fuse Alternator
5
Sp-15 6 200 Red 80A
230 Red 201 Red B A
T-4

GT-1A M-1B
G1

TCT012427 —UN—19MAR15
225 Red M1
Battery
M Starter Motor
1
2

A20— PDU G1—Battery S17— Seat Switch 1— Unswitched Power

C12— Cab Power Connector G2—Alternator S25— Park Brake Switch 2— Switched Power
C24— Service Connector M1—Starter Motor S37— Headlights Switch
EF1— Fuse, 80A S7— Cruise Control Switch
Continued on next page CB12260,000062F -19-19MAR15-3/4

TM130419 (24FEB16) 230-15-8 030916

PN=706
 Theory of Operation, Tier 4

Switched Power Schematic, T4 (3 of 3)

S21
PTO Switch
7 9

3
2
516 Yel 1
5 6
4
8 10
On
Off K2 K3 K11
EGR Valve Relay Start Relay Cab Power Relay
85 86 85 86 85 86
30 87 30 87 30 87
87a 207 Red 87a
212 Red

K1

243 Red
Glow Plug Relay
85 86

220 Red 30 87
87a 207 Red Sp-4

212 Red

240 Red 240 Red

TCT009606 —UN—26DEC13
1
2

K1—Glow Plug Relay K3—Start Relay S21— PTO Switch 2— Switched Power
K2—EGR Valve Relay K11— Cab Power Relay 1— Unswitched Power
CB12260,000062F -19-19MAR15-4/4

TM130419 (24FEB16) 230-15-9 030916

PN=707
 Theory of Operation, Tier 4

Cranking Circuit Operation, T4 Theory of Operation

Function
The power circuit provides power to the key switch.
To energize the starting motor solenoid and engage the With the key switch in the start position, switched power
starting motor. flows from the key switch to the Engine Control Unit
(ECU), Vehicle Control Unit (VCU), and Primary Display
Operating Conditions Unit (PDU) as well as the park brake switch. When the
controllers determine that operating conditions are met,
To crank the engine, the following conditions must be met:
a message is transmitted over the CAN bus to the ECU.
• Park brake set The ECU then sends battery voltage out over the 706 Pur
• Key switch in start position wire to the starter relay, causing its contacts to close and
• Engine not running (RPM limit for starter to engage) energize the starter solenoid. This engages the starting
motor and cranks the engine.
NOTE: There must be no pressure in the hydraulic
system in order to engage the park brake.

NOTE: If PTO is on while attempting to crank, the

engine will start, but internal logic will not
allow PTO operation.

Continued on next page CB12260,000002D -19-04JUN14-1/3

TM130419 (24FEB16) 230-15-10 030916

PN=708
 Theory of Operation, Tier 4

Vehicle Control
Unit (VCU)
Start Input (Open/VBat) 704 Pur

Brake Switch Input (Open/VBat) 708 Pur 708 Pur

VBAT Unswitched L1 208 Red

+12V Switched M1 514 Yel
C
A
Switched +12V 513 Yel Sp-13
N
Starter Permission 1 (LSD) 707 Pur
Start Relay 706 Pur 706 Pur
VBat 213 Red
Engine Control
VBat 214 Red Sp-6
Unit (ECU) VBat 215 Red
Start - Key Switch In 709 Pur Sp-9
Engine Start Request 0.5A 710 Pur Sp-14

2 1

703 Pur
242 Red 20A 203 Red
Keyswitch
4 3
211 Red 25A 205 Red
ECU
6 5
10A
Aux Power
8 7
208 Red 15A 209 Red
VCU
C15
525 Yel
S2 S1
599 Yel
B A
242 Red 525 Yel
M G 500 Yel
203 Red

Start S23
Run
Off Key Switch
705 Pur
Sp-3
240 Red 207 Red
201 Red T-4 80A
230 Red 201 Red B A
747 Pur
Sp-1 Sp-15
1 M-1B

TCT009607 —UN—24JUN14
GT-1A
2
G1
3 M1
M Starter Motor
4

C15— Fuse Block G1—Battery 1— Unswitched Power 4— Start Output

CAN—Controller Area Network M1—Starter Motor 2— Switched Power
ECU—Engine Control Unit S23— Key Switch 3— Secondary Switch Power
VCU—Vehicle Control Unit
Continued on next page CB12260,000002D -19-04JUN14-2/3

TM130419 (24FEB16) 230-15-11 030916

PN=709
 Theory of Operation, Tier 4

708 Pur

706 Pur
706 Pur

S25
Park Brake Switch
A
500 Yel 507 Yel C
Sp-2 B 708 Pur
K3 D
Start Relay Off
On
85 86
705 Pur
30 87
207 Red 87a

747 Pur

TCT009608 —UN—24DEC13
1
2
3
4

K3—Start Relay 1— Unswitched Power 3— Secondary Switch Power

S25— Park Brake Switch 2— Switched Power 4— Start Output
CB12260,000002D -19-04JUN14-3/3

TM130419 (24FEB16) 230-15-12 030916

PN=710
 Theory of Operation, Tier 4

Charging Circuit Operation, T4 in the alternator. The rotating magnetic field induces
alternating current in the stator coils. The rectifier converts
Function: this alternating current into the direct current to charge the
To maintain battery voltage between 12.4 volts DC and battery. Current is supplied to the battery via the 200 Red
15 volts DC. wire through the EF-1 80A fuse and the positive battery
cable.
Operating Conditions:
A fully charged battery signals the regulator to turn off the
The key switch must be in the run position, with the engine field windings, stopping the charge current.
running, for the charging system to operate.
The alternator is grounded to the frame through the 100
Theory of Operation: series Blk wires.
The main charging system components are the battery, With the engine running, a rotating permanent magnet
alternator, and the internal voltage regulator/rectifier. The in the alternator induces AC current in the alternator
regulator/rectifier controls the charging output. The status stator coils. The AC current flows to the voltage
of the charge rate is indicated by the discharge indicator regulator/rectifier. The voltage regulator/rectifier converts
on the display panel based on system voltage. The 600 AC current to DC current needed to charge the battery.
Brn wire initially sends discharge information to the Engine
Control Unit (ECU). Charging information is transmitted If the voltage on the sensing circuit falls below system
via the CAN bus to the Primary Display Unit (PDU). usage or is insufficient to maintain a preset voltage, the
display panel senses the lowered voltage and turns on
When the voltage regulator detects lower-than-normal the discharge indicator.
system voltage, it energizes the rotating windings (field)

Continued on next page CB12260,000002E -19-19MAR15-1/3

TM130419 (24FEB16) 230-15-13 030916

PN=711
 Theory of Operation, Tier 4

C28 B
CAN1H 54 F250 Yel 121
CAN1L 76 F150 Grn R5606
X5058 A
CAN2L 53 F107 Grn F107 Grn
CAN2H 75 F207 Yel F207 Yel

Discharge 66 600 Brn 600 Brn

Switched +12V 88 513 Yel
VB 1 213 Red
Engine Control VB 3 214 Red
VB 5 S23
Unit (ECU) 215 Red
Key Switch
S2 S1

Sp-13 B A
242 Red 500 Yel
M G

Start
Run
Vehicle Control Off
Unit (VCU)

VBAT Unswitched L1 208 Red

+12V Switched M1 514 Yel

Sp-6
C15
2 1
242 Red 20A 203 Red 230 Red
Keyswitch Sp-1
4 3
211 Red 25A

TCT009609 —UN—26DEC13
ECU
6 5
1 10A
Aux Power
2 8 7
208 Red 15A
3 VCU

ECU—Engine Control Unit C28— Engine Connector (Red) X5058—Engine Connector 3— Battery Discharge
VCU—Vehicle Control Unit S123— Key Switch 1— Unswitched Power
C15— Fuse Block 2— Switched Power
Continued on next page CB12260,000002E -19-19MAR15-2/3

TM130419 (24FEB16) 230-15-14 030916

PN=712
 Theory of Operation, Tier 4

F107 Grn
F207 Yel

600 Brn

500 Yel 506 Yel

Sp-2

F207 Yel
F107 Grn

Sp-CAN7
C36
Sp-CAN3 A
F204 Yel F206 Yel F208 Yel
F104Grn F106 Grn F108 Grn 121
Sp-CAN4 Sp-CAN8 B

1 +12V
2 Gnd
3 Backlight A20
F203 Yel 4 J1939+ PDU

600 Brn
F103 Grn 5 J1939-

506 Yel
6 Output (SWG)

G-2B
200 Red G-2A
G

A
B
EF1 G2
3
Fuse Alternator
200 Red 80A
230 Red 201 Red B A
Sp-15 T-4
102 Blk
GT-1A M-1B

TCT012428 —UN—19MAR15
G1
1 Battery M1
2 M Starter Motor
3

A20— PDU EF1— 80A Fuse 1— Unswitched Power 3— Battery Discharge

C36— CAN Terminator G1—Battery 2— Switched Power
G2—Alternator M1—Starter Motor
CB12260,000002E -19-19MAR15-3/3

TM130419 (24FEB16) 230-15-15 030916

PN=713
 Theory of Operation, Tier 4

Operator Presence and PTO Interlock Circuit • All electronic controllers (ECU, VCU, and PDU).
Operation, T4 When the operator is sitting on the seat, current flows
Function: across the seat switch contacts to the Vehicle Control
Unit (VCU).The operator must be on the seat to energize
The purpose of the “operator presence” portion of this the PTO. Engaging the park brake disengages the PTO.
circuit is to automatically stop the engine whenever the Current is removed from the PTO input (pin K1) of the VCU.
operator rises from the seat for more than one second
when PTO is ENGAGED and/or park brake is UNLOCKED. PTO Interlock Circuit

The purpose of the “PTO interlock” portion of the circuit NOTE: For safety reasons, the PTO interlock circuit
is to provide the following: contains a logical latching circuit. Because of this,
the PTO switch must be at the DISENGAGED
• Require the operator to be sitting on the seat and park position before the PTO can be ENGAGED.
brake UNLOCKED before the PTO can be ENGAGED.
• Automatically disengages the PTO whenever any of The PTO interlock circuit is controlled by various inputs
the following occurs: and signals fed to the controllers.
- Park brake lock is engaged
- Engine coolant temperature exceeds 110° C (230° F) These signals are:
- Engine oil pressure drops below safe operating • B19 engine oil pressure switch. Pressure must be
pressure >41—62 kPa (6—9 psi) for the PTO to engage or
- Hydraulic oil temperature exceeds safe operating remain engaged.
temperature • Primary Display Unit (PDU)
- Key switch is placed in the START position and the • B3A hydraulic oil temperature switch. The ECU and
PTO was left in the ON position when shut down VCU will disengage the PTO if the hydraulic pressure
• Provide a means for the engine to continue operating drops below a certain point.
when the operator is not on the seat. • S21 PTO switch. This switch only sends a PTO request.
The controllers determine if the PTO engages or not.
Operating Conditions:
• S17 seat switch. Operator must be on the seat to
• Key switch in ON position. initially engage the PTO.
• PTO switch on or off • S25 park brake switch. Park brake must be set to
• Operator on or off seat engage PTO if the seat switch is open.
• B5208 coolant temperature switch. The ECU and VCU
Theory of Operation will disengage the PTO if the coolant temperature
exceeds a certain point.
Unswitched and Switched Power Circuits
NOTE: See the operator’s manual for specific
The switched and unswitched power circuits power the operating conditions.
PTO and operator presence circuits. (See Unswitched
Power Circuit Operation, T4 and Switched Power Circuit PTO Solenoid Circuit
Operation, T4.) Switched power flows to the following
components: With the PTO circuit logically latched and the PTO
switched in the engaged position, current will flow to
• Seat switch (S17). the PTO solenoid thereby energizing the solenoid and
• PTO switch (S21). engaging the PTO.
• Park brake switch (S25)

Continued on next page CB12260,000002F -19-19MAR15-1/2

TM130419 (24FEB16) 230-15-16 030916

PN=714
 Theory of Operation, Tier 4

Engine Control B5208

Unit (ECU) Coolant
X5057 t˚ Temperature
7
A5501 Sensor
Coolant Temp Snsr 28 407 Grn B19 Engine Oil
Coolant Temp Snsr Gnd 29 408 Blu Pressure Switch
8

Low Oil Pressure SW 15 620 Tan

Sp-CAN5
CAN2H 75 F207 Yel P
A5502 CAN2L 53 F107 Grn
Sp-CAN6

F104 Grn
F204 Yel
A20
PDU
101 Blk 2 Gnd
Sp-CAN3 501 Yel 1 +12V
F201 Yel F203 Yel 4 J1939+
F101 Grn F103 Grn 5 J1939-
Sp-CAN4

S14
A Park Brake Switch
507 Yel C
B
708 Pur
A1 B1
Vehicle Control D

Unit (VCU) Off

On
Brake Switch (Open/VBat) J1 708 Pur

PTO Solenoid 1.7A Supply J4 755 Blu B Y19

PTO Solenoid - Return M3 680 Gry A PTO Solenoid T B11
102 Blk B Hydraulic
Hydro Overtemp Sw (Open/Gnd) G4 901 Gry 901 Gry A
Oil Temp.
Annunciator E4 302 Org A H8
143 Blk B Buzzer
PTO Knob (Open/VBat) K1 760 Pnk

Seat SW Input (Open/VBat) C1 640 Grn

7 9

3
2 760 Pnk
516 Yel 1
6
S9 5
4
1 4 PTO Switch 8 10

TCT009611 —UN—19DEC14
On
2 5 Off
Off Seat
3 On Seat
510 Yel A S17
640 Grn B
Seat Switch

A20— Primary Display Unit C19— PTO Solenoid Connector S25— Park Brake Switch 3— PTO Shutdown Circuit
B19— Engine Oil Pressure Switch C27— Engine Connector (Red) VCU—Vehicle Control Unit 4— PTO Switch Out
B3A— Hydraulic Oil Temperature ECU—Engine Control Unit Y19— PTO Solenoid 5— PTO Solenoid Circuit
Switch S17— Seat Switch 1— Switched Power
B5208—Coolant Temperature S21 — PTO Switch 2— Operator Presence Circuit
Sensor (engine harness)
CB12260,000002F -19-19MAR15-2/2

TM130419 (24FEB16) 230-15-17 030916

PN=715
 Theory of Operation, Tier 4

Engine Oil Pressure Circuit Operation, T4 pressure is below a safe operating level, the engine oil
pressure switch will provide a path to ground for the
Function: Engine Control Unit (ECU). The ECU will then transmit a
message or messages over the CAN bus to the Vehicle
To possibly derate the engine and or disengage the PTO
Control Unit (VCU) and A20 Primary Display Unit (PDU).
clutch and warn the operator if the engine oil pressure
All controllers will transmit and receive other vehicle data
drops below the safe operating level.
and each controller will decide what action to take - such
Operating Conditions: as engine derate, or PTO shutdown.

• Key switch in RUN position. A low oil pressure warning will display on the PDU.
• Engine RUNNING. When the engine oil pressure rises to a safe operating
Theory of Operation: level, such as when the engine is initially started, the
contacts of the engine oil pressure switch open, causing
The engine oil pressure light and buzzer circuit is the engine oil pressure light to go off and the buzzer to
controlled by engine oil pressure switch. When oil de-activate.

Engine Control B19 Engine Oil

Unit (ECU) Pressure Switch
Low Oil Pressure SW 15 620 Tan
Sp-CAN5
CAN2H 75 F207 Yel P
A5502 CAN2L 53 F107 Grn
Sp-CAN6
F104 Grn
F204 Yel

A20
PDU
101 Blk 2 Gnd
Sp-CAN3 501 Yel 1 +12V
F201 Yel F203 Yel 4 J1939+
F101 Grn F103 Grn 5 J1939-
Sp-CAN4

A1 B1
Vehicle Control

TCT009612 —UN—18DEC14
Unit (VCU)
Annunciator E4 302 Org A H8
143 Blk B Buzzer

A20— Primary Display Unit H8—Buzzer VCU—Vehicle Control Unit

B19— Engine Oil Pressure Switch ECU—Engine Control Unit
CB12260,0000032 -19-18MAR15-1/1

TM130419 (24FEB16) 230-15-18 030916

PN=716
 Theory of Operation, Tier 4

Engine Coolant Temperature Circuit Theory of Operation

Operation, T4
The engine coolant temperature indicator is controlled by
Function: the engine coolant temperature switch.
To warn the operator if the engine coolant temperature When the coolant temperature exceeds 110° C (230°
exceeds the safe operating level and have the controllers F) the engine coolant temperature switch closes and
take protective action if deemed necessary. completes the circuit to ground causing the coolant
temperature indicator to come on. The engine coolant
Operating Conditions:
temperature switch also completes the buzzer ground
• Key switch in RUN position. circuit, causing the buzzer to come on. The controllers are
• Engine RUNNING. used to isolate the coolant temperature light from other
• Engine coolant temperature greater than 110° C (230° circuits that turn on the buzzer by transmitting messages
F). over the CAN bus. The controllers will decide what action
to take: engine de-rate, PTO shutdown.

Continued on next page CB12260,0000033 -19-18MAR15-1/2

TM130419 (24FEB16) 230-15-19 030916

PN=717
 Theory of Operation, Tier 4

Engine Control B5208

Unit (ECU) Coolant
X5057 t˚ Temperature
7
A5501 Sensor
Coolant Temp Snsr 28 407 Grn B19 Engine Oil
Coolant Temp Snsr Gnd 29 408 Blu Pressure Switch
8

Low Oil Pressure SW 15 620 Tan

Sp-CAN5
CAN2H 75 F207 Yel P
A5502 CAN2L 53 F107 Grn
Sp-CAN6

F104 Grn
F204 Yel
A20
PDU
101 Blk 2 Gnd
Sp-CAN3 501 Yel 1 +12V
F201 Yel F203 Yel 4 J1939+
F101 Grn F103 Grn 5 J1939-
Sp-CAN4

S14
A Park Brake Switch
507 Yel C
B
708 Pur
A1 B1
Vehicle Control D

Unit (VCU) Off

On
Brake Switch (Open/VBat) J1 708 Pur

PTO Solenoid 1.7A Supply J4 755 Blu B Y19

PTO Solenoid - Return M3 680 Gry A PTO Solenoid T B11
102 Blk B Hydraulic
Hydro Overtemp Sw (Open/Gnd) G4 901 Gry 901 Gry A
Oil Temp.
Annunciator E4 302 Org A H8
143 Blk B Buzzer
PTO Knob (Open/VBat) K1 760 Pnk

Seat SW Input (Open/VBat) C1 640 Grn

7 9

3
2 760 Pnk
516 Yel 1
6
S9 5
4
1 4 PTO Switch 8 10

TCT009611 —UN—19DEC14
On
2 5 Off
Off Seat
3 On Seat
510 Yel A S17
640 Grn B
Seat Switch

A20— Primary Display Unit C19— PTO Solenoid Connector S25— Park Brake Switch 4— Park Brake Circuit
B19— Engine Oil Pressure Switch C27— Engine Connector (Red) VCU—Vehicle Control Unit 5— PTO Solenoid Circuit
B3A— Hydraulic Oil Temperature ECU—Engine Control Unit Y19— PTO Solenoid
Switch H8—Buzzer 1— Unswitched Power
B5208—Coolant Temperature S17— Seat Switch 2— Seat Switch Circuit
Sensor (engine harness) S21 — PTO Switch 3— Coolant Related Circuits
CB12260,0000033 -19-18MAR15-2/2

TM130419 (24FEB16) 230-15-20 030916

PN=718
 Theory of Operation, Tier 4

Hydraulic Oil Temperature Circuit Operation, Theory of Operation

T4
The hydraulic oil temperature light circuit is controlled by
Function: hydraulic oil temperature switch. When the hydraulic oil
To warn the operator if the hydraulic oil temperature temperature is exceeded, the switch closes and ground
exceeds the safe operating level and shutdown the PTO is sent to the Vehicle Control Unit (VCU). The VCU will
if conditions warrant. then transmit messages on the CAN bus to all controllers
declaring the over temp condition. Each controller will
Operating Conditions: decide what action to take depending upon measured
conditions: PTO shutdown, engine de-rate.
• Key switch in RUN position.
• Engine RUNNING. An icon will display on the Primary Display Unit (PDU)
• Hydraulic oil temperature greater than 101—108° C screen as well as any other actions taken by the
(214—226° F). controllers.

Continued on next page CB12260,0000034 -19-18MAR15-1/2

TM130419 (24FEB16) 230-15-21 030916

PN=719
 Theory of Operation, Tier 4

Engine Control B5208

Unit (ECU) Coolant
X5057 t˚ Temperature
7
A5501 Sensor
Coolant Temp Snsr 28 407 Grn B19 Engine Oil
Coolant Temp Snsr Gnd 29 408 Blu Pressure Switch
8

Low Oil Pressure SW 15 620 Tan

Sp-CAN5
CAN2H 75 F207 Yel P
A5502 CAN2L 53 F107 Grn
Sp-CAN6

F104 Grn
F204 Yel
A20
PDU
101 Blk 2 Gnd
Sp-CAN3 501 Yel 1 +12V
F201 Yel F203 Yel 4 J1939+
F101 Grn F103 Grn 5 J1939-
Sp-CAN4

S14
A Park Brake Switch
507 Yel C
B
708 Pur
A1 B1
Vehicle Control D

Unit (VCU) Off

On
Brake Switch (Open/VBat) J1 708 Pur

PTO Solenoid 1.7A Supply J4 755 Blu B Y19

PTO Solenoid - Return M3 680 Gry A PTO Solenoid T B11
102 Blk B Hydraulic
Hydro Overtemp Sw (Open/Gnd) G4 901 Gry 901 Gry A
Oil Temp.
Annunciator E4 302 Org A H8
143 Blk B Buzzer
PTO Knob (Open/VBat) K1 760 Pnk

Seat SW Input (Open/VBat) C1 640 Grn

7 9

3
2 760 Pnk
516 Yel 1
6
S9 5
4
1 4 PTO Switch 8 10

TCT009611 —UN—19DEC14
On
2 5 Off
Off Seat
3 On Seat
510 Yel A S17
640 Grn B
Seat Switch

A20— Primary Display Unit C19— PTO Solenoid Connector S25— Park Brake Switch 4— Park Brake Circuit
B19— Engine Oil Pressure Switch C27— Engine Connector (Red) VCU—Vehicle Control Unit 5— PTO Solenoid Circuit
B3A— Hydraulic Oil Temperature ECU—Engine Control Unit Y19— PTO Solenoid
Switch S17— Seat Switch 1— Unswitched Power
B5208—Coolant Temperature S21 — PTO Switch 2— Seat Switch Circuit
Sensor (engine harness) 3— Coolant Related Circuits
CB12260,0000034 -19-18MAR15-2/2

TM130419 (24FEB16) 230-15-22 030916

PN=720
 Theory of Operation, Tier 4

Cold Start Circuit Operation, T4 temperature alone may not provide enough heat to
ignite the air/fuel mixture. Because of this, glow plugs
Function: are installed to provide added heat to the incoming
combustion air.
To preheat the air entering the engine combustion
chamber to allow for easier starting during cold weather. The cold start circuit may be activated whenever the
key is in the START or RUN position. This controlled by
To provide a means to let the operator know that the cold
various sensors feeding the controllers depending upon
start system is activated.
operating conditions.
Operating Conditions: Messages will be transmitted and received by the
• Key switch in RUN or START position. controllers and cold start status icons and/or messages
will be display on the Primary Display Unit (PDU).
Theory of Operation:
When starting a diesel engine when the ambient
temperature is below 5° C (40° F), compression

Engine Control B5208

Unit (ECU) Coolant
X5057 t˚ Temperature
A5501 7 Sensor
Coolant Temp Snsr 28 407 Grn
Coolant Temp Snsr Gnd 29 408 Blu
8

K1
Glow Plug Relay R26
85 86
Glow Plugs
Glow Plug Relay 70 921 Wht 126 Blk C26
30 87
220 Red 920 Red
87a
A5502
Sp-CAN5
CAN2H F207 Yel 75 F207 Yel
CAN2L F107Grn 53 F107 Grn
Sp-CAN6

A20
F104 Grn
F204 Yel

Primary Display
Unit (PDU)
101 Blk 2 Gnd
Sp-CAN3 501 Yel 1 +12V
F201 Yel F203 Yel 4 J1939+
F101 Grn F103 Grn 5 J1939-
Sp-CAN4

TCT009614 —UN—19DEC14
A1 B1
Vehicle Control
Unit (VCU)

A20— Primary Display Unit C27— Engine Harness Connector K1—Glow Plug Relay
B5208—Coolant Temperature (Red) R26— Glow Plugs
Sensor (engine harness) ECU—Engine Control Unit VCU—Vehicle Control Unit
CB12260,0000036 -19-18MAR15-1/1

TM130419 (24FEB16) 230-15-23 030916

PN=721
 Theory of Operation, Tier 4

Cruise Control Circuit Operation, T4

Theory of Operation:
Function:
NOTE: To engage the cruise control, the cruise control
To provide a means of keeping the speed of the machine switch must be first moved to the engage position
constant without the need of having the operator's foot on to logically latch the circuit.
the forward hydrostatic control pedal.
When the cruise control switch is pressed to the on position
The circuit controls an electromagnet that when energized, (center), battery voltage is sent to the Vehicle Control
holds the forward hydrostatic control pedal at the desired Unit (VCU) cruise on position. A message is sent over
position as selected by the operator. the CAN bus and the cruise on icon is displayed. When
conditions are met, the desired speed is selected and the
Operating Conditions:
cruise set position of the switch is pressed. The logical
• Key switch in RUN position, engine running. latch causes the VCU to send high current to the cruise
• Operator on seat. control electromagnet which physically holds the pedal in
• Brakes UNLOCKED. position. To disengage, turn the cruise switch to off.
• Cruise control switch in the ENGAGE or ON positions. The cruise control function also disengages when any of
the remaining operating conditions are not met.
C-7
S7 A 518 Yel C9
B 833 Pnk 836 Pnk A
Cruise Control C 837 Org
135 Blk B
Switch
Y9
Cruise Control
Engine Control Magnet
Unit (ECU)
CAN2H F207 Yel 75
CAN2L F107 Grn 53

101 Blk 2 Gnd

Sp-CAN3 Sp-CAN3 Sp-CAN7 501 Yel 3 Backlight
F201 Yel F203 Yel 4 J1939+
F101 Grn F103 Grn 5 J1939-
Sp-CAN4 Sp-CAN4 Sp-CAN8 6 Output (SWG)

S25 A20
Park Brake Switch Primary Display
507 Yel
A Unit (PDU)
C
B
708 Pur
A1 B1
Vehicle Control D

Unit (VCU) Off

On
Brake Switch (Open/VBat) J1 708 Pur

Cruise Control Set Switch G1 837 Org

Cruise Contlol On Switch H1 833 Pnk

TCT012429 —UN—19MAR15
Cruise Solenoid 1A J3 836 Pnk

Off Seat
C-17 On Seat
510 Yel A
Seat SW Input (Open/VBat) C1 640 Grn
S17
640 Grn B
Seat Switch

A20— Primary Display Unit S7— Cruise Control Switch S25— Park Brake Switch Y9— Cruise Control Magnet
ECU—Engine Control Unit S17— Seat Switch VCU—Vehicle Control Unit
CB12260,0000030 -19-19MAR15-1/1

TM130419 (24FEB16) 230-15-24 030916

PN=722
 Theory of Operation, Tier 4

CAN Bus
Engine Control
EGR Unit (ECU)
Valve

CAN2 Lo 53
CAN2 Hi 75
CAN1 Lo 76
CAN1 Hi 54
D C

A A5502
121
B R5606
Vehicle Control
Unit (VCU) 1

^ ^ ^ ^ ^ ^ ^ ^ ^ ^ ^ ^
CAN Hi A1 F201 Yel

F207 Yel
F107 Grn
2 F250 YEL

^ ^
CAN Lo B1 F101 Grn
3 F150 GRN
X5058 4
5
6 C28
7 To Engine Harness
8 (Red Connection)
9
10
11
A20 12 A
Primary Display B
F205 Yel C
Unit (PDU) F105 Grn D
E
1 +12V F
2 Gnd Service G
3
H
F203 Yel 4 J1939+ J
F205 Yel

F103 Grn J1939-

F105 Grn

5
6
C24

F103 Grn F207 Yel

TCT009615 —UN—18DEC14
F203 Yel F107 Grn

Sp-CAN3 Sp-CAN7
C36
Sp-CAN5 A
F201 Yel F204 Yel F206 Yel F208 Yel
F101 Grn F104Grn F106 Grn F108 Grn 121
Sp-CAN4 Sp-CAN6 Sp-CAN8 B

A20— Primary Display Unit C36— CAN Bus Terminator R5606—Terminator Resistor,
C24— Service Connector Resistor Connector Engine Harness
C28— Engine Harness Connector ECU—Engine Control Unit VCU—Vehicle Control Unit
(Red)
CB12260,0000031 -19-18MAR15-1/1

TM130419 (24FEB16) 230-15-25 030916

PN=723
 Theory of Operation, Tier 4

TM130419 (24FEB16) 230-15-26 030916

PN=724
 Group 20
Schematics
Summary of References • Engine Controls and Sensors Schematic
• Electrical Components, Non-T4 • Cab Schematic, Lower
• Cab Schematic, Upper
• Main Schematic, Non-T4 • GLC Schematic
• Main Schematic, T4 • Electrical Components, Homologation
• Electrical Components, T4 • Homologation Wiring Schematic
• Engine Connector X5057 Schematic • Front Work Light Wiring Schematic
• Engine Connector X5058 Schematic • Backup Alarm Wiring Schematic
• Engine Connector X5059 Schematic • Beacon Light Wiring Schematic
• Engine Connector X5060 Schematic
OUMX258,0000C22 -19-24JUL14-1/1

Electrical Components, Non-T4 K7 — Cruise Control Relay

K8 — Cab Power Relay
A1 — Control Module M1 — Starter Motor
A2 — Engine Preheat Timer Module R1 — Glow Plugs
A100 — Instrument Cluster S1 — Key Switch
B1 — Coolant Temperature Switch S2 — Seat Switch
B2 — Engine Oil Pressure Switch S3 — PTO Switch
B3A — Hydraulic Oil Temperature Switch S4 — Brake Switch
C101 — Capacitor, 220 µF S5 — Cruise Control Switch
EF1 — Fuse Holder S7 — Cruise Control Brake Switch
F1 — Fuse Holder S8 — Light Switch
G1 — Battery V1 — Diode Pack
G2 — Alternator V2 — Diode Pack
H7 — Buzzer W2 — Ground
K1 — Start Relay Y1 — PTO Solenoid
K2 — Hold-In Relay Y2 — Fuel Solenoid
K3 — PTO Relay Y3 — Cruise Control Magnet
K4 — PTO Shutdown Relay Y4 — Fuel Transfer Pump
K5 — Fuel Pull-In Relay
K6 — Air Heater
OUMX258,0000C27 -19-25JUL14-1/1

TM130419 (24FEB16) 230-20-1 030916

PN=725
 Schematics

Main Schematic, Non-T4

450 Yel

402 Yel

750 Pur
A1
Control Module A1A
S1 Key Switch A 743 Pur
F4 B 830 Pnk
Off A1B 15A C 320 Blu
Run 1 F3 D 748 Pur
Start 400 Yel A 15A E 195 Blk
B
3 H2 F 788 Pur
B A
402 Yel C
4
G
450 Yel D PTO H 640 Grn
5 (Grn)
750 Pur E
F 6 K1
S2 S1
K2 K3

747 Pur
M G Start
Relay
A1C
«
«
«

«
«
«

C2 H1 Hold-In PTO
T-41 Relay Relay
Hold-In (Red)
736 Pur
206 Red

101 Wht
100 Blk
535 Yel

501 Yel

^ ^ ^ ^ ^ ^ 480 Yel
C1 491 Yel 1

^ ^ ^ ^ ^ ^
^ ^ ^ ^ ^ ^
C

D
E
A

B
F

493 Yel 2
250 Red 3
X-1
400 Yel 191 Blk 4
Cab
242 Red
195 Blk

190 Blk

494 Yel 5 Power

Sp-13 775 Grn 6

775 Grn
ACT-1
A/C Compressor
155 Blk
K8 503 Yel A X-4
Cab Power 85 86
480 Yel B
30 87 Cab Power
243 Red 490 Yel
Sp-1
125 Blk
210 Red 210 Red
240 Red 225 Red
Sp-8 250 Red
A B
- + 408 Yel Sp-9 220 Red
230 Red T-8 C101
T-4 Sp-15 404 Yel
747 Pur

611 Brn 610 Brn

EF1 80A Sp-14
Fuse 155 Blk
612 Brn
413 Yel

200 Red 125 Blk

103 Blk
102 Blk 290 Red
GT-1A M-1B
G-2A F1
241 Red

T-5 ^ ^
GT-2 GT-1 B
A

A
G Fuse
3

GT-2A Holder
G2
TCT007264 —UN—26JUN14

M 10A 492 Yel

G1 Battery M1 Alternator A B

Starter Motor

190 Blk

Main Schematic - 1550 (1 of 4)

Continued on next page OUMX258,0000C23 -19-21JUL14-1/4

TM130419 (24FEB16) 230-20-2 030916

PN=726
 Schematics

Main Schematic - 1550 (2 of 4)

450 Yel

402 Yel

750 Pur
K4
PTO Shutdown
85 86
360 Org 430 Yel
30 87
760 Pur 87a
700 Pur

748 Pur

640 Grn
1
S3
2 Sp-3
PTO Switch
3
410 Yel 748 Pur

650 Grn
9

630 Grn
752 Pur
760 Pur 1 4
750 Pur 7
770 Pur
On
Off

480 Yel

743 Pur
830 Pnk
320 Blu
788 Pur
191 Blk
630 Grn
407 Yel
411 Yel
751 Pur
K5
Fuel Pull-In S2
85 86
751 Pur 407 Yel Sp-10 Seat Switch Y1
30 87
210 Red 911 Wht 910 Wht
1 2 Off Seat
On Seat
PTO Solenoid
771 Gry
912 Wht 411 Yel A 770 Pur
A
Y2 831 Pnk B B 120 Blk
Hold
Fuel Pull-In
A 650 Grn
Gnd
B 910 Wht
Solenoid C 101 Blk

220 Red

404 Yel
610 Brn

155 Blk 155 Blk

125 Blk
103 Blk 103 Blk 125 Blk
101 Blk 191 Blk
912 Wht
12
124 Blk
100 Blk 109 Blk
T-35 Sp-5 110 Blk
W2 122 Blk
X2 Power
TCT007265 —UN—02JUL14

831 Pnk
492 Yel A 112 Blk
123 Blk B Sp-6 113 Blk
110 Blk 107 Blk
123 Blk 12 135 Blk
130 Blk 190 Blk

190 Blk

Continued on next page OUMX258,0000C23 -19-21JUL14-2/4

TM130419 (24FEB16) 230-20-3 030916

PN=727
 Schematics

Main Schematic - 1550 (3 of 4)

450 Yel
360 Org
402 Yel

412 Yel

610 Brn

412 Yel
402 Yel
411 Yel
410 Yel
S4
Brake Switch B3A
743 Pur
A Hydraulic
C
752 Pur 1 Sp-2 Oil Temp.

456 Yel
2
B D
788 Pur 700 Pur T

430 Yel
407 Yel
404 Yel
480 Yel
409 Yel
406 Yel
403 Yel
405 Yel
Off
On B 121 Blk
A 527 Blu

480 Yel

112 Blk
403 Yel
830 Pnk 405 Yel
121 Blk
320 Blu 320 Blu

630 Grn 630 Grn

407 Yel
411 Yel
751 Pur 751 Pur
406 Yel
404 Yel
610 Brn
350 Org
Power

Control Fuel
A 406 Yel
B 751 Pur
Logic C 630 Grn
771 Gry Gnd
D 109 Blk
Pre-heat
E 350 Org
120 Blk K6 Wait Light
Hold In Signal
F 330 Grn
Air Heater
A2
85 86
350 Org 409 Yel Engine Preheat Timer
30 87 113 Blk
220 Red 900 Wht
107 Blk
Y4
121 Blk

Sp-11
Fuel Transfer Pump 122 Blk
115 Blk
111 Blk
Red 1 2 116 Blk
M A 456 Yel
126 Blk
R1
Blk B
Sp-12 1 Glow Plugs
2 900 Wht
155 Blk

912 Wht
124 Blk
109 Blk

122 Blk
830 Pnk
TCT007266 —UN—02JUL14

831 Pnk
112 Blk
113 Blk
107 Blk
135 Blk

130 Blk

Continued on next page OUMX258,0000C23 -19-21JUL14-3/4

TM130419 (24FEB16) 230-20-4 030916

PN=728
 Schematics

Main Schematic - 1550 (4 of 4)

360 Org
A100
C100 Instrument Cluster
412 Yel A 12V-16V DC
B Service
330 Grn C Preheater
112 Blk D Ground
625 Tan E Engine Oil Pressure
310 Org F Engine Temperature
610 Brn G Battery Discharge
525 Blu H Hydraulic Temperature
B2
Engine Oil
Pressure Switch H7
Buzzer
625 Tan
626 Tan 403 Yel A
P T-40 360 Org B
315 Grn

B1 V1
Coolant Diode Pack
A
Temp. Switch 626 Tan B
315 Grn C
310 Org 526 Blu D
311 Org 311 Org E
T T-39 525 Blu 320 Blu F

Sp-4
527 Blu 526 Blu H2
112 Blk Homologation Kit
403 Yel
405 Yel A
107 Blk B
320 Blu
H1
330 Grn
S8 K7
Light Switch
2
Headlights Cruise Control
1 E1 Relay
450 Yel
3 452 Yel A
113 Blk B 85 86
5 835 Pnk 130 Blk
4 30 87
834 Pnk 833 Pnk

S7
Cruise Control
Brake 834 Pnk Sp-7
V2 840 Gry 837 Pnk
836 Pnk 1 2
A
Diode Pack C
115 Blk A 830 Pnk B D
111 Blk B 831 Pnk 832 Pnk
116 Blk C
840 Gry D Off S5
771 Gry E On
912 Wht F Cruise Control
840 Gry Switch X-5
A 832 Pnk
B 833 Pnk
Y3 C 837 Pnk
Cruise Control
Magnet Engage
On
830 Pnk Off
836 Pnk
TCT007267 —UN—02JUL14

831 Pnk
835 Pnk A
135 Blk B
135 Blk

130 Blk

OUMX258,0000C23 -19-21JUL14-4/4

TM130419 (24FEB16) 230-20-5 030916

PN=729
 Schematics

Electrical Components, T4 VCU — Vehicle Control Unit

W2 — Ground
Electrical Components Y9 — Cruise Control Magnet
Y19 — PTO Solenoid
A20 — Primary Display Unit (PDU)
Y22 — Fuel Pump
B10 — Accelerator Position Sensor
B19 — Engine Oil Pressure Switch
Engine Sensors and Controls
B3A — Hydraulic Oil Temperature Switch
ECU — Engine Control Unit B5100 — Fuel Rail Pressure Sensor
EF1 — Fuse Holder B5109 — DPF Differential Pressure Sensor
G1 — Battery B5114 — Manifold Air and Exhaust Pressure Sensor
G2 — Alternator B5201 — DOC Inlet Temperature Sensor
H8 — Buzzer B5202 — DOC Outlet Temperature Sensor
K1 — Glow Plug Relay B5206 — Manifold Air Temperature Sensor
K2 — EGR Valve Relay B5207 — EGR Temperature Sensor
K3 — Start Relay B5208 — Engine Coolant Temperature Sensor
K11 — Cab Power Relay B5209 — Fuel Temperature Sensor
M1 — Starter Motor B5216 — Exhaust Manifold Temperature Sensor
PDU — Primary Display Unit B5301 — Crankshaft Position Sensor
R26 — Glow Plugs B5302 — Camshaft Speed Sensor
S7 — Cruise Control Switch Y5006 — Fuel Injector #1
S17 — Seat Switch Y5007 — Fuel Injector #2
S21 — PTO Switch Y5008 — Fuel Injector #3
S23 — Key Switch Y5400 — EGR Valve
S25 — Park Brake Switch Y5401 — Air Throttle Actuator
S37 — Headlights Switch Y5501 — Low Pressure Fuel Pump (Y22)
V13 — Diode
OUMX258,0000C56 -19-19MAR15-1/1

TM130419 (24FEB16) 230-20-6 030916

PN=730
 Schematics

Main Schematic, T4

C7
A 518 Yel C9 Y9
S7 833 Pnk
B 836 Pnk A Cruise Control
Cruise Control C 837 Org 135 Blk B
Magnet
Switch
Engage
On
Off

CAN HI A1 F201 Yel

Regen Request (Ope/VBat) A2
Deck Speed Input A3 518 Yel
Hydraulic Oil Temp A4
CAN LO B1 F101 Grn
Aux Relay Coils 2.5A B2 910 Grn 910 Grn
LED Spare B3 651 Pnk
Engine Coolant Temp B4
Seat SW Input (Open/VBat) C1 640 Grn
Start Input (Open/VBat) C2 704 Pur 710 Pur
LED Spare C3
C4
VCU Diagnostic Lamp/LED D1 640 Grn
Deck Lift (Open/VBat) D2
Hydro Overtemp Lamp/LED D3
Glow Plug Relay 0.5A D4 302 Org
Neutral/Spare (Open/VBat) E1
Preheat Wait Lamp/LED E2
E3 135 Blk
Annunciator 0.03A E4 302 Org
Neutral Switch (Open/VBat) F1
Battery Discharge Lamp/LED F2
Regen Mode Sw (Open/VBat) F3 108 Blk
Engine Run Request 0.5A F4 651 Pnk
Cruise Control Set Switch G1 837 Org
Eng Oil Pressure Lamp/LED G2
Engine Start Request 0.5A G3 710 Pur
Hydro Overtemp Sw (Open/Gnd) G4 901 Gry
Cruise Control On Switch H1 833 Pnk 514 Yel
Eng Overtemp Lamp/LED H2
Eng Overtemp SW (Open/Gnd) H3
Engine Oil Press (Gnd/Open) H4
Brake Switch (Open/VBat) J1 708 Pur 708 Pur
J2
Cruise Solenoid 1A J3 836 Pnk
PTO Solenoid 1.7A Supply J4 755 Blu 704 Pur
PTO Knob (Open/VBat) K1 760 Pnk 760 Pnk
+5V Sensor Supply K2
Fuel Pump 1.5A K3 681 Pnk
K4
VBAT Unswitched L1 208 Red
Ground L2 107 Blk 107 Blk
Ground Speed Input L3
L4
+12V Switched M1 514 Yel
Sensor Return M2
PTO Solenoid - Return M3 680 Gry
Engine Speed M4 Y19
PTO Solenoid
Vehicle Control C6
Unit (VCU) 680 Gry A
755 Blu B
C19
208 Red
B3A T

Hydraulic B 102 Blk 102 Blk

A 901 Gry
Oil Temp.
TCT007282 —UN—03JUL14

Y22 Red 681 Pnk

M A
Fuel Pump Blk B
108 Blk
C22
F101 Grn
F201 Yel

Main Schematic, T4 (1 of 9)
Continued on next page OUMX258,0000C4F -19-19MAR15-1/9

TM130419 (24FEB16) 230-20-7 030916

PN=731
 Schematics

Main Schematic, T4 (2 of 9)

Console T-1
Ground 120 Blk
R26
ECU Case T-6 146 Blk
Glow Plugs
Ground
920 Red

VCU Case T-7 C26

Ground 147 Blk

518 Yel 518 Yel

Sp-12 147 Blk
148 Blk 146 Blk
910 Grn 910 Grn
651 Pnk 651 Pnk

Sp-14 707 Pur

710 Pur 710 Pur 705 Pur

640 Grn 640 Grn

302 Org 302 Org

103 Blk
120 Blk 142 Blk
135 Blk 145 Blk 127 Blk
Sp-11 126 Blk
150 Blk
148 Blk 101 Blk 101 Blk
108 Blk Sp-20
107 Blk 130 Blk 130 Blk
153 Blk 153 Blk
143 Blk 143 Blk
Sp-13
513 Yel
514 Yel
516 Yel
100 Blk 100 Blk

708 Pur 708 Pur

Sp-9
704 Pur 704 Pur 709 Pur
760 Pnk
Off
S21 S23 Run
Start
PTO Switch Key Switch
B A
7 9

3 S2 S1
2
516 Yel 1
500 Yel
6 M G
5
4
8 10
«
«
«

«
«
«

On
Off C2
242 Red
736 Pur
206 Red

101 Wht
100 Blk
535 Yel

501 Yel

760 Pnk
208 Red 208 Red
C1 ^ ^ ^ ^ ^ ^ 123 Blk
102 Blk ^ ^ ^ ^ ^ ^
C

D
E
A

B
F

703 Pur
TCT007283 —UN—03JUL14

599 Yel 525 Yel

123 Blk
F101 Grn F101 Grn
F201 Yel F201 Yel

Continued on next page OUMX258,0000C4F -19-19MAR15-2/9

TM130419 (24FEB16) 230-20-8 030916

PN=732
 Schematics

Main Schematic, T4 (3 of 9)

K1 K3 K2 K11
Glow Plug Relay Start Relay EGR Valve Relay Cab Power Relay
85 86 85 86 85 86 85 86
142 Blk
30 87 30 87 30 87 30 87 590 Yel

910 Grn
420 Org
87a 87a 87a

127 Blk
Aux.Cab

207 Red

212 Red
705 Pur

747 Pur
706 Pur

671 Blu
126 Blk
103 Blk B
920 Red
X4 A Conn.
503 Yel
220 Red
921 Wht

420 Org
243 Red Sp-4
207 Red 240 Red
1

518 Pnk 212 Red

921 Wht
747 Pur
910 Grn
651 Pnk 651 Pnk
706 Pur
707 Pur 707 Pur
705 Pur 513 Yel
142 Blk

640 Grn
500 Yel
518 Yel
302 Org 507 Yel
103 Blk
142 Blk
127 Blk
126 Blk 640 Grn
220 Red
101 Blk 101 Blk
302 Org
130 Blk 130 Blk
153 Blk 153 Blk
143 Blk 143 Blk
513 Yel
516 Yel 516 Yel
100 Blk 100 Blk
150 Blk 150 Blk
708 Pur
671 Blu
709 Pur 709 Pur

A
507 Yel C
B
708 Pur
D
500 Yel S25
Off
On
Park Brake Switch

242 Red 242 Red

208 Red 208 Red

123 Blk
492 Red
C14
TCT007284 —UN—03JUL14

492 Red A
123 Blk B
Power

F101 Grn F101 Grn

F201 Yel F201 Yel

Continued on next page OUMX258,0000C4F -19-19MAR15-3/9

TM130419 (24FEB16) 230-20-9 030916

PN=733
 Schematics

Main Schematic, T4 (4 of 9)

Sp-16 561 Yel 1

560 Yel 2
202 Red 3 C12
191 Blk 4
562 Yel 5 Cab Power
590 Yel 775 Grn 6

T-9
503 Yel A/C Compressor
420 Org 420 Org
551 Yel
240 Red
212 Red 212 Red
921 Wht 921 Wht
747 Pur

651 Pnk 651 Pnk

706 Pur 706 Pur
707 Pur 707 Pur
513 Yel 513 Yel

501 Yel 501 Yel

Sp-2 551 Yel 101 Blk
500 Yel 506 Yel
518 Yel 510 Yel
507 Yel 516 Yel
530 Yel

502 Yel 510 Yel

640 Grn 640 Grn
220 Red
101 Blk
302 Org
130 Blk
153 Blk 153 Blk
143 Blk 302 Org
143 Blk

516 Yel
100 Blk 502 Yel
150 Blk 150 Blk

671 Blu 671 Blu

709 Pur
211 Red 211 Red

506 Yel

709 Pur
130 Blk
530 Yel
100 Blk
191 Blk
747 Pur
C15 202 Red
2 1 240 Red
242 Red 20A 203 Red 203 Red 230 Red 201 Red
Keyswitch Sp-1 Sp-15
4 3
211 Red 25A 205 Red 205 Red
ECU
220 Red
6 5
492 Red 10A 241 Red 241 Red 225 Red
Aux Power Sp-3
TCT007285 —UN—03JUL14

8 7
208 Red 15A 209 Red 209 Red
VCU

F101 Grn F101 Grn

F201 Yel F201 Yel

Continued on next page OUMX258,0000C4F -19-19MAR15-4/9

TM130419 (24FEB16) 230-20-10 030916

PN=734
 Schematics

Main Schematic, T4 (5 of 9)

553 Yel A T-19

153 Blk B 620 Tan
4
S37
5 Headlights Switch C38 B19 P

3
1
551 Yel Headlights Engine Oil
2 Pressure Switch
420 Org 420 Org
551 Yel

212 Red 212 Red

921 Wht 921 Wht

651 Pnk 651 Pnk

706 Pur 706 Pur
707 Pur 707 Pur
513 Yel 513 Yel

501 Yel 501 Yel

101 Blk 101 Blk

Off Seat
C17 On Seat
513 Yel
510 Yel A S17
640 Grn B
Seat Switch

670 Blu
H8
Buzzer
153 Blk
302 Org 302 Org A
143 Blk 143 Blk B

C41 420 Org

502 Yel A
150 Blk B
V13
C40 Diode
671 Blu 670 Blu
A B
211 Red 211 Red
121 Blk

506 Yel
600 Brn
709 Pur 709 Pur
130 Blk 130 Blk
530 Yel 530 Yel
G-2B G-2A
200 Red
G
A
B

202 Red T-8 3

200 Red T-4

747 Pur

201 Red
EF1 80A G2
Fuse Alternator
100 Blk
121 Blk
191 Blk

102 Blk
T-33 GT-1A M-1B
T-34 G1
T-35 M1
TCT007286 —UN—03JUL14

Battery
M Starter Motor

F101 Grn F101 Grn

F201 Yel F201 Yel

Continued on next page OUMX258,0000C4F -19-19MAR15-5/9

TM130419 (24FEB16) 230-20-11 030916

PN=735
 101 Blk
501 Yel

706 Pur
212 Red

651 Pnk

TM130419 (24FEB16)
530 Yel
130 Blk
600 Brn
709 Pur

F203 Yel
121 Blk
212 Red
211 Red

501 Yel
101 Blk

F203 Yel

F103 Grn
F103 Grn
Sp-5
1
1

Sp-6
513 Yel

2
2
Main Schematic, T4 (6 of 9)

670 Blu
707 Pur
620 Tan

921 Wht

6
5
4
3
2
1

C20

F201 Yel
F101 Grn
Gnd
+12V

S-CAN3
J1939-
J1939+
125 Blk

129 Blk
122 Blk
124 Blk
128 Blk
215 Red
214 Red
213 Red

Backlight
A5502

Output (SWG)
213 Red 1 VB
128 Blk 2 Ground

S-CAN4
214 Red 3 VB

A20
PDU
124 Blk 4 Ground
215 Red 5 VB
125 Blk 6 Ground
7

F204 Yel
Unit (ECU)

F104Grn
9 DPF Piling Up Lvl 4 Lamp
Engine Control

10 5VS Ground

S-CAN5

230-20-12
11
F205 Yel 12
Schematics

F105 Grn 13 Permission Speed SW - NC

707 Pur 14 Starter Permission 1 SW (In)

S-CAN6
620 Tan 15 Low Oil Pressure SW
16 Speed 2 SW - NC

Continued on next page

17 High Idle SW - NC
18 DPF Regen SW
19 Speed 1 SW - NC
422 Grn 20 Intake Throttle Actuator Signal
406 Brn 21 Ambient Air Temp Snsr Gnd

F206 Yel
22 Accelerator Pedal SW - NC
421 Pnk 23 5V Supply Intake Throttle

F106 Grn
S-CAN7
480 Pnk 24 5VS DPF Pressure Snsr
25 DPF Regen Lamp

F205 Yel
F105 Grn
26 Isochronous Lamp - NC
27 DPF Disable Regen Lamp

530 Yel
130 Blk

S-CAN8
706 Pur 28 Start-Relay
29 UB2

F207 Yel
J
30

F
E

H
D
C
B
A

G
31 DPF Disable SW

F107 Grn
651 Pnk 32 Shut Down SW
427 Pnk 33 EGR Temp Sensor Signal

C24
34

F208 Yel
F108 Grn
709 Pur 35 Start - Key Switch (12 V In)

Service
36 Analog Reserve Snsr - NC
37

B
A
C36
122 Blk

129 Blk
406 Brn

121
422 Grn
421 Pnk

600 Brn
420 Org

427 Pnk
480 Pnk
513 Yel
670 Blu
921 Wht
A5502

TCT012430 —UN—19MAR15

OUMX258,0000C4F -19-19MAR15-6/9

PN=736
030916
 A5502
38 Starter Permit 2 SW (HSD) NC
403 Wht 39 EGR Isochronous In - Low
F207 Yel
40 Water Separator/Lamp
F107 Grn 41 Air Cleaner Snsr/Lamp
480 Pnk

TM130419 (24FEB16)
42 High Idle Limit SW - NC
991 Org 43 5VS Accelerator Snsr1
44 5VS - NC
401 Pnk 45 5VS EGR Pressure Snsr
46 5VS Accelerator Snsr 2 - NC
47 LOAD Monitor
48 Preheat Lamp
Main Schematic, T4 (7 of 9)

49 Speed Monitor

129 Blk
513 Yel

122 Blk

483 Blk

600 Brn
670 Blu

427 Pnk
422 Grn
420 Org

421 Pnk
401 Pnk
921 Wht

406 Brn
403 Wht
50 Exhaust Temp Alarm Lamp
51 UB3

483 Blk
423 Brn 52 5V Sensor Return
F107 Grn 53 CAN2L
F250 Yel 54 CAN1H (EGR Valve)

Sp-10
55 Accelerator Snsr 3 Gnd - NC
451 Pur 56 Exhaust Manifold Temp Sensor
57
58 Accelerator Snsr 3 In - NC
59
60 Analog Reserve Snsr Gnd - NC
992 Pur 61 Accelerator Snsr 1 Return

489 Blk
487 Blk
990 Brn 62 Accelerator Snsr 1 Gnd

490 Blk
481 Blu 63 DPF Outlet Press Sensr Signal
64
65 YDT Gnd
600 Brn 66 Discharge
67 Engine StopP 2 SW - NC

230-20-13
670 Blu 68 EGR Relay Coil
Schematics

69
921 Wht 70 Glow Plug-Relay

990 Brn

991 Org
992 Pur
71 DPF Piling Up LVL 1 Lamp

B
A

C
72 DPF Piling Up LVL 3 Lamp

C10

Continued on next page

73 UB5
404 Brn 74 5V EGR Snsr Gnd
F207 Yel 75 CAN2H
F150 Grn 76 CAN1L (EGR Valve)
483 Blk 77 5V Snsr Return

B10
78
405 Pnk 79 Ambient Air Temp Snsr

Sensor
486 Brn 80 DOC Mid Temp Snsr
485 Wht 81 DOC Inlet Temp Snsr

489 Blk

490 Blk
487 Blk

481 Blu
482 Grn

486 Brn
480 Pnk

485 Wht
82

Accelerator
83 Accelerator Snsr 2 - NC
84 Accelerator Snsr 2 Gnd - NC
402 Pur 85 EGR Pressure Snsr Return

2
1
2
1
6
5
4
3
2
1
129 Blk 86 Regen Interlock SW - NC
87 D Gnd
513 Yel 88 Switched +12V
89 UB3 - NC
90 UB3
91
92
Unit (ECU)

Failure Lamp

DOC Mid
122 Blk

DOC Inlet
402 Pur

423 Brn
406 Brn
404 Brn

422 Grn
403 Wht

451 Pur

482 Grn
421 Pnk
405 Pnk
401 Pnk

420 Org

427 Pnk
F250 Yel

93 DPF Piling Up Lvl 2 Lamp

F150 Grn

94 Water Coolant Lamp

Engine Control

Temp Sensor
Temp Sensor
C34 to B5202
C31 to B5109

C33 to B5201
DPF Differential
Pressure Sensor
A5502

TCT007288 —UN—03JUL14

OUMX258,0000C4F -19-19MAR15-7/9

PN=737
030916
 1 Inj 4CYL-2L

A5501

122 Blk
2 Inj 4CYL-3L

406 Brn

451 Pur
402 Pur

420 Org

423 Brn
404 Brn

422 Grn
403 Wht

482 Grn
405 Pnk

F250 Yel

421 Pnk
401 Pnk

427 Pnk
F150 Grn
3
468 Grn 468 Grn 4 Suction control Valve H
471 Wht 471 Wht 5 Suction control Valve L
6

TM130419 (24FEB16)
440 Pnk 7 5V Rail Pressure Snsr
443 Pnk 8 5V Cam Speed Snsr
9
10
449 Blu 11 Fuel Temp Snsr Signal
482 Grn 12 DPF Pressure Snsr H
Main Schematic, T4 (8 of 9)

13
14
15 Speed Change Lamp - NC
465 Brn 16 Inj 3CYL-3L, Inj 4CYL-4L
463 Blu 17 Inj 3CYL-2L, Inj 4CYL-1L
461 Org 18 Inj 3CYL-1L
424 Org 19 Intake Throttle Motor H
425 Wht 20 Intake Throttle Motor L
21
22
23
24
442 Wht 25 Rail Pressure Snsr Signal
441 Grn 26 Rail Pressure Snsr Return
27
407 Grn 28 Coolant Temp Snsr
408 Blu 29 Coolant Water Temp Signal
30 UB5 - NC
31 Inj 4CYL-2H

230-20-14
32 Inj 4CYL-3H
464 Gry 33 Inj 3CYL-3H, Inj 4CYL-4H
Schematics

34 Backup DPF Lamp - NC

35
36
444 Blu 37 Cam Position Snsr Return

Continued on next page

448 Blk 38 Crank Position Snsr Shield Gnd
446 Pnk 39 Crank Position Snsr Signal
40
41
42
43

122 Blk

424 Org
402 Pur

408 Blu

423 Brn
406 Brn
404 Brn

422 Grn
407 Grn

421 Pnk

425 Wht
403 Wht

44
420 Org
F250 Yel

427 Pnk
405 Pnk
401 Pnk

F150 Grn
45
Unit (ECU)

46
462 Wht 47 Inj 3CYL-2H, Inj 4CYL-1H
460 Grn 48 Inj 3CYL-1H
Engine Control

49
50 UB3
450 Brn 51 5V Snsr Signal
445 Wht 52 Cam Position Snsr Signal
53
447 Org 54 Crank Position Snsr Return
55
56
57
58
Manifold Air Temp Snsr

448 Blk

463 Blu
59

449 Blu
444 Blu 426 Pur

461 Org
451 Pur

465 Brn
450 Brn

464 Gry
460 Grn
441 Grn

462 Wht
447 Org
442 Wht

445 Wht

468 Grn
471 Wht
446 Pnk
443 Pnk
440 Pnk

60 UB2
A5501

TCT007289 —UN—03JUL14

OUMX258,0000C4F -19-19MAR15-8/9

PN=738
030916
 Schematics

Main Schematic, T4 (9 of 9)

X5057 (Red Connection)

401 Pnk 1 5V Manifold Air and Exhaust Pressure Sensor
402 Pur 2 Manifold Air and Exhaust Pressure Sensor Return
403 Wht 3 Manifold Air and Exhaust Pressure Sensor Low
404 Brn 4 Manifold Air and Exhaust Pressure Sensor
405 Pnk 5 Ambient Air Temp Sensor (Not Used - Turbo only)
406 Brn 6 Ambient Air Temp Sensor Gnd (Not Used - Turbo only)
407 Grn 7 Coolant Water Temp Sensor
408 Blu 8 Coolant Water Temp Signal

X5058 (Red Connection)

420 Org 1 EGR Vbat from main harness EGR valve relay
F250 Yel 2 CAN1H (EGR Valve)
F150 Grn 3 CAN1L (EGR Valve)
122 Blk 4 Battery Ground
421 Pnk 5 5V Intake Throttle Signal
422 Grn 6 TPS Return
423 Brn 7 5V Sensor Supply Return
424 Org 8 Intake Throttle Motor H
425 Wht 9 Intake Throttle Motor L
426 Pur 10 Manifold Air Temp Sensor
427 Pnk 11 EGR Temp Sensor Signal
12
X5059 (Gray Connection)
440 Pnk 1 5V Rail Pressure Sensor
441 Grn 2 Rail Pressure Sensor Return
442 Wht 3 Rail Pressure Sensor Pump
443 Pnk 4 5VS Cam Speed Sensor
444 Blu 5 Cam Position Sensor Signal
445 Wht 6 Cam Position Sensor Return
446 Pnk 7 Crank Position Sensor Signal
447 Org 8 Crank Position Sensor Return
448 Blk 9 Crank Position Sensor Shield Gnd
451 Pur 10 Exhaust Manifold Temp Sensor
449 Blu 11 Fuel Temp Sensor Signal
450 Brn 12 5V Sensor Supply

1 X5060 (Yellow Connection)

2
460 Grn 3 Injector-1H
461 Org 4 Injector-1L
TCT007290 —UN—03JUL14

462 Wht 5 Injector-2H

463 Blu 6 Injector-2L
464 Gry 7 Injector-3H
465 Brn 8 Injector-3L
Sp-7 466 Grn 9 Suction Control Valve H
468 Grn 467 Grn 10 Suction Control Valve H
471 Wht 469 Wht 11 Suction Control Valve L
Sp-8 470 Wht 12 Suction Control Valve L

OUMX258,0000C4F -19-19MAR15-9/9

TM130419 (24FEB16) 230-20-15 030916

PN=739
 Schematics

Engine Connector X5057 Schematic

B5114 B5208
Manifold Air Engine
and Exhaust Coolant
Pressure Sensor Temperature
1 2 3 4 5 6 Sensor
2
t/U
1

2-45

2-85

2-39

2-74

1-28

1-29
X5057 1 2 3 4 5 6 7 8
Interconnect
E 1 2 3 4 5 6 7 8
401 Pnk

405 Pnk
403 Wht

407 Grn
404 Brn

406 Brn
402 Pur

408 Blu
EGR Pressure Isochronous In - Low

Engine Coolant Water Temp Pump

5V EGR Pressure Sensor Return

Air Temperature Sensor Ground

Air Temperature Sensor Signal
EGR Pressure Sensor Return

Cam Temperature Sensor

5 V Sensor Supply #2 +

TCT009969 —UN—28FEB14
02- 02- 02- 02- 02- 02- 01- 01-
45 85 39 74 79 21 28 29

A5502 ECU Connection A5501 ECU Connection

A5501—ECU Connector B5208—Engine Coolant

A5502—ECU Connector Temperature Sensor
B5114—Manifold and Exhaust X5057—Main Harness to Engine
Pressure Sensor Harness Connector, Red
OUMX258,00001A1 -19-03JAN14-1/1

TM130419 (24FEB16) 230-20-16 030916

PN=740
 Schematics

Engine Connector X5058 Schematic

B5206 B5207
Y5400 Y5401 Manifold Air EGR
EGR Air Throttle Temperature Temperature
Valve Actuator 2-52 Sensor Sensor
A B C D A B C D E F
A A

2-76

2-54

1-20

1-19

2-52

2-23

2-20
t/U t/U
B B

R5606
Resistor
2-76 A B 2-54 Battery +

Battery -
2-54

2-76

2-23

2-20

2-52

1-19

1-20

1-59

2-33
1 2 3 4 5 6 7 8 9 10 11 12
X5058 1 2 3 4 5 6 7 8 9 10 11 12
Interconnect
F
F150 Grn
F250 Yel

421 Pnk
420 Org

425 Wht

427 Pnk
422 Grn

424 Org
423 Brn

426 Pur
122 Blk

K2
EGR Valve
Relay
Battery +

85 86

Manifold Air Temperature Sensor Signal

Battery -

30 87
87a
EGR Temperature Sensor Signal

Air Throttle Actuator Drive High

Air Throttle Actuator Drive Low

Air Throttle Actuator Signal

5 V Sensor Supply Return

5 V Sensor Supply #2 +
Engine CAN High

Engine CAN Low

02- 02- 02- 02- 02- 02- 01- 01- 01-

54 76 23 20 52 33 19 20 59

A5502 ECU Connection A5501 ECU Connection

TCT009968 —UN—28FEB14
+
G5000
Battery
-

A5501—ECU Connector B5207—EGR Temperature Sensor Y5400—EGR Valve

A5502—ECU Connector K2—EGR Valve Relay Y5401—Air Throttle Actuator
B5206—Manifold Air Temperature X5058—Main Harness to Engine
Sensor Harness Connector, Red
OUMX258,00001A2 -19-03JAN14-1/1

TM130419 (24FEB16) 230-20-17 030916

PN=741
 Schematics

Engine Connector X5059 Schematic

B5216 B5209
B5302 Exhaust Manifold Fuel
Camshaft Temperature Temperature
Speed Sensor Sensor
Sensor
B5301
3 2 1 Crankshaft 1 2
Position
B5100 Sensor
Fuel Rail t/U t/U
Pressure
Sensor 2 1
2

p/U 2 1

3
1-07

1-26

1-25

1-08

1-37

1-52

1-39

1-54

2-56

1-11

1-51
1 2 3 4 5 6 7 8 9 10 11 12 X5059
1 2 3 4 5 6 7 8 9 10 11 12
Interconnect
G
442 Wht

445 Wht
440 Pnk

443 Pnk

446 Pnk
441 Grn

447 Org

450 Brn
451 Pur
444 Blu

449 Blu
448 Blk

Exhaust Manifold Temperature Sensor Signal

Fuel Rail Pressure Sensor Return

Crankshaft Speed Sensor Return

Crankshaft Speed Sensor Signal
Fuel Rail Pressure Sensor Signal

Crankshaft Sensor Wiring Shield

5 V Rail Pressure Sensor Supply

Fuel Temperature Sensor Signal

Camshaft Speed Sensor Return
Camshaft Speed Sensor Signal
5 V Camshaft Sensor Supply

5 V Sensor Supply Return

TCT009970 —UN—28FEB14
01- 01- 01- 01- 01- 01- 01- 01- 01- 01- 01- 02-
07 26 25 08 37 52 39 54 38 11 51 56

A5501 ECU Connection A5502 ECU Connection

A5501—ECU Connector B5209—Fuel Temperature Sensor B5301—Crankshaft Position

A5502—ECU Connector B5216—Exhaust Manifold Sensor
B5100—Fuel Rail Pressure Temperature Sensor B5302—Camshaft Speed Sensor
Sensor X5059—Main Harness to Engine
Harness Connector, Gray
OUMX258,00001A3 -19-03JAN14-1/1

TM130419 (24FEB16) 230-20-18 030916

PN=742
 Schematics

Engine Connector X5060 Schematic

A5501 ECU Connection

01- 01- 01- 01- 01- 01- 01- 01-
48 18 47 17 33 16 04 05

High Pressure Pump High

High Pressure Pump Low

Injector #1 Drive High

Injector #3 Drive High

Injector #2 Drive High
Injector #1 Drive Lo

Injector #3 Drive Lo
Injector #2 Drive Lo

Y5002
2 1
Suction
Control
Valve

1-05 1-33 1 2
Y5008
470 Wht 12 12 Fuel
1-05 1-16 Injector
469 Wht 11 11
Connector 3
10 10 1-04
467 Grn
9 9 1-04 Y5007
466 Grn 1-47 1 2
1-16
Fuel
465 Brn 8 8 Injector
1-17
7 7 1-33 Connector 2
464 Gry
6 6 1-17
463 Blu
1-47 1-48 1 2
Y5006
462 Wht 5 5 Fuel
Injector

TCT009971 —UN—28FEB14
4 4 1-18 1-18
461 Org Connector 1
3 3 1-48
460 Grn
2 2 X5060 A Flywheel
Interconnect
1 1 H

A5501—ECU Connector Y5007—Fuel Injector Connector 2 X5060—Main Harness to Engine

Y5002—Suction Control Valve Y5008—Fuel Injector Connector 3 Harness Connector,
Y5006—Fuel Injector Connector 1 Yellow
OUMX258,00001A4 -19-03JAN14-1/1

TM130419 (24FEB16) 230-20-19 030916

PN=743
 Schematics

Engine Controls and Sensors Schematic

K3 681 Pnk 1
X5058
1 Interconnect
C2 704 Pur
A B

420 Org
C6
Y22 / Y5501 K2 B19
VCU Low-Pressure
Connection Fuel Pump EGR Valve Engine Oil
Relay Pressure
85 86 85 86
Switch
30 87 30 87 620 Tan
703 Pur T-19
87a 87a

671 Blu
P

Engine Oil Pressure Switch Signal

K1 S2 S1
921 Wht

709 Pur

Glow Plug
B A
Relay V13
M G Diode

Start - Key Switch

Start - Key Switch

Start S23
Cold Start Aid

670 Blu
Run
Off Key Switch

02- 02- 02- 02-

70 35 68 15
A5501 ECU Connection
02- 02- 02-
A5502 ECU Connection 02- 02- 02- 02- 01- 02-
43 61 62 81 80 77 24 12 63

5 V Sensor Supply Return

5 V Sensor Supply #3 +

DPF Inlet Pressure Sensor Signal

DPF Differential Pressure Sensor Signal

DOC Inlet Temp Sensor Signal

DOC Outlet Temp Sensor Signal

5V Sensor Supply +

5V Sensor Ground
5V Sensor Return

B5201 B5202

483 Blk
991 Org

992 Pur
990 Brn

DOC Inlet DOC Outlet

485 Wht

486 Brn

Temperature Temperature
Sensor Sensor

2 1
480 Pnk
t/U t/U 482 Grn
481 Blu
487 Blk

3 2 1 C10 1 2 490 Blk

B10

TCT009972 —UN—06JUN14
489 Blk
Accelerator
Sensor 1 2 3 4 5 6

B5109
Pressure Sensor

A5501—ECU Connector B5109—DPF Differential Pressure C6—VCU Connector X5058—Main Harness to Engine
A5502—ECU Connector Sensor K1—Glow Plug Relay Harness Connector, Red
B10— Accelerator Sensor, Hall B5201—DOC Inlet Temperature K2—EGR Valve Relay
Effect Sensor S23— Key Switch
B19— Engine Oil Pressure Switch B5202—DOC Outlet Temperature V13— Diode
Sensor Y22 / Y5501—Fuel Pump, Low
Pressure
OUMX258,00001A5 -19-16FEB16-1/1

TM130419 (24FEB16) 230-20-20 030916

PN=744
 Schematics

Cab Schematic, Lower

X-S20
Wiper Switch
Off
Low
High

P
224A Yel

L
245B Dk Grn

B
1

245D Dk Grn

2
226A Lt Blu
272D Yel

4
122A Red

X-FH T1
1 2
20A
Switched
3 4

5 6

272L Red
272D Yel
072A Yel

7 8
30A 20A
9 10
072 Yel

20A
C12 X-FW 11 12
Main Firewall Sp-272A
052A Red

Schematic Bulkhead
272C Yel

T2
561 Yel 1 072B Yel Sp-072
560 Yel 2 072C Yel
202 Red 3 002A Red
191 Blk 4 010PT Blk
562 Yel 5 072D Yel
775 Grn 6 216A Grn
062A Red

T-9
A/C Compressor
TCT008553 —UN—07JUL14

010BK Blk
010CE Blk
Sp-010G 010AF Blk
010PT Blk 010CB Blk

Continued on next page OUMX258,000015A -19-17JUL14-1/2

TM130419 (24FEB16) 230-20-21 030916

PN=745
 Schematics

Cab Schematic, Lower (2 of 2)

103L Red
103H Org 103J Org
Sp-103C
B A Sp-103A
103F Org
X-D2
OFF

103D Org

103M Org
103E Org
HAZARD
S08 ROAD
Work Light FIELD
DETENTS (ALL)
Switch
1

2
B
157L Pur
3 S12
122C Red

Beacon
147K Pur
4 Switch
010BK Blk 7 8
010CA Blk 163E Org
3
2
122A Red 122E Red 122E Red 1
Sp-122 6
5

163F Org
4
9 10
On
Off

103J Org

S09
103M ORG

Turn signal
Switch
1 3 C
2 D 2
120D Org 3
272L Red 1 E
010CE Blk 4
5 6

X-FR 6 A 5
010CA Blk
4
Flasher Relay

A B Sp-103B
103E Org 103N Org 103G Org
X-D1

216A Grn 1 216B Grn

103L Red 2 103R Red
103K Red 3 103P Red
120D Org 4 120A Org
157L Pur 5 157C Pur
147K Pur 6 147G Pur
163F Org 7 163D Org
052A Red 8 052B Red
245D Dk Grn 9 245A Dk Grn
062A Red 10 062B Red
226A LT Blu 11 226 Lt Blu
TCT008554 —UN—07JUL14

272C Yel 12 272E Yel

224A Yel 13 224 Yel
010AF Blk 14 010AE Blk
15
010CB Blk 16 010CR Blk
17
X-RFR 18
19
X-RFP

OUMX258,000015A -19-17JUL14-2/2

TM130419 (24FEB16) 230-20-22 030916

PN=746
 Schematics

Cab Schematic, Upper

1
2
X-S52 3
Dome Door
Off
Light On

1
2
3
4
Wiper

Grn
Org
Gry
Brn
Blk
Motor X-M08 X-M07
^ ^ ^ ^ ^ ^ RH Blower LH Blower

1
6
3
2
5
4
X-WP Motor Motor
M M

245A Dk Grn
010CC BLK
226 LT BLU
227C PUR

272H YEL
224 YEL
7 9

3 ^ ^ ^ ^ ^ ^ ^ ^

C
D

C
D
A
B

A
B
2 214 YEL
1

010CM Blk
010CG Blk
S22

010CF Blk
052E Red

213B Org

213A Org
221C Brn
227D Pur

221B Brn
227E Pur
6
5
4 HVAC Enable
8 10
On Switch
Off Sp-221

214 YEL 216B GRN

052C Red
T23 S23
HVAC P HI-LO
t˚ Temp Pressure Sp-052
Switch Switch

052D Red
T24
215 DK GRN Sp-227

062B Red
213B Org
227B Pur

216A GRN 1 216B GRN 221A Brn

103L RED 2 103R RED 103R Red
103K RED 3 103P RED 103P Red
120D ORG 4 120A ORG 120A Org
157L PUR 5 157C PUR 157C Pur
147K PUR 6 147G PUR 147G Pur
163F ORG 7 163D ORG 163D Org
052A RED 8 052B RED 052B Red
245D Dk Grn 9 245A Dk Grn
062A RED 10 062B RED 010CG Blk
226A Lt Blu 11 226 Lt Blu 010AE Blk
272C YEL 12 272E YEL 010CR Blk
224A YEL 13 224 YEL
010AF Blk 14 010AE Blk
15 272H Yel
010CB Blk 16 010CR Blk 272E Yel
TCT008555 —UN—17JUN14

17
18
19
X-RFR X-RFP

Continued on next page OUMX258,000015B -19-18JUL14-1/4

TM130419 (24FEB16) 230-20-23 030916

PN=747
 Schematics

Cab Schematic, Upper (2 of 4)

157G Pur 157G Pur

157D Pur 157D Pur
010BP Blk
010BT Blk
157K Dk Grn 157K Dk Grn

Sp-157 157H Pur 157H Pur

157E Pur 157E Pur

157J Dk Grn 157J Dk Grn
052C Red 052C Red
010CM Blk
010CF Blk
010CC Blk
X-E23 X-E24 X-E22
LH Rear RH Rear LH Rear
Beacon Work Light < B< Work Light Amber Light
< A<

< A<
< B<

145F Dk Grn
Light
M
147H Pur

147J Pur
010BW Blk
157C Pur

X-E16 T14
157F Pur

< B<
< A<
010BL Blk 010BV Blk
Sp-147

Sp-010F

062B Red
213B Org
227B Pur
213A Org
221A Brn
103R Red
103P Red
120A Org

147G Pur
163D Org
010BU Blk
010BW Blk
010CG Blk
010AE Blk
010CR Blk 230A Blk
052D Red
157F Pur
272H Yel
272E Yel
TCT008556 —UN—17JUN14

Continued on next page OUMX258,000015B -19-18JUL14-2/4

TM130419 (24FEB16) 230-20-24 030916

PN=748
 Schematics

Cab Schematic, Upper (3 of 4)

157G Pur
157D Pur
010BP Blk
010BT Blk
157K Dk Grn

X27-W20
157H Pur R2 RH Front X-E20
Marker Light
RH Front

< A<
< B<
Work Light
157E Pur
157J Dk Grn
052C Red
157J Dk Grn
145F Dk Grn
135D Dk Grn
X-H03 Sp-135
X-E26 X-E25
Left <A < 237A Pur RH Rear RH Front
Speaker <B < 236A Lt Blu Amber Light Amber Light

135E Dk Grn
135F Dk Grn

Right <A < 235A Dk Grn

< B<
< A<

< B<
< A<
Speaker <B < 234A Yel

X-H04
062B Red
213B Org
227B Pur
213A Org
221A Brn
103R Red
103P Red
120A Org
010BX Blk
010BY Blk
010BR Blk Sp-010E
010BU Blk
010BW Blk
010CG Blk
010CH Blk

010AE Blk

Sp-272B
272H Yel
272E Yel 272J Yel
TCT008557 —UN—07JUL14
235A Dk Grn
236A Lt Blu
052D Red

237A Pur
157F Pur

230A Blk
272G Yel

234A Yel
272F Yel

X-A01
10
11
12
13
14
15
16
1
2
3
4
5
6
7
8
9

Radio

Continued on next page OUMX258,000015B -19-18JUL14-3/4

TM130419 (24FEB16) 230-20-25 030916

PN=749
 Schematics

Cab Schematic, Upper (4 of 4)

157G Pur
157D Pur
010BP Blk X26-W20 X55
R2 LH Front
Marker Light
010CW Blk
85 86 K14
30 87
052C Red
87a
Left Blower
< B<
< A<

LH Front Relay
X-E19 Amber 292 Red
LH Front Light 272K Red
010CW Blk
Work Light X-E21 85 86 K13
< B<
< A<

010CN Blk
135D Dk Grn 30 87 RH Amber
87a
010BT Blk Lights Relay
120B Org
157J Dk Grn
Sp-145
145F Dk Grn 145E Dk Grn 103P Red
010CN Blk
010CL Blk
85 86 K12
145D Dk Grn 30 87 LH Amber
87a
Lights Relay
Sp-120 120C Org
157K Dk Grn
103R Red
272K Red
120A Org 010CL Blk
010CK Blk
85 86 K11
062B Red 30 87 Right
87a
Blower Relay
282C Red
272J Yel
Sp-282

010CK Blk
85 86
010CJ Blk K10
30 87
282B Red
87a
R HI-Speed
Blower Relay
213B Org
S24 225C Dk Grn
OFF Blower
LOW 010CJ Blk
MED Switch 85 86 K9
282A Red

010CH Blk
HIGH
DETENTS (ALL) 292 Red 30 87 L HI-Speed
87a
Blower Relay
227B Pur
1
221A Brn
B 2
TCT008558 —UN—07JUL14

225A Dk Grn 225B Dk Grn

3 Sp-225
213A Org

OUMX258,000015B -19-18JUL14-4/4

TM130419 (24FEB16) 230-20-26 030916

PN=750
 Schematics

GLC Schematic
X2
1
YEL
2
40 C VIO
Oil
Temperature
Switch
X3
1
YEL
2
80 C GRY
Oil X7
Overtemperature
Switch YEL 1
X4 2
1
BRN
2
BLK
3
Hydraulic BLK
Valve
X1 6 9 2 14 7

Controller

X1 3 12 13 4 10
4
ORG

X5 5
1 RED
VIO
2 6
VIO VIO

Collector
Switch
BRN

WHT X12
1
RED

K1 87 87a K2 87 87a
85
Fan
85
Fan BLK BLK
Reverse Normal
86 30 Relay 86 30 2
Relay BLK

TCT010859 —UN—20MAY14
BLK

X6
M1 1
Fan 2
Motor BLU

GLC System (1 of 2)
K1—Fan reverse Relay X3— Oil Overtemperature Switch X5— Collector Switch Connector
K2—Fan normal Relay Connector X7— Harness Connector
M1—Fan Motor X4— Hydraulic Valve Connector X12— Power Connector
X2— Oil Temperature Switch
Connector
Continued on next page OUMX258,0000447 -19-23JUL14-1/2

TM130419 (24FEB16) 230-20-27 030916

PN=751
 Schematics

GLC Schematic

X8
1

X7 S2
X9
Seat
1 2 Switch
YEL
2
YEL 1

3
BLK

X10
X10
5
7
3 S1
4 ON
ORG Switch
5 10
RED
2 Oil Temperature
6 Warning LED
VIO

D1

X12 B+
F1 to alternator
1
RED 20A

GND
to alternator
2
BLK

TCT010860 —UN—20MAY14

GLC System (2 of 2)
D1—Diode, Mini 1.5 A S2— Seat Switch X9— Seat Switch Connector
F1— Fuse, 20A X8— Seat Switch Connector X10— ON switch Connector
S1— GLC ON Switch
OUMX258,0000447 -19-23JUL14-2/2

TM130419 (24FEB16) 230-20-28 030916

PN=752
 Schematics

Electrical Components, Homologation HF5 — Brake Light Fuse

HF6 — Not Used
HFL16 — Flasher Unit HF7 — Headlight
HE1 — RH Brake, Turn, Position Light HF8 — Headlight
HE4CO — Headlight HK1 — Headlight Relay
HE5 — LH Brake, Turn, Position Light HH1 — Horn
HE5CO — Headlight HS3 — Brake Switch
HE6 — LH Front Turn Position Light HS4 — Turn Signal Switch
HE7 — RH Front Turn Position Light HS5 — Headlight Switch
HE11 — Position Lights Green Indicator HS7 — Hazard Switch
HE23 — License Plate Light HS18 — Horn Switch
HF1 — Headlight, Horn, Flasher Fuse HV1 — 6 Amp Diode
HF2 — Headlight Relay Fuse
HF3 — LH Position Lights Fuse
HF4 — RH Rear and FH Front Position and License Plate
Light Fuse
CB12260,0000115 -19-23JUL14-1/1

TM130419 (24FEB16) 230-20-29 030916

PN=753
 Schematics

Homologation Wiring Schematic

Homologation Wiring Schematic (1 of 3)

T-17 Brake Switch

Horn 500 Blu Engaged
101 Blk Disengaged
Turn Pos Light T-18
A 302 Grn
Blk 306 Grn C
Pos A 703 Pur
Grn B 803 Pnk B D
Turn Wht C 105 Blk 900 Pnk 901 Pnk
X-7A X-3A

900 Pnk
703 Pur
301 Gr
126 Blk
X-4A 801 Pnk
Yel A A A 300 Grn 803 Pnk
LO Blk B B B 102 Blk
POS Gry C C C
HI Wht D D D
Headlight X-4B CO
306 Gr
101 Blk 500 Blu
105 Blk Spl-1A
X-5A 102 Blk 126 Blk 300 Gr
Yel A A A 301 Grn 106 Blk
Lo Blk B B B 106 Blk 104 Blk
Pos Gry C C C
Hi Wht D D D
Headlight X-5B CO
802 Pnk
Turn Pos Light 800 Pnk
Blk A 704 Pur
Pos Grn B 801 Pnk
Turn Wht C 104 Blk
X-6A 112 Blk
700 Pur

X-17 302 Grn

706 Pur
710 Pur A 704 Pur
118 Blk B L-23
License Plate Light
701 Pur
702 Pur
Brake Light RH
X-1B

700 Pur
Grn A A 806 Pnk
Turn Wht B B 109 Blk
Pos Blk C C 705 Pur
Brake Blu D D 304 Grn
305 Grn 203 Red
118 Blk Spl-9
109 Blk 113 Blk 202 Red
108 Blk
707 Red
Brake Light LH X-5B
Grn Spl-11
Turn A A 807 Pnk 708 Pur
Wht B B 108 Blk
Pos Blk C C 710 Pur
203 Red
202 Red

Brake Blu D D 305 Grn

Spl-8
Spl-7

302 Grn 1 1 304 Grn

112 Blk 2 2 113 Blk
200 Red Fuselink
201 Red Fuselink

802 Pnk 3 3 806 Pnk

702 Pur 4 4 705 Pur
800 Pnk 5 5 807 Pnk
701 Pur 6 6 706 Pur
X-11 X-10
TCT011516 —UN—20JUN14

1
+12 VDC
T-15
Main Power Fuse

Continued on next page CB12260,0000114 -19-26FEB15-1/3

TM130419 (24FEB16) 230-20-30 030916

PN=754
 Schematics

Homologation Wiring Schematic (2 of 3)

800 Pnk
Cruise Control V-1
Interface 6 Amp
302 Grn A
B 900 Pnk
C
D 901 Pnk A B
X-3B

808 Pnk
803 Pnk
804 Pnk
900 Pnk
703 Pur
301 Grn
Gr
126 Blk
801 Pnk
803 Pnk

Spl-5 111 Blk

126 Blk 100 Blk
110 Blk

110 Blk
Spl-6
112 Blk 107 Blk
103 Blk
700 Pur
K-1
85 86
404 Yel 107 Blk
204 Red 30 87 403 Yel
87A
Headlight Relay

205 Red 421 Yel 15A 306 Grn

203 Red 30A 207 Red A B
A B
__A
202 Red 30A 204 Red C D
C D
704 Pur 423 Yel 10A 300 Grn
707 Red 10A 702 Pur E F
E F
703 Pur 422 Yel 10A 301 Grn
708 Pur 10A 701 Pur G H
G H Spl-10 H-1
X-14
X-15 +12VDC A 404 Yel
Hot In Run B
Position

407 Yel
TCT011517 —UN—20JUN14

Continued on next page CB12260,0000114 -19-26FEB15-2/3

TM130419 (24FEB16) 230-20-31 030916

PN=755
 Schematics

Homologation Wiring Schematic (3 of 3)

125 Blk
X-4 X-5 X-7
4 407 Yel 3
122 Blk 5 5 122 Blk
4

405 Yel
808 Pnk

411 Yel
3 5
2 800 Pnk 2 1 700 Pur
1 805 Pnk 709 Pur 1
804 Pnk
410 Yel

214 Red
802 Pnk
409 Yel

Left

805 Pnk
Lights
Off ON

801 Pnk
Markers
Right

410 Yel
Off OFF
Turn Signals Headlight Switch Hazard Switch

Spl-3
205 Red

Spl-4
403 Yel 405 Yel
421 Yel
111 Blk Spl-2
115 Blk
218 Red

Position Lights
T-16 T-1 115 Blk
Green
500 Blu 218 Red Indicator
Horn Switch T-6

709 Pur
T-7

78 -96
3 Watt
49A 49
X-16
100 Blk

49a A 409 Yel

C B
49 C 207 Red
W-1 C3 D
C2 E
31 F 103 Blk
Flasher Unit
TCT011518 —UN—20JUN14

CB12260,0000114 -19-26FEB15-3/3

TM130419 (24FEB16) 230-20-32 030916

PN=756
 Schematics

Front Work Light Wiring Schematic

Right C-4
Column Right
A
Column
Light B
Light
Harness
Interface
203 YEL
A 202 YEL
B 101 BLK
100 BLK
C-3

C-5
F-1 85 86 S-1
30 87 1 2
15A 204 YEL 206 YEL
A B
87A
Fuse Holder Work Light
with Cover Relay

S-2
1 2

C-1
Right
A 200 YEL
X-1 Work B 102 BLK
Light

TCT011520 —UN—12SEP14
(+) A 205 YEL
(-) B 104 BLK
X-1 Connexts to Switched Power Reft C-2
Connector on Main Harness Work A 201 YEL
B 103 BLK
Light

WC-1— RH Work Light WC-4— Column Light WSp-1—Switched Power Splice

WC-2— LH Work Light WF-1— Fuse Holder WSp-2—Ground Splice
WC-3— Column Light Interface WK-5— Work Light Relay WX-1— To Vehicle Switched
Power
CB12260,0000120 -19-23JUL14-1/1

TM130419 (24FEB16) 230-20-33 030916

PN=757
 Schematics

Backup Alarm Wiring Schematic

Reverse Switch
Forward
Reverse
Main Harness A C
Switched Power
SPL-01
1 2 B D
A 401 YEL 401 YEL 402 YEL
B 101 BLK C-05
C-01
C-04 601 ORG A
102 BLK B
403 YEL
Beeper

TCT011521 —UN—12SEP14
C-03
A 403 YEL SPL-02
A 1 2
B 103 BLK 101 BLK 102 BLK
C-02
103 BLK

BAC-01—Reverse Switch BAC-03—Cap BAC-05—Alarm BSp-02—Ground Splice

Connector BAC-04—To Vehicle Switched BSp-01—Switched Power Splice
BAC-02—Power Pass Through Power
CB12260,0000121 -19-23JUL14-1/1

TM130419 (24FEB16) 230-20-34 030916

PN=758
 Schematics

Beacon Light Wiring Schematic

BSpl-2
1 2
150 Blk 113 Blk

152 Blk

BC-42
A 503 Yel BSpl-1
1 2
B 152 Blk 504 Yel

151 Blk
Vehicle Harness 502 Yel
Switched Power BT-12
Interface
302 Grn

BC-41 113 Blk

A 502 Yel
B 150 Blk
BT-13

BX-8
151 Blk
504 Yel

302 Grn
1
2

TCT011522 —UN—09JUL14
On

Off

Beacon Switch

BC-41—Power From Vehicle BSp-2—Ground Splice BT-13—Beacon Lamp Ground

BC-42—Power Out BT-12—Beacon Lamp Power Terminal
BSp-1—Switched Power Splice Terminal BX-8— Beacon Lamp Switch
Connector
CB12260,0000122 -19-23JUL14-1/1

TM130419 (24FEB16) 230-20-35 030916

PN=759
 Schematics

TM130419 (24FEB16) 230-20-36 030916

PN=760
 Group 30
Diagnosis
Power Circuit Diagnosis, Non-T4
Power Circuit Diagnosis
OUMX258,0000C28 -19-17SEP14-1/15

Unswitched Power Circuit

OUMX258,0000C28 -19-17SEP14-2/15

•1 Battery Check Is there 11.8—13.2 VDC measured at the battery terminals? YES: Go to next step.

NO: Clean battery

terminals and retest. If the
voltage is too high, check
charging circuit.

OUMX258,0000C28 -19-17SEP14-3/15

•2 Alternator Is there 11.8—13.2 VDC measured at the alternator connector Red cable connection?
(See Alternator Connector, Non-T4.)
YES: Go to next step.

NO: Check EF-1 fuse and

wire connections.

OUMX258,0000C28 -19-17SEP14-4/15

•3 Fuel Pull-In Relay Is there 11.8—13.2 VDC measured at the relay Red wire? (See Fuel Pull-In Relay
Connector.)
YES: Go to next step.

NO: Check 200 series Red

wires and connections.

OUMX258,0000C28 -19-17SEP14-5/15

•4 Air Heater Relay Is there 11.8—13.2 VDC measured at the relay Red wire? (See Air Heater Relay
Connector.)
YES: Go to next step.

NO: Check 200 series Red

wires and connections.

OUMX258,0000C28 -19-17SEP14-6/15

•5 Cab Power Relay Is there 11.8—13.2 VDC measured at the relay connector Red wire? (See Cab Power
Relay Connector.)
YES: Go to next step.

NO: Check 200 series Red

wires and connections.

OUMX258,0000C28 -19-17SEP14-7/15

•6 Auxiliary Power Outlet Is there 11.8—13.2 VDC measured at the power outlet? YES: Go to next step.

NO: Check F1 fuse. Check

200 series Red wires and
connections.

Continued on next page OUMX258,0000C28 -19-17SEP14-8/15

TM130419 (24FEB16) 230-30-1 PN=761

030916
 Diagnosis

•7 Key Switch Is there 11.8—13.2 VDC measured at the key switch connector red wire, B terminal?
(See Key Switch Connector.)
YES: Unswitched power
circuit is functional.

NO: Check 200 series Red

wires and connections.
OUMX258,0000C28 -19-17SEP14-9/15

Switched Power Circuit (Lights Only)

OUMX258,0000C28 -19-17SEP14-10/15

•1 Control Module Is there 11.8—13.2 VDC measured at each side of the F4 control module fuse? YES: Go to next step.

NO: Replace fuse if power

is only on one side of fuse.
NO: Check 400 Yel wire
and key switch if no power
is present on each side of
fuse. (See Key Switch Test.)
OUMX258,0000C28 -19-17SEP14-11/15

•2 Light Switch Is there 11.8—13.2 VDC measured at the light switch connector 450 Yel wire? (See
Light Switch Connector.)
YES: Go to next step.

NO: Check 450 Yel wire

and connections. Check
control module connector
contacts.

OUMX258,0000C28 -19-17SEP14-12/15

•3 Headlights Is there 11.8—13.2 VDC measured at the headlights E-1 connector Yel wire with the
light switch in the On position? (See Headlights Connector.)
YES: Light circuit is
functional.

NO: Test light switch?

OUMX258,0000C28 -19-17SEP14-13/15

Switched Power
OUMX258,0000C28 -19-17SEP14-14/15

•1 Control Panel Fuse Is there 11.8—13.2 VDC measured at each side of the F3 control module fuse? YES: Go to next step.

NO: Replace fuse if power

is only on one side of fuse.
NO: Check 400 Yel wire
and key switch if no power
is present on each side of
fuse. (See Key Switch Test.)

OUMX258,0000C28 -19-17SEP14-15/15

TM130419 (24FEB16) 230-30-2 PN=762

030916
 Group 40
Tests and Adjustments
Summary of References • Fuse Test
• Battery Test • A/C (HVAC) Switch Test
• A/C Temperature Control Switch Test
• Battery Load Test • Dome Light Switch Test
• Battery Charge • Door Switch Test
• Regulated Voltage Output Test • PTO Switch Test, Non-T4
• Key Switch Test • PTO Switch Test, T4
• Beacon Light Switch Test • Park Brake Switch Test
• Relay Test • PTO Solenoid Test
• Relay Test, Cab Power • Hydraulic Temperature Switch Test
• Glow Plug Test • Engine Oil Pressure Switch Test
• Air Preheater Test • Coolant Temperature Switch Test
• Diode Pack AMT386 Test • Fuel Pump Test
• Diode Pack AMT477 Test • Fuel Shutoff Solenoid Test, Non-T4
• Headlight Switch Test (Single) • Cruise Control Magnet Test
• Turn Signal Switch Test • Seat Switch Test
• Rotary Light Switch Test • Warning Alarm Test
• Rotary Blower Switch Test • DPF Differential Pressure Sensor Test, T4
• Cruise Control Switch Test • DPF Inlet Temperature Sensor, T4
• Cruise Brake Switch Test, Non-T4 • DPF Mid Temperature Sensor, T4
• Wiper Switch Test • Accelerator Sensor Test, T4
• Diode Test
OUMX258,0000C4C -19-16SEP14-1/1

TM130419 (24FEB16) 230-40-1 030916

PN=763
 Tests and Adjustments

Battery Test

CAUTION: Sulfuric acid in battery electrolyte is

poisonous. It is strong enough to burn skin,
eat holes in clothing, and cause blindness
if splashed into the eyes.
Avoid hazard by:

MXAL36375 —UN—26JUL12
1. Filling batteries in well ventilated area.
2. Wearing eye protection and rubber
gloves and vest.
3. Avoiding breathing fumes when
electrolyte is added.
4. Avoid spilling or dripping electrolyte.
5. Use proper jump-start procedure.
If you spill acid on yourself:
1. Flush your skin with water. 8. Use a hydrometer to check for a minimum specific
2. Apply baking soda or lime to help gravity of 1.225 with less than 50 point variation in
neutralize the acid. each cell.
3. Flush your eyes with water for 10 - 15 minutes.
Get medical attention immediately. Results:
If acid is swallowed: • If all cells are less than 1.175, charge battery at 10 amp
1. Drink large amounts of water or milk. rate.
2. Then drink milk of magnesia, beaten • If all cells are less than 1.225 with less than 50 point
eggs, or vegetable oil. variation, charge battery at 10 amp.
3. Get medical attention immediately. • If all cells are more than 1.225 with less than 50 point
variation, load test battery.
Reason: • If more than 50 point variation, replace battery.
• Use a voltmeter or JT05685 Battery Tester to check for
To check condition of battery and determine battery a minimum battery voltage of 12.4 volts.
voltage.
Results:
Equipment:
• If battery voltage is less than 12.4 VDC, charge battery
• Hydrometer (See “Charge Battery”).
• JT05685 Battery Tester or equivalent • If battery voltage is more than 12.4 VDC, test specific
gravity.
Procedure:
1. Park machine safely with park brake locked. (See
“Safety Section”).
2. Raise hood.
3. Clean cable ends, battery terminals and top of battery.
4. Remove battery to workbench.
5. Inspect battery terminals and case for breakage or
cracks.
6. Check electrolyte level in each battery cell. Add
distilled water as needed. If water is added, charge
battery for 20 minutes at 10 amps.
7. Remove surface charge by placing a small load on
the battery for 15 seconds.
CB12260,0000074 -19-16SEP14-1/1

TM130419 (24FEB16) 230-40-2 030916

PN=764
 Tests and Adjustments

Battery Load Test

Reason:
To check condition of battery under load.
Equipment:

MXAL36377 —UN—26JUL12
• JT05685 Battery Tester or equivalent
Procedure:
1. Park machine safely with park brake locked. (See
“Safety Section”.)
2. Raise hood.
3. Clean cable ends, battery terminals and top of battery. A—Load Knob D—Amperage Reading
B—Tester Positive (Red) Cable E—DC Volts Scale
4. Remove battery. to Battery Positive (+)
Terminal
5. Turn load knob (A) counterclockwise to OFF position. C—Tester Negative (Black)
Cable to Battery Negative
6. Connect tester positive (red) cable to battery positive (–) Terminal
(+) terminal (B).
7. Connect tester negative (black) cable to battery
negative (–) terminal (C). 10. Repeat Steps 8 and 9 above and read condition of
8. Turn load knob (A) of tester clockwise (in) until battery at DC Volts scale (E).
amperage reading (D) is equal to: Results:
• Cold cranking amperage rating of battery (use blue • If battery DOES NOT pass test and has NOT been
scale), or
charged, charge battery and retest.
• Three times ampere hour rating (use black scale).
• If battery DOES NOT pass test and HAS BEEN
9. Hold for 15 seconds and turn load knob (A) of tester charged, replace battery.
counterclockwise to OFF position.
CB12260,0000073 -19-16SEP14-1/1

TM130419 (24FEB16) 230-40-3 030916

PN=765
 Tests and Adjustments

Battery Charge

MXT001932 —UN—22DEC11
Reason:
To increase battery charge after battery has been
discharged.
Procedure:
1. Connect variable rate charger to battery.
NOTE: Maximum charge time at boost setting is 10
minutes. Allow an additional 5 minutes for each
10 degrees below 21°C (70°F). 4. Set charger at 15—25 amps.
NOTE: If battery was discharged at slow or unknown
2. Start charger at slow rate. Increase charge rate one rate, charge at 10—15 amps for 6—12 hours
setting at a time. Check charger ammeter after 1 (Maintenance—free battery: 12—24 hours). If
minute at each setting. Maintain 10 A charge rate. battery was discharged at fast rate, charge at
Use boost setting as necessary. 20—25 amps for 2—4 hours (Maintenance—free
3. Check if battery is accepting a 10 A charge after 10 battery: 4—8 hours).
minutes at boost setting.
5. Check specific gravity after 30 minutes (60 minutes for
• Battery will not accept 10 A charge after 10 minutes maintenance—free battery).
at boost setting: replace battery.
• Battery is accepting 10 A charge after 10 minutes at • More than 50 point variation between cells: replace
boost setting, and battery did not need water: go to battery.
steps 6 and 7. • Less than 50 point variation between cells: go to
• Battery is accepting 10 A charge after 10 minutes at steps 6 and 7.
boost setting, but battery did need water or all cells 6. Continue charging battery until specific gravity is
were below 1.175: go to steps 4 and 5. 1.230—1.265 points.
IMPORTANT: Decrease charge rate if battery 7. Load test battery. (See “Battery Load Test”.)
gases or bubbles excessively or becomes
too warm to touch.
OUMX258,00002EA -19-11AUG14-1/1

Regulated Voltage Output Test Special or Required Tools

Reason
To check the regulated voltage (charging) output of the
alternator and system voltage.
CB12260,00001C5 -19-15AUG14-1/3

Multimeter.......................................................... JT05791A
Used to measure voltage.
Continued on next page CB12260,00001C5 -19-15AUG14-2/3

TM130419 (24FEB16) 230-40-4 030916

PN=766
 Tests and Adjustments

Procedure 9. Read meter several times during 5 minutes of running

1. Park machine on a level surface. time. Voltage should remain at specification.
Specification
2. Key switch OFF.
Regulated
3. Park brake LOCKED. Voltage—Voltage.............................................................13.2 - 14.7 volts

4. Remove surface charge from battery by turning on the Results

lights for one minute. If the machine is not equipped
with work lights, crank engine until it operates and • If the DC voltage remains below the minimum
then turn off engine. specification: Check belt tension. Test fuse links and
power cables between alternator and battery. Check
5. Set multimeter to measure voltage. any lamps, fuses, resistors, diodes and relays in the
circuit that supply the field/regulator terminal. Inspect
6. Connect meter black lead to battery negative (-) alternator for worn/damaged brushes, slip rings, shorted
terminal. diodes, burnt wires etc. If all appears OK, replace
7. Connect meter red lead to battery positive (+) voltage regulator.
• If the DC voltage goes above the maximum
8. Start and run engine at fast idle. specification, replace the voltage regulator.
CB12260,00001C5 -19-15AUG14-3/3

Key Switch Test

Reason:
To verify that the key switch is operating properly.

TCAL29043 —UN—22JUN12
Special or Required Tools

• Ohmmeter or Continuity Tester

Procedure:
1. Park machine safely.
2. Disengage PTO.
Key Switch Continuity
3. Turn key switch to STOP position. Switch Position Terminal Continuity
4. LOCK park brake. Stop C and D
Run E and F
5. Remove upper steering column cover.
Start E and F
6. Disconnect key switch connector. A and B

7. Use an ohmmeter or continuity tester to test switch • If any continuity is not correct, or continuity exists
continuity in STOP, run, and start positions. in any other combination than listed above, replace
the switch.
NOTE: Do not refer to markings stamped on terminals.
Identify by art keys only. Terminal combinations
other than those listed should not have continuity.

Results:
OUO1086,1001370 -19-17APR13-1/1

TM130419 (24FEB16) 230-40-5 PN=767

030916
 Tests and Adjustments

Beacon Light Switch Test

Reason:
2
To verify light switch is operating properly. 3 8
Equipment: 7 + 8

TCT008552 —UN—18NOV13
-
• Ohmmeter or Continuity Tester 2 7
• 12 VDC Power Supply
Procedure: 3
1. Park machine safely. (See the “Safety Section”.)
2. Disconnect switch from harness.
NOTE: The ohmmeter can not be used to check the LED.
2— Common 8— LED positive
3. Use an ohmmeter or continuity tester to test the switch 3— Terminal 7— LED negative
in all positions.
IMPORTANT: LED must be checked with correct Switch Continuity
polarity on positive and negative terminals. POS 1 ON 2—3
POS 2 NONE
4. Use 12 volt power supply to test LED. POS 3 OFF —

Results:
If continuity is not correct, replace the switch.
OUMX258,000015E -19-18NOV13-1/1

TM130419 (24FEB16) 230-40-6 030916

PN=768
 Tests and Adjustments

Relay Test
Reason
To check relay terminal continuity in the energized and
de-energized conditions.

TCAL27858 —UN—06JUN12
Special or Required Tools

• Digital Multimeter—JT05791A
Procedure
1. Park machine on level surface.
2. Move key switch to OFF position.
3. Park brake LOCKED. A—Terminal 30 D—Terminal 87
B—Terminal 86 E—Terminal 85
4. Remove right-side control console cover. C—Terminal 87a

5. Raise and latch seat platform.

6. Disconnect relay(s) from harness. 10. Connect a jumper wire from battery positive (+) to
7. Using JT05791A Digital Multimeter, check for relay terminal 86 (E). Connect a jumper wire from
continuity between terminals 87a (C) and 30 (A). There battery negative (-) to relay terminal 85 (B). The relay
should be continuity between terminals 87a and 30. should energize with an audible click.

8. Using a digital multimeter, check for continuity 11. Using a digital multimeter, check for continuity
between terminals 87 (D) and 30 (A). There should between terminals 87 (D) and 30 (A). There should be
NOT be continuity between terminals 87 and 30. continuity between terminals 87 and 30.

9. Using a digital multimeter, check for resistance Results

between terminals 85 (E) and 86 (B). There should
be approximately 65-70 ohms resistance @ 20°C
• If continuity is not correct, replace relay.
between terminals 85 and 86.
SH24924,00001FE -19-18APR14-1/1

Relay Test, Cab Power

1. Remove relay.
2. Use multimeter to check continuity between relay D
terminals A and C.
3. Check for no continuity between terminals B and D. B A

TCT007007 —UN—16APR13
C
4. Connect a jumper wire from battery positive (+) post
to relay terminal A. Connect a jumper wire from relay
terminal B to ground (—). Continuity should now exist
between terminals A and C. D C A
B
Results:

• If continuity is not correct, replace relay.

• If resistance between terminals A and C does not meet
specification, replace relay. A—Coil C—Coil
B—NO D—NO
Specification
Relay Coil—Resistance.................................................... 75 ohms ±10%

OUMX258,0000C4B -19-15SEP14-1/1

TM130419 (24FEB16) 230-40-7 030916

PN=769
 Tests and Adjustments

Glow Plug Test

3. Measure resistance between glow plug terminal and
Reason: engine ground. Repeat for all glow plugs.
To test operation of glow plugs. NOTE: Subtract the residual test lead resistance
(offset) from measurement for meters without
Equipment: a “zero ohms” function.
• Digital ohmmeter with a resolution no less than 100 4. Record glow plug resistance values. Replace glow
milliohms.
plugs as a set if defective or if values between plugs
1. Remove electrical connections from glow plug vary widely.
terminals; clean off any oil, dirt, or corrosion. Specification
2. Locate a clean ground connection on the engine block Glow Plug—Resistance.....................................................0.2—2.0 ohms
or starter motor.
OUMX068,00002BC -19-11DEC15-1/1

Air Preheater Test

TCAL29041 —UN—22JUN12
Reason:
To test the condition of the engine air preheater.
Special or Required Tools

• Ohmmeter
Procedure:
1. Park machine safely.
A—Air Preheater Element B—Terminal
2. Disengage PTO.
3. Turn key switch to STOP position.
Specification
4. LOCK park brake. Air Preheater—Resis-
5. Remove air preheater. tance..................................................................................0.3—0.5 ohms

6. Check continuity across terminal (B) and air preheater Results:

element (A). • Resistance should be within specification.
• If resistance across the air preheater element is high, or
completely open, replace the element.
OUMX258,0000C21 -19-06JUN14-1/1

Diode Pack AMT386 Test

Reason:
To verify proper diode pack operation.
OUO1086,1001377 -19-24DEC13-1/3

Digital Multimeter............................................... JT05791A Used to check diode pack.

Continued on next page OUO1086,1001377 -19-24DEC13-2/3

TM130419 (24FEB16) 230-40-8 PN=770

030916
 Tests and Adjustments

Procedure:
1. Remove diode from wiring harness.
2. Set meter to test diode.

TCAL29050 —UN—22JUN12
3. Connect digital meter or ohmmeter leads between
terminals indicated in the appropriate table.
NOTE: If using digital multimeter for test, meter must be
set to diode test function; digital multimeters cannot
test diodes when set to the ohmmeter function.
With the meter set to diode test, meter will measure
and display forward voltage drop across diode
when meter leads are connected between diode
terminals in one position, indicating the diode is
conducting. When the meter lead positions are NOTE: If using analog ohmmeter for test, meter will indicate continuity
reversed, meter will measure and display OL, or a very low resistance when meter leads are connected
between diode terminals in one position, indicating the diode
indicating the diode is not conducting. is conducting. When the meter lead positions are reversed,
meter will indicate no continuity or infinite resistance.
Digital Multimeter Test
Diode Red Lead Black Lead Result Analog Ohmmeter Test
1 C B 0.500-0.700 Diode Red Lead Black Lead Result
1 B C OL 1 C B Continuity
2 C A 0.500-0.700 1 B C No Continuity
2 A C OL 2 C A Continuity
3 C E 0.500-0.700 2 A C No Continuity
3 E C OL 3 C E Continuity
4 C D 0.500-0.700 3 E C No Continuity
4 D C OL 4 C D Continuity
5 E F 0.500-0.700 4 D C No Continuity
5 F E OL 5 E F Continuity
6 D F 0.500-0.700 5 F E No Continuity
6 F D OL 6 D F Continuity
7 B F 0.500-0.700 6 F D No Continuity
7 F B OL 7 B F Continuity
4-6, 3-5 C F 1.000-0.900 7 F B No Continuity
4-6, 3-5 F C OL 4-6, 3-5 C F Continuity
4-6, 3-5 F C No Continuity

Results:
If measurements are not correct, replace diode pack.
OUO1086,1001377 -19-24DEC13-3/3

TM130419 (24FEB16) 230-40-9 PN=771

030916
 Tests and Adjustments

Diode Pack AMT477 Test

Reason:
To verify proper diode pack operation.

TCAL29051 —UN—22JUN12
Special or Required Tools

• Digital Multimeter
Procedure:
1. Remove diode from wiring harness.
2. Set meter to test diode.
3. Connect digital meter or ohmmeter leads between
terminals indicated in the appropriate table.
NOTE: If using analog ohmmeter for test, meter will indicate continuity
NOTE: If using digital multimeter for test, meter must be or a very low resistance when meter leads are connected
between diode terminals in one position, indicating the diode
set to diode test function; digital multimeters cannot is conducting. When the meter lead positions are reversed,
test diodes when set to the ohmmeter function. meter will indicate no continuity or infinite resistance.
With the meter set to diode test, meter will measure
and display forward voltage drop across diode Analog Ohmmeter Test
when meter leads are connected between diode Diode Red Lead Black Lead Result
terminals in one position, indicating the diode is 1 A D Continuity
conducting. When the meter lead positions are
1 D A No Continuity
reversed, meter will measure and display OL,
indicating the diode is not conducting. 2 B E Continuity
2 E B No Continuity
Digital Multimeter Test 3 C F Continuity
Diode Red Lead Black Lead Result 3 F C No Continuity
1 A D 0.500-0.700
1 D A OL Results:
2 B E 0.500-0.700
If measurements are not correct, replace diode pack.
2 E B OL
3 C F 0.500-0.700
3 F C OL

OUO1086,1001378 -19-24DEC13-1/1

Headlight Switch Test (Single)

Reason:
To make sure the headlight switch terminals have
continuity when the headlight switch is in the on position.
Equipment: LVAL22750 —UN—27APR12

• Ohmmeter or Continuity Tester

A
Procedure:
B
1. Park machine safely. (See the “Safety Section”.)
2. Disconnect headlight switch from connector.
A—Terminal B—Terminal
3. Move headlight switch to the ON and then the OFF
position. Check continuity between terminals (A and
B).
• Terminals should not have continuity with switch OFF.
Results: • If continuity is not correct, replace headlight switch.
• Terminals should have continuity with switch ON.
SH24924,0000181 -19-24DEC13-1/1

TM130419 (24FEB16) 230-40-10 030916

PN=772
 Tests and Adjustments

Turn Signal Switch Test

1. Park machine safely.
2. Disconnect switch from wiring harness and remove
switch from machine.

MXT001137 —UN—03OCT11
3. Use ohmmeter to check continuity across switch
terminals A, B, and C in each position.
4. Measure resistance of indicator lamps across switch
terminals A — D and C — D.
Results:

• If continuity is not correct, replace switch.

• If resistance across terminals A — D and C — D does A—Left Turn and Indicator C—Right Turn and Indicator
not meet specification, replace switch. Lamp Lamp
Specification B—Switch Common D—Indicator Lamp Common
Turn Signal
Switch Indicator
Switch Continuity
Lamps—Resistance......................................................... 18 ohms ±20%
Off (center) position None
Left Turn position A — B
Right Turn position B — C

SH24924,00000C1 -19-26OCT11-1/1

Rotary Light Switch Test

(0) Off
Reason (1) Hazard 3
(2) Road
To verify that light switch functions properly. 2
(3) Field
Equipment

LVAL12987 —UN—05NOV10
1

• Ohmmeter or multimeter
2
B
Procedure
3 B
1. Park machine safely in neutral with park brake locked. 1 Not Used
4 4
2. Disconnect light switch from wiring harness.
3. Remove light switch from machine.
1— Terminal 1 (not used) 4— Terminal 4
4. Use an ohmmeter or multimeter to test switch 2— Terminal 2 B—Terminal B (BAT)
continuity in Off, Hazard, Road, and Field positions. 3— Terminal 3

Light Switch Continuity Table

Switch Position Terminals
B 1 2 3 4
OFF • •
HAZARD • • •
ROAD • • • •
FIELD • • • •

Results

• If any continuity is not correct, replace the switch.

SH24924,000018A -19-06JUN14-1/1

TM130419 (24FEB16) 230-40-11 030916

PN=773
 Tests and Adjustments

Rotary Blower Switch Test

OFF
Reason LOW 3
MED
To verify that the fan speed switch functions properly. HIGH 2
DETENTS (ALL)

Equipment
1

TCT008666 —UN—30DEC13
• Ohmmeter or multimeter
2
Procedure B
B
1. Park machine safely in neutral with park brake locked. 3 1
4
2. Remove blower switch from machine or disconnect
wiring connector.
3. Use an ohmmeter or multimeter to test switch
continuity.
1— Terminal 1 4— Terminal 4 (not used)
Fan Speed Switch Continuity 2— Terminal 2 B—Terminal B
Switch Position Terminal Continuity 3— Terminal 3

Off —
Low B and 1
B and 1 Results
Medium
B and 2
B and 1
• If any continuity is not correct, replace the switch.
High B and 2
B and 3

SH24924,0000185 -19-06JUN14-1/1

Cruise Control Switch Test

Reason:
To verify proper cruise control switch operation.
Special or Required Tools

• Ohmmeter or Multimeter
Procedure:

TCAL29055 —UN—22JUN12
1. Park machine safely.
2. Remove upper steering column cover.
3. Disconnect switch from wiring harness.
4. Use an ohmmeter tester to test switch continuity.
Cruise Control Switch Continuity
Switch Position Terminal Continuity
A—Terminal A C—Terminal C
Off None
B—Terminal B
On A—C
Engage (momentary) A—B—C

Results:
• If continuity is not correct or exists in any other
combination than shown above, replace the switch.
CB12260,0000076 -19-15SEP14-1/1

TM130419 (24FEB16) 230-40-12 030916

PN=774
 Tests and Adjustments

Cruise Brake Switch Test, Non-T4

1. Park machine safely.
2. Disconnect switch from wiring harness.
3. Use ohmmeter to check continuity across switch
terminals.

LVT001669 —UN—29NOV10
a. If continuity is not present between terminals listed
for each switch position, replace switch
b. If continuity exists between terminals not listed for
each switch position, replace switch.
Switch Continuity
Released A — C
Pressed B — D
A—Common C—Normally Closed
B—Common D—Normally Open

SH24924,0000184 -19-15SEP14-1/1

Wiper Switch Test Off

Low
Washer High
Reason
To verify that the wiper switch functions properly. P
L
Equipment L 1
• Ohmmeter or multimeter B
1 B
Procedure

TCT009787 —UN—31DEC13
2
1. Park machine safely in neutral with park brake locked. 4
2. Access wiper switch and remove from machine. 3
3
3. Use an ohmmeter or multimeter to test switch 4 2
continuity. P
Wiper Switch Continuity Table
Switch Position Terminal Continuity
OFF L and P
LOW Speed B and 1 B—Battery 3— (not used)
HIGH Speed B and 2 1— Low Speed 4— Washer
2— High Speed L, P— Park
WASH (momentary push) B and 4

Results

• If any continuity is not correct, replace the switch.

CB12260,0000061 -19-31DEC13-1/1

TM130419 (24FEB16) 230-40-13 030916

PN=775
 Tests and Adjustments

Diode Test

TCAL27857 —UN—06JUN12
Reason:
To determine if diode has failed.
Special or Required Tools:

• Digital Multimeter—JT05791A
Procedure:
1. Remove diode from fuse block.
2. Set meter to diode test. Results:

3. Connect meter test lead to each lead of diode. Check Diode must have a low resistance reading in one direction
for continuity. only. Replace defective diode.

4. Reverse test leads. Check for continuity.

SH24924,0000202 -19-22JUL14-1/1

Fuse Test
Reason:
To verify that the fuse has continuity.
Equipment:

LVAL21827 —UN—17APR12
• Ohmmeter or Continuity Tester
Procedure:
1. Park machine safely. (See the “Safety Section”.)
2. Remove fuse to be tested.
3. Check fuse visually for broken filament (A).
4. Connect ohmmeter or continuity tester to each end A—Broken Filament
of fuse.
5. Check for continuity.
Results:

• If continuity is not indicated, replace fuse.

OUMX068,00002B4 -19-05DEC12-1/1

TM130419 (24FEB16) 230-40-14 030916

PN=776
 Tests and Adjustments

A/C (HVAC) Switch Test

Off
Reason
On
A
To verify proper operation of the A/C (HVAC) switch.

LVAL13008 —UN—05NOV10
Equipment
B
• Ohmmeter or multimeter
Procedure
1. Park machine safely in neutral with park brake locked.
2. Disconnect A/C switch from wiring harness.
A—Terminal B—Terminal
3. Check continuity across switch terminals (A and B).
There should be no continuity in the off position.
4. Toggle the switch to the on position. Continuity should Results
exist between terminals (A and B).
• If continuity is not correct, replace A/C (HVAC) switch.
SH24924,0000188 -19-19DEC13-1/1

A/C Temperature Control Switch Test

Reason
To verify that the A/C temperature control switch functions
properly.

LVAL13001 —UN—05NOV10
Equipment A

• Ohmmeter or multimeter
• Ice and saltwater solution B
• Thermometer
Procedure
1. Disconnect switch from wiring harness.
A—Terminal B—Terminal
2. Remove capillary tube from evaporator/heater core.
3. Connect ohmmeter across switch terminals (A and B).
close between 3°C (37°F) and 16°C (60°F), depending
4. Warm end of capillary tube between hands. There on the lever position.
should be less than 0.5 ohms across switch terminals.
Results
Specification
A/C Temperature Control If continuity is not correct, replace switch.
Switch—Resistance................................................. Less than 0.5 Ohms

5. Insert capillary tube into ice and saltwater solution.

Switch contacts should be open at -1°C (3°F) and
SH24924,0000189 -19-19DEC13-1/1

TM130419 (24FEB16) 230-40-15 030916

PN=777
 Tests and Adjustments

Dome Light Switch Test

Reason
To verify that dome light switch functions properly. A

Equipment B

• Ohmmeter or multimeter C

LV19166 —UN—25SEP13
Procedure
1. Park machine safely.
2. Remove dome light cover and remove mounting
screws.
3. Disconnect dome light from connector.
4. Check continuity across switch terminals (A and B) A—Terminal C—Terminal
B—Terminal
and (B and C). There should be no continuity in the
Off position.
5. Check continuity across switch terminals (B and C).
There should be continuity in the On position.
6. Check continuity across switch terminals (A and B).
There should be continuity in the Door position.
SH24924,0000193 -19-31DEC13-1/1

Door Switch Test

Reason
To verify that the door switch functions properly.

LVAL12997 —UN—05NOV10
Equipment

• Ohmmeter or multimeter
B
Procedure
1. Park machine safely in neutral with park brake locked. A

2. Disconnect door switch from wiring harness.

3. Use an ohmmeter or multimeter to test switch
A—Terminal B—Terminal
continuity.
Specification
Switch Position Terminal Continuity
Switch Released A and B
Results
Switch Depressed No Continuity If continuity is not correct, replace switch.
SH24924,000018B -19-19DEC13-1/1

TM130419 (24FEB16) 230-40-16 030916

PN=778
 Tests and Adjustments

PTO Switch Test, Non-T4

1. Disconnect switch.
2. Use ohmmeter to check continuity across switch
terminals.

LVT001325 —UN—27OCT10
a. If continuity is not present between terminals listed
for each switch position, replace switch.
b. If continuity exists between terminals not listed for
each switch position, replace switch.
Switch Continuity
Off 1 — 7 and 3 — 9
On 1 — 4

1— Common Terminal 7— Normally Closed

4— Normally Open 9— Normally Closed
3— Common Terminal

SH24924,000017D -19-04JUN14-1/1

PTO Switch Test, T4

Reason

TCT001638 —UN—28FEB14
To verify proper operation of PTO switch.
Procedure
1. Park machine safely.
2. Access wiring connectors located inside command
arm.
3. Unplug connector from PTO switch. 1— Terminal 3— Terminal
2— Terminal
4. Connect tester leads to switch terminals as directed.
5. Position switch rocker towards palm guard and check
for the following: a. Continuity between terminals (2 and 1).
a. Continuity between terminals (2 and 3). b. No continuity between terminals (2 and 3).
b. No continuity between terminals (2 and 1). Results
6. Position switch rocker away from palm guard and If any continuity is not correct, replace switch.
check for the following:
SH24924,0000191 -19-15SEP14-1/1

TM130419 (24FEB16) 230-40-17 030916

PN=779
 Tests and Adjustments

PTO Solenoid Test

Reason

TCT009784 —UN—16DEC13
To determine if the PTO solenoid is operating properly.
Equipment:

• Digital Multimeter
Procedure
1. Park machine safely; engine off.
2. Unplug PTO solenoid from harness. A—Terminal C—Solenoid Body
B—Terminal
3. Measure solenoid coil resistance across terminals (A)
and (B). Resistance must be to specification.
Specification Results
PTO Solenoid—Resis-
tance....................................................................................... 8~10 ohms • If resistance does not meet specification, replace PTO
solenoid.
4. Check for grounds or shorts between connector • If continuity exists between connector terminals and
terminals (A, B) and the solenoid metal housing and solenoid body, replace PTO solenoid.
core (C). There must be NO continuity between a
terminal and the solenoid body.
CB12260,000006A -19-23JUL14-1/1

Hydraulic Temperature Switch Test

1. Park machine safely.

B A
C
2. Allow machine to cool before servicing the hydraulic
system.
A
3. Disconnect and remove hydraulic temperature switch.
4. Attach ohmmeter to connector terminals (C). B

CAUTION: DO NOT allow switch or thermometer

TCT011622 —UN—09JUL14
to rest against the side or bottom of glass
container when heating liquid. Either may rupture
if overheated. Do not exceed 120° C (250° F).

5. Suspend switch (A) in hydraulic oil to bottom of

mounting threads (B).
6. Heat oil in test container and observe temperature
when switch continuity occurs.
A—Temperature Switch C—Connector Terminals
7. Remove heat from test container and observe B—Mounting Threads
temperature when switch contacts reopen.
8. Inspect pipe sealant on mounting threads; replace Specifications
sealant as needed.
Switch Closes (continuity) 90° ±1.4° C (195° ±2.5° F)
Switch Reopens No lower than 85° C (186° F)
Mounting Torque 42 N·m (31 lb.-ft.)

SH24924,000023F -19-29JAN15-1/1

TM130419 (24FEB16) 230-40-18 030916

PN=780
 Tests and Adjustments

Engine Oil Pressure Switch Test

LVAL12984 —UN—05NOV10
Reason A

To determine if engine oil pressure switch is functioning

properly, to warn operator that oil pressure has dropped
below minimum operating pressure. P

Equipment

• Ohmmeter
A—Oil Pressure Switch
Procedure
NOTE: Perform test with engine at room temperature.
NOTE: Be sure to apply pipe sealant with TEFLON® to
1. Park machine safely in neutral with park brake locked. threads of switch anytime it is installed.
2. Raise hood and secure with prop rod.
1. Start and run engine.
3. Disconnect wire from engine oil pressure switch (A).
2. Measure resistance between terminal and engine
4. Connect black lead of ohmmeter to engine block and block.
red lead of ohmmeter to terminal of switch.
Results
5. Measure resistance between terminal and engine
block. There should be no continuity between switch terminal
and ground with the engine running.
Results
• If the switch does have continuity to engine block
• There should be continuity between terminal and (ground) with engine running, check engine oil pressure.
ground. • If oil pressure meets specification, replace the oil
• If there is no continuity between terminal and ground, pressure switch.
replace the oil pressure switch.
TEFLON is a trademark of Du Pont Co.
SH24924,000018C -19-19DEC13-1/1

TM130419 (24FEB16) 230-40-19 030916

PN=781
 Tests and Adjustments

Coolant Temperature Switch Test

1. Park machine safely.
2. Allow engine to cool before servicing the cooling
system.
3. Remove coolant temperature switch.

LVT001671 —UN—29NOV10
CAUTION: DO NOT allow switch or thermometer
to rest against the side or bottom of glass
container when heating water. Either may
rupture if overheated.

4. Suspend sensor (A) in water and coolant mixture.

5. Bring water and coolant mixture to specified
temperatures while measuring resistance of switch. A—Temperature Switch
Use ohmmeter to check resistance across terminals.
6. Heat and stir the mixture. Observe temperature
Specifications
when continuity occurs. Temperature must be to
specification. Switch Closes (continuity) 108—114° C (226—237° F)

7. Install temperature switch using pipe sealant with

TEFLON®, or PM37397 Pipe Sealant to switch
threads.
TEFLON is a trademark of Du Pont Co.
OUMX258,000019C -19-30DEC13-1/1

Fuel Pump Test

Reason
To determine if the fuel pump is operating properly.
Procedure
1. Disconnect fuel pump connector.
2. Connect jumper wire from battery positive (+) terminal
to fuel pump red wire, terminal (A).

LVAL20867 —UN—31JAN12
3. Connect another jumper wire from battery negative (-)
terminal to fuel pump black wire, terminal (B). Fuel
pump must operate.
4. Reverse jumper wire connections to (A) and (B). Fuel
pump must not operate.
Results

• If fuel pump does not operate with correct polarity and A—Terminal B—Terminal
power applied, replace fuel pump.
• If fuel pump operates with reverse polarity, internal
circuitry is shorted. Replace fuel pump.
SH24924,00001BE -19-11MAR13-1/1

TM130419 (24FEB16) 230-40-20 030916

PN=782
 Tests and Adjustments

Fuel Shutoff Solenoid Test, Non-T4

Reason
To determine if the fuel shutoff solenoid is operating C
properly.

LVAL23642 —UN—07MAY12
Equipment:

• Digital Multimeter D
A
B
Procedure
1. Disconnect fuel shutoff solenoid.
2. Check hold-in coil resistance at terminals (A and C).
Resistance must be to specification. A—Solenoid Terminal A C—Solenoid Terminal C
B—Solenoid Terminal B D—Solenoid Housing
Specification
Fuel Shutoff
Solenoid (Hold-In
Coil)—Resistance........................................................ 23.6 ohms (±10%) 5. Check for grounds or shorts between solenoid
terminals (A, B and C) and solenoid housing (D).
3. Check pull-in coil resistance at terminals (B and C).
There must be NO continuity between a terminal and
Resistance must be to specification.
the solenoid housing.
Specification
Fuel Shutoff Results
Solenoid (Pull-In
Coil)—Resistance.......................................................... 0.4 ohms (±10%)
• If resistance does not meet specification, replace fuel
shutoff solenoid.
4. Check resistance of both coils (combined), terminals • If continuity exists between connector terminals and
(A and B). Resistance must be to specification. solenoid housing, replace fuel shutoff solenoid.
Specification
Fuel Shutoff Solenoid
(Total Resistance)—Re-
sistance.......................................................................... 24 ohms (±10%)
SH24924,0000180 -19-04JUN14-1/1

TM130419 (24FEB16) 230-40-21 030916

PN=783
 Tests and Adjustments

Cruise Control Magnet Test

Reason:
To verify proper cruise control magnet operation.
Special or Required Tools

TCAL29056 —UN—22JUN12
• Ohmmeter or Multimeter
Procedure:
1. Park machine safely on a level surface.
2. Disengage PTO.
3. Turn key switch to STOP position.
4. LOCK park brake.
A—Terminal C—Cruise Control Magnet
5. Raise seat platform. B—Terminal Body

6. Disconnect cruise control magnet connector from

harness.
Results:
7. Use an ohmmeter or continuity tester to test magnet
and terminal-to-housing continuity. • If continuity is not correct or resistance is not to
Cruise Control Magnet Continuity specification, replace the magnet.
A to B See Specification Specification
A to Magnet Housing (C) None Cruise Control
B to Magnet Housing (C) None Magnet—Resistance...........................................Approximately 20 ohms

CB12260,0000079 -19-15SEP14-1/1

Seat Switch Test

Reason:
To verify that the seat switch functions properly.

TCAL29045 —UN—22JUN12
Special or Required Tools

• Ohmmeter or Continuity Tester

Procedure:
1. Park machine safely.
2. Disengage PTO.
3. Turn key switch to STOP position.
A—Terminal Of Seat Switch B—Terminal Of Seat Switch
4. LOCK park brake.
5. Raise seat platform and open engine cover.
Results:
6. Disconnect seat switch connector from wiring harness.
• If any continuity is not correct, replace seat switch.
7. Use an ohmmeter or continuity tester to check Refer to Service Kit AT365412.
continuity across connector terminals. There should
be no continuity.
8. Depress seat. Continuity should exist between
terminals (A and B).
SH24924,000017F -19-24DEC13-1/1

TM130419 (24FEB16) 230-40-22 PN=784

030916
 Tests and Adjustments

Park Brake Switch Test

Reason:
To determine proper operation of the brake switch.

MXAL33361 —UN—19JUL12
Equipment:

• Ohmmeter or Multimeter
Test Procedure:
1. Park machine safely with park brake locked. See the
“Safety Section”.
2. Remove connector from the switch. Remove switch if
needed to access terminals properly.
Switch plunger on (not pressed)—Specification
3. Connect meter leads to pairs of switch posts and —Continuity...................................................................between B and D
compare to specifications.
Results:
4. Press and release plunger of switch.
Switch plunger off (not pressed)—Specification
• If continuity is not correct, or exists in any other
combination than shown above, replace the brake
—Continuity................................................... between C and E terminals
switch.
BS62576,0001650 -19-15SEP14-1/1

Warning Alarm Test

Reason:
To verify proper operation of warning alarm.

MXT005799 —UN—01NOV12
Equipment:

• 12 volt power source

• (2) Jumper Leads
Procedure:
1. Park machine safely.
2. Access wiring connectors and unplug warning alarm. Warning Alarm

3. Attach a jumper lead to each terminal of warning alarm.

Results:
4. Connect the jumper leads to the 12 volt supply.
IMPORTANT: Observe polarity of connections! There should be a loud beeping tone with 12 volts applied
to the alarm. Replace warning alarm if tone is faulty or
missing.
SH24924,00001C3 -19-16DEC13-1/1

DPF Differential Pressure Sensor Test, T4

See engine CTM for operation information and
replacement.
CB12260,000006F -19-16FEB16-1/1

DPF Inlet Temperature Sensor, T4

See engine CTM for operation information and
replacement.
CB12260,0000070 -19-16FEB16-1/1

TM130419 (24FEB16) 230-40-23 PN=785

030916
 Tests and Adjustments

DPF Mid Temperature Sensor, T4

See engine CTM for operation information and
replacement.
CB12260,0000071 -19-16FEB16-1/1

Accelerator Sensor Test, T4

A—Hall Effect Sensor B—Mechanical Sensor

E56628 —UN—26JAN09
CB12260,0000072 -19-03JUL14-1/2

NOTE: Hall Effect sensor (shown) requires power

to check output voltage.

1. Disconnect harness connector from sensor.

2. Turn ignition key to ON position.
3. Connect voltmeter to harness connector terminals

E56658 —UN—03FEB09
analogous to terminals (A and C) of sensor. Verify that
5 volts is present.
4. Checking output voltage:
• Install jumper wires between sensor and connector
at terminals (A and C).
• Connect voltmeter to sensor terminals (A and B)
and observe voltage. Voltage should be within A—Sensor Terminal (Ground) C—Sensor Terminal (Power
specification and will vary with rotation of sensor B—Sensor Terminal (Output Supply)
shaft. Voltage)

Specification
Sensor—Voltage..................................................................... 0.5—4.5 V
CB12260,0000072 -19-03JUL14-2/2

TM130419 (24FEB16) 230-40-24 030916

PN=786
 Group 50
Connectors
Summary of References • Seat Switch Connector
• Accelerator Sensor Connector • Light Switch Connector
• Headlights Connector
• Alarm Buzzer Connector, Non-T4 • PTO Switch Connector, Non-T4
• Alarm Buzzer Connector, T4 • PTO Switch Connector, T4
• Alternator Connector, Non-T4 • PTO Solenoid Connector
• Alternator Connector, T4 • Air Heater Relay Connector
• Power Outlet Connector • Cab Power Relay Connector
• Auxiliary Cab Power Connector • Cruise Control Relay Connector
• Control Module Connector, 8 Pin • Fuel Pull-In Relay Connector
• Control Module Connector, 6 Pin • PTO Shutdown Relay Connector
• Engine Preheat Timer Module Connector • Cruise Control Switch Connector
• Engine Control Module (ECU) Connector, 94 Pin • Cruise Control Brake Switch Connector
• Engine Control Module (ECU) Connector, 60 Pin • Cruise Control Magnet Connector
• Fuel Shutoff Solenoid Connector • Flasher Relay Connector
• Fuel Transfer Pump Connector, Non-T4 • Diode Pack Connector
• Fuel Transfer Pump Connector, T4 • Cab Power Connector
• Hydraulic Oil Temperature Switch Connector, Non-T4 • Wiper Switch Connector
• Hydraulic Oil Temperature Switch Connector, T4 • Fan Speed Switch Connector
• Instrument Cluster Connector, Non-T4 • Beacon Switch Connector
• Display Unit Connector, T4 • Homologation Harness Connector
• Key Switch Connector
• Brake Switch Connector
OUMX258,0000C2C -19-07JUL14-1/1

Accelerator Sensor Connector

Accelerator Sensor Connector
Schematic: Main Schematic, T4
Wiring Harnesses:

RXA0060730 —UN—05NOV02
Terminal Circuit Number
A 990 Brn A B C
B 992 Pur
C 991 Org

SH24924,000022C -19-04JUN14-1/1

LVT001881 —UN—01JUL11
Alarm Buzzer Connector, Non-T4
Alarm Connector, Non-T4
Schematic: Main Schematic, Non-T4
Wiring Harnesses: Main Wiring Harness, Non-T4
Terminal Circuit Number
A [1] 403 Yel
B [2] 360 Org, 315 Grn

OUMX258,0000C3A -19-08APR13-1/1

TM130419 (24FEB16) 230-50-1 030916

PN=787
 Connectors

LVT001881 —UN—01JUL11
Alarm Buzzer Connector, T4
Alarm Connector, T4
Schematic: Main Schematic, T4
Wiring Harnesses: Main Wiring Harness, T4
Terminal Circuit Number
A [1] 403 Yel
B [2] 360 Org, 315 Grn

SH24924,0000232 -19-27JUN14-1/1

Alternator Connector, Non-T4

Alternator Connector, Non-T4

TCT007002 —UN—09APR13
Schematic: Main Schematic, Non-T4
Wiring Harnesses: Main Wiring Harness, Non-T4
B A
Terminal Circuit Number
A [1] 612 Brn
B [2] 413 Yel

OUMX258,0000C43 -19-10APR13-1/1

Alternator Connector, T4
Alternator Connector, T4

TCT007002 —UN—09APR13
Schematic: Main Schematic, T4
Wiring Harnesses: Main Wiring Harness, T4
B A
Terminal Circuit Number
A [1] 600 Brn
B [2] 506 Yel

SH24924,0000233 -19-27JUN14-1/1

Power Outlet Connector

TCT007001 —UN—09APR13
Power Outlet Connector
Schematic: Main Schematic, Non-T4
Main Schematic, T4
Wiring Harnesses: Main Wiring Harness, Non-T4
Main Wiring Harness, T4
Terminal Circuit Number
A 492 Yel
B 123 Blk

OUMX258,0000C41 -19-27JUN14-1/1

TM130419 (24FEB16) 230-50-2 030916

PN=788
 Connectors

Auxiliary Cab Power Connector

TCT007001 —UN—09APR13
Auxiliary Cab Power Connector
Schematic: Main Schematic, Non-T4
Main Schematic, T4
Wiring Harnesses: Main Wiring Harness, Non-T4
Main Wiring Harness, T4
Terminal Circuit Number
A 503 Yel
B 103 Blk
SH24924,000023C -19-07JUL14-1/1

Control Module Connector, 8 Pin

Control Module Connector, 8 Pin
Schematic: Main Schematic, Non-T4
Wiring Harness: Main Wiring Harness, Non-T4

RXA0064154 —UN—17DEC02
Terminal Circuit Number
A 743 Pur
B 830 Pnk
H G F E
C 320 Blu
D 748 Pur A B C D
E 195 Blk
F 788 Pur
G —
H 640 Grn
Layout
OUMX258,0000C45 -19-27JUN14-1/1

Control Module Connector, 6 Pin

Control Module Connector, 6 Pin
Schematic: Main Schematic, Non-T4

TCT007004 —UN—09APR13
Wiring Harness: Main Wiring Harness, Non-T4
Terminal Circuit Number A B
A 400 Yel
B — C D E F
C 402 Yel
D 450 Yel
E 750 Pur
F 747 Pur
Layout
OUMX258,0000C46 -19-27JUN14-1/1

TM130419 (24FEB16) 230-50-3 030916

PN=789
 Connectors

Engine Preheat Timer Module Connector

Engine Preheat Timer Module Connector
Schematic: Main Schematic, Non-T4
Wiring Harness: Main Wiring Harness, Non-T4

RXA0064080 —UN—16DEC02
Terminal Circuit Number
A 406 Yel
F E D
B 751 Pur
C 630 Grn A B C
D 109 Blk
E 350 Org
F 330 Grn
Layout
OUMX258,0000C42 -19-27JUN14-1/1

TM130419 (24FEB16) 230-50-4 030916

PN=790
 Connectors

Engine Control Module (ECU) Connector, 94

Pin
ECU Connector, 94 Pin
Schematic: Main Schematic, T4
Wiring Harnesses: Main Wiring Harness, T4
Terminal Circuit Number
1 213
2 128
3 214
4 124
5 215
6 125
7-13 —
14 707
15 620
94 73 6 5
16-19 —

MXT009804 —UN—18DEC13
20 422
21 406
22 —
28 7 2 1
23 421
24 480
25-27 —
28 706
29-31 —
32 651 ECU Connector, 94 Pin
33 427 Schematic: Main Schematic, T4
34 — Wiring Harnesses: Main Wiring Harness, T4
35 709 Terminal Circuit Number
36-38 —
68 670
39 403 69 —
40-42 —
70 921
43 991 71-73 —
44 —
74 404
45 401 75 F207
46-51 —
76 F150
52 423 77 483
53 F107 78 —
54 F250 79 405
55 —
80 486
56 451 81 485
57-60 — —
82-84
61 992 85 402
62 990 86 129
63 481 87 —
64-65 —
88 513
66 600 89-94 —
67 —

SH24924,0000186 -19-27JUN14-1/1

TM130419 (24FEB16) 230-50-5 030916

PN=791
 Connectors

Engine Control Module (ECU) Connector, 60

Pin
ECU Connector, 60 Pin
Schematic: Main Schematic, T4
Wiring Harnesses: Main Wiring Harness, T4
Terminal Circuit Number
1-3 —
4 468
5 471
6 —
7 440
8 443
9-10 —
11 449 1 15
12 482
13-15 —

MXT009805 —UN—18DEC13
16 465
17 463
18 461 46 60
19 424
20 425
21-24 —
25 442
26 441
27 —
28 407
29 408
30-32 —
33 464
34-36 —
37 444
38 448
39 446
40-46 —
47 462
48 460
49-50 —
51 450
52 445
53 —
54 447
55-58 —
59 426
60 —

SH24924,0000187 -19-27JUN14-1/1

TM130419 (24FEB16) 230-50-6 030916

PN=792
 Connectors

Fuel Shutoff Solenoid Connector

Fuel Shutoff Solenoid Connector
Schematic: Main Schematic, Non-T4
Wiring Harness: Main Wiring Harness, Non-T4
C

LVT001847 —UN—10APR13
Terminal Circuit Number
A 650 Grn
B 910 Wht B A
C 101 Blk
Layout

OUMX258,0000C25 -19-27JUN14-1/1

Fuel Transfer Pump Connector, Non-T4

Fuel Transfer Pump Connector, Non-T4
Schematic: Main Schematic, Non-T4
Wiring Harness: Main Wiring Harness, Non-T4
Terminal Circuit Number

TCT004351 —UN—21JUN12
A 456 Yel
B 126 Blk
Layout

OUMX258,0000C37 -19-27JUN14-1/1

Fuel Transfer Pump Connector, T4

Fuel Transfer Pump Connector, T4
Schematic: Main Schematic, T4
Wiring Harness: Main Wiring Harness, T4
Terminal Circuit Number

TCT004351 —UN—21JUN12
A 681 Pnk
B 108 Blk
Layout

SH24924,0000234 -19-27JUN14-1/1

TM130419 (24FEB16) 230-50-7 030916

PN=793
 Connectors

Hydraulic Oil Temperature Switch Connector,

LVT001841 —UN—21JUN11
Non-T4
Hydraulic Oil Temperature Switch Connector, Non-T4
Schematic: Main Schematic, Non-T4
Wiring Harness: Main Wiring Harness, Non-T4
Terminal Circuit Number
A 527 Blu
B 121 Blk
Layout
OUMX258,0000C30 -19-08APR13-1/1

Hydraulic Oil Temperature Switch Connector,

LVT001841 —UN—21JUN11
T4
Hydraulic Oil Temperature Switch Connector, T4
Schematic: Main Schematic, T4
Wiring Harness: Main Wiring Harness, T4
Terminal Circuit Number
A 901 Gry
B 102 Blk
Layout
SH24924,0000235 -19-27JUN14-1/1

Instrument Cluster Connector, Non-T4

Instrument Cluster Connector, Non-T4
Schematic: Main Schematic, Non-T4

MXT001675 —UN—10OCT11
Wiring Harness: Main Wiring Harness, Non-T4
Terminal Circuit Number
A 412 Yel
B Plug
C 330 Grn
D 112 Blk
E 625 Tan
F 310 Org
G 610 Brn
H 525 Blu
Layout
OUMX258,0000C24 -19-27JUN14-1/1

Display Unit Connector, T4

Display Unit Connector, T4
Schematic: Main Schematic, T4
Wiring Harness: Main Wiring Harness, T4
RXA0087053 —UN—23FEB06

Terminal Circuit Number 1 6

1 501 Yel
2 5
2 101 Blk
3 — 3 4
4 F203 Yel
5 F103 Grn
6 —

SH24924,0000236 -19-27JUN14-1/1

TM130419 (24FEB16) 230-50-8 030916

PN=794
 Connectors

Key Switch Connector

Key Switch Connector
Schematic: W1 Main Schematic

MXT001669 —UN—10OCT11
Wiring Harness: W1 Main Harness
Terminal Circuit Number
A 400 Yel
B 242 Red
M —
G —
S1 190 Blk
S2 195 Blk
Layout
OUMX258,0000C44 -19-09APR13-1/1

Brake Switch Connector

LVT001851 —UN—20JUN11
Brake Switch Connector
Schematic: W1 Main Schematic
Wiring Harness: W1 Main Harness
Terminal Circuit Number
A 743 Pur
B 788 Pur
C 752 Pur
D 700 Pur
Layout
OUMX258,0000C2F -19-08APR13-1/1

Seat Switch Connector

MXT005854 —UN—27NOV12
Seat Switch Connector
Schematic: W1 Main Schematic
Wiring Harnesses: W1 Main Harness
Terminal Circuit Number
A 411 Yel A B
B 831 Pnk

OUMX258,0000C3B -19-08APR13-1/1

Light Switch Connector

Light Switch Connector
Schematic: W1 Main Schematic
MXT001666 —UN—10OCT11

Wiring Harnesses: W1 Main Harness

Terminal Circuit Number
1 450 Yel
2 452 Yel

OUMX258,0000C3E -19-09APR13-1/1

TM130419 (24FEB16) 230-50-9 030916

PN=795
 Connectors

Headlights Connector

TCT007001 —UN—09APR13
Headlights Connector
Schematic: W1 Main Schematic
Wiring Harnesses: W1 Main Harness
Terminal Circuit Number
A 452 Yel
B 113 Blk

OUMX258,0000C3F -19-09APR13-1/1

LVT001839 —UN—21JUN11
PTO Switch Connector, Non-T4
PTO Switch Connector, Non-T4
Schematic: Main Schematic, Non-T4
Wiring Harness: W1 Main Harness
Terminal Circuit Number
1 750 Pur / 760 Pur
2 —
3 410 Yel
4 770 Pur
5 —
7 —
8 —
9 748 Pur / 752 Pur
Layout
OUMX258,0000C31 -19-07JUL14-1/1

PTO Switch Connector, T4

TCT006804 —UN—27DEC13
PTO Switch Connector
Schematic: Main Schematic, T4
Wiring Harnesses: —
Terminal Circuit Number
1 —
2 516 Yel
3 760 Pnk
4-10 —

SH24924,0000192 -19-04JUN14-1/1

PTO Solenoid Connector

PTO Solenoid Connector
Schematic: W1 Main Schematic
Wiring Harness: W1 Main Harness
Terminal Circuit Number
TCT004351 —UN—21JUN12

A 771 Gry / 770 Pur

B 120 Blk
Layout

OUMX258,0000C38 -19-26APR13-1/1

TM130419 (24FEB16) 230-50-10 030916

PN=796
 Connectors

Air Heater Relay Connector

Air Heater Relay Connector 30 85
Schematic: W1 Main Schematic

TCT001622 —UN—11APR14
Wiring Harness: W1 Main Harness 87a
Terminal Circuit Number
86 87
30 220 Red
85 350 Org
86 409 Yel
87 900 Wht
87a —
Layout
OUMX258,0000C35 -19-08APR13-1/1

Cab Power Relay Connector

Cab Power Relay Connector
Schematic: W1 Main Schematic 87

TCT007006 —UN—10APR13
Wiring Harness: W1 Main Harness
86 85
Terminal Circuit Number
30 243 Red
30
85 155 Blk
86 480 Yel
87 490 Yel
Layout
OUMX258,0000C48 -19-10APR13-1/1

Cruise Control Relay Connector

Cruise Control Relay Connector 30 85
Schematic: W1 Main Schematic

TCT001622 —UN—11APR14
Wiring Harness: W1 Main Harness 87a
Terminal Circuit Number
86 87
30 834 Pnk
85 835 Pnk
86 130 Blk
87 833 Pnk
87a —
Layout
OUMX258,0000C36 -19-08APR13-1/1

Fuel Pull-In Relay Connector

Fuel Pull-In Relay Connector 30 85
Schematic: W1 Main Schematic
TCT001622 —UN—11APR14

Wiring Harness: W1 Main Harness 87a

Terminal Circuit Number
86 87
30 210 Red
85 751 Pur
86 407 Yel
87 911 Wht
87a —
Layout
OUMX258,0000C34 -19-08APR13-1/1

TM130419 (24FEB16) 230-50-11 030916

PN=797
 Connectors

PTO Shutdown Relay Connector

PTO Shutdown Relay Connector 30 85
Schematic: W1 Main Schematic

TCT001622 —UN—11APR14
Wiring Harness: W1 Main Harness 87a
Terminal Circuit Number
86 87
30 760 Pur
85 360 Org
86 430 Yel
87 —
87a 700 Pur
Layout
OUMX258,0000C33 -19-08APR13-1/1

Cruise Control Switch Connector

Cruise Control Switch Connector
Schematic: W1 Main Schematic
Wiring Harness: W1 Main Harness

RXA0064150 —UN—17DEC02
Terminal Circuit Number
A 832 Pnk
A B C
B 833 Pnk
C 837 Pnk
Layout

OUMX258,0000C3C -19-08APR13-1/1

Cruise Control Brake Switch Connector

LVT001851 —UN—20JUN11
Cruise Control Brake Switch Connector
Schematic: W1 Main Schematic
Wiring Harness: W1 Main Harness
Terminal Circuit Number
A —
B 830 Pnk / 831 Pnk
C —
D 832 Pnk
Layout
OUMX258,0000C2E -19-08APR13-1/1

Cruise Control Magnet Connector

TCT007001 —UN—09APR13

Cruise Control Magnet Connector

Schematic: W1 Main Schematic
Wiring Harnesses: W1 Main Harness
Terminal Circuit Number
A 835 Pnk / 836 Pnk
B 135 Blk

OUMX258,0000C40 -19-09APR13-1/1

TM130419 (24FEB16) 230-50-12 030916

PN=798
 Connectors

Flasher Relay Connector

TCT009786 —UN—26DEC13
3 2 1
Flasher Relay Connector 49A C 49
Schematic: Cab Schematic, Lower
Wiring Harness: Cab Wiring Harness 31 C2 C3
4 5 6
Terminal Circuit Number
1 103M Org
2 —
3 120D Org
4 010CE Blk
5, 6 —
Layout
SH24924,0000190 -19-26DEC13-1/1

Diode Pack Connector

V1 Diode Pack Connector
Schematic: W1 Main Schematic
Wiring Harness: W1 Main Harness

TCT006867 —UN—09APR13
Terminal Circuit Number
A —
B 625 Tan
F E D C B A
C 315 Grn
D 526 Blu
E 311 Org
F 320 Blu
V1 Diode Pack Layout
V2 Diode Pack Connector
Schematic: W1 Main Schematic
Wiring Harness: W1 Main Harness
Terminal Circuit Number
A 115 Blk
B 111 Blk
C 116 Blk
D 840 Gry
E 771 Gry
F 912 Wht
V2 Diode Pack Layout
OUMX258,0000C3D -19-10APR13-1/1

Cab Power Connector

Cab Power Connector
Schematic: W1 Main Schematic
Wiring Harness: W1 Main Harness
TCT007005 —UN—10APR13

1 2
Terminal Circuit Number
1 491 Yel 3 4

2 493 Yel 5 6
3 250 Red
4 191 Blk
5 494 Yel
6 775 Grn
Layout
OUMX258,0000C47 -19-10APR13-1/1

TM130419 (24FEB16) 230-50-13 030916

PN=799
 Connectors

Wiper Switch Connector

Wiper Switch Connector
Schematic: —
Wiring Harnesses:
2

RXA0062556 —UN—05NOV02
Terminal Circuit Number
P 4 L
1 245B, 245D
3 1
2 226A
3, 4 —
B 272D B
L 245B
P 224A

SH24924,000018E -19-23DEC13-1/1

Fan Speed Switch Connector

Fan Speed Switch Connector
Schematic: —
Wiring Harnesses:
2
Terminal Circuit Number
1 227B B

3
2 221A 4

RXA0079965 —UN—07APR05
3 225A
4 —
1
B 282A

SH24924,000018F -19-23DEC13-1/1

Beacon Switch Connector

Beacon Switch Connector
Schematic: —
Wiring Harnesses: 10 9
Terminal Circuit Number 3 6
2 122E
3 163E, 163F
2 5
TCT007682 —UN—19JUL13
7 010BK, 010CA
8 163E 1 4
1, 4~6, 9~10 —
8 7

OUMX258,000015F -19-18NOV13-1/1

TM130419 (24FEB16) 230-50-14 030916

PN=800
 Connectors

Homologation Harness Connector

LVT001841 —UN—21JUN11
Homologation Harness Connector
Schematic: W1 Main Schematic
Wiring Harness: W1 Main Harness
Terminal Circuit Number
A 405 Yel
B 107 Blk
Layout
OUMX258,0000C2D -19-08APR13-1/1

TM130419 (24FEB16) 230-50-15 030916

PN=801
 Connectors

TM130419 (24FEB16) 230-50-16 030916

PN=802
 Section 235
Controllers Operation, Tests, and Adjustments
Contents

Page
Page
Group 10—Adjustments
Summary of References.............................. 235-10-1 CAN Trace................................................... 235-30-2
Approved Software for Control Diagnostic Trouble Codes (DTCs)
Units ........................................................ 235-10-1 Overview.................................................. 235-30-3
Service Timer Menu .................................... 235-10-2 Primary Display Unit (PDU) ......................... 235-30-3
Display Setup Screens ................................ 235-10-4 Hour Meter................................................... 235-30-3
Service ADVISOR Based
Calibrations.............................................. 235-10-5 Group 35—Checks, Tests, and Procedures
Summary of References.............................. 235-35-1
Group 15—DPF Functions and DTCs Diagnostic Essential or
Summary of References.............................. 235-15-1 Recommended Tools............................... 235-35-1
Exhaust Filter System Overview.................. 235-15-1 CAN Message Not Received....................... 235-35-2
Understanding Diesel Particulate CAN Message Received Error .................... 235-35-3
Filter (DPF) Regeneration ....................... 235-15-2 CAN Message Received Is
Diesel Particulate Filter (DPF) Incorrect................................................... 235-35-4
Regeneration Indicators .......................... 235-15-2 Terminal Test ............................................... 235-35-5
Accessing Diesel Particulate Filter Verification Procedure ................................. 235-35-7
Displays ................................................... 235-15-4 Procedure ....................................................235-35-7
Diesel Particulate Filter Operator Wiggle Test .................................................. 235-35-8
Display..................................................... 235-15-6 Short to Voltage Procedure ......................... 235-35-9
Active Regeneration .................................... 235-15-9 Diagnostic Procedure ..................................235-35-9
Inhibiting Active Regeneration................... 235-15-10 Problem Not Found Procedure.................. 235-35-10
Parked Regeneration................................. 235-15-10 Diagnostic Procedure ...............................235-35-10
Parked Regeneration Interlocks ................ 235-15-12 Accessing the Addresses and
Recovery Regeneration............................. 235-15-12 Diagnostic Trouble Codes ..................... 235-35-11
DPF Status Screens .................................. 235-15-14 CAN Communication Fault
DPF Load Level......................................... 235-15-16 Checks................................................... 235-35-12
Tier 4 Warning Popups .............................. 235-15-17 CAN Bus Terminator Test .......................... 235-35-13
Aftertreatment Verification Control Unit Messaging Errors .................. 235-35-13
Procedure .............................................. 235-15-17 CAN Network Voltage Checks................... 235-35-14
DOC Calibration—Instructions .................. 235-15-18 Erroneous Diagnostic Trouble
DPF Calibration—Instructions ................... 235-15-18 Codes .................................................... 235-35-16
Troubleshooting Electronic Control
Group 20—Set Up, PDU Units ...................................................... 235-35-16
Summary of References.............................. 235-20-1 Diagnostic Information............................... 235-35-17
Main Screens Navigation, PDU ................... 235-20-1 Readings Overview ................................... 235-35-17
Language Select.......................................... 235-20-4 Control Unit Readings—VCU .................... 235-35-18
Text Selection .............................................. 235-20-4 PDU I-O Status Readings.......................... 235-35-18
Machine Status Screens.............................. 235-20-4 ECU Data Points Used in Service
Active DTC Flow Description....................... 235-20-5 ADVISOR .............................................. 235-35-22
Stored DTC Flow Description ...................... 235-20-6 Electronic Injector—Calibration
Pass Codes ................................................. 235-20-7 Information............................................. 235-35-24
Machine Start Pass Code Entry .................. 235-20-8 Service ADVISOR Based Tests................. 235-35-24
Display Setup Screen Detailed.................... 235-20-8
Version Information.................................... 235-20-11 Group 40—Diagnose—DTCs, PDU
Reprogramming, PDU ............................... 235-20-11 Start Interlock Violations.............................. 235-40-1
Run Interlock Screen ................................... 235-40-1
Group 30—Theory of Operation Service Required ......................................... 235-40-2
Summary of References.............................. 235-30-1 Coolant Over Temp...................................... 235-40-2
CAN Bus Message Structure....................... 235-30-1 Park Brake Off and Attempting to
CAN Bus Operation ..................................... 235-30-2 Crank Engine........................................... 235-40-2
Data Bus Systems ....................................... 235-30-2 Crank Time Exceeded Warning................... 235-40-2

Continued on next page

TM130419 (24FEB16) 235-1 030916

PN=1
 Contents

Page Page

Crank Time Exceeded Warning VCU 000639.12 — CAN, Lost

Delay ....................................................... 235-40-3 Message................................................235-45-12
PTO Engaged and Operator Out of VCU 000639.14 — CAN, Bus Off..............235-45-12
Seat ......................................................... 235-40-3 VCU 000677.04 — Starter Relay ..............235-45-13
Hydraulic Oil Over Temp.............................. 235-40-3 VCU 000677.14 — Crank Time
Charge System Failure Low ........................ 235-40-3 Exceeded ..............................................235-45-13
Low Oil Pressure ......................................... 235-40-4 VCU 000677.31 — Starter Cool Down
Filter Cleaning Required.............................. 235-40-4 in Process .............................................235-45-14
Parked Cleaning Required .......................... 235-40-4 VCU 000920.03 — Buzzer Short to
Ash Clean Required .................................... 235-40-4 High.......................................................235-45-14
Park Brake Not Engaged and VCU 000920.04 — Buzzer Short to
Attempting to Activate Parked Low........................................................235-45-15
Regeneration ........................................... 235-40-5 VCU 000931.03 — Fuel Pump Short to
Charge System Failure High ....................... 235-40-5 High.......................................................235-45-15
Park Brake Engaged, Not Procedure ..................................................235-45-15
Mowing .................................................... 235-40-5 VCU 000931.04 — Fuel Pump Short to
PTO Engaged, Not Mowing......................... 235-40-5 Low........................................................235-45-16
PTO Engaged and Attempting to Procedure ..................................................235-45-16
Activate Parked Regeneration................. 235-40-6 VCU 001504.31 — Out of Neutral and
Parked Cleaning Stopped............................ 235-40-6 Out of Seat ............................................235-45-17
Engine Oil Service ....................................... 235-40-6 Procedure ..................................................235-45-17
Hydraulic Oil Service ................................... 235-40-6 VCU 001638.00 — Hydraulic Oil ...............235-45-18
Engine Stop ................................................. 235-40-7 Procedure ..................................................235-45-18
Engine Warning ........................................... 235-40-7 VCU 003509.03 — Sensor Power
Machine General Warning Fault.................. 235-40-7 Supply High...........................................235-45-19
Machine General Info Fault ......................... 235-40-7 Procedure ..................................................235-45-19
VCU 003509.04 — Sensor Power
Group 45—Diagnose—DTCs, VCU Supply Low............................................235-45-20
VCU DTC Quick Reference Table................ 235-45-1 Procedure ..................................................235-45-20
VCU 000070.14 — Park Brake VCU 003941.14 — Seat Switch On
Switch......................................................235-45-3 with PTO Output On..............................235-45-21
Procedure ....................................................235-45-3 VCU 003941.31 — Park Brake On with
VCU 000158.00 — Switched Power PTO Output On .....................................235-45-21
Fault ........................................................235-45-4 VCU 516124.03 — Engine Run
VCU 000158.01 — Switched Power Request Short to High...........................235-45-22
Fault ........................................................235-45-4 Procedure ..................................................235-45-22
Procedure ....................................................235-45-4 VCU 516124.04 — Engine Run
VCU 000168.00 — Supply Voltage Request Short to Low............................235-45-23
(VBAT) Fault............................................235-45-5 Procedure ..................................................235-45-23
Procedure ....................................................235-45-5 VCU 516200.03 — PTO Low Side
VCU 000168.01 — Supply Voltage Driver.....................................................235-45-24
(VBAT) Fault............................................235-45-6 Procedure ..................................................235-45-24
Procedure ....................................................235-45-6 VCU 516200.04 — PTO Low Side
VCU 000168.16 — Supply Voltage Driver.....................................................235-45-25
(VBAT) Fault............................................235-45-7 Procedure ..................................................235-45-25
Procedure ....................................................235-45-7 VCU 516206.03 — PTO High Side
VCU 000168.18 — Supply Voltage Driver.....................................................235-45-26
(VBAT) Fault............................................235-45-8 Procedure ..................................................235-45-26
Procedure ....................................................235-45-8 VCU 516206.04 — PTO High Side
VCU 000595.03 — Cruise Control Driver.....................................................235-45-26
Switch Short to High................................235-45-9 Procedure ..................................................235-45-27
Procedure ....................................................235-45-9 VCU 516206.05 — PTO High Side
VCU 000595.04 — Cruise Control Driver.....................................................235-45-27
Short to Low ..........................................235-45-10 Procedure ..................................................235-45-27
Procedure ..................................................235-45-10 VCU 516399.03 — Auxiliary (Cab)
VCU 000629.12 — Watch Dog Time Relay Driver Short to High ....................235-45-28
Out ........................................................235-45-11 Procedure ..................................................235-45-28
Procedure ..................................................235-45-11

Continued on next page

TM130419 (24FEB16) 235-2 030916

PN=2
 Contents

Page Page

VCU 516399.04 — Auxiliary (Cab) ECU 000102.13 — Manifold Air

Power Relay Driver Short to Pressure Signal Calibration
Low........................................................235-45-29 Fault ......................................................235-50-20
Procedure ..................................................235-45-29 Diagnostic Procedure ................................235-50-21
VCU 520870.31 — EEPROM ECU 000105.03 — Manifold Air
Checksum Fail ......................................235-45-30 Temperature Signal Out of Range
Procedure ..................................................235-45-30 High.......................................................235-50-23
VCU 520871.31 — EEPROM Non Diagnostic Procedure ................................235-50-24
Critical Data Checksum Fail..................235-45-30 ECU 000105.04 — Manifold Air
Procedure ..................................................235-45-31 Temperature Signal Out of Range
VCU 520872.31 — EEPROM Critical Low........................................................235-50-25
Data Checksum Failure.........................235-45-31 Diagnostic Procedure ................................235-50-26
Procedure ..................................................235-45-31 ECU 000108.03 — Barometric
VCU 520873.31 — EEPROM Vehicle Pressure Signal Out of Range
Hours Data Checksum Failure ..............235-45-32 High.......................................................235-50-27
Procedure ..................................................235-45-32 Diagnostic Procedure ................................235-50-27
VCU 522011.08 — Display Heartbeat ECU 000108.04 — Barometric
Abnormal Rate ......................................235-45-32 Pressure Signal Out of Range
VCU 524265.31 — EOL Checksum Low........................................................235-50-28
Failure ...................................................235-45-33 Diagnostic Procedure ................................235-50-28
Procedure ..................................................235-45-33 ECU 000108.10 — Barometric
Pressure Signal Abnormal ....................235-50-29
Group 50—Diagnose—DTCs, ECU 000001—000199 Diagnostic Procedure ................................235-50-29
ECU 000028.00 — Analog Throttle ECU 000110.00 — Engine Coolant
Signal Extremely High.............................235-50-1 Temperature Signal Extremely
Procedure ....................................................235-50-1 High.......................................................235-50-30
ECU 000028.01 — Analog Throttle Diagnostic Procedure ................................235-50-30
Signal Extremely Low..............................235-50-2 ECU 000110.03 — Engine Coolant
Procedure ....................................................235-50-2 Temperature Signal Out of Range
ECU 000028.03 — Analog Throttle High.......................................................235-50-32
Signal Out of Range High .......................235-50-3 Diagnostic Procedure ................................235-50-32
Procedure ....................................................235-50-3 ECU 000110.04 — Engine Coolant
ECU 000028.04 — Analog Throttle Out Temperature Signal Out of Range
of Range Low ..........................................235-50-4 Low........................................................235-50-34
Procedure ....................................................235-50-4 Diagnostic Procedure ................................235-50-34
ECU 000051.03 — Air Throttle ECU 000157.00 — Fuel Rail Pressure
Actuator Position Signal Out of Signal Extremely High...........................235-50-36
Range High .............................................235-50-5 Diagnostic Procedure ................................235-50-37
Diagnostic Procedure ..................................235-50-6 ECU 000157.03 — Fuel Rail Pressure
ECU 000051.04 — Air Throttle Signal Out of Range High .....................235-50-39
Actuator Position Signal Out of Diagnostic Procedure ................................235-50-39
Range Low ..............................................235-50-7 ECU 000157.04 — Fuel Rail Pressure
Diagnostic Procedure ..................................235-50-8 Signal Out of Range Low ......................235-50-41
ECU 000100.01 — Engine Oil Pressure Diagnostic Procedure ................................235-50-41
Signal Extremely Low............................235-50-10 ECU 000157.15 — Fuel Rail Pressure
Diagnostic Procedure ................................235-50-10 Signal Slightly High ...............................235-50-43
ECU 000100.04 — Engine Oil Pressure Diagnostic Procedure ................................235-50-44
Signal Out of Range Low ......................235-50-12 ECU 000157.16 — Fuel Rail Pressure
Diagnostic Procedure ................................235-50-12 Limiter Open..........................................235-50-46
ECU 000102.03 — Manifold Air Diagnostic Procedure ................................235-50-47
Pressure Signal Out of Range ECU 000157.18 — Fuel Rail Pressure
High.......................................................235-50-14 Signal Moderately Low..........................235-50-49
Diagnostic Procedure ................................235-50-15 Diagnostic Procedure ................................235-50-50
ECU 000102.04 — Manifold Air ECU 000167.01 — Charging System
Pressure Signal Out of Range Voltage Extremely Low..........................235-50-52
Low........................................................235-50-17 Diagnostic Procedure ................................235-50-52
Diagnostic Procedure ................................235-50-18 ECU 000167.05 — Charging System
Circuit Out of Range Low ......................235-50-53

Continued on next page

TM130419 (24FEB16) 235-3 030916

PN=3
 Contents

Page Page

Diagnostic Procedure ................................235-50-53 Diagnostic Procedure ................................235-51-27

ECU 000173.03 — Exhaust Manifold ECU 000653.06 — Injector #2 Circuit
Temperature Signal Out Of Range Has Low Resistance .............................235-51-29
High.......................................................235-50-54 Diagnostic Procedure ................................235-51-30
Diagnostic Procedure ................................235-50-55 ECU 000654.03 — Injector #1 Circuit
ECU 000173.04 — Exhaust Manifold Out of Range High ................................235-51-32
Temperature Signal Out Of Range Diagnostic Procedure ................................235-51-32
Low........................................................235-50-56 ECU 000654.05 — Injector #1 Circuit
Diagnostic Procedure ................................235-50-56 Has High Resistance.............................235-51-34
ECU 000174.00 — Fuel Temperature Diagnostic Procedure ................................235-51-35
Signal Extremely High...........................235-50-58 ECU 000654.06 — Injector #1 Circuit
Diagnostic Procedure ................................235-50-58 Has Low Resistance .............................235-51-37
ECU 000174.03 — Fuel Temperature Diagnostic Procedure ................................235-51-38
Signal Out Of Range High.....................235-50-60
Diagnostic Procedure ................................235-50-60 Group 52—Diagnose—DTCs, ECU 000700—001999
ECU 000174.04 — Fuel Temperature ECU 001209.03 — Exhaust Manifold
Signal Out Of Range Low .....................235-50-62 Pressure Signal Out of Range
Diagnostic Procedure ................................235-50-62 High.........................................................235-52-1
ECU 000190.00 — Engine Speed Diagnostic Procedure ..................................235-52-1
Extremely High......................................235-50-64 ECU 001209.04 — Exhaust Manifold
Diagnostic Procedure ................................235-50-64 Pressure Signal Out of Range
Low..........................................................235-52-3
Group 51—Diagnose—DTCs, ECU 000200—000699 Diagnostic Procedure ..................................235-52-3
ECU 000412.03 — EGR Temperature ECU 001209.13 — Exhaust Manifold
Signal Out of Range High .......................235-51-1 Pressure Signal Calibration
Diagnostic Procedure ..................................235-51-1 Fault ........................................................235-52-6
ECU 000412.04 — EGR Temperature Diagnostic Procedure ..................................235-52-6
Signal Out Of Range Low .......................235-51-3
Diagnostic Procedure ..................................235-51-3 Group 53—Diagnose—DTCs, ECU 002000—002999
ECU 000630.12 — ECU EEPROM ECU 002791.00 — EGR Valve
Error ........................................................235-51-5 Drive Circuit Voltage Extremely
Diagnostic Procedure ..................................235-51-5 High.........................................................235-53-1
ECU 000633.03 — Suction Control Diagnostic Procedure ..................................235-53-1
Valve Circuit Out of Range ECU 002791.01 — EGR Valve Drive
High.........................................................235-51-6 Circuit Voltage Extremely Low ................235-53-3
Diagnostic Procedure ..................................235-51-6 Diagnostic Procedure ..................................235-53-3
ECU 000633.05 — Suction ECU 002791.07 — EGR Valve Position
Control Valve Circuit Has High Error ........................................................235-53-6
Resistance ..............................................235-51-9 Diagnostic Procedure ..................................235-53-6
Diagnostic Procedure ..................................235-51-9 ECU 002791.09 — EGR Valve
ECU 000633.06 — Suction Communication Error ..............................235-53-7
Control Valve Circuit Has Low Diagnostic Procedure ..................................235-53-7
Resistance ............................................235-51-12 ECU 002791.12 — EGR Valve Actuator
Diagnostic Procedure ................................235-51-12 Internal Error ...........................................235-53-8
ECU 000652.03 — Injector #3 Circuit Diagnostic Procedure ..................................235-53-8
Out of Range High ................................235-51-15 ECU 002797.06 — Injector High
Diagnostic Procedure ................................235-51-16 Voltage Supply #1 Circuit Has Low
ECU 000652.05 — Injector #3 Circuit Resistance ..............................................235-53-9
Has High Resistance.............................235-51-18 Diagnostic Procedure ..................................235-53-9
Diagnostic Procedure ................................235-51-18 ECU 002798.06 — Injector High
ECU 000652.06 — Injector #3 Circuit Voltage Supply #2 Circuit Has Low
Has Low Resistance .............................235-51-20 Resistance ............................................235-53-10
Diagnostic Procedure ................................235-51-21 Diagnostic Procedure ................................235-53-10
ECU 000653.03 — Injector #2 Circuit ECU 002950.03 — Air Throttle
Out of Range High ................................235-51-23 Actuator Drive Circuit 1 Out of
Diagnostic Procedure ................................235-51-24 Range High ...........................................235-53-11
ECU 000653.05 — Injector #2 Circuit Diagnostic Procedure ................................235-53-11
Has High Resistance.............................235-51-26

Continued on next page

TM130419 (24FEB16) 235-4 030916

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 Contents

Page Page

ECU 002950.04 — Air Throttle ECU 003251.13 — DPF Differential

Actuator Drive Circuit 1 Out of Pressure Sensor Calibration
Range Low ............................................235-53-13 Fault ......................................................235-54-21
Diagnostic Procedure ................................235-53-13 Diagnostic Procedure ................................235-54-21
ECU 002950.05 — Air Throttle ECU 003609.03 — DPF Inlet Pressure
Actuator Drive Circuit Has High Signal Out of Range High .....................235-54-23
Resistance ............................................235-53-15 Diagnostic Procedure ................................235-54-23
Diagnostic Procedure ................................235-53-15 ECU 003609.04 — DPF Inlet Pressure
ECU 002950.06 — Air Throttle Signal Out of Range Low ......................235-54-25
Actuator Drive Circuit Has Low Diagnostic Procedure ................................235-54-25
Resistance ............................................235-53-18 ECU 003695.14 — Exhaust Filter
Diagnostic Procedure ................................235-53-18 Cleaning Inhibited by Operator
ECU 002951.03 — Air Throttle Interface (PDU) .....................................235-54-27
Actuator Drive Circuit 2 Out of ECU 003719.00 — Calculated Soot
Range High ...........................................235-53-21 Level Extremely High ............................235-54-28
Diagnostic Procedure ................................235-53-21 Diagnostic Procedure ................................235-54-28
ECU 002951.04 — Air Throttle ECU 003719.07 — DPF Recovery
Actuator Drive Circuit 2 Out of Prohibited ..............................................235-54-30
Range Low ............................................235-53-24 Diagnostic Procedure ................................235-54-30
Diagnostic Procedure ................................235-53-24 ECU 003719.09 — DPF Recovery
Failed ....................................................235-54-32
Group 54—Diagnose—DTCs, ECU 003000—003999 Diagnostic Procedure ................................235-54-32
ECU 003242.00 — DOC Inlet ECU 003719.16 — Calculated Soot
Temperature Extremely High...................235-54-1 Level Moderately High ..........................235-54-34
Diagnostic Procedure ..................................235-54-1 Diagnostic Procedure ................................235-54-34
ECU 003242.03 — DOC Inlet ECU 003720.00 — Calculated Ash
Temperature Signal Out of Range Level Extremely High ............................235-54-36
High.........................................................235-54-3 Diagnostic Procedure ................................235-54-36
Diagnostic Procedure ..................................235-54-3 ECU 003720.16 — Calculated Ash
ECU 003242.04 — DOC Inlet Level Moderately High ..........................235-54-37
Temperature Signal Out of Range Diagnostic Procedure ................................235-54-37
Low..........................................................235-54-5
Diagnostic Procedure ..................................235-54-5 Group 55—Diagnose—DTCs, ECU 004000—529999
ECU 003250.00 — DOC Outlet ECU 004257.12 — Injector
Temperature Extremely High...................235-54-7 High Voltage Supply Internal
Diagnostic Procedure ..................................235-54-7 Failure .....................................................235-55-1
ECU 003250.01 — DOC Outlet Diagnostic Procedure ..................................235-55-1
Temperature Extremely Low ...................235-54-9 ECU 522243.05 — Glow Plug
Diagnostic Procedure ..................................235-54-9 Relay Driver Circuit Has High
ECU 003250.03 — DOC Outlet Resistance ..............................................235-55-2
Temperature Signal Out of Range Procedure ....................................................235-55-2
High.......................................................235-54-11 ECU 522243.06 — Glow Plug
Diagnostic Procedure ................................235-54-11 Relay Driver Circuit Has Low
ECU 003250.04 — DOC Outlet Resistance ..............................................235-55-3
Temperature Signal Out of Range Procedure ....................................................235-55-3
Low........................................................235-54-13 ECU 522329.00 — Water-In-Fuel
Diagnostic Procedure ................................235-54-13 Level Extremely High ..............................235-55-4
ECU 003251.00 — DPF Differential Diagnostic Procedure ..................................235-55-4
Pressure Extremely High ......................235-54-15 ECU 522400.02 — Crankshaft Position
Diagnostic Procedure ................................235-54-15 Signal Invalid...........................................235-55-7
ECU 003251.03 — DPF Differential Diagnostic Procedure ..................................235-55-7
Pressure Signal Out of Range ECU 522400.05 — Crankshaft Position
High.......................................................235-54-17 Signal Missing .........................................235-55-9
Diagnostic Procedure ................................235-54-17 Diagnostic Procedure ..................................235-55-9
ECU 003251.04 — DPF Differential ECU 522401.02 — Camshaft Position
Pressure Signal Out of Range Signal Invalid.........................................235-55-11
Low........................................................235-54-19 Diagnostic Procedure ................................235-55-11
Diagnostic Procedure ................................235-54-19

Continued on next page

TM130419 (24FEB16) 235-5 030916

PN=5
 Contents

Page Page

ECU 522401.05 — Camshaft Position ECU 522585.12 — ECU Internal Fault

Signal Missing .......................................235-55-14 17 ..........................................................235-55-44
Diagnostic Procedure ................................235-55-14 Diagnostic Procedure ................................235-55-44
ECU 522401.07 — Camshaft Position ECU 522588.12 — ECU Internal
and Crankshaft Position Signals Out Voltage High Error.................................235-55-45
of Sync ..................................................235-55-17 Diagnostic Procedure ................................235-55-45
Diagnostic Procedure ................................235-55-17 ECU 523489.12 — ECU Internal
ECU 522571.03 — Suction Control Voltage Low Error..................................235-55-46
Valve Low Side Drive Circuit Out of Diagnostic Procedure ................................235-55-46
Range High ...........................................235-55-20 ECU 522591.12 — Sensor Supply #2
Diagnostic Procedure ................................235-55-20 Voltage Error .........................................235-55-47
ECU 522571.06 — Suction Control Diagnostic Procedure ................................235-55-49
Valve Low Side Drive Circuit Has ECU 522592.12 — Sensor Supply #3
Low Resistance.....................................235-55-23 Voltage Error .........................................235-55-50
Diagnostic Procedure ................................235-55-23 Diagnostic Procedure ................................235-55-51
ECU 522572.06 — Suction Control ECU 522596.09 — No CAN Message
Valve High Side Drive Circuit Has Received From Source Address
Low Resistance.....................................235-55-26 1 ............................................................235-55-52
Diagnostic Procedure ................................235-55-26 ECU 522597.09 — No CAN Message
ECU 522572.11 — Suction Control Received From Source Address
Valve High Side Drive Circuit 2 ............................................................235-55-53
Current Fault .........................................235-55-29 ECU 522599.09 — Vehicle Controller
Diagnostic Procedure ................................235-55-29 CAN Communication Error #1...............235-55-53
ECU 522573.00 — Calculated Soot ECU 522600.09 — Vehicle Controller
Level High .............................................235-55-32 CAN Communication Error #2...............235-55-54
Diagnostic Procedure ................................235-55-32 ECU 522601.09 — Vehicle Controller
ECU 522574.00 — DPF Differential CAN Communication Error #3...............235-55-54
Pressure Soot Level High .....................235-55-33 ECU 522609.09 — Vehicle Controller
Diagnostic Procedure ................................235-55-33 CAN Communication Error #4...............235-55-55
ECU 522575.07 — Parked ECU 522610.09 — EGR Valve CAN
Regeneration Failed..............................235-55-34 Communication Error ............................235-55-56
Diagnostic Procedure ................................235-55-34 Diagnostic Procedure ................................235-55-56
ECU 522576.12 — ECU EEPROM ECU 522617.12 — EGR Valve Position
Read Error.............................................235-55-35 Mismatch...............................................235-55-57
Diagnostic Procedure ................................235-55-35 Diagnostic Procedure ................................235-55-57
ECU 522577.11 — Parked ECU 522618.09 — Vehicle Controller
Regeneration Not Performed ................235-55-36 CAN communication Error #5 ...............235-55-58
ECU 522578.12 — ECU EEPROM ECU 522619.09 — Vehicle Controller
Write Error.............................................235-55-37 Communication Error ............................235-55-59
Diagnostic Procedure ................................235-55-37 ECU 522744.04 — ECU Power
ECU 522579.12 — EGR Valve Actuator Supply Output #1 Circuit Has Low
Low Resistance Error............................235-55-38 Resistance ............................................235-55-59
Diagnostic Procedure ................................235-55-38 Diagnostic Procedure ................................235-55-59
ECU 522580.12 — EGR Valve Position ECU 522994.04 — ECU Power
Internal Error .........................................235-55-39 Supply Output #2 Circuit Has Low
Diagnostic Procedure ................................235-55-39 Resistance ............................................235-55-60
ECU 522582.07 — EGR Valve Diagnostic Procedure ................................235-55-60
Initialization Error ..................................235-55-40 ECU 523249.05 — Crankshaft Position
Diagnostic Procedure ................................235-55-40 and Camshaft Position Signals
ECU 522583.01 — EGR Valve Invalid....................................................235-55-61
Actuator High Temperature Sensor Diagnostic Procedure ................................235-55-62
Fault ......................................................235-55-42 ECU 523460.07 — Fuel Rail Pressure
Diagnostic Procedure ................................235-55-42 Error For a Duration ..............................235-55-63
ECU 522584.01 — EGR Valve Diagnostic Procedure ................................235-55-64
Actuator Low Temperature Sensor ECU 523462.13 — Injector #1
Fault ......................................................235-55-43 Calibration Error ....................................235-55-65
Diagnostic Procedure ................................235-55-43 Diagnostic Procedure ................................235-55-65

Continued on next page

TM130419 (24FEB16) 235-6 030916

PN=6
 Contents

Page

ECU 523463.13 — Injector #2

Calibration Error ....................................235-55-66
Diagnostic Procedure ................................235-55-66
ECU 523464.13 — Injector #3
Calibration Error ....................................235-55-67
Diagnostic Procedure ................................235-55-67
ECU 523468.09 — Rail Pressure
Limiter Open..........................................235-55-68
Diagnostic Procedure ................................235-55-68
ECU 523469.00 — Rail Pressure
Limiter Occurrence Count Extremely
High.......................................................235-55-70
Diagnostic Procedure ................................235-55-70
ECU 523470.00 — Rail Pressure
Limiter Cumulative Time Extremely
High.......................................................235-55-72
Diagnostic Procedure ................................235-55-72
ECU 523489.00 — Fuel Rail Pressure
Extremely High For a Duration..............235-55-74
Diagnostic Procedure ................................235-55-74
ECU 523491.00 — Fuel Temperature
Extremely High For a Duration..............235-55-76
Diagnostic Procedure ................................235-55-76

TM130419 (24FEB16) 235-7 030916

PN=7
 Contents

TM130419 (24FEB16) 235-8 030916

PN=8
 Group 10
Adjustments
Summary of References • Service Timer Menu
• Approved Software for Control Units • Display Setup Screens
CB12260,0000081 -19-10FEB15-1/1

Approved Software for Control Units software. However, not all software versions
can be used on every machine.
IMPORTANT: Avoid Damage! When reprogramming
electronic control units, always comply with the NOTE: The software for reprogramming is either
relevant instructions (for example, installation supplied with the Service ADVISOR data DVD,
instructions, DTAC, or PIP). or else it must be downloaded from John Deere's
Do NOT reprogram the control unit if the version Intranet (John Deere Custom Performance
numbers of the new and current software (Software Delivery System)).
are identical, or if the control unit is already
programmed with a newer software version, For the current summary of software, see PATHWAYS
unless for troubleshooting purposes. or DTAC.

NOTE: New software always includes the properties

that were newly introduced with the previous
CB12260,000062D -19-26MAR15-1/1

TM130419 (24FEB16) 235-10-1 030916

PN=811
 Adjustments

Service Timer Menu

Once the number of operating hours counted reaches the
This menu allows the operator to adjust whether an target number of operating hours, there will be an alert to
engine or hydraulic oil timer is turned on or off. This menu the operator. The operator is able to acknowledge the
also sets service intervals for engine or hydraulic oil. alert, but in order for the alert to go away, the OWNER must
access the service timer menu, and do one of three things:
NOTE: A left press always sends you back to a previous
subscreen or the main screen of the menu. • Disable the timer
• Reset the counter
NOTE: Setting a new interval time only changes • Change the target number of operating hours to a
the interval. Elapsed time remains the higher number.
same unless it is reset.
See Main Screens Navigation, PDU to access the service
NOTE: By default, both the engine oil and hydraulic oil timers.
service timers are enabled and set to a 50-hour timer.
A

C HRS
E F H #
I
G
B D
J

L HRS
M N O #
K

C HRS
E F H #
Q
I
G
D
J

TCT012092 —UN—01DEC14
L HRS
M N O #
K

Continued on next page CB12260,00002A4 -19-27MAR15-1/2

TM130419 (24FEB16) 235-10-2 030916

PN=812
 Adjustments

A—Engine oil service alarm setup F— Service alarm enabled. Right L— Center press to disable or P—Right press to return to
B—Center press to go to press to disable. enable service alarm. service alarm menu.
hydraulic oil setup. G—Center press “E” to set M—Service alarm disabled. Right Q—Center press to go to service
C—Right press if disabled to interval. press to enable. alarm main screen.
enable or dismiss H—Center press “F” to adjust N—Service alarm enabled. Right
D—Right press if enabled to set current interval. press to disable.
up or adjust interval I— Left or right press. O—Center press from “N” to set
E—Service alarm disabled. Right J— Right press resets timer. service interval. Center press
press to enable K—Returns to main service timer to increment.
menu.
CB12260,00002A4 -19-27MAR15-2/2

TM130419 (24FEB16) 235-10-3 030916

PN=813
 Adjustments

Display Setup Screens

A
ae

C
af
B E
D B

F ag
G ad
1 1

ae # #
ah ai
H I
J af aj
K
2 2
B
al
# #
ak
L M
am
N
2 2 an

# #
B
B O
ao
P

ap

M L B

Q
A A
B B T
C R C

B S

U aa
A 1 A 1 A 1 A 1
B B V B ab B
C C C C
ac

W aa

A 2 A 2 A 2 A 2
B B X B B
C C C C

B ab ab
TCT012093 —UN—01DEC14

Continued on next page CB12260,00002C3 -19-10FEB15-1/2

TM130419 (24FEB16) 235-10-4 030916

PN=814
 Adjustments

A—Setup intro K—Enable/disable operator W—Language setup intro ai— Right press for correct
B—Text off passcode X—Text on “Change 2nd password or invalid
C—Text on “DISPLAY SETUP” L— Passcode disabled Language” password
D—Left press to top-level screen M—Passcode enabled Y—Version info aj— Enter new password
E—Center press to I/O status N—Change operator passcode Z— Software version (SW) and ak— Text off. Center press
intro O—Text on “CHANGE KEY” revision (RV) returns to previous screen
F— Right press to setup P—Enable/disable start aa— Language select al— Text on “NEW KEY”
selection. Left press from passcode ab— Language choice am—Repeat enter new password
set up selection to return to Q—Text on-off setup ac— 2nd language choice an— Text on “REPEAT KEY”
setup intro. R—Enter password ad— Text on “INVALID KEY” ao— Store new password
G—Change owner passcode S—Uses factory defined ae— Invalid password successful
H—No text password found in operator’s af— Enter owner passcode ap— Text on “KEY STORED”
I— Text on “CHANGE KEY” manual = 702 ag— Enter password
J— Always center press to T— Text on “TEXT ON” ah— Center press previous digit
advance to the next setting U—Language setup intro until first digit and then back
V—Text on “Change 1st to previous menu
Language”
CB12260,00002C3 -19-10FEB15-2/2

Service ADVISOR Based Calibrations

This calibration is only to be used when replacing the
NOTE: Follow on-screen instructions. diesel particulate filter.

Engine Hour Meter NOTE: Key switch must be switched off for 2 min.
after completing calibration.
Changes hour meter value.
Fuel Rail Pressure Relief Valve Counter Reset
NOTE: New operating hours cannot be less than
current operating hours. NOTE: Perform this only if a component indicated in the
CTM is replaced. Key switch must be turned off
DOC Calibration for 2 min. after completing calibration.
This calibration is only to be used when replacing the Injector Calibration
diesel oxidation catalyst.
This is used to program the ECU with the injector code
NOTE: Key switch must be switched off for 2 min. after replacing a failed injector.
after completing calibration.
NOTE: Key switch must be switched off for 2 min.
DPF Calibration after completing calibration.
CB12260,00002FA -19-26MAR15-1/1

TM130419 (24FEB16) 235-10-5 030916

PN=815
 Adjustments

TM130419 (24FEB16) 235-10-6 030916

PN=816
 Group 15
DPF Functions and DTCs
Summary of References • Parked Regeneration
• Exhaust Filter System Overview • Parked Regeneration Interlocks
• Recovery Regeneration
• Understanding Diesel Particulate Filter (DPF) • DPF Status Screens
Regeneration
• DPF Load Level
• Diesel Particulate Filter (DPF) Regeneration Indicators • Tier 4 Warning Popups
• Accessing Diesel Particulate Filter Displays • Aftertreatment Verification Procedure
• Diesel Particulate Filter Operator Display • DOC Calibration—Instructions
• Active Regeneration • DPF Calibration—Instructions
• Inhibiting Active Regeneration
OUMX258,00002CF -19-24MAR15-1/1

Exhaust Filter System Overview aid in the oxidation of the particulate matter. The oxidation
of the particulate matter in the DPF is called regeneration.
The exhaust filter contains the diesel oxidation catalyst
(DOC) and the diesel particulate filter (DPF). Exhaust gas IMPORTANT: Avoid Damage! Under normal machine
flows through the filter radial inlet, DOC, DPF, and an axial operation, the system is in auto regeneration
or radial outlet, depending on the application. and requires minimal operator interaction.
With the engine under load, Nitric Oxide (NO) oxidizes in IMPORTANT: Avoid Damage! Soot builds up during
the DOC into Nitrogen Dioxide. NO is an agent that allows times when engine exhaust gas temperature
particulates to oxidize easier in the DPF. During active is lower (lower engine speed, lower engine
regeneration, fuel is dosed into the exhaust system using load). Performing extended operations at either
an in-cylinder dosing strategy. The extra fuel is oxidized in low engine speed, or low engine load, results
the DOC. The ECU monitors the DOC outlet temperature in needing a parked regeneration.
to determine the temperature increase across the DOC.
The DPF traps particulate matter, or soot. Exhaust gas To avoid unnecessary buildup of diesel particulates or
passes through channels in the ceramic filter core. Every soot in the exhaust filter system:
other channel is obstructed at the outlet. Exhaust gas • Avoid unnecessary idling.
moves through porous channel walls until it exits through • Use proper engine oil.
an open outlet. While the exhaust gas circulates through
the filter, particulates are trapped on the channel walls.
• Use only ultra low sulfur fuel.
The channel walls are coated with precious metals that
OUMX258,0000866 -19-24MAR15-1/1

TM130419 (24FEB16) 235-15-1 030916

PN=817
 DPF Functions and DTCs

Understanding Diesel Particulate Filter (DPF) active regeneration will be initiated. During an active
Regeneration regeneration, the ECU initiates the in-cylinder fuel dosing
strategy, modifies fuel injection timing, and closes the air
Regeneration throttle to increase exhaust gas temperatures to promote
rapid oxidation and removal of the soot in the DPF. The
Regeneration is the process of increased exhaust exhaust gas temperatures during the active regeneration
temperatures to oxidize the accumulated particulate are higher than the temperatures in the enhanced passive
matter, or soot, from the walls of the DPF. There are regeneration. During this regeneration, the engine is
five types of regeneration that can occur. Passive allowed to be operated normally.
Regeneration, Enhanced Passive Regeneration, Active
Regeneration, Parked Regeneration, and DPF Recovery. Parked Regeneration
Passive Regeneration When the soot level reaches a predetermined level, the
ECU mandates a parked regeneration be performed.
Passive regeneration occurs naturally in the DPF when When a parked regeneration is needed, the ECU derates
the operating conditions produce sufficient exhaust gas the engine to encourage the parked regeneration be
temperatures for the oxidation of soot to occur. The engine performed. During a parked regeneration, the ECU
ECU takes no action during passive regeneration. There increased the engine speed to 2200 rpm, initiates the
is no fuel dosing or closing of the air throttle to increase in-cylinder fuel dosing strategy, modifies fuel injection
exhaust gas temperatures. No indicators are present on timing, and closes the air throttle to increase exhaust gas
the operators interface during the passive regeneration. temperatures to promote rapid oxidation and removal of
Enhanced Passive Regeneration the soot in the DPF. The vehicle must remain parked until
the parked regeneration has ended.
When the soot level in the DPF reaches a predetermined
level and the vehicle operating conditions are not resulting Recovery Regeneration
in sufficient exhaust gas temperatures to promote If the soot in the DPF reaches a severe level, a recovery
sufficient passive regeneration, the engine ECU activates regeneration is required to reduce the soot level.
the enhanced passive regeneration strategy. During Running the vehicle with the regenerations inhibited or
enhanced passive regeneration, the engine ECU closes not performing a parked regeneration when needed can
the air throttle and changes injection timing to increase the cause the recovery regeneration to be needed. During
exhaust gas temperature to a level that promotes passive a recovery regeneration, the vehicle must be parked,
regeneration. The engine is allowed to be operated the ECU closes the air throttle, and changes injection
normally and no fuel is dosed during the enhanced passive timing to increase the exhaust gas temperature to a
regeneration. No indicators are present on the operators level that promotes passive regeneration. No fuel is
interface during the enhanced passive regeneration. dosed during the portion of the recovery. After sufficient
Active Regeneration time has passed and the soot level is at a low level, a
parked regeneration is performed before the recovery
When the soot level in the DPF reaches a predetermined regeneration is complete. The vehicle must remain parked
level or soot is accumulating at a rate greater than can until the recovery regeneration has ended.
be managed by the enhanced passive regeneration, an
OUMX258,0000865 -19-19MAR15-1/1

Diesel Particulate Filter (DPF) Regeneration

AUTO

Indicators
TCT012083 —UN—26NOV14
High Exhaust Temperature Indicator
Description Recommended Procedure
Active regeneration is taking place. Do not interrupt active
Exhaust temperatures are high. regeneration unless necessary. P
Continued on next page OUMX258,000086C -19-24MAR15-1/3

TM130419 (24FEB16) 235-15-2 030916

PN=818
 DPF Functions and DTCs

Parked Regeneration Required

PARK

! P
Description Recommended Procedure
CLEAN

TCT012086 —UN—28NOV14
High level of soot at exhaust filter; Perform Parked Regeneration.
the exhaust filter requires cleaning. See ECU DTC 003719.16 or
NOTE: Engine power is reduced
003720.16. REQD
and machine function
limited. 003719.16

ASH

! CLEAN

TCT012087 —UN—28NOV14
REQUIRED
003720.16
OUMX258,000086C -19-24MAR15-2/3

Recovery Regeneration Required

AUTO
Description Recommended Procedure
STOP

TCT012090 —UN—28NOV14
Extreme level of soot in exhaust Perform Recovery Regeneration.
filter. When this level of See ECU DTC 003719.00 or
contamination is reached, recovery 003720.00.

P
regeneration must be performed.

NOTE: Engine power is reduced

and machine function
limited.

OUMX258,000086C -19-24MAR15-3/3

TM130419 (24FEB16) 235-15-3 030916

PN=819
 DPF Functions and DTCs

Accessing Diesel Particulate Filter Displays

A A
E

AUTO
1234.5
B ABC1 D

TCT012437 —UN—23MAR15
A
2600 A

AUTO
n/min
C ABC1
F

A—Center Button D—Active Regeneration Screen F— Active Regeneration Screen

B—Top-Level Screen (ON) (OFF)
C—Engine Status Screen E—Service Mode Screen

Primary Display Active Regeneration Status

The Primary Display Unit (PDU) top-level screen (B) Pressing the right button toggles the active regeneration
shows an hour meter icon. status from on (D) to off (F). When toggled, the On-Off
Pressing the center button cycles through the top-level arrow changes direction and the AUTO filter icon changes
menu screens (B, C, D, and E). from active to off. See Inhibiting Active Regeneration.

Pressing the right button changes the language. The Pressing the center button (A) on the Active Regeneration
language options are set under the display menu. screen (D) displays the Service Mode screen (E).

Pressing the center button (A) displays the Engine Status Service Mode
screen (C) (rpm and engine on or off). Pressing the right button displays the Pass Code Entry
Engine Status screen. See Pass Codes, and Machine Start Pass Code
Entry for more information on entering pass codes.
Pressing the center button (A) on the engine status screen
(C) displays the Active Regeneration status screen (D). Pressing the center button (A) of the service mode screen
(E) displays the first top menu screen (B).
Pressing the right button changes the language.
Continued on next page OUMX258,000086A -19-25MAR15-1/2

TM130419 (24FEB16) 235-15-4 030916

PN=820
 DPF Functions and DTCs

KEY
1
1 XX B

DISPLAY
SETUP
C C SERVICE
ACTIVE TIMERS
DTC

C
C

I/O
STORED
STATUS
DTC

DPF LVL

TCT012438 —UN—23MAR15
C C

A—Service Mode Screen C—Center Button

B—Pass Code Entry Screen D—Right Button to DPF Menus

Pressing the Service Mode screen (A) right button • DPF Level
displays the Pass Code Entry screen (B). • Input-Output Status
Entering the pass code at the Pass Code Entry screen,
• Service Timers
and then pressing the right button, displays the service
• Display Setup
menu screens. Pressing the right button at any of the service sublevel
screens menus for that service function.
Service Menu Screens
DPF Level Screen
The screens are cycled through (C) by pressing the
center button. The left return arrow button on each screen Pressing the right button (D) of the DPF Level screen
returns to the Service Mode screen (A). displays DPF Load Level screens and menus. See DPF
Load Level.
• Active DTC
• Stored DTC
OUMX258,000086A -19-25MAR15-2/2

TM130419 (24FEB16) 235-15-5 030916

PN=821
 DPF Functions and DTCs

Diesel Particulate Filter Operator Display

AUTO
Status Detection

TCT012078 —UN—26NOV14
The screen icons are determined by the state of the Diesel
Particulate Filter and whether the machine is parked.
No Regeneration Required
NOTE: Button 2 and 3 have the same functions for all
DPF Status screens in the DPF section.
Buttons 2 and 3
• Button 2: Proceed to Main Screen
• Button 3: Enable/Disable Auto Regeneration
• DPF Auto Icon: when Auto Regeneration is enabled, an
image is shown. When disabled, a line crosses through
the icon.
BS62576,00015AC -19-24FEB15-1/8

Parked Regeneration Available

AUTO
NOTE: Button 1 has the same function for all DPF

TCT012099 —UN—01DEC14
Status Screens in section.

• Before starting a Parked Regeneration Cleaning, the

operator must:
a. Park the vehicle on a paved surface.
b. Engage the park brake (ON).
P
c. Disengage the cutting units (PTO Switch OFF).
d. Move the throttle lever to the slow idle position. Parked Regeneration Enabled
• When button 1 (Filter with “P”) icon shown is flashing,
operator presses and holds the button for two seconds

AUTO
to initiate a Parked Regeneration operation.

TCT012091 —UN—28NOV14
NOTE: A delay occurs before the engine RPMs
increase and the parked regeneration starts.

• When button 1 icon shown is solid, and operator

presses and holds the button for two seconds, an
interlock regeneration notification displays. This display
P
indicates that regeneration is available to be performed
but is not required. The machine must be parked with Parked Regeneration Disabled
the cutting units turned off to begin regeneration.
BS62576,00015AC -19-24FEB15-2/8

This icon (cloud with thermometer in center-left

AUTO

area) shows as the top-level screen during Parked

Regeneration. The progress bar shows the percentage
P
TCT012080 —UN—26NOV14

complete of the Parked Regeneration process.

Top-Level Parked Regeneration

Continued on next page BS62576,00015AC -19-24FEB15-3/8

TM130419 (24FEB16) 235-15-6 030916

PN=822
 DPF Functions and DTCs

Warning Indicators

AUTO
When regeneration is occurring and exhaust temperatures

TCT012083 —UN—26NOV14
are higher than normal, the cloud with thermometer in the
center area displays.
Auto Cleaning Required, Regeneration Disabled
The pop-up screen displays when the ‘Auto’ Regeneration
button is disabled and the filter needs cleaning. This
P
fault can be remedied by setting the ‘Auto’ Regeneration
button to ‘Enabled’. Exhaust Temperature High

The information button 3 displays: AUTO

□ DTC 003695.14: Disabled

TCT012084 —UN—26NOV14
Filter cleaning required.
Active Cleaning Required, Auto Regeneration
Disabled
Regen Rqd
The icon (filter in center-left area) indicates that an active
cleaning is required, but the Auto Regeneration feature is
003695.14
disabled. The operator should enable Auto Regeneration
via button 3 (‘Enable’ icon).
Auto Cleaning Required, Regeneration Disabled

AUTO

TCT012085 —UN—26NOV14
P
Active Cleaning Required, Auto Regeneration Disabled
BS62576,00015AC -19-24FEB15-4/8

Cleaning Required, Engine Power Limited

PARK

! P
The following DTCs are displayed when the DPF soot
CLEAN

TCT012086 —UN—28NOV14
has reached an elevated level and cleaning is required.
Engine power is limited until a cleaning is performed. REQD
Parked Cleaning Required (Amber Warning Lamp)
The pop-up screen displays when the filter particulate 003719.16
level is too high. A parked cleaning operation is required.
See Parked Regeneration Available section.
DTC 003719.16
The icon on the left-hand side indicates that a warning
light DTC exists. Parked cleaning is required.
The information button 3 displays:
□ DTC 003719.16: Parked cleaning required. Engine
power limited.
Continued on next page BS62576,00015AC -19-24FEB15-5/8

TM130419 (24FEB16) 235-15-7 030916

PN=823
 DPF Functions and DTCs

Ash Cleaning Required (Amber Warning Lamp)

ASH

!
The pop-up screens displays when the filter particulate
CLEAN

TCT012087 —UN—28NOV14
level is too high. A parked cleaning operation is
required. Additional service may be required. See Parked
Regeneration Available section.
REQUIRED
The information button 3 displays:
003720.16
□ DTC 003720.16: Ash cleaning required.

DTC 003720.16
BS62576,00015AC -19-24FEB15-6/8

DPF Status Screen When DTC 003719.16 or 003720.16

AUTO
is Active

TCT012088 —UN—28NOV14
The icon on the left-hand side indicates that a warning
light DTC exists. Parked cleaning is required.
Cleaning Required, Engine Power and PTO
Power Disabled
The following DTCs are displayed when the DPF has
P
reached its maximum soot levels and requires service.
Engine power is limited and PTO power is disabled. Parked Cleaning Required (Amber Light)

The right side Button 3: Enables or Disables Auto

Regeneration
BS62576,00015AC -19-24FEB15-7/8

DPF Status Screen When DTC 003719.00 or 003720.00

AUTO
is Active
STOP

TCT012090 —UN—28NOV14
The icon on the left-hand side flashes to indicate that a
stop DTC exists. Parked regeneration is required. DPF
may require additional service.
□ DTC 003719.00: Service regeneration required. Engine
power limited.
□ DTC 003720.00: Ash cleaning required. Engine power
P
limited.
DTC 003719.00 or DTC 003720.00
BS62576,00015AC -19-24FEB15-8/8

TM130419 (24FEB16) 235-15-8 030916

PN=824
 DPF Functions and DTCs

Active Regeneration

AUTO
Active regeneration starts when soot in the exhaust filter

TCT012083 —UN—26NOV14
reaches a certain level. Cleaning occurs less frequently if
the engine is operated for long periods under conditions
where passive regeneration takes place.
If the system determines that soot buildup in the exhaust
filter requires cleaning, an active regeneration is initiated.
Active regeneration is performed without any intervention
P
on the part of the operator. High exhaust temperature
indicator remains visible on the diesel particulate filter
status screen during the exhaust filter cleaning. the area of the engine and exhaust filter.
Regeneration uses high temperature.
CAUTION: Avoid injury! To prevent fires, be
sure to clear any combustible materials from
OUMX258,0000867 -19-20MAR15-1/2

Auto Cleaning Required, Regeneration Disabled

The pop-up screen displays when the ‘Auto’ Regeneration
AUTO
Disabled

TCT012084 —UN—26NOV14
button is disabled and the filter needs cleaning. This
fault can be remedied by setting the ‘Auto’ Regeneration
button to ‘Enabled’. See Accessing Diesel Particulate
Regen Rqd
Filter Displays.
The information button 3 displays:
003695.14
□ DTC 003695.14: Filter cleaning required.
Auto Cleaning Required, Regeneration Disabled
Active Cleaning Required, Auto Regeneration
Disabled

AUTO
The icon (filter in center-left area) indicates that an active

TCT012085 —UN—26NOV14
cleaning is required, but the Auto Regeneration feature is
disabled. The operator should enable Auto Regeneration
via button 3 (‘Enable’ icon).

P
Active Cleaning Required, Auto Regeneration Disabled
OUMX258,0000867 -19-20MAR15-2/2

TM130419 (24FEB16) 235-15-9 030916

PN=825
 DPF Functions and DTCs

Inhibiting Active Regeneration

AUTO
IMPORTANT: Avoid damage! Under normal machine
operation, the system is in auto regeneration
mode and requires minimal operator interaction.

If your vehicle must be used in a situation not suited for

higher temperatures created during active regeneration,
temporarily disable the system.

AUTO
To disable the auto regeneration function temporarily,

TCT012431 —UN—19MAR15
depress button 3 on the top menu Active Regeneration
status screen. The auto regeneration symbol appears
with a line through the symbol indicating auto regeneration
is disabled. To avoid soot buildup in the exhaust filter,
be sure to return to auto regeneration mode as soon as
possible. See Accessing Diesel Particulate Filter Displays.
NOTE: Auto regeneration is enabled whenever the
key switch is cycled off.

OUMX258,0000868 -19-20MAR15-1/2

While active regeneration is inhibited, if the system

determines that soot buildup in the exhaust filter requires AUTO
cleaning, the AUTO Disabled Regen Rqd DTC 003695.14
Disabled

TCT012084 —UN—26NOV14
appears on the PDU. To enable the automatic Active
Regeneration cycle through the PDU screens to the active Regen Rqd
regeneration enable-disable screen. See Accessing
Diesel Particulate Filter Displays.
Do not disable active regeneration unless it is necessary.
003695.14
If active regeneration is disabled frequently, the system
eventually activates a parked regeneration. This means
that the engine performance is reduced, machine function
is limited, and does not return to normal until a parked
regeneration is performed.
OUMX258,0000868 -19-20MAR15-2/2

Parked Regeneration
AUTO
IMPORTANT: Avoid damage! If operator disregards

!
TCT012088 —UN—28NOV14
indicators and continues to operate machine
without allowing an automatic cleaning,
engine performance is reduced and machine
function limited. A parked regeneration
procedure must be performed. P
The following occurs when exhaust filter becomes
restricted: Parked Cleaning Required (Amber Light)

• PDU alert with DTC 003719.16 or DTC 003720.16

active. Before starting a parked exhaust filter cleaning, the
• Engine power is reduced and machine function limited. following criteria must be met:
A parked exhaust filter cleaning is required. • Engine running at low idle.
NOTE: The engine must be at operating temperature • Coolant temperature Must be above 60°C (140°F).
to perform a parked regeneration. The parked • Park brake Must be engaged.
regeneration symbol and “P” do not display unless • PTO Must be turned off.
the engine has reached temperature.
Continued on next page OUMX258,0000869 -19-26MAR15-1/3

TM130419 (24FEB16) 235-15-10 030916

PN=826
 DPF Functions and DTCs

IMPORTANT: Avoid damage! No other machine

AUTO
functions are able to be used while regeneration
is taking place with the machine parked.

TCT012099 —UN—01DEC14
Excluded are functions that are required for an
emergency shutdown of the machine.
Do not start regeneration if the fuel gauge has
been showing a low fuel level for a long time.
Only stop engine if necessary due to heat
P
build up in the engine compartment.

AUTO
NOTE: When the previous criteria are met, the parked
regeneration icon blinks indicating parked

TCT012577 —UN—26MAR15
regeneration can be initiated.

1. Press and hold button 1 under the blinking parked

regeneration icon for 2 sec..
NOTE: While the button is being pressed and held, an
animated “hold” icon appears and counts up to
P
provide feedback to continue holding the button
until regeneration is initiated. After the icon
disappears, the button may be released.
OUMX258,0000869 -19-26MAR15-2/3

2. During parked regeneration process, the high exhaust

AUTO
temperature icon with progress bar appears on the
DPF status screen as shown.
P

TCT012080 —UN—26NOV14
3. The engine speed elevates to 2200 rpm.
4. After completion of parked regeneration process, the
system defaults to auto regeneration mode and the
machine operates as normal.
NOTE: If not returning machine to operation, allow
engine time to return to normal operating
temperature before stopping engine.
engine performance is reduced and machine
IMPORTANT: Avoid damage! If operator disregards function limited. A recovery regeneration
indicators and continues to operate machine procedure is required.
without allowing a parked regeneration,
OUMX258,0000869 -19-26MAR15-3/3

TM130419 (24FEB16) 235-15-11 030916

PN=827
 DPF Functions and DTCs

Parked Regeneration Interlocks

If the Parked Regeneration button is pressed when it is not
flashing (regeneration required, but interlocks not met),
then one of the interlock status notifications appears.
Park Brake Not Set
P P
The park brake must be set to start a parked regeneration.
PTO Switch ON

TCT012432 —UN—20MAR15
The PTO switch must be in the off position to start a
parked regeneration. P

CB12260,00000A6 -19-20MAR15-1/1

Recovery Regeneration

AUTO
The following occurs when exhaust filter becomes

TCT012088 —UN—28NOV14
restricted:
• PDU alert with DTC 003719.16 or DTC 003720.16
active.
• Engine power is reduced and machine function limited.
Before completing a recovery regeneration, the following
P
criteria must be met:
Parked Cleaning Required (Amber Light)
• Engine running at low idle.
• Coolant temperature Must be above 60°C (140°F).
• Park brake Must be engaged. Follow on-screen instructions under the Tests and
• PTO Must be turned off. Calibrations tab.
A DPF recovery situation is always accompanied by one 1. Select Tests and Calibrations in the left-hand shortcut
or more DTCs. bar.
Recovery regeneration for diesel particulate filter occurs 2. Select Connected Calibrations.
when DTC 3719.00 or DTC 3720.00 is active. 3. Select Interactive Calibrations.
4. Select ECU.
Service ADVISOR Procedure: 5. Select Service Regeneration.
CB12260,0000096 -19-06APR15-1/4

Primary Display Unit (PDU) Procedure:

DPF Recovery or Regeneration Pass Code
TCT012578 —UN—27MAR15

• Pass-code entry screens follow the same format as R

the Owner/Operator pass-codes, but with an ‘R’ icon 0 XX
instead of the ‘1’ or ‘2’.
• The code required is hard-coded as “463”.

Continued on next page CB12260,0000096 -19-06APR15-2/4

TM130419 (24FEB16) 235-15-12 030916

PN=828
 DPF Functions and DTCs

IMPORTANT: Avoid damage! No other machine

AUTO
functions are able to be used while regeneration
is taking place with the machine parked.

TCT012099 —UN—01DEC14
Excluded are functions that are required for an
emergency shutdown of the machine.
Do not start regeneration if the fuel gauge has
been showing a low fuel level for a long time.
Only stop engine if necessary due to heat
P
build up in the engine compartment.

AUTO
NOTE: When the previous criteria are met, the
regeneration icon blinks indicating regeneration

TCT012577 —UN—26MAR15
can be initiated.

1. Press and hold button 1 under the blinking parked

regeneration icon for 2 sec.
NOTE: While the button is being pressed and held, an
animated “hold” icon appears and counts up to
P
provide feedback to continue holding the button
until regeneration is initiated. After the icon
disappears, the button may be released.
CB12260,0000096 -19-06APR15-3/4

2. During parked regeneration process, the high exhaust

AUTO
temperature icon with progress bar appears on the
DPF status screen as shown.
P

TCT012080 —UN—26NOV14
3. The engine speed elevates to 2200 rpm.
4. After completion of parked regeneration process, the
system defaults to auto regeneration mode and the
machine operates as normal.
NOTE: If not returning machine to operation, allow
engine time to return to normal operating
temperature before stopping engine.
CB12260,0000096 -19-06APR15-4/4

TM130419 (24FEB16) 235-15-13 030916

PN=829
 DPF Functions and DTCs

DPF Status Screens Regeneration States

NOTE: These screens are machine specific to shadow
the procedures and functions outlined in the engine
CTM. Use these screens with the CTM. If using
Service ADVISOR, use the engine CTM only.

A
AUTO

P R

B D E

AUTO
AUTO
AUTO

STOP

C
P P P
Q

AUTO
AUTO
STOP

F G
P P
AUTO
AUTO

H P I
P
AUTO

AUTO

J O K
P P

TCT012989 —UN—26FEB15
AUTO

AUTO

L N M

A—Regen States (Left and Center F— Power Derate with DTC J— Auto regen disabled, Regen M—Auto Regen Enabled, Regen
Icons) 003719.16. Amber LED, “!” enabled. DTC 003703 active. Disabled
B—Priority 1 - Regen Force is and DPF icons all flash. Auto “P” flashes if interlocks are N—Priority 6
Active or Recovery Cleaning regen on. met. If DTC 004175 is active, O—Priority 5
in Progress G—Limp Derate, DTC 003719.00. press left button. P—Priority 4
C—No Derate, Auto Regen off. RED LED, Stop, and DPF K—Auto regen enabled, Regen Q—Priority 2
DPF icon flashes. icons flash. Auto Regen on. disabled.DTC 003703 active. R—Priority 1
D—Power Derate with DTC H—DPF icon solid with DTC “P” flashes if interlocks are
003719.16. Amber LED, “!” 003698 active. met. If DTC 004175 is active,
and DPF icons all flash. Auto I— DPF icon solid with DTC press left button.
regen off. 003698 active. Indicates that L— Auto Regen disabled, Regen
E—Limp Derate, DTC 003719.00. parked regen is available. enabled.
RED LED, Stop, and DPF “P” flashes if interlocks are
icons flash. Auto Regen off. met. Solid “P” if available but
interlocks are not met.
Continued on next page CB12260,00000A2 -19-26MAR15-1/2

TM130419 (24FEB16) 235-15-14 030916

PN=830
 DPF Functions and DTCs

Other Regeneration States

AUTO
AUTO
P
P
B C

AUTO
AUTO

R
H
P P
E G
F P

S
AUTO

AUTO
P
J
P
I K

L O R AUTO
AUTO

P
STOP
#
N O
P

TCT012579 —UN—26MAR15
Q
M
P

A—Exhaust Temp States (Center H—Hold icon only appears as J— Left Button Hold O—Enter pass-code
Icon) the button is held and counts K—Auto Regen Enabled, Regen P—Valid Pass-code
B—Exhaust icon solid up to provide feedback to Disabled Q—DTC 004175 active
C—Exhaust icon flashes continue hold. Always use L— Limp Derate with DTC R—Right Button Hold
D—Hold Feedback Icon with these three button icons 003719.00.Red LED, Stop, S—Forced Regeneration Activate
E—Auto Regen Disabled, Regen when using DPF control. and DPF icons flash. - Left Button Press
Enabled I— Auto Regen Disabled, Regen M—Left Button Press
F— Progress circle. increments Enabled N—Invalid pass-code sends back
every 0.5 sec.. to initial unit setting screen
G—Auto Regen Enabled, Regen
Disabled
CB12260,00000A2 -19-26MAR15-2/2

TM130419 (24FEB16) 235-15-15 030916

PN=831
 DPF Functions and DTCs

DPF Load Level

The DPF load level screen informs the operator of the not linearly related to the actual soot loading value. If the
state of the diesel particulate filter status. There are four notepad button is selected, the actual soot loading value
states that this status can be in, but the progress bars are is displayed.
A
B

DPF LVL DPF LVL

H I

C D
J K
DPF LVL DPF LVL

E F L M
N

DPF LVL

TCT009954 —UN—22JAN14
G

A—DPF Load Level Screen E—DPF state moderate J— Center press

B—DPF Bar Graph States F— DPF state high K—DPF status screen
C—Regen not needed G—DTC 004175 active L— Right hold
D—DPF state low H—Left press M—DPF level screen
I— DPF timer screens N—DPF Regen force
enable/disable states (right
button)
CB12260,00000A3 -19-25MAR15-1/2

TCT009955 —UN—22JAN14
DPF Load Value
DPF LVL DPF LVL DPF LVL
A—Represents 4.5 g per liter C—Represents an error in
B—Represents out of range determining DPF loading 4.50 g/L N/A g/L ERROR g/L

A B C

CB12260,00000A3 -19-25MAR15-2/2

TM130419 (24FEB16) 235-15-16 030916

PN=832
 DPF Functions and DTCs

Tier 4 Warning Popups

A
B K O
C L P
AUTO PARK ASH

003695.14
Disabled
Regen Rqd
003695.14
P
003719.16
PCLEAN
REQD
003719.16 003720.16 003720.16
CLEAN
REQUIRED

D E D E D E
DTC 003719.16 Engine DTC 003720.16
003695.14 : AUTO
M power limited Start M Ash level High
diasabled Enable N parked filter cleaning N Contact Service Rep
F G AUTO filter cleaning

ENGINE ENGINE
kW kW kW kW
POWER POWER
LIMITED LIMITED
H 003719.16 003720.16
D E D E
I

PARK
F F
P
003702.01
P CLEAN
STOPD
Q S
D E R T

Park clean stopped SRVC SRVC

due to disabled STOP STOP REQD STOP STOP REQD
F J button activation
003719.00 003720.00
D E D E
DTC 003719.00 DTC 003720.00
M Service required M Service required
N Contact Service Rep N Contact Service Rep

TCT012109 —UN—27JAN15
ENGINE ENGINE
kW kW kW kW
POWER POWER
LIMITED LIMITED
003719.00 003720.00
D E D E

F F

A—Tier 4 warning popup screens H—Force regeneration stopped L— Power derate, amber LED R—Limp derate, Red LED
B—No derate popup popup flashes and DTC 003719.16 flashing and DTC 003719.00
C—No derate, DTC 003695.14 and I— DTC 003702.01 and disabled M—Left or center press S—Limp derate popup
amber LED flashes button pressed N—Right press T— Limp derate, Red LED
D—Text off J— Right press for “Park clean O—Power derate popup flashing and DTC 003720.00
E—Text on stopped due to disabled P—Power derate, amber LED
F— Left or center press to DPF button activation” message flashes and DTC 003720.16
status screen K—Power derate popup Q—Limp derate popup
G—Right press for auto
regeneration enable or
disable
CB12260,00002A3 -19-18FEB15-1/1

Aftertreatment Verification Procedure 4. Monitor DTCs. If any DTCs become active, go to

1. Ignition ON, engine running. those troubleshooting procedures.
2. Ensure that the auto exhaust filter cleaning is enabled NOTE: Upon key cycle, DTCs related to the aftertreatment
and throttle is at slow idle. system may become stored.

3. In Service ADVISOR, monitor Engine Coolant 5. Clear all stored DTCs and verify that no active DTCs
Temperature and allow it to reach 70°C (158°F). reappear.
IMPORTANT: If exhaust filter cleaning begins,
allow it to complete.
OUMX258,00002CE -19-20FEB15-1/1

TM130419 (24FEB16) 235-15-17 030916

PN=833
 DPF Functions and DTCs

DOC Calibration—Instructions 3. In Service ADVISOR,

NOTE: This calibration is performed only when the Diesel a. Select Tests and Calibrations in the left-hand
Oxidation Catalyst (DOC) is replaced. shortcut bar.
NOTE: Replacing a DOC to test for a bad DOC (part b. Select Connected Calibrations.
swapping) is not recommended.
c. Select Interactive Calibrations.
The new DOC part number and serial number are needed d. Select ECU - Level B1.
to complete the procedure. The information particular to
the new DOC is loaded into the ECU using this procedure. e. Select DOC Calibration.
For more information see the engine CTM, Section 03,
Group 137. f. Follow instructions in the DOC calibration procedure.

1. Obtain DOC part number and serial number for 4. Ignition OFF, Engine OFF for two min..
manual entry of DOC information. 5. Connect to the Deere network to automatically send
2. Ignition ON, Engine OFF the return file to Custom Performance.
OUMX258,00002D1 -19-16FEB16-1/1

DPF Calibration—Instructions 3. In Service ADVISOR,

NOTE: This calibration is performed only when the Diesel a. Select Tests and Calibrations in the left-hand
Particulate Filter (DPF) is replaced. shortcut bar.
NOTE: Replacing a DPF to test for a bad DPF (part b. Select Connected Calibrations.
swapping) is not recommended.
c. Select Interactive Calibrations.
The new DPF part number and serial number are needed d. Select ECU - Level B1.
to complete the procedure. The information particular to
the new DPF is loaded into the ECU using this procedure. e. Select DPF Calibration.
For more DPF information see the engine CTM, Section
03, Group 137. f. Follow instructions in the DPF calibration procedure.

1. Obtain DPF part number and serial number for manual 4. Ignition OFF, Engine OFF for two min..
entry of DPF information. 5. Connect to the Deere network to automatically send
2. Ignition ON, Engine OFF the return file to Custom Performance.
OUMX258,00002D2 -19-16FEB16-1/1

TM130419 (24FEB16) 235-15-18 030916

PN=834
 Group 20
Set Up, PDU
Summary of References • Stored DTC Flow Description
• Main Screens Navigation, PDU • Pass Codes
• Machine Start Pass Code Entry
• Language Select • Display Setup Screen Detailed
• Text Selection • Version Information
• Machine Status Screens • Reprogramming, PDU
• Active DTC Flow Description
CB12260,00000C7 -19-30MAR15-1/1

Main Screens Navigation, PDU

These are the main navigation screens for entering the
various service and set up menus.

1234.5 D
A
ABC1

C E 0 n/min
ABC1

TCT012573 —UN—20MAR15
D

B
1234.5
ABC1

A—Hour Meter C—Screens may toggle E—Tachometer screen

B—Hour Meter with glow plugs D—Center press to go to next
active screen

A right press takes you to the language selection options.

See Language Select and Display Setup Screen Detailed.
CB12260,00002FB -19-31MAR15-1/4
AUTO

AUTO

G
TCT012574 —UN—20MAR15

F— Active Regeneration ON G—Active Regeneration OFF

This screen allows you to turn active DPF regeneration

on or off.
Continued on next page CB12260,00002FB -19-31MAR15-2/4

TM130419 (24FEB16) 235-20-1 030916

PN=835
 Set Up, PDU

A center press takes you back to the hour meter screen.

The operator pass code is required to enter the service
mode menus. See Pass Codes and Machine Start Pass
Code Entry.
NOTE: A left press returns you to the Service
Mode screen (H). H

H—Service Mode J— Pass Code Entry

I— Right press to enter pass I
code for Service Mode

J KEY
1

TCT012575 —UN—20MAR15
1 XX

Continued on next page CB12260,00002FB -19-31MAR15-3/4

TM130419 (24FEB16) 235-20-2 030916

PN=836
 Set Up, PDU

Active DTC Messages

See Active DTC Flow Description. ACTIVE
• Left: Return DTC
• Center: Next
• Right: Enter active DTCs K
Stored DTC Messages
L
See Stored DTC Flow Description.
• Left: Return
• Center: Next STORED
• Right: Enter stored DTCs DTC
DPF Level
M
See Accessing Diesel Particulate Filter Displays.
• Left: Return
• Center: Next L
• Right: DPF level numerical value
I-O Status DPF LVL
See PDU I-O Status Readings.
• Left: Return
• Center: Next N
• Right: Enter I-O status
Service Timers L
See Service Timer Menu.
I/O
• Left: Return
• Center: Next STATUS
• Right: Enter service timers
Display Setup O
See Display Setup Screens and Display Setup Screen
Detailed. L
• Left: Return
• Center: Next SERVICE
• Right: Enter display setup TIMERS
K—Active DTC sub menu O—I/O Status sub menu
L— Center Press to Advance to P—Service Timer sub menu P
Next Sub Menu Q—Display Setup sub menu
M—Stored DTC sub menu
N—DPF level sub menu
L

DISPLAY
TCT012576 —UN—20MAR15

SETUP
Q

CB12260,00002FB -19-31MAR15-4/4

TM130419 (24FEB16) 235-20-3 030916

PN=837
 Set Up, PDU

Language Select • Spanish

The display has the ability to show text in the following
• Portuguese
languages:
• Russian
• Chinese
• English All displayed text may be turned off as well. For setup
• French information (See Display Setup Screens, Display Setup
• German Screen Detailed, and Main Screens Navigation, PDU).
• Italian
CB12260,0000628 -19-23MAR15-1/1

Text Selection
The display text may be toggled On or Off and has the
ability to display multiple languages. (See Display Setup
Screens and Display Setup Screen Detailed).
CB12260,0000629 -19-19MAR15-1/1

Machine Status Screens

These screens will appear when an unsafe operating
condition is encountered. (See “Diagnose-DTCs, PDU
in this manual).
CB12260,000062C -19-27FEB14-1/1

TM130419 (24FEB16) 235-20-4 030916

PN=838
 Set Up, PDU

Active DTC Flow Description

Shows the sequence for observing active faults using the
PDU.
A
R
I
NO
B ACTIVE
ENGINE
DTC
J E F
C P
G O S
D
L K Q T X
L U Further info
ECU about DTC
654321.00 L
E
M G J
Y
NO N
ACTIVE
DTC L

TCT011106 —UN—25NOV14
F G
L V
G H L
H
W

A—Active DTC menu J— Right press R—No active faults V—Next active DTC
B—Active fault from any control K—Next device S—Note: These screens can W—Last active DTC
unit L— Center press be displayed if during the X—DTC description text
C—No active faults from any M—Last device search, the no active DTC Y—DTC Internal code, SPN.FMI,
device N—Note: Only devices with message was received, or a and occurrence count
D—No active faults active faults are available in DTC message timed out.
E—Text off list. T— List
F— Text on O—Search complete U—DTC (example)
G—Left press P—No active faults
H—Service screens Q—1 or more active faults
I— Controller or intelligent
device list
CB12260,00002C8 -19-18FEB15-1/1

TM130419 (24FEB16) 235-20-5 030916

PN=839
 Set Up, PDU

Stored DTC Flow Description

This function allows you to view a list of all stored DTCs the last reset, and the fault has not reoccurred, that DTC
since the last reset. If a given DTC was present before is not displayed.
A
I P
T
B
ENGINE N ECU
654321.00 G
OCC 7 U
J O J
C
G G
D
K Q
G G G
E
L R
NO
STORED G G
DTCs
M
F S
N

G H

V W X
H
CLEAR CLEAR CLEAR
DTC DTC ? DTC DTC DTC

TCT011107 —UN—01DEC14
DTC OK? DONE
Y Y

F E F E F
G

A—Stored DTC menu J— Right press for stored DTC P—Stored DTC list sub-menu V—Clear DTC sub-menu
B—Stored faults are present search Q—Next stored DTC W—Confirm clear DTC sub-menu
C—Stored faults are not present K—Next control unit or intelligent R—Last stored DTC X—Completed DTC clear
D—No stored faults screens device S—Center press from last DTC to sub-menu
E—Text off L— Last device clear sub-menu Y—Right hold
F— Text on M—Note: Only devices with T— DTC description long text Z— To stored DTC search screen
G—Center press previously active faults are U—DTC description. Use
H—Return to stored DTC main available in list. up-down arrows to scroll
screen N—Left press
I— Controller or intelligent O—Searching complete
device list screens

NOTE: Screens are representations only. Appearance

may be different based upon vehicle application.
CB12260,00002C7 -19-18FEB15-1/1

TM130419 (24FEB16) 235-20-6 030916

PN=840
 Set Up, PDU

Pass Codes The operator level pass code is capable of setting the
There are two levels of password protection to enhance following:
machine security and restrict access to certain features.
• Start and operate the machine only. The operator can
There is also a text enable and disable pass code. This not change any internal settings.
code is “702” and cannot be changed. • Set cruise control speed
• Owner level NOTE: The operator pass code is disabled by default.
• Operator level
The operator pass code is set at the owner level.
Owner Level
Owner Pass Code Reset:
The owner pass code is capable of performing the
following: At start-up the display turns on, displaying the John Deere
logo for 2 sec. During these 2 sec. the Pass-code can
• Owner pass code change be reset to factory default (000) with a specific button
• Operator pass code enable or disable sequence.
• Reset operator pass code without knowing operator
pass code 1. Turn key switch to run position.
• Machine start pass code feature enable or disable 2. Within 2 sec., hold center and right buttons for 3 sec.
• Change owner pass code
• Access Service screens 3. Press center button.
• Access all sub service screens
• Enter machine start pass code whether operator pass 4. Press right button.
code is enabled or not. 5. Hold left and right buttons for 3 sec.
• Machine start and operate
6. If the wrong key combinations are pressed or the
The owner pass code can access the following screens: procedure times out, the screen revert to the main
• PDU setup operational screen.
• Service menus 7. If the procedure was successful, the default factory
• Machine start pass code enable or disable pass code of “000” is set. The display shows text
The default owner pass code is “000”. “Reset Password to Factory Default”.

In the event of a lost pass code, Service ADVISOR (under NOTE: This procedure automatically disables the
the Tests and Calibrations tab), or a manual procedure is operator pass code if it was set.
required to reset.
Operator Level
CB12260,00000A0 -19-25MAR15-1/1

TM130419 (24FEB16) 235-20-7 030916

PN=841
 Set Up, PDU

Machine Start Pass Code Entry

This pass code is required for machine start operation.
It should be obtained from the machine owner before
servicing.

A
B C

0 XX 1 XX
E
D D

10X 11X
E
D D

11 0 111
E
D D

TCT012108 —UN—23JAN15
H

1234.5 I
G C

A—Splash screen with key on D—Number increment key F— Valid pass code I— Return (left press)
B—2 second delay (center press) G—Main operational screen
C—Enter pass code screens E—Next screen (right press) H—Invalid pass code screens

NOTE: Left press returns to first “Enter Pass

Code” screen for retry.
CB12260,000009F -19-05FEB15-1/1

TCT009938 —UN—30DEC13
Display Setup Screen Detailed
Change Owner Pass-Code
NOTE: Requires successful owner pass-code
entry to change.

Left— Return Right— Reset Owner

Center—Next Pass-Code subscreens

Continued on next page CB12260,00000A1 -19-19MAR15-1/10

TM130419 (24FEB16) 235-20-8 030916

PN=842
 Set Up, PDU

TCT009939 —UN—30DEC13
Change Owner Pass-Code with Text
NOTE: Requires successful owner pass-code
entry to change.

Left— Return Right— Reset Owner

Center—Next Pass-Code subscreens

CB12260,00000A1 -19-19MAR15-2/10

TCT009940 —UN—30DEC13 TCT009941 —UN—30DEC13

Enable—Disable Operator Pass-Code
NOTE: Requires successful owner pass-code
entry to change.

Left— Return Right— Enable or Disable

Center—Next

CB12260,00000A1 -19-19MAR15-3/10

TCT009951 —UN—30DEC13
Change Operator Pass-Code
NOTE: Requires successful owner pass-code
entry to change.

Left— Return Right— Reset Operator

Center—Next Pass-Code subscreens

CB12260,00000A1 -19-19MAR15-4/10

TCT009942 —UN—30DEC13
Change Operator Pass-Code with Text
NOTE: Requires successful owner pass-code
entry to change.

Left— Return Right— Reset Operator

Center—Next Pass-Code subscreens

CB12260,00000A1 -19-19MAR15-5/10

TCT009943 —UN—30DEC13
Machine Start Pass-Code Entry Enable—Disable
NOTE: Enabled shown. Disabled shows lock icons in
opposite states from enabled shown.

Left— Return Right— Unlock (Disable

Center—Next pass-code)

Continued on next page CB12260,00000A1 -19-19MAR15-6/10

TM130419 (24FEB16) 235-20-9 030916

PN=843
 Set Up, PDU

Text On—Off Setup

NOTE: Requires successful text passcode A

TCT012993 —UN—26FEB15
entry to change. B
C
Left— Return Right— Enable/Disable
Center—Next

CB12260,00000A1 -19-19MAR15-7/10

Text On—Off Setup with Text

NOTE: Requires successful text passcode A TEXT

TCT012994 —UN—26FEB15
entry to change. B ON
C
Left— Return Right— Enable/Disable
Center—Next

CB12260,00000A1 -19-19MAR15-8/10

Language Selection Setup: Primary and Secondary

A 1
B

TCT012995 —UN—26FEB15
Left— Return Right— Enter Language Setup
Center—Next
C

A 2
B

TCT012996 —UN—26FEB15
C

Continued on next page CB12260,00000A1 -19-19MAR15-9/10

TM130419 (24FEB16) 235-20-10 030916

PN=844
 Set Up, PDU

Language Selection Setup with Text: Primary

and Secondary A 1 CHANGE 1st
B LANGUAGE

TCT012997 —UN—26FEB15
Left— Return Right— Enter Language Setup
Center—Next C

A 2 CHANGE 2nd
B LANGUAGE

TCT012998 —UN—26FEB15
C

CB12260,00000A1 -19-19MAR15-10/10

Version Information • Software version number in the format of {Phase}

{Revision Number}
The current PDU software version can be displayed
under the “Display Setup” sub-menu. (See Display
• Date in the format of MM/DD/YYYY
Setup Screens and Display Setup Screen Detailed). The NOTE: More detailed version information can be
following information is shown: viewed using Service ADVISOR.
• Software part number
CB12260,000062A -19-31MAR15-1/1

Reprogramming, PDU
See Approved Software for Control Units for more
information.
CB12260,0000627 -19-27FEB14-1/1

TM130419 (24FEB16) 235-20-11 030916

PN=845
 Set Up, PDU

TM130419 (24FEB16) 235-20-12 030916

PN=846
 Group 30
Theory of Operation
Summary of References • CAN Trace
• CAN Bus Message Structure • Diagnostic Trouble Codes (DTCs) Overview
• Primary Display Unit (PDU)
• CAN Bus Operation • Hour Meter
• Data Bus Systems
CB12260,00000C8 -19-06APR15-1/1

CAN Bus Message Structure • End signal - Indicates the end of the frame.
Basically, the electronic control units consist of two The sender (electronic control unit) initiates a data transfer
elements. by sending a data frame. However, the receiver (electronic
control unit) can also request data from the sender. To do
- The electronic control unit this, the receiver issues a request. Question (request) and
- The interface control unit answer both have the same identifier. The only difference
lies in the control bit.
The electronic control unit is fully occupied with performing
its tasks. An acceptance check is carried out within the electronic
control units. This means that only data with an identifier
The interface control unit manages the vast amount of stored in a list is actually accepted by the control units.
data that is broadcast and recalled via the CAN BUS [CAN The code numbers that are otherwise required for data
= CONTROLLER AREA NETWORK] communication transmission are thus eliminated.
lines. The data it passes on to the electronic control unit
is only the data that the control unit actually requires. The identifier determines the priority with which the data
is transmitted. Each electronic control unit can transmit
The electronic control units share their monitoring, its data, provided the CAN communication lines are
operational and display data with each other by continually free. If several want to transmit at the same time, the
"broadcasting" it on the CAN BUS line. data sent first are the ones with the highest priority. The
other electronic control units then go automatically to the
In CAN BUS systems, addresses are allocated according "receive" mode and do not send their data until the CAN
to the importance of the data. BUS communication lines are free.
• Start signal - Indicates the start of the data frame and If a malfunction is registered, the electronic control
synchronizes all the electronic control units. unit interrupts the current transmission. The electronic
• Assignment field - Consists of identifier and control bit. control units are capable of telling the difference
The identifier indicates the priority accorded to the data. between malfunctions that only occur occasionally and
During transmission of this field, the sender checks malfunctions that persist. This is achieved by making a
that it has the right to transmit, or if priority should be statistical assessment of the error situation.
given to another electronic control unit. The control bit
indicates whether the data is a question or an answer. All the electronic control units send and receive data
• Control field - Contains information on the size of the while the key switch is on, so the CAN communication
data in the data field. lines are continually carrying "broadcast" data. Some
• Data field - Contains the actual data. are ”broadcast” more frequently than others, depending
• Cyclic redundancy check (CRC) field - To recognize any on what data it is.
errors that may occur in transmission, this field contains
a CRC code name; this code name must be known by A terminating resistor is located at the end of the
every electronic control unit. CAN-BUS communication lines. The terminating resistor
• Acknowledgement field - Contains the acceptance is required to reduce faults in the communication lines.
signals from data that have been received without error
by the various electronic control units.
SW00544,000016D -19-21NOV14-1/1

TM130419 (24FEB16) 235-30-1 030916

PN=847
 Theory of Operation

CAN Bus Operation

Each control unit can send and receive digital messages
The Control unit Area Network (CAN-Bus) is used to via the CAN-Bus.
allow communication between control units on a machine.
When the key switch is turned on, the electronic control In order to regulate the information being transmitted,
units start to send and receive information over the each electronic control unit has an interface control unit
CAN-Bus. Information may also continue to be transmitted built in. While the electronic control unit is fully occupied
by some control units for a short time after the key switch performing its own tasks, the interface control unit
is turned off. Some of the information is broadcast more manages the large amount of information being broadcast
frequently than others, depending on what the data is and on the CAN-Bus and only passes required information
which control unit is sending it. onto the bus.

The CAN Bus has a terminating resistor after the last Diagnostic Trouble Codes (DTCs) are based on the CAN
physical control unit on each end of the bus. The ISO and J1939 SAE Standards. These are worldwide
terminating resistors are required to reduce faults in the standards for automotive and off-highway machines and
communication lines. are controlled by an ISO industry committee.
SW00544,000016E -19-29APR14-1/1

Data Bus Systems The data Bus system forms a communication network for
The following electronic control units are equipped. data-sharing between control units.

• VCU - Vehicle Control Unit The lines that link up the elements of a data Bus system
• PDU - Primary Display Unit are known as communication lines.
• ECU - Engine Control Unit
The electronic control units are connected to each
other via data CAN bus systems (CAN bus [CAN =
CONTROLLER AREA NETWORK]).
SW00544,000016F -19-25NOV14-1/1

CAN Trace DTAC has the ability to create custom filters to allow
CAN Trace allows one to record and view all or some only certain data to be recorded if a particular system is
messaging traffic on the CAN bus. This is useful for suspect. This speeds the troubleshooting process. If this
diagnosing difficult to troubleshoot problems. Service is the case, DTAC should be informed beforehand in order
ADVISOR™ is required to use CAN Trace. for the filter to be created and applied to the CAN Trace
function in Service ADVISOR™.
If this data needs to be used for diagnostic purposes,
it should be sent to DTAC though Service ADVISOR for
analysis.
SW00544,0000170 -19-08AUG14-1/1

TM130419 (24FEB16) 235-30-2 030916

PN=848
 Theory of Operation

FMI Condition
Diagnostic Trouble Codes (DTCs) Overview
Data valid but above normal operating
SPN.FMI Codes 00 range—most severe level
Data valid but below normal operational
Diagnostic Trouble Codes (DTC) are based on the 01 range—most severe level
CAN ISO and J1939 SAE Standards. These DTCs are
02 Data erratic, intermittent, or incorrect
worldwide standards for automotive and off-highway
03 Voltage above normal, or shorted to high source
vehicles and are controlled by an ISO industry committee.
There are two main parts that make up a DTC: 04 Voltage below normal, or shorted to low source
05 Current below normal or open circuit
SPN (Suspect Parameter Number)—the SPN identifies
06 Current above normal or grounded circuit
where the problem exists. An example is 94 which the
standard defines as Fuel Delivery System. Any vehicles 07 Mechanical system not responding or out of adjustment
using the 94 in the DTC therefore are defining a problem 08 Abnormal frequency or pulse width or period
with the fuel delivery system. The list of possible SPNs 09 Abnormal update rate
is too large to provide here. Codes in the lower numbers 10 Abnormal rate of change
(currently, below 5000) are assigned numbers that are 11 Root cause not known
set standards. SPNs that contain six digits, such as
12 Bad intelligent device or component
524255 are called proprietary, and are set up in blocks.
13 Out of calibration
An example would be 520000—540000 which might be
assigned to John Deere Waterloo to use for parameters 14 Special instructions
that are not already defined. At some point, if these Data valid but above normal operating
proprietary numbers are approved by SAE and the CAN 15 range—least severe level
committee, they may be assigned a lower number and Data valid but above normal operating
become available industry-wide. 16 range—moderately severe level
Data valid but below normal operating
FMI (Failure Mode Indicator) is a standard set of numbers 17 range—least severe level
that defines how the SPN failed. FMIs are defined by the Data valid but below normal operating
J1939 standard. 18 range—moderately severe level
19 Received network data in error
By combining the SPN and FMI, the code 94.03 means the
Fuel Delivery System input voltage is high. The universal 20-30 Reserved for SAE assignment
standard would applies to any CAN-based vehicle. 31 Too long

Failure Modes
SW00544,0000171 -19-25NOV14-1/1

Primary Display Unit (PDU)

If the PDU displays dashes and a mode icon or otherwise
The PDU is a graphic and text-based user interface for appears to be missing information, it means that the PDU
machine control, settings, and diagnostics. is not receiving information from the supplying control
unit for that information. Service ADVISOR is required
The PDU is interactive with the operator or technician. It to diagnose this condition.
receives information from all on-board control units as
well as sending commands to all on-board control units.
This information is transmitted via the CAN bus.
SW00544,0000172 -19-24MAR15-1/1

Hour Meter while the key switch is in the on position and the engine is
off. Hour data is stored in nonvolatile memory of the VCU
The PDU displays total engine operating hours on the and ECU. The hour meter count may be changed using
main (default) screen. This data is recorded by the VCU Service ADVISOR. The number may be increased, but
and ECU and is transmitted over the CAN bus to the PDU. not decreased.
Hours are only recorded when the engine is running, not
SW00544,0000173 -19-26MAR15-1/1

TM130419 (24FEB16) 235-30-3 030916

PN=849
 Theory of Operation

TM130419 (24FEB16) 235-30-4 030916

PN=850
 Group 35
Checks, Tests, and Procedures
Summary of References • CAN Bus Terminator Test
• Diagnostic Essential or Recommended Tools • Control Unit Messaging Errors
• CAN Network Voltage Checks
• CAN Message Not Received • Erroneous Diagnostic Trouble Codes
• CAN Message Received Error • Troubleshooting Electronic Control Units
• CAN Message Received Is Incorrect • Diagnostic Information
• Terminal Test • Readings Overview
• Verification Procedure • Control Unit Readings—VCU
• Wiggle Test • PDU I-O Status Readings
• Short to Voltage Procedure • ECU Data Points Used in Service ADVISOR
• Problem Not Found Procedure • Electronic Injector—Calibration Information
• Accessing the Addresses and Diagnostic Trouble Codes • Service ADVISOR Based Tests
• CAN Communication Fault Checks
CB12260,0000083 -19-06APR15-1/1

Diagnostic Essential or Recommended Tools ESSENTIAL TOOLS listed are required to perform
NOTE: Order tools from the SERVICEGARD™ Catalog. the job correctly and are obtainable only from the
SERVICEGARD™ Catalog.
SERVICEGARD is a trademark of Deere & Company
OUMX258,0000460 -19-17APR14-1/14

Cord, Patch...................................................... J-35616-20

Engine Tests and Adjustments
OUMX258,0000460 -19-17APR14-2/14

Test Box, Diagnostic ......................................... JDG10273 Engine Tests and Adjustments

OUMX258,0000460 -19-17APR14-3/14

Kit, Flex Probe .................................................. JDG10466

Engine Tests and Adjustments
OUMX258,0000460 -19-17APR14-4/14

Probe, Flex Male Blue/Gray (3PK) ....................JDG11233 Engine Tests and Adjustments
OUMX258,0000460 -19-17APR14-5/14

Probe, Flex (Female) (3PK)...............................JDG11348 Engine Tests and Adjustments

OUMX258,0000460 -19-17APR14-6/14

Probe, Flex (Male) (3 PK)..................................JDG11349 Engine Tests and Adjustments

OUMX258,0000460 -19-17APR14-7/14

Probe, Flex (3PK) ..............................................JDG11524 Engine Tests and Adjustments

OUMX258,0000460 -19-17APR14-8/14

Probe, Flex (3PK) ..............................................JDG11525 Engine Tests and Adjustments

Continued on next page OUMX258,0000460 -19-17APR14-9/14

TM130419 (24FEB16) 235-35-1 030916

PN=851
 Checks, Tests, and Procedures

Probe, Flex (3PK) ..............................................JDG11536 Engine Tests and Adjustments

OUMX258,0000460 -19-17APR14-10/14

Probe, Flex (3PK) ..............................................JDG11537 Engine Tests and Adjustments

OUMX258,0000460 -19-17APR14-11/14

Probe, Flex (3PK) ..............................................JDG11548 Engine Tests and Adjustments

OUMX258,0000460 -19-17APR14-12/14

Probe, Flex (3PK) ..............................................JDG11549 Engine Tests and Adjustments

OUMX258,0000460 -19-17APR14-13/14

RECOMMENDED TOOLS, as noted, are suggested to Meter, Fluke 88-5/A ..............................................JT07306

perform the job correctly. Some tools may be available
from local suppliers or may be fabricated. Engine Repair
OUMX258,0000460 -19-17APR14-14/14

CAN Message Not Received 4. From the list, determine which control unit is no longer
The control unit did not receive a CAN message from communicating.
another control unit. IMPORTANT: If the control unit source address
When DTC is Displayed: is not listed, it is not communicating on
When the control unit does not receive a CAN message the communication bus.
from another control unit.
Were you able to identify the control unit that is not
Related Information: communicating?
NOTE: The last three digits of the SPN you just Yes: Look for an open or short connection of the CAN
came from correlate to the Source Address of wiring between the control unit and the other control unit.
the control unit in question. Repair problem. Perform Verification Procedure.

To determine which control unit has stopped sending No, all control units are communicating: While
messages to the other control unit, use the following performing the Wiggle Test, close displayed list, repeat
procedure: step 3 and watch for a new control unit to be displayed.
If a new control unit is displayed look for an intermittent
1. Ignition ON, Engine OFF. connection of the CAN wiring between the control unit
and the other control unit or corrosion at the connectors.
2. Using Service ADVISOR, go to the Readings menu
Repair problem. Perform Verification Procedure.
and select Get Control units.
3. Service ADVISOR should now be displaying a list of
control units communicating.
CB12260,0000617 -19-21NOV14-1/1

TM130419 (24FEB16) 235-35-2 030916

PN=852
 Checks, Tests, and Procedures

CAN Message Received Error b. Disconnect control unit connector(s) and connector
of control unit identified in step 1.
The control unit received a CAN message error when c. Look for corrosion at the disconnected connectors
communicating to another control unit. and the mating connectors in the CAN wiring
When DTC is Displayed: terminals.
When the control unit receives a CAN message error d. Look for chaffed or pinched places in the harness
when communicating to another control unit. between the control unit and the identified control
unit.
Related Information: Were any problems found?
Yes: Repair problem. Perform Verification Procedure.
NOTE: The last three digits of the SPN you just No: Go to next step.
came from correlate to the Source Address of
the control unit in question. 3. Reprogram control unit
a. Ignition ON, Engine OFF.
To determine which control unit has the b. Reprogram control unit.
communication error, use the following procedure. c. Refresh codes.
1. Identify Control Unit Is DTC that sent you here active?
a. Ignition ON, Engine OFF. Yes: Go to next step.
b. In Service ADVISOR, go to Readings menu and No: Problem resolved. Perform Verification
select Get Control units. Procedure.
c. Service ADVISOR should now be displaying a list
of control units communicating on your application. 4. Troubleshoot Identified Control unit
d. Look for the last three digits of the diagnostic a. Ignition OFF, Engine OFF.
trouble code that sent you here in the source b. Ignition ON, Engine OFF.
address column of the displayed list to identify c. Refresh codes.
the control unit the suspect control unit is having Is DTC that sent you here active?
communications problems with. Yes: Go to next step.
Were you able to identify the control unit that is No: Problem resolved. Perform Verification
generating the communication error? Procedure.
Yes: Go to next step.
No, source address is not in the displayed list: 5. Replace control unit
While performing the Wiggle Test, close displayed list, a. Ignition OFF, Engine OFF.
repeat step c and watch for a new control unit to be b. Replace control unit programmed with identical
displayed. If a new control unit is displayed look for an software that was in the removed control unit.
intermittent connection of the CAN wiring between the c. Ignition ON, Engine OFF.
control unit and the other control unit(s) or corrosion at d. Refresh codes.
the connectors. Repair problem. Perform Verification Is DTC that sent you here active?
Procedure. Yes: Contact DTAC for support.
2. Inspect Connectors and Harness No: Problem resolved. Perform Verification
a. Ignition OFF, Engine OFF. Procedure.
CB12260,0000618 -19-21NOV14-1/1

TM130419 (24FEB16) 235-35-3 030916

PN=853
 Checks, Tests, and Procedures

CAN Message Received Is Incorrect d. Look for chaffed or pinched places in the harness
between the control unit and the identified control
The control unit received a CAN message that was unit.
incorrect when communicating to another control unit. Were any problems found?
When DTC is Displayed: Yes: Repair problem. Perform Verification Procedure.
When the control unit receives a CAN message that is No:Go to next step.
incorrect when communicating to another control unit.
3. Reprogram Control unit
Related Information: a. Ignition ON, Engine OFF.
b. Reprogram control unit.
Additional references: c. Refresh codes.
Appropriate engine CTM Is DTC that sent you here active?
To determine which control unit has the Yes: Go to next step.
communication error, use the following procedure. No: Problem resolved. Perform Verification
Procedure.
1. Identify Control Unit
a. Ignition ON, Engine OFF. 4. Troubleshoot Identified Control unit
b. Connect Service ADVISOR. a. Ignition OFF, Engine OFF.
c. In Service ADVISOR, go to Readings menu and b. Troubleshoot identified control unit.
select Get Control units. c. Ignition ON, Engine OFF.
d. Service ADVISOR should now be displaying a list d. Refresh codes.
of control units communicating on your application. Is DTC that sent you here active?
Were you able to identify the control unit that is Yes: Go to next step.
generating the communication error? No: Problem resolved. Perform Verification
Yes: Go to next step. Procedure.
No, source address is not in the displayed list:
While performing the Wiggle Test, close displayed list, 5. Replace Control unit
repeat step c and watch for a new control unit to be a. Ignition OFF, Engine OFF.
displayed. If a new control unit is displayed look for an b. Replace control unit programmed with identical
intermittent connection of the CAN wiring between the software that was in the removed control unit.
control unit and the other control unit or corrosion at c. Ignition ON, Engine OFF.
the connectors. Repair problem. Perform Verification d. Refresh codes.
Procedure. Is DTC that sent you here active?
Yes: Contact DTAC for support.
2. Inspect Connectors and Harness No: Problem resolved. Perform Verification
a. Ignition OFF, Engine OFF. Procedure.
b. Disconnect suspect control unit connector and
connector of control unit identified in step 1.
c. Look for corrosion at the disconnected connectors
and the mating connectors in the CAN wiring
terminals.
CB12260,0000619 -19-16FEB16-1/1

TM130419 (24FEB16) 235-35-4 030916

PN=854
 Checks, Tests, and Procedures

Terminal Test
The purpose of this test is to check for electrical terminal Terminals are crimped to wire ends to provide electrical
and connector problems. and mechanical connection to the wire. The wire end may
Terminal Basics pull out of the terminal if not crimped correctly or if the
wire has been pulled on with too much force. This results
Terminals are typically made from a base metal that is in an open circuit or an intermittent open circuit if the wire
plated with tin, gold, or an alloy. The plating material helps end makes contact with the terminal.
protect the base metal of the terminal from corroding.
There are two main varieties of terminals; pins (male) Terminal Test Visual Inspection
and sockets (female). The male pins are inserted into Inspect the terminals on both sides of the connection
the female sockets to provide the electrical connection including the control unit or sensor for the following
between wires or electrical devices. The female socket problems:
terminals typically contain one or more contact springs
which provide firm contact points with the male pin • Corrosion on the terminals or in the connector.
terminal. • Water or other foreign material in the connector.
Terminal Problems
• Bent terminals.
• Pushed out terminals.
The five main types of terminal problems are corrosion, Replace or reinsert terminals. Replace connector if
loose fit, bent terminals, pushed out terminals, and crimp damaged.
problems.
Terminal Test Loose Fit Check
Corrosion or foreign material on terminals acts as a series
resistance between the contact spring and the mating • Select the proper terminal adapter from the JDG10466
terminal. This series resistance can decrease the voltage Flex Probe Kit that matches the terminal you are testing.
measured by the control unit at its inputs. Corrosion, • Gently insert the male pin terminal fully into the female
liquids, or other foreign material in a connector may also socket terminal without twisting or bending.
provide a parallel resistance that permits current to flow • Slowly pull the male pin terminal out of the female
between other terminals in the connector. This parallel socket terminal. There should be a noticeable tension
path can increase or decrease the voltage measured by as terminal probe is withdrawn.
the control unit at its inputs. Once terminals are corroded,
they must be replaced. Scraping the layer of corrosion Replace terminals that have a loose fit.
from the terminal also removes any remaining plating Terminal Test Crimp Check
material resulting in a rapid reappearance of the corrosion. • Remove connector back shell to gain access to wire
A loose fit between the pin and the socket terminals insertion end of connector, if applicable.
may result in an intermittent open circuit. The loose • Gently pull on each wire in the connector.
fit is usually due to a damaged or worn contact spring Replace terminal if wire end pulls out of the terminal.
inside the female socket terminal. Loose fitting terminals
may be caused by misaligned terminals or by previous Terminal Tips
troubleshooting procedures where a probe was inserted
into the female socket terminal to obtain a measurement. • Use the specified extraction tools to remove terminals.
• Always use the specified terminal as a replacement.
Bent male pin terminals may cause an open circuit and The plating on mating terminals must be compatible
possibly a short circuit with adjacent pins in the connector. or corrosion could occur.
Bent terminals are often caused by connector alignment • Always use the specified seals for those connectors
or improper terminal crimping techniques. that require them.
Terminals that are partially pushed out of the connector
• Always use the correct crimping tool to attach
replacement terminals.
may cause an open circuit or an intermittent connection if • After crimping a terminal to the wire end, pull gently on
the tip of the partially pushed out terminal makes electrical the terminal to make sure that it is securely crimped.
contact with the tip of the mating terminal. Pushed out
terminals are caused by misaligned terminals or by
terminals that were not fully seated in the connector
during assembly.

Continued on next page CB12260,000061A -19-29JAN15-1/2

TM130419 (24FEB16) 235-35-5 030916

PN=855
 Checks, Tests, and Procedures

RG16615 —UN—25NOV08
RG16614 —UN—25NOV08
2-pin female- Corroded Pins

Fuse- Worn and Corroded Pins

RG16616 —UN—25NOV08

RG16617 —UN—25NOV08
3-pin male- Worn Pins 2-pin male- Worn and Corroded Pins

RG16619 —UN—25NOV08
Faulty Wire- Not Crimped Correctly
CB12260,000061A -19-29JAN15-2/2

TM130419 (24FEB16) 235-35-6 030916

PN=856
 Checks, Tests, and Procedures

Verification Procedure
CB12260,000061B -19-08AUG14-1/6

Procedure
CB12260,000061B -19-08AUG14-2/6

•1 DTC Check Did you come to this procedure from a DTC procedure? YES: Go to step 2.

NO: Go to step 4.
CB12260,000061B -19-08AUG14-3/6

•2 Harness Diagnostic
Mode Test
1. Ignition OFF, Engine OFF.

2. Reconnect all components and connectors.

3. Ignition ON, Engine OFF
4. In Service ADVISOR, perform Harness Diagnostic Mode Test and record codes. YES: Return to DTC
Procedure step 1 due
to possible change in
conditions.
Is DTC you are troubleshooting active? NO: Go to step 3.
CB12260,000061B -19-08AUG14-4/6

•3 Operating Conditions Operate machine under conditions where DTC became active. YES: Return to DTC
procedure step 1 due
to possible change in
conditions.
Did DTC you were troubleshooting become active? NO: Procedure complete.
Continue troubleshooting
any other DTCs, if present.

CB12260,000061B -19-08AUG14-5/6

•4 Operating Conditions Operate machine under conditions where observable symptom was present. YES: Return to observable
procedure step 1 due
to possible change in
conditions.
Did observable symptom you were troubleshooting become active? NO: Procedure complete.
Continue any other
necessary troubleshooting.

CB12260,000061B -19-08AUG14-6/6

TM130419 (24FEB16) 235-35-7 PN=857

030916
 Checks, Tests, and Procedures

Wiggle Test partially pulled out of connector terminals, damaged

connectors, poorly positioned terminals, and corroded or
NOTE: For appropriate connector and terminal damaged terminals. Look for broken wires, damaged
identification, reference the diagram in the splices, and wire-to-wire shorts.
DTC that you are diagnosing.
NOTE: The control unit is the component LEAST
This is to help diagnose intermittent faults. likely to fail. Only replace the control unit if
the diagnostic procedure indicates that control
Intermittent DTCs are problems that periodically “go unit replacement is necessary.
away”. A problem such as a loose terminal that
intermittently does not make contact with its mating Inspect harness and connectors for signs of damage such
terminal is a likely cause of an intermittent fault. Other as heat damage, chaffing, corrosion, and other possible
intermittent DTCs may only be set under certain operating causes.
conditions such as heavy load, extended idle, and others.
When diagnosing intermittent DTCs, take special note While monitoring or making measurements, watch for
of the condition of wiring and connectors since a high changes and perform the following:
percentage of intermittent problems originate here. Check
for loose, dirty, or partially disconnected connectors. • Beginning at the suspect component, gently wiggle the
Inspect the wiring routing looking for possible intermittent harness.
shorts to ground caused by contact with external parts • Continue to gently wiggle the harness at different
(for example, rubbing against sharp sheet metal edges). points along the harness until reaching the control unit
Inspect the connector vicinity looking for wires that are connectors.
CB12260,000061C -19-21NOV14-1/1

TM130419 (24FEB16) 235-35-8 030916

PN=858
 Checks, Tests, and Procedures

Short to Voltage Procedure

NOTE: For appropriate connector and terminal
identification, reference the Diagram in the
DTC that you are diagnosing.
OUMX258,00002CA -19-21NOV14-1/6

Diagnostic Procedure
OUMX258,00002CA -19-21NOV14-2/6

•1 Unswitched Voltage
Check
NOTE: For appropriate connector and terminal identification, reference the
Diagram in the DTC that you are diagnosing.

1. Ignition OFF, Engine OFF.

2. Disconnect Diagnostic Test Box, if connected.
3. On the harness, use multimeter to measure voltage between component connector YES: Disconnect battery
signal (+) and return (-) terminals. and go to next step..
Is voltage greater than 0.5 volts? NO: Go to next step.
OUMX258,00002CA -19-21NOV14-3/6

•2 Signal Circuit
Continuity Check
1. Disconnect applicable control unit connector containing the component signal
wire terminal.

2. On the harness, measure resistance between the component signal wire terminal
in control unit connector and component connector signal wire terminal.
3. On the harness, measure resistance between the component return wire terminal YES: Go to next step.
in control unit connector and component connector return wire terminal.
Are both measurements less than 5 ohms? NO: Repair mis-pin.
Perform Verification
Procedure.
OUMX258,00002CA -19-21NOV14-4/6

•3 Wire to Wire Short

Check
1. Disconnect battery if not already disconnected.

2. On the harness, measure resistance between component signal terminal in control YES: Repair short to signal
unit connector to all other terminals in applicable control unit connector. wire. Perform Verification
Procedure.
Are any measurements less than 100k ohms? NO: Go to next step.

OUMX258,00002CA -19-21NOV14-5/6

•4 Wire to Wire Short

Check
1. Disconnect all other control unit connectors.

2. On the harness, measure resistance between component signal terminal in control YES: Repair short to signal
unit connector to all other terminals in all other control unit connectors. wire. Perform Verification
Procedure.
Are any measurements less than 100k ohms? NO: Contact DTAC for
support.

OUMX258,00002CA -19-21NOV14-6/6

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030916
 Checks, Tests, and Procedures

Problem Not Found Procedure

OUMX258,00002C9 -19-21NOV14-1/6

Diagnostic Procedure
OUMX258,00002C9 -19-21NOV14-2/6

•1 Read DTCs and Store

Snapshot Information
1. Review Snapshot Information stored from previous diagnostics.

2. Ignition OFF, Engine OFF.

3. Reconnect all components and connectors.
4. Operate engine under condition where DTC became active. YES: Perform diagnostics
for active DTC.
Did DTC reappear active? NO: Go to next step.
OUMX258,00002C9 -19-21NOV14-3/6

•2 Obtain More
Information
1. Speak with the operator that observed the problem and obtain more information
about when problem occurred.

2. Operate engine under same conditions as when problem occurred. YES: Perform diagnostics
for active DTC.
Did DTC reappear active? NO: Go to next step.
OUMX258,00002C9 -19-21NOV14-4/6

•3 Search DTAC
Solutions
Search DTAC solutions in Service ADVISOR for known issues which may cause DTC
you are troubleshooting.
YES: Perform steps found
in DTAC solution.

Are DTAC solutions found? NO: Go to next step.

OUMX258,00002C9 -19-21NOV14-5/6

•4 Control unit
Reprogram
Search Custom Performance for control unit software updates. YES: Reprogram control
unit with newest version
of software. Perform
Verification Procedure.
Is a new version of software available? NO: Contact DTAC for
support.

OUMX258,00002C9 -19-21NOV14-6/6

TM130419 (24FEB16) 235-35-10 030916

PN=860
 Checks, Tests, and Procedures

Accessing the Addresses and Diagnostic - Switch off ignition and turn it on again after five
Trouble Codes seconds (re-initiate the control units)
- If no active diagnostic trouble codes are present,
Every control unit monitors certain electrical circuits within deal with the ”SAVED” codes
the network of circuits for which it is responsible. The - If it is not possible to (re-)produce a relevant
unit then stores the relevant diagnostic trouble code if diagnostic trouble code by means of a functional
there is a malfunction (error) or if the operator makes a check or test-drive, and the circuit problem
mistake. However, not all of the diagnostic trouble codes persists, the cleared diagnostic trouble codes must
indicate a current problem, since most of the circuits are be checked; if the codes are associated with the
monitored only at the actual moment of activation or when problem on the machine, they must be processed.
they are actually activated (switched on). To make sure
that the diagnostic trouble code you are troubleshooting is NOTE: Cleared diagnostic trouble codes should only
”active”, you should proceed as follows: be dealt with if it is not possible to (re-)produce
the problem on the machine (no active or saved
1. General procedure for dealing with diagnostic trouble codes are present after a functional test/test drive
codes: has been carried out) and when the description
of diagnostic trouble code(s) can be associated
• Access the diagnostic trouble codes with the machine problem.
• Note and clear the diagnostic trouble code(s)
• Carry out an operational test (activate the circuit 3. Processing cleared diagnostic trouble codes using
affected) or test drive the machine
Service ADVISOR:
• Switch off ignition and turn it on again after five
seconds (re-initiate the control units) • Every time a diagnostic trouble code is accessed, it is
• Access the diagnostic trouble codes again and saved in Service ADVISOR in the “Readings Logs” of
process them the job that is being processed. Before it is cleared,
• If it is not possible to (re-)produce a relevant the diagnostic trouble code status of the machine
diagnostic trouble code by means of a functional can be accessed via the “Session” menu or “Logs”.
check and the problem is still present in the circuit,
deal with the codes you noted earlier. 4. Status of diagnostic trouble codes in Service
ADVISOR:
2. Procedure for dealing with diagnostic trouble codes
using Service ADVISOR: • Status:“ACTIVE” (priority I):
- Diagnostic trouble code cannot be cleared.
• Access diagnostic trouble codes via the ”Diagnostics” - Current problem with the machine.
tab
• “Active” diagnostic trouble codes take priority • Status: “SAVED” (priority 2):
• If no “Active” diagnostic trouble codes are present: - Diagnostic trouble code can be cleared
- Delete diagnostic trouble code(s) - At present the problem is not recognized by the
- Carry out an operational test (activate the circuit control unit (example: faulty solenoid valve, switch
affected) or test drive the machine or circuit not activated at the moment).
CB12260,000061E -19-09FEB15-1/1

TM130419 (24FEB16) 235-35-11 030916

PN=861
 Checks, Tests, and Procedures

CAN Communication Fault Checks

Condition 2:
Reason:
NOTE: Control units only display missing messages DTCs
To check the physical integrity of the CAN bus. from other control units required for their operation.
Therefore, some control units may be missing but
Equipment: not generate a code from other control units. Some
control units may not appear as missing if they are
• Multimeter not present on the network upon start-up.
Procedure:
1. If entire control unit is missing, check power and
NOTE: CAN related DTCs (SPN/FMI xxxxxx.09) usually ground circuits for that control unit.
indicate a physical problem with the CAN bus,
a failed control unit, or a control unit that has 2. If control unit is present but messages missing,
lost its power or ground circuits. disconnect CAN connector from control unit and check
CAN Hi and CAN Lo continuity between suspect
There are several CAN bus error conditions that may control unit and control unit reporting error.
exist. Find the one that best describes the situation: 3. If entire control unit is missing and using Service
• Condition 1: More than one control unit function reports ADVISOR, check can bus continuity between affected
one missing message xxxxxx.09 code. control unit and diagnostic interface.
• Condition 2: One or more control unit functions that 4. If a component based error should be displayed and
should be displaying in Service ADVISOR™ or on the isn’t, troubleshoot affected component circuit.
PDU display do not appear. There may or may not be
associated missing message codes. 5. If control unit is missing using PDU, disconnect CAN
• Condition 3: More than one control unit reports multiple connector from control unit and check CAN Hi and CAN
missing message xxxxxx.09 codes. Lo continuity between suspect control unit and PDU.
• Condition 4: Only one unit displays multiple missing
Condition 3:
message xxxxxx.09 codes.
NOTE: Intermittent missing message DTCs can be 1. Disconnect CAN connector from all affected control
caused by excessive CAN bus traffic as well as poor units and check continuity of CAN Hi and CAN Lo
connections or failing wiring. It may be necessary to between control units.
simulate field conditions by moving suspect wiring 2. Check power and ground circuits to all affected control
around or putting mild strain on connections. units.
Condition 1: 3. Possible erroneous code(s).
NOTE: It is rare for multiple control units to display Condition 4:
only one missing message code without another
component DTC to be present as well. 1. Suspect bad CAN wiring to reporting control unit.
Disconnect CAN connector from all affected control unit
1. Disconnect CAN connector from all affected control and check continuity of CAN Hi and CAN Lo between
units and check continuity of CAN Hi and CAN Lo between reporting control unit and closest CAN connector.
control units.
Service ADVISOR is a trademark of Deere & Company
CB12260,000061F -19-21NOV14-1/1

TM130419 (24FEB16) 235-35-12 030916

PN=862
 Checks, Tests, and Procedures

CAN Bus Terminator Test

Reason:

TCT006817 —UN—09APR13
To determine the resistance value of the CAN Bus
terminator.
Equipment:
B A
• Ohmmeter
Procedure:
1. Park machine safely in neutral with park brake locked.
2. Unplug the CAN bus terminator from the harness. A— Terminal B— Terminal

3. Connect the ohmmeter to terminals A and B of the

CAN terminator.
If, after accounting for equipment tolerances, the reading
Results: is not within specification, replace the terminator.
• Resistance should measure 121 ±2 ohms.
NOTE: Readings are affected by meter accuracy
and test lead resistance.
CB12260,0000620 -19-11FEB14-1/1

Control Unit Messaging Errors but not generate a code from other control
units. The PDU displays a missing message
With the machine turned on, control units are constantly for any control unit that is present at start-up,
exchanging messages (data) for proper machine but becomes missing after start-up. The PDU
operation. will NOT display missing messages for optional
NOTE: Control units only display missing messages from control units that are not present at start-up.
other control units required for their operation. Example: bad fuse to control unit.
Therefore, some control units may be “missing”
CB12260,0000621 -19-21NOV14-1/1

TM130419 (24FEB16) 235-35-13 030916

PN=863
 Checks, Tests, and Procedures

CAN Network Voltage Checks

NOTE: These procedures should be followed in sequence
until the problem is resolved.

Reason:

LVAL10288 —UN—23JUL10
To check the CAN Hi(+) and CAN Lo(-) signals for proper
voltage.
Equipment:

• Multimeter
Check for proper voltage:
1. Turn key to on position (engine off).
A—CAN Hi C—Ground
2. Use a multimeter to measure CAN Hi (A) and CAN B—CAN Lo
Lo (B) voltages at the Service ADVISOR™ diagnostic
connector.
d. Voltages out of specification but between 1—5 V.
3. Correct readings (desired):
a. CAN Hi: 2.50—3.50 V Ground Checks:

b. CAN Lo: 1.50—2.49 V 1. Turn key to off position.

4. Incorrect readings: 2. Locate and remove passive terminator.

a. One or both voltages above 5 V. 3. Check resistance to ground (C).

b. One or both voltages below 1 V. 4. Resistance should be less than 1 ohm.

c. CAN Hi and CAN Lo voltages are equal.

Service ADVISOR is a trademark of Deere & Company
Continued on next page CB12260,0000622 -19-21NOV14-1/2

TM130419 (24FEB16) 235-35-14 030916

PN=864
 Checks, Tests, and Procedures

Check for Short Circuits to CAN Hi and CAN Lo:

1. This check should only be performed if the previous
checks of CAN Hi and CAN Lo indicated:
a. Voltage at or near battery voltage.

LVAL10288 —UN—23JUL10
b. Voltage above 5 volts and ground checks OK.
c. Voltage below 1 volt.
d. Voltages of CAN Hi and CAN Lo were equal.
2. Verify all connectors and terminators are connected.
3. Turn key switch to RUN position (engine OFF).
4. Use a multimeter to measure CAN Hi (A) and CAN
Lo (B) voltages at the Service ADVISOR diagnostic A—CAN Hi C—Ground
B—CAN Lo
connector, from CAN ground (C) to CAN Hi and CAN
Lo. Record values.
5. Remove CAN passive terminator. a. CAN differential voltage is OK.
NOTE: Voltage higher than 5 V on either CAN Hi 4. If results are not within acceptable limits according
or CAN Lo indicates a short to high voltage. to table:
Voltage lower than 1 V indicates a short to
ground. If CAN Hi and CAN Lo are equal, a. CAN Hi result approximately 2X CAN Lo result.
they could be shorted together. Loss of CAN Lo between control unit and passive
terminator.
6. Check for a change in voltage on CAN Hi and CAN
b. CAN Lo result approximately 2X CAN Hi result.
Lo from value recorded. If voltage changed, replace
Loss of CAN Hi between control unit and passive
passive terminator.
terminator.
Compare CAN Hi and CAN Lo Voltages:
Voltages Within Range but Out of Specification:
NOTE: The CAN bias voltage is 2.5 V. To evaluate
Perform the following until voltages are within specification:
the CAN Hi and CAN Lo circuits, the voltage
recorded for each must be calculated in 1. Check voltages at Service ADVISOR diagnostic
reference to this bias. connector after each of the next steps. (Turn key
switch to the OFF position when removing fuses or
1. To calculate CAN voltage bias differential where X = disconnecting control units and to the RUN position
CAN Hi voltage and where Y = CAN Lo voltage and: (engine OFF) when measuring voltages.)
a. CAN Hi: Recorded voltage—2.5V = X a. One at a time, remove fuse or connector supplying
power to each control unit and repeat voltage
b. CAN Lo: 2.5V—Recorded voltage = Y
checks.
2. Compare results from CAN Hi and CAN Lo
b. One at a time, disconnect all connectors at each
calculations. Values must be within 35% of each other.
control unit and repeat voltage checks.
Use the following table to evaluate:
CAN Hi Result (X) CAN Lo Result (Y) c. Results:
0.1V 0.06—0.14 d. If removing fuse to any control unit causes voltage
0.2V 0.13—0.27 to come within specification, check CAN Hi and
0.3V 0.21—0.4 CAN Lo, power and ground circuits to control unit.
0.4V 0.26—0.54 Replace control unit if circuits check OK. If removing
0.5V 0.33—0.67
fuse did not cause voltage to return to normal but
disconnecting control unit resulted in voltage within
0.6V 0.39—0.81
specification, replace control unit.
0.7V 0.46—0.94
0.8V 0.52—1.0 2. Replace or test passive terminator.
0.9V 0.59—1.0 3. With keys switch off terminator removed, perform
1.0V 0.65—1.0 continuity checks on all CAN bus circuits.

3. If results are within acceptable limits according to table:

CB12260,0000622 -19-21NOV14-2/2

TM130419 (24FEB16) 235-35-15 030916

PN=865
 Checks, Tests, and Procedures

Erroneous Diagnostic Trouble Codes component in a circuit is switched on or off. These may
consist of:
On occasion, a DTC may appear or be recorded due to
various anomalies such as electromagnetic interference, • Glow plugs
voltage or current spikes, lightning, or other similar but • Blower motors
temporary conditions. These factors should be taken into • A/C compressors
account when performing diagnostic procedures. • Horn
A snapshot of the DTC in question can be analyzed in
• Strobe/beacon lights
Service ADVISOR™ to aid in the determination as to
• Electric PTO clutches
whether the code is erroneous or not.
• Electric solenoids
Gather as much information as possible about the
Often times, these codes will be “missing or erratic data” operating conditions at the time the suspect code became
or “abnormal update rate” types. These can also be active. If a component is suspect, cycle the component on
caused by excessive CAN bus traffic that prevent lower and off several times to see if the DTC reoccurs.
priority messages from being transmitted.
A component on the machine or attachment may cause a
false DTC as well. Commonly, false DTCs occur when a
Service ADVISOR is a trademark of Deere & Company
CB12260,0000623 -19-11FEB14-1/1

Troubleshooting Electronic Control Units

NOTE: This reference is a guideline for troubleshooting
problems that still exist after standard diagnostics Problems Due to Intermittent Electrical Failures:
have been performed. These problems are NOTE: Electrical intermittent failures are
typically due to specific operating conditions, usually caused by harness, terminal, or
intermittent failures or, in rare cases, control unit connector problems.
failures. Depending on the situation, some or all
of the following may be important.
• Inspect all connectors and terminals of related circuits.
Problems Due to Specific Operating Conditions:
• Inspect mechanical linkages for interference with
harnesses or connectors.
Review all recorded codes and consult with operator • Inspect harnesses for missing or improperly installed
to determine operating and vehicle conditions when the clamps or bands. Loose harnesses that are allowed to
problem occurs. Record details. move too freely or harnesses that are banded too tightly
may result in worn or damaged wires.
• Does code/problem occur at the same time as other • Inspect mechanical linkages for proper operating
problems? condition.
• Does code/problem occur when vehicle is warm or cold?
• Does code/problem occur during field or transport Problems Due to Control Unit Failures:
operation?
NOTE: Before replacing control unit, review all tests.
• Does code/problem occur while performing a specific
Control units are the least likely cause of failure!
action such as shifting, turning, braking, operating
certain hydraulics?
• When did code/problem first appear? Was there any • If all checks have been made with no problems identified,
check power and ground circuits. Power inputs must be
maintenance performed recently? (If yes, inspect areas
within 1 V of battery voltage and ground circuits must
of maintenance for inadvertent damage or improper
be less than 1.0 ohm to the vehicle single point ground.
installations.)
• Inspect all connectors and terminals of associated
Attempt to recreate code/problem based on conditions. If control units.
possible, repeat operational, system, electrical, hydraulic,
or mechanical checks under these conditions.
CB12260,0000624 -19-06APR15-1/1

TM130419 (24FEB16) 235-35-16 030916

PN=866
 Checks, Tests, and Procedures

Diagnostic Information
The diagnostic procedures are used to test the When performing the test or check, be sure to set your
complete circuit regardless of the problem or complaint. machine up to the TEST POINT/PROCEDURES listed in
Select a symptom or system from the quick check or the first column and follow the sequence carefully. The
troubleshooting chart and follow the test procedures under middle RESULTS column gives the reading or condition
that heading. that should be obtained in BOLD print. If the results of
The diagnostic procedure lists: the test or check are not normal, perform the test, check,
or adjustment listed below the BOLD print. The system
• Test conditions diagram that accompanies each test procedure is drawn
• Test sequence to resemble machine components. The leader line points
• Test location to the exact point the test is to be made.
• Normal reading
• Check or test to perform if reading is not normal
CB12260,0000625 -19-12FEB14-1/1

Readings Overview
The readings, whether displayed in Service ADVISOR™ simultaneously. The display panel can show certain
or on the display panel, are shown live - voltages, readings, but only a few at a time. (See PDU I-O Status
pressures, positions, etc. These are shown for reference, Readings).
diagnostics, adjustment, or calibration purposes.
It is recommended that Service ADVISOR™ be used to
take readings as multiple components can be checked
Service ADVISOR is a trademark of Deere & Company
CB12260,0000626 -19-27FEB14-1/1

TM130419 (24FEB16) 235-35-17 030916

PN=867
 Checks, Tests, and Procedures

Reading Data
Control Unit Readings—VCU Point Reading Units Normal Range
Reading Data Boot Block PHxxxxxx - - - -
Point Reading Units Normal Range Program
Hydraulic Oil Temperature - - 0-1 Software Part
Temp Normal/ Number
Temperature Boot Block xx.xx - - - -
Too Hot Program
Park Brake Disen- - - 0-1 Software
Switch gaged/Engaged Version Number
- - 0-1 EOL Data SWxxxxxx - - - -
Seat Switch Operator Not In
Seat/ Software
Operator In Part Number
Seat (Factory
- - Software
Key Start Switch Off/Run 0-1 Version)
Cruise Control Off/On - - 0-1 xx.xx - - - -
EOL Data
On Switch Software
Cruise Control Off/On - - 0-1 Version Number
Set Switch (Factory Data)
PTO Switch Off/On - - 0-1 Operating PHxxxxxx - - - -
- - System Part
Warning Buzzer Off/On 0-1
Number
Engine Run Off/On - - 0-1
Operating xx.xx - - - -
Request
System Version
Engine Start Off/On - - 0-1 Number
Request - - - -
Base Program SWxxxxxx
Fuel Pump Off/On - - 0-1 Software Part
Mow (PTO) Off/On - - 0-1 Number
Solenoid (+) Base Program xx.xx - - - -
Mow (PTO) Off/On - - 0-1 Software
Solenoid (-) Version Number
Control Unit TCA20984 - - - -
Vref 1 Voltage V 4.95-5.05
(Sensor Hardware Part
Reference Number
Voltage) Control Unit xxxxxx - - - -
Vbattery V 9.0-16.0 Hardware Serial
Voltage (Battery Number
Voltage) Software TCAxxxxx - - - -
Velx Voltage V 9.0-16.0 Assembly Part
(Controller Input Number
Voltage) Software xx.xx - - - -
M50 Onboard DegF -20 to +185 Assembly
Temperature Version Number
Sensor (VCU Current Vehicle 1TCxxxxxxxxxx- - - - -
Ambient Temp) Identification xxxx
VCU Number (VIN)

CB12260,00002FD -19-30MAR15-1/1

PDU I-O Status Readings

I/O Status Menu displays status information for inputs and
P
TCT012991 —UN—26FEB15

outputs for enabled circuits. Each screen shows 2 or 3

switches and indicates their status.
• Status is either ‘ON’ (black image on white background)
or ‘OFF’ (white image on black background).
• Input/output is OFF, and inverted icon displays.
• Input/output is ON, and normal icon displays (all icons
shown are in the ON or normal state)
Seat Park
• Right: Park brake input
• Left: Seat switch input
Continued on next page CB12260,000009A -19-02APR15-1/8

TM130419 (24FEB16) 235-35-18 030916

PN=868
 Checks, Tests, and Procedures

Key, Run, Fuel

• Left: Key run position switch

TCT012116 —UN—26FEB15
• Center: Run output
• Right: Fuel pump enable output

CB12260,000009A -19-02APR15-2/8

PTO and Mow

• PTO switch status

TCT012117 —UN—26FEB15
• Hydraulic oil temp

CB12260,000009A -19-02APR15-3/8

PTO Solenoid HS, LS

NOTE: The PTO driver uses pulse width modulation

TCT012095 —UN—28NOV14
to control the PTO operation in order to
reduce total current.
(+) (-)
• Left: Mow output (high side driver)
• Right: Mow output (low side driver)

CB12260,000009A -19-02APR15-4/8

Crank

• Left: Key switch start position status

TCT012094 —UN—28NOV14
• Right: Starter Relay output status :

Continued on next page CB12260,000009A -19-02APR15-5/8

TM130419 (24FEB16) 235-35-19 030916

PN=869
 Checks, Tests, and Procedures

Battery Voltage

• Battery voltage
12.1V

TCT012115 —UN—26FEB15
CB12260,000009A -19-02APR15-6/8

Cruise Control Status

• Left: Enables cruise control ON/

TCT012118 —UN—26FEB15
• Right: Sets cruise control speed SET
OFF

CB12260,000009A -19-02APR15-7/8

Cruise Control, Auxiliary Output

• Left: Cruise control output

TCT012119 —UN—26FEB15
• Auxiliary relay coil power AUX

CB12260,000009A -19-02APR15-8/8

TM130419 (24FEB16) 235-35-20 030916

PN=870
 Checks, Tests, and Procedures

TM130419 (24FEB16) 235-35-21 030916

PN=871
 Checks, Tests, and Procedures

ECU Data Points Used in Service ADVISOR

Following is a list of the data points that can be read in
Service ADVISOR. Included in the list is a brief description
of each data point and its unit of measurement.
Data Point Units Description
Metric (English)
Air Throttle Actuator Position - Actual Percent Current position of Air Throttle Actuator indicated by Air Throttle Actuator position
sensor.
Air Throttle Actuator Position - Desired Percent Air Throttle Actuator position commanded by ECU.
Air Throttle Actuator Position Input Voltage Volts Input voltage measured by the ECU.
Barometric Air Pressure kPa (bar) (psi) Atmospheric pressure indicted by barometric air pressure sensor (internal to ECU).
Cold Start Aid Status None Indicates if cold start aid relay is on.
Desired Fuel mg/stroke Value of fuel delivered to the cylinder commanded by the ECU.
DOC Inlet Temperature ° C (° F) Temperature at inlet of DOC indicated by exhaust filter temperature module.
DOC Inlet Temperature Input Voltage Volts Input voltage measured by the ECU.
DOC Outlet Temperature ° C (° F) Temperature at outlet of DOC indicated by exhaust filter temperature module.
DOC Outlet Temperature Input Voltage Volts Input voltage measured by the ECU.
DPF Ash Load g/L Calculated amount of soot in DPF. A value of “not needed” means that the DPF
does not need a regeneration currently. A value of “Service Only” means that
the DPF is full of soot.
DPF Differential Pressure kPa (psi) (bar) Pressure drop across DPF measured by the DPF differential pressure sensor
DPF Differential Pressure Input Voltage Volts Input voltage measured by the ECU.
DPF Inlet Pressure kPa (bar) (psi) Pressure at the inlet of the DPF indicated by the aftertreatment pressure sensor.
DPF Inlet Pressure Input Voltage Volts Input voltage measured by the ECU.
DPF Regeneration Mode Switch None Indicates the status of an active regeneration. Deep Clean regenerations occur
once out of every 10 regenerations.
DPF Soot Load - Differential g/L DPF soot load calculated by DPF differential pressure.
Pressure Based
DPF Soot Load - Fuel Based g/L DPF soot load calculated by fuel usage.
ECU Map Data Part Number None Part number for the ECU map data.
ECU Part Number None Part number for the ECU hardware.
ECU Serial Number None Serial number of the ECU.
EGR Temperature ° C (° F) Temperature indicated by EGR temperature sensor.
EGR Temperature Input Voltage Volts Input voltage measured by the ECU.
EGR Valve Position - Actual Percent Current position of EGR valve indicated by EGR valve position sensor.
EGR Valve Position - Desired Percent EGR valve position commanded by ECU.
Engine Coolant Temperature ° C (° F) Temperature indicated by coolant temperature sensor.
Engine Coolant Temperature Input Voltage Volts Input voltage measured by the ECU.
Engine Hours hr Stored engine hours.
Engine Mode None Current engine mode.
Engine Serial Number None Serial number of the engine.
Engine Speed rpm Engine speed measured by crankshaft position sensor or camshaft position sensor.
Exhaust Filter Cleaning Inhibit Status None Value of not inhibited means that regenerations are allowed.
Exhaust Filter Cleaning Request None Status of the exhaust filter cleaning request switch as seen by the ECU.
Switch Status
Exhaust Manifold Pressure kPa (psi) (bar) Pressure (gauge) indicated by exhaust manifold pressure sensor.
Exhaust Manifold Pressure Input Voltage Volts Input voltage measured by the ECU.
Exhaust Manifold Temperature ° C (° F) The calculation is based on manifold air temperature measurements and air-to-fuel
ratio calculations made by the ECU.
Exhaust Manifold Temperature Volts Input voltage measured by the ECU.
Input Voltage
Fuel Rail Pressure - Actual MPa (psi) (bar) Pressure indicated by the fuel rail pressure sensor.
Fuel Rail Pressure - Desired MPa (psi) (bar) Fuel rail pressure commanded by ECU.
Fuel Rail Pressure Input Voltage Volts Input voltage measured by the ECU.

Continued on next page OUMX258,00002D0 -19-24FEB15-1/2

TM130419 (24FEB16) 235-35-22 PN=872

030916
 Checks, Tests, and Procedures

Data Point Units Description

Metric (English)
Fuel Temperature ° C (° F) Temperature indicated by fuel temperature sensor.
Fuel Temperature Input Voltage Volts Input voltage measured by the ECU.
Governor Reference Speed rpm Target speed of the governor.
High-Pressure Fuel Pump Current—Actual mA Current indicated by the suction control valve.
High-Pressure Fuel Pump Cur- mA Current commanded by the ECU.
rent—Desired
Manifold Air Pressure kPa (psi) (bar) Pressure (gauge) indicated by manifold air pressure sensor.
Manifold Air Pressure Input Voltage Volts Input voltage measured by the ECU.
Manifold Air Temperature ° C (° F) Temperature indicated by manifold air temperature sensor.
Manifold Air Temperature Input Voltage Volts Input voltage measured by the ECU.
Percent Load at Current Speed Percent The load currently put on the machine.
Pilot Injection mg/stroke Amount of fuel delivered to the cylinder at the start of the injection process.
Primary Analog Throttle Input Voltage Volts Input voltage measured by the ECU.
Service Tool Version None The version of the service tool currently being used.
Tertiary Analog Throttle Input Voltage Volts Input voltage measured by the ECU.
Throttle Position Percent Percent of the throttle being used.
Intake Air Temp ° C (° F) Temperature indicated by intake air temperature sensor.
Intake Air Temp Input Voltage Volts Input voltage measured by the ECU.
Unswitched Battery Voltage Volts Battery voltage measured by the ECU.
Data Parameter List
OUMX258,00002D0 -19-24FEB15-2/2

TM130419 (24FEB16) 235-35-23 030916

PN=873
 Checks, Tests, and Procedures

Electronic Injector—Calibration Information

Purpose: • Print
The purpose of this test is to place the proper injector part Change Information
number, serial number, and calibration code information
in the ECU for each injector. Information in the ECU is If an injector is being replaced, then the information for
specific for each injector and the cylinder number that it is that injector must be loaded into the ECU. This is done by
installed in. If the information is not correct, it may cause selecting the “Change Information” button. The screen
the engine to be out of emissions compliance or cause displays a table showing the existing information that is
poor engine performance. stored in the ECU. There is a “Change To” box for each
cylinder. Enter the correct injector Part Number, Serial
IMPORTANT: Injector number 1 is located on the Number, and Calibration Code in the appropriate box.
flywheel end of the engine. Once all the injector information has been updated, click
the “Next” button, verify that the data entered is correct,
1. Ignition ON, Engine OFF. and then click the “Yes” button.
2. In Service ADVISOR, Exit
a. Select Tests and Calibrations in the left-hand Stops test and asks for Cancel confirmation. If “Yes” is
shortcut bar. Selected, test is exited. If “No” is selected then you are
returned to the opening screen to start testing again.
b. Select Connected Calibrations.
NOTE: If you have changed some information and press
c. Select Interactive Calibrations. Exit you will need to turn the key off for 120 seconds
d. Select ECU - Level B1. for the data to be properly stored in the ECU.

e. Select Injector Calibration. Print

f. Select the desired operation from the test menu. Allows you to print what is displayed on the screen. For
more information see engine CTM, Section 04, Group 160.
Operation:
IMPORTANT: When you connect back up to the
Options:
Deere network the information you changed
• Change Information will be uploaded to Deere.
• Exit
OUMX258,00002D3 -19-16FEB16-1/1

Service ADVISOR Based Tests Cylinder Cutout Test

NOTE: Follow the on-screen instructions for all This test shuts off a selected cylinder while the engine
tests and procedures. is running by removing the fuel supply to the selected
cylinder.
Actuator Test
Service Regeneration
This test causes the EGR valve or intake air throttle
to drive to a desired position. The engine must not be NOTE: Engine must be running with engine coolant
running for this test. Select the desired actuator and temperature above 60°C (140°F) and all conditions
position. While this test is being performed, you should for parked regeneration met. See CTM for more
see or hear movement of the EGR valve or air throttle. information on regeneration modes.
Control Unit Information and Overview This allows one of three modes of DPF regeneration.
NOTE: This test is useful if the ECU is swapped from These are:
another machine or an issue has been identified
that can be corrected with a payload update.
• Enhanced passive regeneration
• Service regeneration
This displays basic ECU information.
• DPF service regeneration
CB12260,00002F9 -19-18MAR15-1/1

TM130419 (24FEB16) 235-35-24 030916

PN=874
 Group 40
Diagnose—DTCs, PDU
Start Interlock Violations
A

B P E

000070.14 000677.14

C C

D N F 60
000604.14 000677.31

C C

TCT011105 —UN—27JAN15
000976.14

A—Start interlock violations D—Traction pedals not in neutral F— Crank time exceeded - starter
B—Park brake off E—Crank time exceeded warning cool down period
C—Left or center press to return G—PTO switch on
to previous screen

CB12260,00002A6 -19-23MAR15-1/1

Run Interlock Screen

DTC 001504.31 - PTO switch on and operator out of seat
TCT012992 —UN—26FEB15

+
001504.31

CB12260,00002A5 -19-26FEB15-1/1

TM130419 (24FEB16) 235-40-1 030916

PN=875
 Diagnose—DTCs, PDU

Service Required
SRVC

!
This screen indicates that the DPF soot or level is high.

TCT011114 —UN—21NOV14
It causes DTCs 003719.00 and/or 003720.00 from the
ECU. See “Calculated Soot Level Extremely High” and/or
REQD
“Calculated Ash Level Extremely High” in ECU diagnostics.
003719.00

CB12260,00002A7 -19-05FEB15-1/1

Coolant Over Temp

This screen indicates that the engine coolant is over

TCT012054 —UN—25NOV14
A
temperature. It causes DTC 000110.00 to become active.
This DTC may be issued by the ECU, VCU, or both.

A—“STOP”
000110.00

CB12260,00002A8 -19-05FEB15-1/1

Park Brake Off and Attempting to Crank

Engine

TCT012055 —UN—25NOV14
This screen indicates that the park brake is off while
attempting to start the engine. It causes DTC VCU
000070.14 to become active. See “Park Brake Switch” in
diagnostics.
000070.14

CB12260,00002A9 -19-05FEB15-1/1

Crank Time Exceeded Warning

This screen indicates that the engine has been cranked

TCT012056 —UN—25NOV14
for at least 15 seconds without starting. DTC 000677.14
becomes active.

000677.14

CB12260,00002AA -19-05FEB15-1/1

TM130419 (24FEB16) 235-40-2 030916

PN=876
 Diagnose—DTCs, PDU

Crank Time Exceeded Warning Delay

This screen indicates that the VCU is forcing a 60 second
60

TCT012057 —UN—25NOV14
wait period for the starter to cool down after being cranked
for two consecutive 15 second periods. It causes VCU
DTC 000677.31 to go active. This code will appear
immediately after DTC VCU 000677.14. See “Starter Cool
Down in Process” in the diagnostics section. 000677.31

CB12260,00002AB -19-05FEB15-1/1

PTO Engaged and Operator Out of Seat

This screen indicates that the operator is out of the seat
+

TCT012100 —UN—01DEC14
with the PTO switch in the on position. The PTO will
logically not be engaged but DTC 001504.31 becomes
active. This is an informational screen. Once the operator
is on the seat, the PTO switch has to be cycled to resume
operation. 001504.31

CB12260,00002AC -19-05FEB15-1/1

Hydraulic Oil Over Temp

This screen indicates that the hydraulic oil temperature

TCT012058 —UN—25NOV14
has exceeded a preset limit. This causes DTC 001638.00
to become active. The machine derates until the
STOP
temperature is reduced to a normal operational level. See
“VCU 001638.00 “Hydraulic Oil” in diagnostics.
001638.00

CB12260,00002AD -19-05FEB15-1/1

Charge System Failure Low

This screen indicates that battery or system voltage is

TCT010294 —UN—04FEB14
extremely low. This will cause DTC 000168.01 to become A
active and the machine will shut down. This code can be
initiated by the VCU and/or the ECU. See the appropriate
diagnostics section for more information.

A—“STOP”

CB12260,00002AE -19-05FEB15-1/1

TM130419 (24FEB16) 235-40-3 030916

PN=877
 Diagnose—DTCs, PDU

Low Oil Pressure

This screen indicates that the engine oil pressure is below

TCT012060 —UN—25NOV14
a preset limit. DTC 000100.01 becomes active. The A
machine will have limited function. The PTO will stop.
See DTC ECU 000100.01 “Engine Oil Pressure Extremely
Low” in the diagnostics section.
000100.01
A—“STOP”

CB12260,00002AF -19-05FEB15-1/1

Filter Cleaning Required

This screen indicates that the DPF filter requires an active AUTO

TCT012061 —UN—25NOV14
regeneration cleaning but the operator has inhibited it.
DTC 003695.14 becomes active. See engine CTM for
Disabled
more information. Regen Rqd
003695.14

CB12260,00002B0 -19-16FEB16-1/1

Parked Cleaning Required

PARK

! P
This screen indicates that a DPF parked cleaning is
CLEAN

TCT012062 —UN—25NOV14
required. DTC 003719.16 becomes active and the engine
derates. See DTC ECU 003719.16 “Calculated Soot
Level Moderately High” in the diagnostics section.
REQD
003719.16

CB12260,00002B1 -19-05FEB15-1/1

Ash Clean Required

ASH

!
This screen indicates that DPF ash cleaning is required.
CLEAN
TCT012063 —UN—25NOV14
DTC 003720.16 becomes active and the engine derates.
See DTC ECU 003720.16 “Calculated Ash Level
Moderately High” in the diagnostics section.
REQUIRED
003720.16

CB12260,00002B2 -19-05FEB15-1/1

TM130419 (24FEB16) 235-40-4 030916

PN=878
 Diagnose—DTCs, PDU

Park Brake Not Engaged and Attempting to

Activate Parked Regeneration

P P

TCT010299 —UN—04FEB14
This screen indicates that the park brake is not
engaged while a parked DPF regeneration is attempted.
Regeneration will not occur until the park brake is set.

CB12260,00002B3 -19-05FEB15-1/1

Charge System Failure High

This screen indicates that battery or system voltage is

TCT012066 —UN—25NOV14
high. This causes DTC 000168.00 to become active and A
the machine shuts down. This code can be initiated by
the VCU and/or the ECU. See the appropriate diagnostics
section for more information.
000168.00
A—“STOP”

CB12260,00002B5 -19-05FEB15-1/1

Park Brake Engaged, Not Mowing

This screen indicates that the park brake was turned on

TCT012068 —UN—25NOV14
while the PTO output was engaged. DTC 003941.31
becomes active after a preset amount of time. This screen
is only an informational for the operator. If screen persists
after correcting the condition, see appropriate diagnostic
section. 003941.31

CB12260,00002B7 -19-05FEB15-1/1

PTO Engaged, Not Mowing

This screen indicates that the PTO is still on after the

TCT012069 —UN—25NOV14
PTO output was deactivated. DTC 003941.14 becomes
active after a preset amount of time. If screen persists
after correcting the condition, see appropriate diagnostic
section.
003941.14

CB12260,00002B8 -19-05FEB15-1/1

TM130419 (24FEB16) 235-40-5 030916

PN=879
 Diagnose—DTCs, PDU

PTO Engaged and Attempting to Activate

Parked Regeneration

TCT012070 —UN—25NOV14
This screen indicates that a parked DPF regeneration is
being attempted while the PTO is engaged. When this
P
state becomes active the system will not initiate an active
regeneration, or exits an active regeneration.

CB12260,00002B9 -19-05FEB15-1/1

Parked Cleaning Stopped

PARK

! P
The screen indicates that the parked regeneration has
CLEAN

TCT012071 —UN—25NOV14
been stopped. The system will not initiate an active
regeneration, or exits an active regeneration. STOPD

CB12260,00002BA -19-05FEB15-1/1

Engine Oil Service

!
This screen indicates that the engine oil timer has expired.

TCT012072 —UN—25NOV14
This screen is informational only. There is no associated
DTC.

CB12260,00002BB -19-05FEB15-1/1

Hydraulic Oil Service

!
This screen indicates that the hydraulic oil service timer

TCT012073 —UN—25NOV14
has expired. This screen is informational only. There is
no associated DTC.

CB12260,00002BC -19-05FEB15-1/1

TM130419 (24FEB16) 235-40-6 030916

PN=880
 Diagnose—DTCs, PDU

Engine Stop
This screen shows that the engine has stopped due to

TCT012074 —UN—25NOV14
a fault severe enough to shut down the engine due to
electrical, mechanical, or safety reasons. The DTCs
STOP
display in the lower right portion of the screen. The fault
conditions must be corrected before operation can resume.
000000.00

CB12260,00002BD -19-05FEB15-1/1

Engine Warning
This screen shows that the machine has a major fault,

! !

TCT012075 —UN—25NOV14
but not severe enough to stop the engine. The engine
may or may not derate. The DTCs display in the lower
right portion of the screen. The fault conditions must be
corrected before normal operation can resume.
000000.00

CB12260,00002BE -19-05FEB15-1/1

Machine General Warning Fault

This screen indicates that there are multiple faults

TCT012076 —UN—25NOV14
occurring with the machine. The machine may or may
not derate.

000000.00

CB12260,00002BF -19-05FEB15-1/1

Machine General Info Fault

This screen indicates there are multiple minor faults with

TCT012077 —UN—25NOV14
the machine. DTCs display in the lower right portion of
the screen.

000000.00

CB12260,00002C0 -19-05FEB15-1/1

TM130419 (24FEB16) 235-40-7 030916

PN=881
 Diagnose—DTCs, PDU

TM130419 (24FEB16) 235-40-8 030916

PN=882
 Group 45
Diagnose—DTCs, VCU
VCU DTC Quick Reference Table
SPN.FMI (DTC) Drive Controller Response Other Controlled Response Fault Clear Method
000070.14 Informational Indicator only Park Brake Switch Off during Start Depress parking brake
No Lamp Switch On (attempting to crank) to start machine
000158.00 Red Lamp Engine shuts down Switched Power (ELX) Fault voltage Check electrical
above normal operating range system.
(>18V persist and 1 sec)
000158.01 Red Lamp Engine shuts down Switched Power Fault voltage below Check electrical
normal operating range when not system.
cranking (<8V persistence 1 sec)
000168.00 Red Lamp Engine shuts down Supply Voltage (VBAT) Fault - Check electrical
Voltage above normal operating system.
range. (>18V persist and 1 sec)
000168.01 Red Lamp Engine shuts down Switched Power (VBAT) Fault Check electrical
voltage below normal operating system.
range when not cranking (<8V
persistence 1 sec)
000168.16 Limit Function Does not allow mowing. Supply Voltage (VBAT) Fault Check voltage. Test
Amber Lamp 16>X<18V for 5000 msec when alternator.
NOT in engine start mode.
000168.18 Limit Function Does not allow mowing. Supply Voltage (VBAT) Fault 8>X<9 Check voltage. Test
Amber Lamp for 5000 msec when NOT in engine battery and alternator..
start mode.
000595.03 Limit Function Cruise Control Switch Short to High Check electrical
Amber Lamp system.
000595.04 Limit Function Cruise Control Switch Short to Low Check electrical
Amber Lamp system.
000629.12 Limit Function Watch Dog Time Out
Red Lamp
000639.12 Limit Function CAN, Lost Message Check electrical
Amber Lamp system.
000639.14 Limit Function CAN, Bus Off Check electrical
Amber Lamp system.
000677.04 Amber Lamp Indicator/Alarm only Starter Relay Short to Low Check electrical
connections in starter
circuit for moisture.
Verify no exposed
wires shorting out.
000677.14 Informational Indicator only Crank Time Exceeded (>20 Crank time should
No Lamp seconds) not exceed 15
seconds.with a
maximum of two 15
second attempts.
000677.31 Informational Indicator only Starter Cool Down in Process (for Allow starter to cool for
No Lamp 60 seconds) at least 60 seconds.
000920.03 Amber Lamp Indicator/Alarm only Buzzer Short to High Check electrical
system.
000920.04 Amber Lamp Indicator/Alarm only Buzzer Short to Low Check electrical
system.
000931.03 Amber Lamp Indicator/Alarm only Fuel Pump Short to High Check electrical
system.
000931.04 Amber Lamp Indicator/Alarm only Fuel Pump Short to Low Check electrical
system.
001504.31 Informational Indicator only Out of Seat with PTO Switch On Operator must remain
No Lamp on seat. Cycle PTO,
restart machine with
operator remaining in
seat.
001638.00 Limit Function Does not allow mowing. Hydraulic Oil Temperature High Investagate debris on
Amber Lamp oil cooler. Allow engine
to run so hydraulic oil
is being circulated.
003509.03 Red Lamp Engine shuts down Voltage Reference Out of Range Check electrical
High >5 V system.

Continued on next page OUMX258,0000D95 -19-02FEB15-1/2

TM130419 (24FEB16) 235-45-1 PN=883

030916
 Diagnose—DTCs, VCU

003509.04 Red Lamp Engine shuts down Voltage Reference Out of Range Check electrical
Low <4.5 V system.
003941.14 Informational Indicator only PTO On but Blades Off Cycle PTO switch to
No Lamp restart PTO (as long
as engine is running).
003941.31 Informational Indicator only PTO On-Park Brake On Release park brake
No Lamp if intent is to use
machine, then cycle
PTO switch.
516124.03 Red Lamp Engine shuts down Engine Run Request Shorted to High Check electrical
system.
516124.04 Red Lamp Engine shuts down Engine Run Request Shorted to Check electrical
Ground system.
516200.03 Service Alert PTO solenoid low side driver, Short Check electrical
Limit Function to High system.
Amber Lamp
516200.04 Service Alert PTO solenoid low side driver, Short Check electrical
Limit Function to Low system.
Amber Lamp
516206.03 Service Alert PTO High side driver, Short to High Check electrical
Limit Function system.
Amber Lamp
516206.04 Service Alert PTO High side driver, Short to Low Check electrical
Limit Function system.
Amber Lamp
516206.05 Service Alert PTO High Side Driver, Open Circuit Check electrical
Amber Lamp system.
516399.03 Service Alert Indicator/Alarm only Cab (Auxiliary) Power Relay Driver Check electrical
Amber Lamp Short to High system.
516399.04 Service Alert Indicator/Alarm only Cab (Auxiliary) Power Relay Driver Check electrical
Amber Lamp Short to Low system.
520870.31 Service Alert EEPROM Checksum Failure
Amber Lamp
520871.31 Service Alert EEPROM Non-Critical Data
Amber Lamp Checksum Failure
520872.31 Service Alert EEPROM Critical Data Checksum
Amber Lamp Failure
520873.31 Service Alert EEPROM Vehicle Hours Checksum
Red Lamp Failure
522011.08 Limit Function CAN Display Heartbeat, Abnormal
Red Lamp Rate
524265.31 Red Lamp Engine shuts down EOL Checksum Failure
OUMX258,0000D95 -19-02FEB15-2/2

TM130419 (24FEB16) 235-45-2 030916

PN=884
 Diagnose—DTCs, VCU

VCU 000070.14 — Park Brake Switch None

Code Caused By: Preliminary Checks:
Park brake switch off during start switch on (attempting • Ensure that park brake switch is turned to on.
to crank) • Using Service Advisor or the display panel, look
for readings or messages that could assist with
Alarm Level: troubleshooting
Informational - no audible alarm Diagnosis:
SAE Lamp: • Recall, record, and clear codes.
None Service ADVISOR™ : This procedure can be performed
by making a connection to the machine and using
Alarm Frequency: the ”Diagnostics” tab to view and clear codes. Use
Snapshot Test under Interactive Test tab for specific
Resettable control unit to record fault.
Control Unit Response: • Clear codes using Diagnostic tab
• Recall codes again and check for return of this code.
Does not allow engine to start • Recreate operating conditions that caused code.
Snapshot Recorded:
• End of tests if code does not return.
NOTE: Common conditions to cause code.
No
Required Tools: • Park brake on

Service ADVISOR is a trademark of Deere & Company

OUMX258,0000D96 -19-03FEB15-1/3

Procedure
OUMX258,0000D96 -19-03FEB15-2/3

•1 Park Brake Switch Remove park brake switch and test. (See Park Brake Switch Test.) Does switch test OK? YES: Check wiring harness
and connections. (See
Cranking Circuit Operation,
T4 for further information).
NO: Replace switch.
OUMX258,0000D96 -19-03FEB15-3/3

TM130419 (24FEB16) 235-45-3 PN=885

030916
 Diagnose—DTCs, VCU

VCU 000158.00 — Switched Power Fault

Preliminary Checks:
Code Caused By: • Check for any other power related messages or codes.
Switched VCU power high (>18 VDC) Diagnosis:
Alarm Level: • Recall, record (Snapshot test under Interactive Tests),
and clear codes.
Stop alert - no audible alarm Service ADVISOR™ : This procedure can be performed
SAE Lamp: by making a connection to the machine and using
the ”Diagnostics” tab to view and clear codes. Use
Red Snapshot Test under Interactive Test tab for specific
control unit to record fault.
Alarm Frequency:
• Clear codes using Diagnostic tab
Continuous • Recall codes again and check for return of this code.
• Recreate operating conditions that caused code.
Control Unit Response: • End of tests if code does not return.
Shutdown NOTE: Common conditions to cause code.
Snapshot Recorded: • Shorted wiring
Yes • Faulty voltage regulator. (See Regulated
Voltage Output Test.)
Required Tools:
Multimeter and Service ADVISOR™
Service ADVISOR is a trademark of Deere & Company
OUMX258,0000D99 -19-03FEB15-1/1

VCU 000158.01 — Switched Power Fault Yes

Code Caused By: Required Tools:
Switched power (ELX) to VCU below normal operating Multimeter and Service ADVISOR™
range (<8 VDC)
Preliminary Checks:
Alarm Level:
Diagnosis:
Stop
• Recall, record (Snapshot test under Interactive Tests),
SAE Lamp: and clear codes.
Service ADVISOR™ : This procedure can be performed
Red by making a connection to the machine and using
To Clear Display: the ”Diagnostics” tab to view and clear codes. Use
Snapshot Test under Interactive Test tab for specific
Correct problem control unit to record fault.
Alarm Frequency:
• Clear codes using Diagnostic tab
• Recall codes again and check for return of this code.
Continuous • Recreate operating conditions that caused code.
• End of tests if code does not return.
Control Unit Response:
NOTE: Common conditions to cause code.
E-stop
• Low system voltage
Snapshot Recorded: • Switched power shorted to ground
Service ADVISOR is a trademark of Deere & Company
OUMX258,0000D98 -19-30MAR15-1/3

Procedure
Continued on next page OUMX258,0000D98 -19-30MAR15-2/3

TM130419 (24FEB16) 235-45-4 030916

PN=886
 Diagnose—DTCs, VCU

•1 Alternator Test alternator output and system voltage. (See Regulated Voltage Output Test.) Is
voltage OK?
YES: End of test.

NO: Repair or replace

alternator.
OUMX258,0000D98 -19-30MAR15-3/3

VCU 000168.00 — Supply Voltage (VBAT)

Required Tools:
Fault
Multimeter and Service ADVISOR™
Code Caused By:
Diagnosis:
Battery voltage (VBAT), critical high voltage (above
normal operating range (>18 VDC). • Recall, record (Snapshot test under Interactive Tests),
and clear codes.
Alarm Level: Service ADVISOR™ : This procedure can be performed
by making a connection to the machine and using
Stop alert - no audible alarm the ”Diagnostics” tab to view and clear codes. Use
SAE Lamp: Snapshot Test under Interactive Test tab for specific
control unit to record fault.
Red • Clear codes using Diagnostic tab
Alarm Frequency:
• Recall codes again and check for return of this code.
• Recreate operating conditions that caused code.
Continuous • End of tests if code does not return.

Control Unit Response: NOTE: Common conditions to cause code.

E-stop • Low system voltage

• Switched power shorted to ground
Snapshot Recorded:
Yes

Service ADVISOR is a trademark of Deere & Company

OUMX258,0000D9A -19-03FEB15-1/3

Procedure
OUMX258,0000D9A -19-03FEB15-2/3

•1 Alternator Test alternator output and system voltage. (See Regulated Voltage Output Test.) Is
voltage OK?
YES: End of tests.

NO: Repair or replace

alternator.

OUMX258,0000D9A -19-03FEB15-3/3

TM130419 (24FEB16) 235-45-5 030916

PN=887
 Diagnose—DTCs, VCU

VCU 000168.01 — Supply Voltage (VBAT)

Required Tools:
Fault
Multimeter
Code Caused By:
Diagnosis:
Supply Voltage (VBAT) Fault - Voltage below normal
operating range. (<8V for more than 1 sec) • Recall, record (Snapshot test under Interactive Tests),
and clear codes.
Alarm Level: Service ADVISOR™ : This procedure can be performed
by making a connection to the machine and using
Stop alert - no audible alarm the ”Diagnostics” tab to view and clear codes. Use
SAE Lamp: Snapshot Test under Interactive Test tab for specific
control unit to record fault.
Red • Clear codes using Diagnostic tab
Alarm Frequency:
• Recall codes again and check for return of this code.
• Recreate operating conditions that caused code.
Continuous • End of tests if code does not return.

Control Unit Response: NOTE: Common conditions to cause code.

E-stop • Low system voltage

• Switched power shorted to ground
Snapshot Recorded:
Yes

Service ADVISOR is a trademark of Deere & Company

OUMX258,0000D9B -19-20MAR15-1/3

Procedure
OUMX258,0000D9B -19-20MAR15-2/3

•1 Alternator Test alternator output and system voltage. (See Regulated Voltage Output Test.) Is
voltage OK?
YES: End of tests.

NO: Repair or replace

alternator.
OUMX258,0000D9B -19-20MAR15-3/3

TM130419 (24FEB16) 235-45-6 030916

PN=888
 Diagnose—DTCs, VCU

VCU 000168.16 — Supply Voltage (VBAT) Multimeter and Service ADVISOR™

Fault
Preliminary Checks:
Code Caused By: Check alternator output. See Regulated Voltage Output
Battery voltage (VBAT) High (16> and <18 VDC for 0.5 Test.
sec when not in start mode) Diagnosis:
Alarm Level:
• Recall, record (Snapshot test under Interactive Tests),
Warning alert - no audible alarm and clear codes.
Service ADVISOR™ : This procedure can be performed
SAE Lamp: by making a connection to the machine and using
the ”Diagnostics” tab to view and clear codes. Use
Amber Snapshot Test under Interactive Test tab for specific
Alarm Frequency: control unit to record fault.
• Clear codes using Diagnostic tab
Continuous • Recall codes again and check for return of this code.
Control Unit Response: • Recreate operating conditions that caused code.
• End of tests if code does not return.
Limited functionality
NOTE: Common conditions to cause code.
Snapshot Recorded:
• High system voltage
Yes • Switched power shorted to ground
Required Tools:
Service ADVISOR is a trademark of Deere & Company
OUMX258,0000D9C -19-03FEB15-1/3

Procedure
OUMX258,0000D9C -19-03FEB15-2/3

•1 Alternator Test alternator output and system voltage. (See Regulated Voltage Output Test.) Is
voltage OK?
YES: End of tests.

NO: Repair or replace

alternator.
OUMX258,0000D9C -19-03FEB15-3/3

TM130419 (24FEB16) 235-45-7 030916

PN=889
 Diagnose—DTCs, VCU

VCU 000168.18 — Supply Voltage (VBAT)

Preliminary Checks:
Fault
Check battery voltage and test battery. See Battery Load
Code Caused By: Test.
Supply Voltage (VBAT) Fault 8>volts<9 for 5000 msec Check alternator output. See Regulated Voltage Output
when NOT in engine start mode. Test.
Alarm Level: Diagnosis:
Warning alert - no audible alarm • Recall, record (Snapshot test under Interactive Tests),
and clear codes.
SAE Lamp: Service ADVISOR™ : This procedure can be performed
Amber by making a connection to the machine and using
the ”Diagnostics” tab to view and clear codes. Use
Alarm Frequency: Snapshot Test under Interactive Test tab for specific
control unit to record fault.
Continuous • Clear codes using Diagnostic tab
Control Unit Response: • Recall codes again and check for return of this code.
• Recreate operating conditions that caused code.
Limited functionality • End of tests if code does not return.
Snapshot Recorded: NOTE: Common conditions to cause code.
Yes • Low system voltage
Required Tools:
• Switched power shorted to ground
Multimeter
Service ADVISOR is a trademark of Deere & Company
OUMX258,0000D9D -19-26FEB15-1/4

Procedure
OUMX258,0000D9D -19-26FEB15-2/4

•1 Alternator Test alternator output and system voltage. (See Regulated Voltage Output Test.) Is
voltage OK?
YES: Go to next step.

NO: Repair or replace

alternator.
OUMX258,0000D9D -19-26FEB15-3/4

•2 Battery Test battery. (See Battery Load Test.) YES: End of tests.

NO: Replace battery.

OUMX258,0000D9D -19-26FEB15-4/4

TM130419 (24FEB16) 235-45-8 030916

PN=890
 Diagnose—DTCs, VCU

VCU 000595.03 — Cruise Control Switch Ensure that switch is not stuck in momentary position.
Short to High
Diagnosis:
Code Caused By: • Recall, record (Snapshot test under Interactive Tests),
Cruise control switch momentary position stuck or shorted and clear codes.
to high. Service ADVISOR™ : This procedure can be performed
by making a connection to the machine and using
Alarm Level: the ”Diagnostics” tab to view and clear codes. Use
Snapshot Test under Interactive Test tab for specific
Amber lamp control unit to record fault.
Alarm Frequency: • Clear codes using Diagnostic tab
• Recall codes again and check for return of this code.
Continuous • Recreate operating conditions that caused code.
Control Unit Response: • End of tests if code does not return.
NOTE: Common conditions to cause code:
Limited functionality
Required Tools: • Internally shorted switch
• Physically damaged switch
Multimeter • Faulty wiring
Preliminary Checks:

Service ADVISOR is a trademark of Deere & Company

CB12260,0000047 -19-16SEP14-1/4

Procedure
CB12260,0000047 -19-16SEP14-2/4

•1 Cruise Control Switch Test cruise control switch. (See Cruise Control Switch Test.) Does switch test OK? YES: Go to next step.

NO: Replace switch.

CB12260,0000047 -19-16SEP14-3/4

•2 Wiring Check 833 Pnk wire from switch to VCU for shorts and continuity. Does it check OK? YES: Suspect faulty VCU.
Update VCU with latest
software. (See Approved
Software for Control Units).
NO: Repair wiring as
required.

CB12260,0000047 -19-16SEP14-4/4

TM130419 (24FEB16) 235-45-9 PN=891

030916
 Diagnose—DTCs, VCU

VCU 000595.04 — Cruise Control Short to None

Low
Diagnosis:
Code Caused By: • Recall, record (Snapshot test under Interactive Tests),
Cruise control switch shorted to low. and clear codes.
Service ADVISOR™ : This procedure can be performed
Alarm Level: by making a connection to the machine and using
the ”Diagnostics” tab to view and clear codes. Use
Amber lamp Snapshot Test under Interactive Test tab for specific
Alarm Frequency: control unit to record fault.
• Clear codes using Diagnostic tab
Continuous • Recall codes again and check for return of this code.
Control Unit Response: • Recreate operating conditions that caused code.
• End of tests if code does not return.
Limited functionality
NOTE: Common conditions to cause code:
Required Tools:
• Internally shorted switch
Multimeter • Physically damaged switch
• Faulty wiring
Preliminary Checks:

Service ADVISOR is a trademark of Deere & Company

CB12260,0000048 -19-16SEP14-1/4

Procedure
CB12260,0000048 -19-16SEP14-2/4

•1 Cruise Control Switch Test cruise control switch. (See Cruise Control Switch Test.) Does switch test OK? YES: Go to next step.

NO: Replace switch.

CB12260,0000048 -19-16SEP14-3/4

•2 Wiring Check 833 Pnk wire from switch to VCU for shorts and continuity. Does it check OK? YES: Suspect faulty VCU.
Update VCU with latest
software. (See Approved
Software for Control Units).
NO: Repair wiring as
required.

CB12260,0000048 -19-16SEP14-4/4

TM130419 (24FEB16) 235-45-10 PN=892

030916
 Diagnose—DTCs, VCU

VCU 000629.12 — Watch Dog Time Out

Required Tools:
Code Caused By: Multimeter and/or Service ADVISOR
VCU is not receiving messeges from any other control unit Preliminary Checks:
Alarm Level: None
Stop alert - no audible alarm Diagnosis:
SAE Lamp: • Recall, record (Snapshot test under Interactive Tests),
and clear codes.
Red Service ADVISOR™ : This procedure can be performed
Alarm Frequency: by making a connection to the machine and using
the ”Diagnostics” tab to view and clear codes. Use
Continuous Snapshot Test under Interactive Test tab for specific
control unit to record fault.
Control Unit Response:
• Clear codes using Diagnostic tab
E-stop • Recall codes again and check for return of this code.
• Recreate operating conditions that caused code.
Snapshot Recorded: • End of tests if code does not return.
Yes
Service ADVISOR is a trademark of Deere & Company
OUMX258,0000DA0 -19-03FEB15-1/3

Procedure
OUMX258,0000DA0 -19-03FEB15-2/3

•1 Payload Install latest payload. (See Approved Software for Control Units). Is problem corrected? YES: End of test.

NO: Suspect faulty VCU.

OUMX258,0000DA0 -19-03FEB15-3/3

TM130419 (24FEB16) 235-45-11 030916

PN=893
 Diagnose—DTCs, VCU

VCU 000639.12 — CAN, Lost Message

Preliminary Checks:
Code Caused By: None
Communication error between control units Diagnosis:
Alarm Level: • Recall, record (Snapshot test under Interactive Tests),
and clear codes.
Warning alert - no audible alarm Service ADVISOR™ : This procedure can be performed
SAE Lamp: by making a connection to the machine and using
the ”Diagnostics” tab to view and clear codes. Use
Amber Snapshot Test under Interactive Test tab for specific
control unit to record fault.
Alarm Frequency:
• Clear codes using Diagnostic tab
Continuous • Recall codes again and check for return of this code.
• Recreate operating conditions that caused code.
Control Unit Response: • End of tests if code does not return.
Limited functionality NOTE: Common conditions to cause code.
Snapshot Recorded: • Faulty CAN bus wiring. (See CAN Bus and
No CAN Message Not Received).
• Faulty CAN terminator(s). (See CAN Bus
Required Tools: Terminator Test.)
None
Service ADVISOR is a trademark of Deere & Company
OUMX258,0000DA1 -19-03FEB15-1/1

VCU 000639.14 — CAN, Bus Off None

Code Caused By: Diagnosis:
No communication over CAN bus • Recall, record (Snapshot test under Interactive Tests),
and clear codes.
Alarm Level: Service ADVISOR™ : This procedure can be performed
Warning alert - no audible alarm by making a connection to the machine and using
the ”Diagnostics” tab to view and clear codes. Use
SAE Lamp: Snapshot Test under Interactive Test tab for specific
control unit to record fault.
Amber • Clear codes using Diagnostic tab
Alarm Frequency: • Recall codes again and check for return of this code.
• Recreate operating conditions that caused code.
Continuous • End of tests if code does not return.
Control Unit Response: NOTE: Common conditions to cause code.
Limited functionality • CAN bus wiring compromised. Check
wiring and connections.
Snapshot Recorded:
• CAN terminators faulty. Test terminators. (See
No CAN Bus Terminator Test.)

Required Tools:

Service ADVISOR is a trademark of Deere & Company

OUMX258,0000DA2 -19-03FEB15-1/1

TM130419 (24FEB16) 235-45-12 030916

PN=894
 Diagnose—DTCs, VCU

VCU 000677.04 — Starter Relay

Required Tools:
Code Caused By: None
Starter Relay output shorted to low Diagnosis:
Alarm Level: • Recall, record (Snapshot test under Interactive Tests),
and clear codes.
Warning alert - no audible alarm Service ADVISOR™ : This procedure can be performed
SAE Lamp: by making a connection to the machine and using
the ”Diagnostics” tab to view and clear codes. Use
Amber Snapshot Test under Interactive Test tab for specific
control unit to record fault.
Alarm Frequency:
• Clear codes using Diagnostic tab
Continuous • Recall codes again and check for return of this code.
• Recreate operating conditions that caused code.
Control Unit Response: • End of tests if code does not return.
Engine does not crank NOTE: Common conditions to cause code.
Snapshot Recorded: • Faulty wiring.
No

Service ADVISOR is a trademark of Deere & Company

OUMX258,0000DA4 -19-26FEB15-1/1

VCU 000677.14 — Crank Time Exceeded

Required Tools:
Code Caused By: None
Crank Time Exceeded (>15 seconds) Diagnosis:
Alarm Level: • Recall, record (Snapshot test under Interactive Tests),
and clear codes.
Informational - no audible alarm Service ADVISOR™ : This procedure can be performed
SAE Lamp: by making a connection to the machine and using
the ”Diagnostics” tab to view and clear codes. Use
None Snapshot Test under Interactive Test tab for specific
control unit to record fault.
Alarm Frequency:
• Clear codes using Diagnostic tab
Resettable • Recall codes again and check for return of this code.
• Recreate operating conditions that caused code.
Control Unit Response: • End of tests if code does not return.
Does not allow cranking until key switch is turned back NOTE: Common conditions to cause code.
to ‘RUN’ or ‘OFF’ position.
• Crank time of 15 seconds exceeded.
Snapshot Recorded:
No

Service ADVISOR is a trademark of Deere & Company

OUMX258,0000DA3 -19-20MAR15-1/1

TM130419 (24FEB16) 235-45-13 030916

PN=895
 Diagnose—DTCs, VCU

VCU 000677.31 — Starter Cool Down in

Required Tools:
Process
Multimeter
Code Caused By:
Diagnosis:
Starter Cool Down in Process (for 60 seconds)
• Recall, record (Snapshot test under Interactive Tests),
Alarm Level: and clear codes.
Service ADVISOR™ : This procedure can be performed
Informational - no audible alarm by making a connection to the machine and using
SAE Lamp: the ”Diagnostics” tab to view and clear codes. Use
Snapshot Test under Interactive Test tab for specific
None control unit to record fault.
Alarm Frequency:
• Clear codes using Diagnostic tab
• Recall codes again and check for return of this code.
Resettable • Recreate operating conditions that caused code.
• End of tests if code does not return.
Control Unit Response:
NOTE: Common conditions to cause code:
Will not allow crank for 1 minute
• Starter cool down. Allow 60 seconds before
Snapshot Recorded: attempting to crank again.
No

Service ADVISOR is a trademark of Deere & Company

OUMX258,0000DA5 -19-03FEB15-1/1

VCU 000920.03 — Buzzer Short to High

Preliminary Checks:
Code Caused By: None
Battery voltage detected on buzzer driver when in “buzzer Diagnosis:
off” state.
• Recall, record (Snapshot test under Interactive Tests),
Alarm Level: and clear codes.
Service ADVISOR™ : This procedure can be performed
Warning alert - no audible alarm by making a connection to the machine and using
SAE Lamp: the ”Diagnostics” tab to view and clear codes. Use
Snapshot Test under Interactive Test tab for specific
Amber control unit to record fault.
Alarm Frequency: • Clear codes using Diagnostic tab
• Recall codes again and check for return of this code.
Continuous • Recreate operating conditions that caused code.
• End of tests if code does not return.
Control Unit Response:
NOTE: Common conditions to cause code.
Buzzer output is shut off
• Shorted wiring. Check wires and connections on
Required Tools: 302 Org circuit between buzzer and VCU.
Multimeter

Service ADVISOR is a trademark of Deere & Company

CB12260,0000049 -19-26FEB15-1/1

TM130419 (24FEB16) 235-45-14 030916

PN=896
 Diagnose—DTCs, VCU

VCU 000920.04 — Buzzer Short to Low

Diagnosis:
Code Caused By: • Recall, record (Snapshot test under Interactive Tests),
and clear codes.
Buzzer active driver shorted to low. Service ADVISOR™ : This procedure can be performed
Alarm Level: by making a connection to the machine and using
the ”Diagnostics” tab to view and clear codes. Use
Warning alert - no audible alarm Snapshot Test under Interactive Test tab for specific
control unit to record fault.
SAE Lamp:
• Clear codes using Diagnostic tab
Amber • Recall codes again and check for return of this code.
• Recreate operating conditions that caused code.
Alarm Frequency: • End of tests if code does not return.
Continuous NOTE: Common conditions to cause code.
Control Unit Response: • Faulty wiring. Check 302 Org circuit
Buzzer output turned off. and connections.
• Faulty buzzer. Test buzzer. (See Warning
Required Tools: Alarm Test.)
Multimeter
Service ADVISOR is a trademark of Deere & Company
CB12260,000004A -19-03FEB15-1/1

VCU 000931.03 — Fuel Pump Short to High Check for any other high voltage codes. If present,
troubleshoot underlying DTCs first.
Code Caused By:
Diagnosis:
Fuel pump driver shorted to high voltage.
• Recall, record (Snapshot test under Interactive Tests),
Alarm Level: and clear codes.
Warning alert - no audible alarm Service ADVISOR™ : This procedure can be performed
by making a connection to the machine and using
SAE Lamp: the ”Diagnostics” tab to view and clear codes. Use
Snapshot Test under Interactive Test tab for specific
Amber control unit to record fault.
Alarm Frequency: • Clear codes using Diagnostic tab
• Recall codes again and check for return of this code.
Continuous • Recreate operating conditions that caused code.
Control Unit Response:
• End of tests if code does not return.
NOTE: Common conditions to cause code.
Fuel pump output is shut off
Required Tools:
• This code could be present if operating conditions
do not warrant fuel pump operation, such as
Multimeter unsafe operating conditions. If this is the case,
an informational message will be displayed on
Preliminary Checks: the PDU indicating the condition.

Service ADVISOR is a trademark of Deere & Company

CB12260,000004B -19-26FEB15-1/4

Procedure
Continued on next page CB12260,000004B -19-26FEB15-2/4

TM130419 (24FEB16) 235-45-15 030916

PN=897
 Diagnose—DTCs, VCU

•1 Fuel Pump Wiring and

source Voltage
Disconnect fuel pump and measure voltage across 108 Blk and 681 Pnk wires with key YES: Go to next step.
switch on. Does voltage measure between 12 and 14 volts?

NO: If voltage is above

range, check 681 Pnk wire
and connections for short to
high source.
NO: If wiring is OK, suspect
faulty VCU.
CB12260,000004B -19-26FEB15-3/4

•2 Fuel Pump Test fuel pump. (See Fuel Pump Test.) Does fuel pump check out OK? YES: Suspect faulty VCU.

NO: Replace fuel pump.

CB12260,000004B -19-26FEB15-4/4

VCU 000931.04 — Fuel Pump Short to Low Check for any other high voltage codes. If present,
troubleshoot underlying DTCs first.
Code Caused By:
Diagnosis:
Fuel pump driver shorted to high voltage.
• Recall, record (Snapshot test under Interactive Tests),
Alarm Level: and clear codes.
Warning alert - no audible alarm Service ADVISOR™ : This procedure can be performed
by making a connection to the machine and using
SAE Lamp: the ”Diagnostics” tab to view and clear codes. Use
Snapshot Test under Interactive Test tab for specific
Amber control unit to record fault.
Alarm Frequency: • Clear codes using Diagnostic tab
• Recall codes again and check for return of this code.
Continuous • Recreate operating conditions that caused code.
Control Unit Response:
• End of tests if code does not return.
NOTE: Common conditions to cause code.
Fuel pump output is shut off.
Required Tools:
• This code could be present if operating conditions
do not warrant fuel pump operation, such as
Multimeter unsafe operating conditions. If this is the case,
an informational message will be displayed on
Preliminary Checks: the PDU describing the condition.

Service ADVISOR is a trademark of Deere & Company

CB12260,000004C -19-26FEB15-1/4

Procedure
Continued on next page CB12260,000004C -19-26FEB15-2/4

TM130419 (24FEB16) 235-45-16 PN=898

030916
 Diagnose—DTCs, VCU

•1 Fuel Pump Wiring and

source Voltage
Disconnect fuel pump and measure voltage across 108 Blk and 681 Pnk wires with key YES: Go to next step.
switch on. Does voltage measure between 12 and 14 volts?

NO: If voltage is below

range, check 681 Pnk wire
and connections for short to
low source.
NO: If wiring is OK, suspect
faulty VCU.
CB12260,000004C -19-26FEB15-3/4

•2 Fuel Pump Test fuel pump. (See Fuel Pump Test) Does fuel pump check out OK? YES: Suspect faulty VCU.

NO: Replace fuel pump.

CB12260,000004C -19-26FEB15-4/4

VCU 001504.31 — Out of Neutral and Out of Multimeter

Seat
Preliminary Checks:
Code Caused By: Ensure that the operator is on the seat with the park brake
Operator is out of seat and the machine park brake is off set.
(out of neutral) whether while running or attempting to Diagnosis:
start engine.
Alarm Level:
• Recall, record (Snapshot test under Interactive Tests),
and clear codes.
Informational - no audible alarm Service ADVISOR™ : This procedure can be performed
by making a connection to the machine and using
To Clear Display: the ”Diagnostics” tab to view and clear codes. Use
Snapshot Test under Interactive Test tab for specific
Correct condition control unit to record fault.
Control Module Response: • Clear codes using Diagnostic tab
• Recall codes again and check for return of this code.
Machine shuts down • Recreate operating conditions that caused code.
Snapshot Recorded: • End of tests if code does not return.

No NOTE: Common conditions to cause code.

Required Tools: • Operating conditions not met.

Service ADVISOR is a trademark of Deere & Company
CB12260,0000082 -19-20MAR15-1/5

Procedure
CB12260,0000082 -19-20MAR15-2/5

•1 Signal Check Using either Service ADVISOR readings or the PDU, are the operating conditions
are met?
YES: Suspect faulty VCU.

NO: Go to next step.

Continued on next page CB12260,0000082 -19-20MAR15-3/5

TM130419 (24FEB16) 235-45-17 PN=899

030916
 Diagnose—DTCs, VCU

•2 Component Test Test the seat switch and park brake switch. (See Seat Switch Test and Park Brake
Switch Test.) Do they test OK?
YES: Go to next step.

NO: Replace switch as

required.
CB12260,0000082 -19-20MAR15-4/5

•3 Wiring Check related wiring and connections. Do they check out OK? YES: Reload VCU payload.
(See Approved Software for
Control Units).
NO: Repair as necessary.
CB12260,0000082 -19-20MAR15-5/5

VCU 001638.00 — Hydraulic Oil

Required Tools:
Code Caused By: Multimeter and Service ADVISOR™
Hydraulic oil temperature high over 105° C (221° F). Diagnosis:
Alarm Level: • Recall, record (Snapshot test under Interactive Tests),
and clear codes.
Warning alert - no audible alarm Service ADVISOR™ : This procedure can be performed
SAE Lamp: by making a connection to the machine and using
the ”Diagnostics” tab to view and clear codes. Use
Amber Snapshot Test under Interactive Test tab for specific
control unit to record fault.
Alarm Frequency:
• Clear codes using Diagnostic tab
Continuous • Recall codes again and check for return of this code.
• Recreate operating conditions that caused code.
Control Unit Response: • End of tests if code does not return.
Limited functionality NOTE: Common conditions to cause code.
Snapshot Recorded: • Excessive load on hydraulic system.
Yes

Service ADVISOR is a trademark of Deere & Company

OUMX258,0000DA8 -19-03FEB15-1/4

Procedure
OUMX258,0000DA8 -19-03FEB15-2/4

•1 Cool Down Allow machine to cool and return to normal operation. Does code reoccur? YES: Go to next step.

NO: End of test.

OUMX258,0000DA8 -19-03FEB15-3/4

•2 Hydraulic Oil
Temperature Switch
Test hydraulic oil temperature switch. (See Hydraulic Temperature Switch Test.) Does
switch test OK?
YES: Refer to Hydraulics
Section

NO: Replace switch.

OUMX258,0000DA8 -19-03FEB15-4/4

TM130419 (24FEB16) 235-45-18 030916

PN=900
 Diagnose—DTCs, VCU

VCU 003509.03 — Sensor Power Supply High Multimeter

Code Caused By: Preliminary Checks:
Sensor power supply is above 5.5 VDC. Ensure there are no other high voltage related codes.
Alarm Level: Diagnosis:
Stop alert - no audible alarm • Recall, record (Snapshot test under Interactive Tests),
and clear codes.
SAE Lamp: Service ADVISOR™ : This procedure can be performed
Red by making a connection to the machine and using
the ”Diagnostics” tab to view and clear codes. Use
Alarm Frequency: Snapshot Test under Interactive Test tab for specific
control unit to record fault.
Continuous
• Clear codes using Diagnostic tab
Control Unit Response: • Recall codes again and check for return of this code.
• Recreate operating conditions that caused code.
E-stop • End of tests if code does not return.
Snapshot Recorded: NOTE: Common conditions to cause code.
Yes • Shorted wiring
Required Tools:

Service ADVISOR is a trademark of Deere & Company

CB12260,000004D -19-03FEB15-1/4

Procedure
CB12260,000004D -19-03FEB15-2/4

•1 Wiring Check wiring for any possible shorts to a high voltage source. Is wiring OK? YES: Go to next step.

NO: Repair or replace

wiring.
CB12260,000004D -19-03FEB15-3/4

•2 Source Voltage Disconnect any 5 volt sourced sensor and measure voltage at reference wire. Is
voltage above 5.5 volts?
YES: Reload control unit
payload.

NO: Reload control unit

payload
NO: If payload does not
work, suspect faulty control
unit.

CB12260,000004D -19-03FEB15-4/4

TM130419 (24FEB16) 235-45-19 PN=901

030916
 Diagnose—DTCs, VCU

VCU 003509.04 — Sensor Power Supply Low Multimeter and or Service ADVISOR
Code Caused By: Preliminary Checks:
Sensor voltage below 4.5 VDC Ensure that the are no other low voltage codes present.
Alarm Level: Diagnosis:
Stop alert - no audible alarm • Recall, record (Snapshot test under Interactive Tests),
and clear codes.
SAE Lamp: Service ADVISOR™ : This procedure can be performed
Red by making a connection to the machine and using
the ”Diagnostics” tab to view and clear codes. Use
Alarm Frequency: Snapshot Test under Interactive Test tab for specific
control unit to record fault.
Continuous
• Clear codes using Diagnostic tab
Control Unit Response: • Recall codes again and check for return of this code.
• Recreate operating conditions that caused code.
E-stop • End of tests if code does not return.
Snapshot Recorded: NOTE: Common conditions to cause code.
Yes • Broken wire shorted to ground
Required Tools:

Service ADVISOR is a trademark of Deere & Company

CB12260,000004E -19-03FEB15-1/4

Procedure
CB12260,000004E -19-03FEB15-2/4

•1 Wiring Check wiring for any possible shorts to a low voltage source or ground. Is wiring OK? YES: Check wiring for any
possible shorts to a high
voltage source. Is wiring
OK?
NO: Repair or replace
wiring.
CB12260,000004E -19-03FEB15-3/4

•2 Source Voltage Disconnect any 5 volt sourced sensor and measure voltage at reference wire. Is
voltage below 4.5 volts?
YES: Reload control unit
payload.

NO: Reload control unit

payload
NO: If payload does not
solve problem, suspect
faulty control unit.

CB12260,000004E -19-03FEB15-4/4

TM130419 (24FEB16) 235-45-20 030916

PN=902
 Diagnose—DTCs, VCU

VCU 003941.14 — Seat Switch On with PTO

Control Module Response:
Output On
None
Code Caused By:
Snapshot Recorded:
Seat switch on with PTO switch on and PTO output off
No
(with engine running).
Required Tools:
Alarm Level:
None
Informational - no audible alarm
Preliminary Checks:
SAE Lamp:
None
None
Diagnosis:
Alarm Frequency:
Not required
Resettable
OUMX258,0000DAA -19-20MAR15-1/1

VCU 003941.31 — Park Brake On with PTO Resettable

Output On
Control Module Response:
Code Caused By: None
Park brake on with PTO switch on and PTO output off Snapshot Recorded:
(with engine running).
No
Alarm Level:
Required Tools:
Informational - no audible alarm
None
SAE Lamp:
Preliminary Checks:
None
Not required
Control Unit Response:
Diagnosis:
None
None
Alarm Frequency:
OUMX258,0000DAB -19-20MAR15-1/1

TM130419 (24FEB16) 235-45-21 030916

PN=903
 Diagnose—DTCs, VCU

VCU 516124.03 — Engine Run Request Short

Preliminary Checks:
to High
Ensure that key switch is not in start position.
Code Caused By:
Diagnosis:
Engine run request shorted to high
• Recall, record (Snapshot test under Interactive Tests),
Alarm Level: and clear codes.
Service ADVISOR™ : This procedure can be performed
Stop alert - no audible alarm by making a connection to the machine and using
SAE Lamp: the ”Diagnostics” tab to view and clear codes. Use
Snapshot Test under Interactive Test tab for specific
Red control unit to record fault.
Alarm Frequency:
• Clear codes using Diagnostic tab
• Recall codes again and check for return of this code.
Continuous • Recreate operating conditions that caused code.
• End of tests if code does not return.
Control Unit Response:
NOTE: Common conditions to cause code.
E-stop
• Faulty key switch
Snapshot Recorded: • Faulty wiring
Yes For more information, see Cranking Circuit Operation, T4.
Required Tools:
Multimeter
Service ADVISOR is a trademark of Deere & Company
CB12260,000004F -19-03FEB15-1/5

Procedure
CB12260,000004F -19-03FEB15-2/5

•1 Signal Check Using Service ADVISOR, determine if “Engine run request” signal is active. Is signal
active?
YES: Go to next step.

NO: End of tests.

CB12260,000004F -19-03FEB15-3/5

•2 Key Switch Test key switch. (See Key Switch Test.) Does key switch test OK? YES: Go to next step.

NO: Replace key switch.

CB12260,000004F -19-03FEB15-4/5

•3 Wiring Check 700 series Pur wires for shorts to battery voltage. Is wiring OK? YES: Reinstall control
unit payload. Approved
Software for Control Units
NO: Repair wiring as
required.

CB12260,000004F -19-03FEB15-5/5

TM130419 (24FEB16) 235-45-22 030916

PN=904
 Diagnose—DTCs, VCU

VCU 516124.04 — Engine Run Request Short Ensure that key switch is not in start position.
to Low
Diagnosis:
Code Caused By: • Recall, record (Snapshot test under Interactive Tests),
Engine run request shorted to low and clear codes.
Service ADVISOR™ : This procedure can be performed
Alarm Level: by making a connection to the machine and using
the ”Diagnostics” tab to view and clear codes. Use
Stop alert - no audible alarm Snapshot Test under Interactive Test tab for specific
SAE Lamp: control unit to record fault.
• Clear codes using Diagnostic tab
Red • Recall codes again and check for return of this code.
Control Unit Response: • Recreate operating conditions that caused code.
• End of tests if code does not return.
E-stop
NOTE: Common conditions to cause code.
Snapshot Recorded:
• Faulty key switch
Yes • Faulty wiring
Required Tools: For more information, see Cranking Circuit Operation, T4.
Multimeter
Preliminary Checks:
Service ADVISOR is a trademark of Deere & Company
CB12260,0000050 -19-26FEB15-1/5

Procedure
CB12260,0000050 -19-26FEB15-2/5

•1 Signal Check Using Service ADVISOR, determine if “Engine run request” signal is active. Is signal
active?
YES: Go to next step.

NO: End of tests.

CB12260,0000050 -19-26FEB15-3/5

•2 Key Switch Test key switch. (See Key Switch Test.) Does key switch test OK? YES: Go to next step.

NO: Replace key switch.

CB12260,0000050 -19-26FEB15-4/5

•3 Wiring Check 700 series Pur wires for shorts to battery ground. Is wiring OK? YES: Reinstall control
unit payload. Approved
Software for Control Units
YES: Use CAN Trace to
record a snapshot and send
to DTAC.
NO: Repair wiring as
required.

CB12260,0000050 -19-26FEB15-5/5

TM130419 (24FEB16) 235-45-23 030916

PN=905
 Diagnose—DTCs, VCU

VCU 516200.03 — PTO Low Side Driver Multimeter and/or Service ADVISOR
Code Caused By: Preliminary Checks:
PTO low side driver is shorted to high source None
Alarm Level: Diagnosis:
Warning alert - no audible alarm • Recall, record (Snapshot test under Interactive Tests),
and clear codes.
SAE Lamp: Service ADVISOR™ : This procedure can be performed
Amber by making a connection to the machine and using
the ”Diagnostics” tab to view and clear codes. Use
Alarm Frequency: Snapshot Test under Interactive Test tab for specific
control unit to record fault.
Continuous
• Clear codes using Diagnostic tab
Control Unit Response: • Recall codes again and check for return of this code.
• Recreate operating conditions that caused code.
Limited functionality • End of tests if code does not return.
Required Tools:
Service ADVISOR is a trademark of Deere & Company
OUMX258,0000DAC -19-03FEB15-1/4

Procedure
OUMX258,0000DAC -19-03FEB15-2/4

•1 Driver Test • Raise and secure seat

• Start engine
• Engage PTO and ensure that it is running. YES: Go to next step
Measure voltage between PTO connector Gry wire and ground. Is voltage NO: Test PTO solenoid
approximately 0.5 VDC or less? (See PTO Solenoid Test).
OUMX258,0000DAC -19-03FEB15-3/4

•2 Wiring Check related wiring for short to high. Is wiring OK? YES: Suspect faulty VCU.
Reload payload.

NO: Repair or replace

wiring as needed.

OUMX258,0000DAC -19-03FEB15-4/4

TM130419 (24FEB16) 235-45-24 030916

PN=906
 Diagnose—DTCs, VCU

VCU 516200.04 — PTO Low Side Driver Multimeter and/or Service ADVISOR
Code Caused By: Preliminary Checks:
PTO low side driver is shorted to low source None
Alarm Level: Diagnosis:
Warning alert - no audible alarm • Recall, record (Snapshot test under Interactive Tests),
and clear codes.
SAE Lamp: Service ADVISOR™ : This procedure can be performed
Amber by making a connection to the machine and using
the ”Diagnostics” tab to view and clear codes. Use
Alarm Frequency: Snapshot Test under Interactive Test tab for specific
control unit to record fault.
Continuous
• Clear codes using Diagnostic tab
Control Unit Response: • Recall codes again and check for return of this code.
• Recreate operating conditions that caused code.
Limited functionality • End of tests if code does not return.
Required Tools:
Service ADVISOR is a trademark of Deere & Company
OUMX258,0000DAD -19-03FEB15-1/4

Procedure
OUMX258,0000DAD -19-03FEB15-2/4

•1 Driver Test • Raise and secure seat

• Start engine
• Engage PTO and ensure that it is running. YES: Go to next step
Measure voltage between PTO connector Blu wire and ground. Is voltage NO: Test PTO solenoid
approximately battery voltage? (See PTO Solenoid Test).
OUMX258,0000DAD -19-03FEB15-3/4

•2 Wiring Check related wiring for short to high. Is wiring OK? YES: Suspect faulty VCU.
Reload payload.

NO: Repair or replace

wiring as needed.

OUMX258,0000DAD -19-03FEB15-4/4

TM130419 (24FEB16) 235-45-25 030916

PN=907
 Diagnose—DTCs, VCU

VCU 516206.03 — PTO High Side Driver Multimeter and/or Service ADVISOR
Code Caused By: Preliminary Checks:
PTO high side driver is shorted to high source None
Alarm Level: Diagnosis:
Warning alert - no audible alarm • Recall, record (Snapshot test under Interactive Tests),
and clear codes.
SAE Lamp: Service ADVISOR™ : This procedure can be performed
Amber by making a connection to the machine and using
the ”Diagnostics” tab to view and clear codes. Use
Alarm Frequency: Snapshot Test under Interactive Test tab for specific
control unit to record fault.
Continuous
• Clear codes using Diagnostic tab
Control Unit Response: • Recall codes again and check for return of this code.
• Recreate operating conditions that caused code.
Limited functionality • End of tests if code does not return.
Required Tools:
Service ADVISOR is a trademark of Deere & Company
OUMX258,0000DAE -19-03FEB15-1/3

Procedure
OUMX258,0000DAE -19-03FEB15-2/3

•1 Driver Test • Raise and secure seat

• Start engine
• Engage PTO and ensure that it is running. YES: Suspect faulty VCU.
Reload payload.
Measure voltage between PTO connector Blu wire and ground. Is voltage NO: Check wiring and
approximately battery voltage? connections.
OUMX258,0000DAE -19-03FEB15-3/3

VCU 516206.04 — PTO High Side Driver Multimeter and/or Service ADVISOR
Code Caused By: Preliminary Checks:
PTO high side driver is shorted to high source None
Alarm Level: Diagnosis:
Warning alert - no audible alarm • Recall, record (Snapshot test under Interactive Tests),
and clear codes.
SAE Lamp: Service ADVISOR™ : This procedure can be performed
Amber by making a connection to the machine and using
the ”Diagnostics” tab to view and clear codes. Use
Alarm Frequency: Snapshot Test under Interactive Test tab for specific
control unit to record fault.
Continuous • Clear codes using Diagnostic tab
Control Unit Response: • Recall codes again and check for return of this code.
• Recreate operating conditions that caused code.
Limited functionality • End of tests if code does not return.
Required Tools:
Service ADVISOR is a trademark of Deere & Company
Continued on next page OUMX258,0000DAF -19-03FEB15-1/3

TM130419 (24FEB16) 235-45-26 030916

PN=908
 Diagnose—DTCs, VCU

Procedure
OUMX258,0000DAF -19-03FEB15-2/3

•1 Driver Test • Raise and secure seat

• Start engine YES: ?

• Engage PTO and ensure that it is running. NO: ?
OUMX258,0000DAF -19-03FEB15-3/3

VCU 516206.05 — PTO High Side Driver

• Multimeter and/or Service ADVISOR
Code Caused By:
• Clamp on multimeter or current clamp adaptor
Preliminary Checks:
PTO high side driver current is below normal or open
circuit. None
Alarm Level: Diagnosis:
Warning alert - no audible alarm • Recall, record (Snapshot test under Interactive Tests),
and clear codes.
SAE Lamp: Service ADVISOR™ : This procedure can be performed
Amber by making a connection to the machine and using
the ”Diagnostics” tab to view and clear codes. Use
Alarm Frequency: Snapshot Test under Interactive Test tab for specific
control unit to record fault.
Continuous
• Clear codes using Diagnostic tab
Control Unit Response: • Recall codes again and check for return of this code.
• Recreate operating conditions that caused code.
Limited functionality • End of tests if code does not return.
Required Tools:
Service ADVISOR is a trademark of Deere & Company
CB12260,0000051 -19-03FEB15-1/3

Procedure
CB12260,0000051 -19-03FEB15-2/3

•1 Driver Test • Raise and secure seat

• Start engine
• Engage PTO and ensure that it is running. YES: Reload VCU payload.
Attach current clamp to Blu wire on PTO solenoid pigtail harness. Does meter read NO: Check wiring and
approximately 1700mA? connections for open circuit.

CB12260,0000051 -19-03FEB15-3/3

TM130419 (24FEB16) 235-45-27 PN=909

030916
 Diagnose—DTCs, VCU

VCU 516399.03 — Auxiliary (Cab) Relay

Preliminary Checks:
Driver Short to High
Check for any other active codes that could cause limited
Code Caused By: functionality of machine. If present, troubleshoot those
first.
VCU detects a 12 VDC driver signal when it should not
be present. Diagnosis:
Alarm Level: • Recall, record (Snapshot test under Interactive Tests),
and clear codes.
Service alert - amber lamp Service ADVISOR™ : This procedure can be performed
Alarm Frequency: by making a connection to the machine and using
the ”Diagnostics” tab to view and clear codes. Use
Continuous Snapshot Test under Interactive Test tab for specific
control unit to record fault.
Control Unit Response: • Clear codes using Diagnostic tab
Function degraded • Recall codes again and check for return of this code.
• Recreate operating conditions that caused code.
Snapshot Recorded: • End of tests if code does not return.
Yes NOTE: Common conditions to cause code.
Required Tools: • Shorted wiring.
Multimeter

Service ADVISOR is a trademark of Deere & Company

CB12260,0000052 -19-16SEP14-1/4

Procedure
CB12260,0000052 -19-16SEP14-2/4

•1 Wiring - Service
ADVISOR
Is “Auxiliary power relay” signal active with key switch in run position, engine off? YES: Check 910 Grn wire
for short to power.

NO: Reload payload. (See

Approved Software for
Control Units).
CB12260,0000052 -19-16SEP14-3/4

•2 Wiring - Multimeter Remove K11 cab power relay and measure for battery voltage at 910 Grn wire with key YES: Check 910 Grn wire
switch in on position, engine not running. Is battery voltage present? for short to power.

NO: Reload payload. (See

Approved Software for
Control Units).

CB12260,0000052 -19-16SEP14-4/4

TM130419 (24FEB16) 235-45-28 030916

PN=910
 Diagnose—DTCs, VCU

VCU 516399.04 — Auxiliary (Cab) Power Check for any other active codes that could cause limited
Relay Driver Short to Low functionality of machine. If present, troubleshoot those
first.
Code Caused By:
Diagnosis:
VCU does not detect 12 VDC driver signal when it should
be present. • Recall, record (Snapshot test under Interactive Tests),
and clear codes.
Alarm Level: Service ADVISOR™ : This procedure can be performed
by making a connection to the machine and using
Service alert - amber lamp the ”Diagnostics” tab to view and clear codes. Use
Control Unit Response: Snapshot Test under Interactive Test tab for specific
control unit to record fault.
Function degraded • Clear codes using Diagnostic tab
Snapshot Recorded: • Recall codes again and check for return of this code.
• Recreate operating conditions that caused code.
Yes • End of tests if code does not return.
Required Tools: NOTE: Common conditions to cause code.
Multimeter • Shorted wiring.
Preliminary Checks:
Service ADVISOR is a trademark of Deere & Company
CB12260,0000053 -19-16SEP14-1/4

Procedure
CB12260,0000053 -19-16SEP14-2/4

•1 Wiring - Service
ADVISOR
Is “Auxiliary power relay” signal active with key switch in run position, engine running? YES: Reload payload.
(See Approved Software for
Control Units).

NO: Check 910 Grn wire

and connections.
CB12260,0000053 -19-16SEP14-3/4

•2 Wiring - Multimeter Remove K11 cab power relay and measure for battery voltage at 910 Grn wire with key YES: Reload payload.
switch in on position, engine running. Is battery voltage present? (See Approved Software for
Control Units).
NO: Check 910 Grn wire
and connections.

CB12260,0000053 -19-16SEP14-4/4

TM130419 (24FEB16) 235-45-29 030916

PN=911
 Diagnose—DTCs, VCU

VCU 520870.31 — EEPROM Checksum Fail

Required Tools:
Code Caused By: None
VCU internal messaging error. Preliminary Checks:
Alarm Level: See Erroneous Diagnostic Trouble Codes.
Warning alert - no audible alarm Diagnosis:
SAE Lamp: • Recall, record (Snapshot test under Interactive Tests),
and clear codes.
Amber Service ADVISOR™ : This procedure can be performed
Alarm Frequency: by making a connection to the machine and using
the ”Diagnostics” tab to view and clear codes. Use
Continuous Snapshot Test under Interactive Test tab for specific
control unit to record fault.
Control Unit Response:
• Clear codes using Diagnostic tab
E-stop • Recall codes again and check for return of this code.
• Recreate operating conditions that caused code.
Snapshot Recorded: • End of tests if code does not return.
Yes
Service ADVISOR is a trademark of Deere & Company
CB12260,0000054 -19-03FEB15-1/3

Procedure
CB12260,0000054 -19-03FEB15-2/3

•1 VCU Does problem persist? YES: Reload payload.

(See Approved Software for
Control Units).
YES: Replace VCU.
NO: End of test.
CB12260,0000054 -19-03FEB15-3/3

VCU 520871.31 — EEPROM Non Critical Data Yes

Checksum Fail
Required Tools:
Code Caused By: None
VCU internal messaging error. Preliminary Checks:
Alarm Level: See Erroneous Diagnostic Trouble Codes.
Warning alert - no audible alarm Diagnosis:
SAE Lamp:
• Recall, record (Snapshot test under Interactive Tests),
Amber and clear codes.
Service ADVISOR™ : This procedure can be performed
Alarm Frequency: by making a connection to the machine and using
the ”Diagnostics” tab to view and clear codes. Use
Continuous
Snapshot Test under Interactive Test tab for specific
Control Unit Response: control unit to record fault.
• Clear codes using Diagnostic tab
E-stop • Recall codes again and check for return of this code.
Snapshot Recorded: • Recreate operating conditions that caused code.
• End of tests if code does not return.
Service ADVISOR is a trademark of Deere & Company
Continued on next page CB12260,0000055 -19-03FEB15-1/3

TM130419 (24FEB16) 235-45-30 030916

PN=912
 Diagnose—DTCs, VCU

Procedure
CB12260,0000055 -19-03FEB15-2/3

•1 VCU Does problem persist? YES: Reload payload.

(See Approved Software for
Control Units).
YES: Replace VCU.
NO: End of test.
CB12260,0000055 -19-03FEB15-3/3

VCU 520872.31 — EEPROM Critical Data

Required Tools:
Checksum Failure
None
Code Caused By:
Preliminary Checks:
VCU internal messaging error.
See Erroneous Diagnostic Trouble Codes.
Alarm Level:
Diagnosis:
Stop alert - no audible alarm
• Recall, record (Snapshot test under Interactive Tests),
SAE Lamp: and clear codes.
Service ADVISOR™ : This procedure can be performed
Red by making a connection to the machine and using
Alarm Frequency: the ”Diagnostics” tab to view and clear codes. Use
Snapshot Test under Interactive Test tab for specific
Continuous control unit to record fault.
Control Unit Response:
• Clear codes using Diagnostic tab
• Recall codes again and check for return of this code.
E-stop • Recreate operating conditions that caused code.
• End of tests if code does not return.
Snapshot Recorded:
Yes
Service ADVISOR is a trademark of Deere & Company
CB12260,0000056 -19-20MAR15-1/3

Procedure
CB12260,0000056 -19-20MAR15-2/3

•1 VCU Does problem persist? YES: Reload payload.

(See Approved Software for
Control Units).
YES: Replace VCU.
NO: End of test.

CB12260,0000056 -19-20MAR15-3/3

TM130419 (24FEB16) 235-45-31 030916

PN=913
 Diagnose—DTCs, VCU

VCU 520873.31 — EEPROM Vehicle Hours Yes

Data Checksum Failure
Required Tools:
Code Caused By: None
VCU internal messaging error. Preliminary Checks:
Alarm Level: See Erroneous Diagnostic Trouble Codes.
Warning alert - no audible alarm Diagnosis:
SAE Lamp:
• Recall, record (Snapshot test under Interactive Tests),
Amber and clear codes.
Service ADVISOR™ : This procedure can be performed
Alarm Frequency: by making a connection to the machine and using
the ”Diagnostics” tab to view and clear codes. Use
Continuous Snapshot Test under Interactive Test tab for specific
Control Unit Response: control unit to record fault.
• Clear codes using Diagnostic tab
E-stop • Recall codes again and check for return of this code.
Snapshot Recorded: • Recreate operating conditions that caused code.
• End of tests if code does not return.
Service ADVISOR is a trademark of Deere & Company
CB12260,0000057 -19-03FEB15-1/3

Procedure
CB12260,0000057 -19-03FEB15-2/3

•1 VCU Does problem persist? YES: Reload payload.

(See Approved Software for
Control Units).
YES: Replace VCU.
NO: End of test.
CB12260,0000057 -19-03FEB15-3/3

VCU 522011.08 — Display Heartbeat Yes

Abnormal Rate
Required Tools:
Code Caused By: Multimeter
VCU is not receiving a heartbeat from PDU Preliminary Checks:
Alarm Level: See Erroneous Diagnostic Trouble Codes.
Stop alert - no audible alarm Diagnosis:
SAE Lamp: • Recall, record (Snapshot test under Interactive Tests),
Red and clear codes.
Service ADVISOR™ : This procedure can be performed
Alarm Frequency: by making a connection to the machine and using
the ”Diagnostics” tab to view and clear codes. Use
Continuous
Snapshot Test under Interactive Test tab for specific
Control Unit Response: control unit to record fault.
• Clear codes using Diagnostic tab
None • Recall codes again and check for return of this code.
Snapshot Recorded: • Recreate operating conditions that caused code.
• End of tests if code does not return.
Service ADVISOR is a trademark of Deere & Company
CB12260,0000058 -19-03FEB15-1/1

TM130419 (24FEB16) 235-45-32 030916

PN=914
 Diagnose—DTCs, VCU

VCU 524265.31 — EOL Checksum Failure

Required Tools:
Code Caused By: None
VCU internal messaging error. Preliminary Checks:
Alarm Level: See Erroneous Diagnostic Trouble Codes.
Stop alert - no audible alarm Diagnosis:
SAE Lamp: • Recall, record (Snapshot test under Interactive Tests),
and clear codes.
Red Service ADVISOR™ : This procedure can be performed
Alarm Frequency: by making a connection to the machine and using
the ”Diagnostics” tab to view and clear codes. Use
Continuous Snapshot Test under Interactive Test tab for specific
control unit to record fault.
Control Unit Response:
• Clear codes using Diagnostic tab
E-stop • Recall codes again and check for return of this code.
• Recreate operating conditions that caused code.
Snapshot Recorded: • End of tests if code does not return.
Yes
Service ADVISOR is a trademark of Deere & Company
CB12260,0000059 -19-03FEB15-1/3

Procedure
CB12260,0000059 -19-03FEB15-2/3

•1 VCU Does problem persist? YES: Reload payload.

(See Approved Software for
Control Units).
YES: Replace VCU.
NO: End of test.
CB12260,0000059 -19-03FEB15-3/3

TM130419 (24FEB16) 235-45-33 030916

PN=915
 Diagnose—DTCs, VCU

TM130419 (24FEB16) 235-45-34 030916

PN=916
 Group 50
Diagnose—DTCs, ECU 000001—000199
ECU 000028.00 — Analog Throttle Signal
Preliminary Checks:
Extremely High
Check for any other sensor high voltage DTCs.
Code Caused By:
Diagnosis:
Throttle signal voltage extremely high - most severe level.
• Recall, record (Snapshot test under Interactive Tests)
Alarm Level: and clear codes.
Service ADVISOR™ : This procedure can be performed
Red warning indicator by making a connection to the machine and using
Control Unit Response: the ”Diagnostics” tab to view and clear codes. Use
Snapshot Test under Interactive Test tab for specific
Engine stop controller to record fault.
Snapshot Recorded:
• Clear codes using Diagnostic tab
• Recall codes again and check for return of this code.
Yes • Recreate operating conditions that caused code.
• End of tests if code does not return.
Required Tools:
Multimeter
Service ADVISOR is a trademark of Deere & Company
CB12260,0000084 -19-04JUN14-1/4

Procedure
CB12260,0000084 -19-04JUN14-2/4

•1 Sensor Reference
Voltage
Disconnect C10 accelerator and turn key switch to on, engine off. Check voltage
between pins A and C. Is 5VDC present?
YES: Go to next step.

NO: If over voltage, check

sensor wiring for shorts to
high.

CB12260,0000084 -19-04JUN14-3/4

•2 Sensor Test sensor. (See Accelerator Sensor Test, T4). Does sensor test ok? YES: Suspect faulty ECU.

NO: Replace sensor.

CB12260,0000084 -19-04JUN14-4/4

TM130419 (24FEB16) 235-50-1 030916

PN=917
 Diagnose—DTCs, ECU 000001—000199

ECU 000028.01 — Analog Throttle Signal

Preliminary Checks:
Extremely Low
Check for any other sensor low voltage DTCs.
Code Caused By:
Diagnosis:
Throttle signal voltage extremely low - most severe level.
• Recall, record (Snapshot test under Interactive Tests)
Alarm Level: and clear codes.
Service ADVISOR™ : This procedure can be performed
Red warning indicator by making a connection to the machine and using
Control Unit Response: the ”Diagnostics” tab to view and clear codes. Use
Snapshot Test under Interactive Test tab for specific
Engine stop controller to record fault.
Snapshot Recorded:
• Clear codes using Diagnostic tab
• Recall codes again and check for return of this code.
Yes • Recreate operating conditions that caused code.
• End of tests if code does not return.
Required Tools:
Multimeter
Service ADVISOR is a trademark of Deere & Company
CB12260,0000085 -19-04JUN14-1/4

Procedure
CB12260,0000085 -19-04JUN14-2/4

•1 Sensor Reference
Voltage
Disconnect C10 accelerator and turn key switch to on, engine off. Check voltage
between pins A and C. Is 5VDC present?
YES: Go to next step.

NO: If under voltage, check

sensor wiring for shorts to
low or ground.
CB12260,0000085 -19-04JUN14-3/4

•2 Sensor Test sensor. (See Accelerator Sensor Test, T4). Does sensor test ok? YES: Suspect faulty ECU.

NO: Replace sensor.

CB12260,0000085 -19-04JUN14-4/4

TM130419 (24FEB16) 235-50-2 030916

PN=918
 Diagnose—DTCs, ECU 000001—000199

ECU 000028.03 — Analog Throttle Signal Out

Preliminary Checks:
of Range High
Check for any other sensor high voltage DTCs.
Code Caused By:
Diagnosis:
Throttle signal voltage out of range high.
• Recall, record (Snapshot test under Interactive Tests)
Alarm Level: and clear codes.
Service ADVISOR™ : This procedure can be performed
Service alert by making a connection to the machine and using
Control Unit Response: the ”Diagnostics” tab to view and clear codes. Use
Snapshot Test under Interactive Test tab for specific
Notification controller to record fault.
Snapshot Recorded:
• Clear codes using Diagnostic tab
• Recall codes again and check for return of this code.
Yes • Recreate operating conditions that caused code.
• End of tests if code does not return.
Required Tools:
Multimeter
Service ADVISOR is a trademark of Deere & Company
CB12260,0000086 -19-04JUN14-1/4

Procedure
CB12260,0000086 -19-04JUN14-2/4

•1 Sensor Reference
Voltage
Disconnect C10 accelerator and turn key switch to on, engine off. Check voltage
between pins A and C. Is 5VDC present?
YES: Go to next step.

NO: If over voltage, check

sensor wiring for shorts to
high.
CB12260,0000086 -19-04JUN14-3/4

•2 Sensor Test sensor. (See Accelerator Sensor Test, T4). Does sensor test ok? YES: Suspect faulty ECU.

NO: Replace sensor.

CB12260,0000086 -19-04JUN14-4/4

TM130419 (24FEB16) 235-50-3 030916

PN=919
 Diagnose—DTCs, ECU 000001—000199

ECU 000028.04 — Analog Throttle Out of

Preliminary Checks:
Range Low
Check for any other sensor low voltage DTCs.
Code Caused By:
Diagnosis:
Throttle signal voltage low.
• Recall, record (Snapshot test under Interactive Tests)
Alarm Level: and clear codes.
Service ADVISOR™ : This procedure can be performed
Service alert by making a connection to the machine and using
Control Unit Response: the ”Diagnostics” tab to view and clear codes. Use
Snapshot Test under Interactive Test tab for specific
Notification controller to record fault.
Snapshot Recorded:
• Clear codes using Diagnostic tab
• Recall codes again and check for return of this code.
Yes • Recreate operating conditions that caused code.
• End of tests if code does not return.
Required Tools:
Multimeter
Service ADVISOR is a trademark of Deere & Company
CB12260,0000087 -19-04JUN14-1/4

Procedure
CB12260,0000087 -19-04JUN14-2/4

•1 Sensor Reference
Voltage
Disconnect C10 accelerator and turn key switch to on, engine off. Check voltage
between pins A and C. Is 5VDC present?
YES: Go to next step.

NO: If under voltage, check

sensor wiring for shorts to
low or ground.
CB12260,0000087 -19-04JUN14-3/4

•2 Sensor Test sensor. (See Accelerator Sensor Test, T4). Does sensor test ok? YES: Suspect faulty ECU.

NO: Replace sensor.

CB12260,0000087 -19-04JUN14-4/4

TM130419 (24FEB16) 235-50-4 030916

PN=920
 Diagnose—DTCs, ECU 000001—000199

ECU 000051.03 — Air Throttle Actuator

Warning
Position Signal Out of Range High
Control Unit Response:
The air throttle actuator position signal is higher than
The ECU derates the engine.
the sensor high voltage specification.
The ECU commands the Air Throttle Actuator fully open.
Troubleshooting Sequence:
The ECU commands the EGR Valve fully closed.
522591.12
The ECU will abort an active regeneration.
000051.03
Additional references:
When DTC is Displayed:
For sensor location, more air throttle actuator information,
When the ignition is on, engine is running, and the fault
and more information on how to use Diagnostic Test Box,
is active.
see engine CTM.
Related Information:
For complete wiring information:
The air throttle actuator position signal voltage to the ECU
- see Main Schematic, T4
corresponds to a position greater than what is physically
possible for the air throttle actuator position signal sensor. - see Engine Connector X5058 Schematic
Alarm Level: located in Section 230, Group 20.

A5502

28 50 72 94
27 49 71 93
26 48 70 92
25 47 69 91
24
23
46
45
68
67
90
89
X5058
22 44 66 88
21 43 65 87
20 42 64 86
19 41 63 85
18 40 62 84 23 Pnk 421 5
17 39 61 83 6 6 5 4 3 2 1
20 Grn 422
16 38 60 82 52 Brn 423 7
15 37 59 81 8
14 36 58 80
13 35 57 79 9 12 11 10 9 8 7
12 34 56 78
11 33 55 77
10 32 54 76
9 31 53 75
8 30 52 74
7 29 51 73 Y5401
9
2 4 6 12 11 10 9 8 7 8 A
7 B
6 5 4 3 2 1 A B C D E F
1 3 5 6 C
5 E
F
A5501

15 30 45 60
14 29 44 59
13 28 43 58
12 27 42 57
11 26 41 56
10 25 40 55
9 24 39 54 19 Org 424
8 23 38 53 20 Wht 425
7 22 37 52
TCT009802 —UN—13JAN14

6 21 36 51
5 20 35 50
4 19 34 49
3 18 33 48
2 17 32 47
1 16 31 46

Air Throttle Actuator Position Sensor Wiring Diagram

A5502—23—Supply A5502—52—Return A5501—20—Drive (-)
A5502—20—Signal A5501—19—Drive (+)
Continued on next page OUMX258,00001BE -19-16FEB16-1/6

TM130419 (24FEB16) 235-50-5 030916

PN=921
 Diagnose—DTCs, ECU 000001—000199

Diagnostic Procedure
OUMX258,00001BE -19-16FEB16-2/6

•1 Read DTCs and Store

Snapshot Information
1. Connect Service ADVISOR
NOTE: When DTCs are cleared, Snapshot information for ALL DTCs is cleared.

2. Ignition ON, Engine OFF.

3. Refresh codes. YES: See DTC 522591.12.
Is DTC 522591.12 active or stored? NO: Go to next step.
OUMX258,00001BE -19-16FEB16-3/6

•2 Code Check Is DTC 000051.03 active? YES: Go to next step.

NO: Go to “Circuit Check”.

OUMX258,00001BE -19-16FEB16-4/6

•3 Continuity Check 1. Measure resistance between A5502 connector female socket 20 and Y5401
connector female socket F.

2. Measure resistance between A5502 connector female socket 52 and Y5401 YES: See engine CTM.
connector female socket C.
Are both resistance measurements less than 5 ohms? NO: Repair open wire or
mispin in harness.

OUMX258,00001BE -19-16FEB16-5/6

•4 Circuit Check 1. Ignition ON, Engine OFF.

2. In Service ADVISOR, monitor Air Throttle Actuator Position Input Voltage.

Data Point Normal Range
Air Throttle Actuator Position Input Voltage 2.0—4.75 V

3. Perform Wiggle Test. YES: Repair harness

problem.
Does sensor input voltage ever read greater than 4.9 V? NO: See engine CTM.

OUMX258,00001BE -19-16FEB16-6/6

TM130419 (24FEB16) 235-50-6 030916

PN=922
 Diagnose—DTCs, ECU 000001—000199

ECU 000051.04 — Air Throttle Actuator

Alarm Level:
Position Signal Out of Range Low
Warning
The air throttle actuator position signal is lower than
Control Unit Response:
the sensor low voltage specification.
The ECU derates the engine.
Troubleshooting Sequence:
The ECU commands the Air Throttle Actuator fully closed.
522591.12
The ECU commands the EGR Valve fully closed.
000051.03
Additional references:
000051.04
For sensor location, more air throttle actuator information,
When DTC is Displayed:
and more information on how to use Diagnostic Test Box,
When the ignition is on, engine is running, and the fault see engine CTM.
is active.
For complete wiring information:
Related Information:
- see Main Schematic, T4
The air throttle actuator position sensor signal voltage to
- see Engine Connector X5058 Schematic
the ECU corresponds to a position lower than what is
physically possible for the air throttle actuator position located in Section 230, Group 20.
sensor.

A5502

28 50 72 94
27 49 71 93
26 48 70 92
25 47 69 91
24
23
46
45
68
67
90
89
X5058
22 44 66 88
21 43 65 87
20 42 64 86
19 41 63 85
18 40 62 84 23 Pnk 421 5
17 39 61 83 6 6 5 4 3 2 1
20 Grn 422
16 38 60 82 52 Brn 423 7
15 37 59 81 8
14 36 58 80
13 35 57 79 9 12 11 10 9 8 7
12 34 56 78
11 33 55 77
10 32 54 76
9 31 53 75
8 30 52 74
7 29 51 73 Y5401
9
2 4 6 12 11 10 9 8 7 8 A
7 B
6 5 4 3 2 1 A B C D E F
1 3 5 6 C
5 E
F
A5501

15 30 45 60
14 29 44 59
13 28 43 58
12 27 42 57
11 26 41 56
10 25 40 55
9 24 39 54 19 Org 424
8 23 38 53 20 Wht 425
7 22 37 52
TCT009802 —UN—13JAN14

6 21 36 51
5 20 35 50
4 19 34 49
3 18 33 48
2 17 32 47
1 16 31 46

Air Throttle Actuator Position Sensor Wiring Diagram

A5502—23—Supply A5502—52—Return A5501—20—Drive (-)
A5502—20—Signal A5501—19—Drive (+)
Continued on next page OUMX258,00001BF -19-16FEB16-1/9

TM130419 (24FEB16) 235-50-7 030916

PN=923
 Diagnose—DTCs, ECU 000001—000199

Diagnostic Procedure
IMPORTANT: Terminal damage occurs if anything other than the specified flex probes are used.
OUMX258,00001BF -19-16FEB16-2/9

•1 Read DTCs and Store

Snapshot Information
1. Connect Service ADVISOR.

NOTE: When DTCs are cleared, Snapshot Information for ALL DTCs is cleared.

2. Ignition ON, Engine OFF.

3. Refresh codes. YES: See DTC 522591.12.
Is DTC 522591.12 stored? NO: Go to next step.
OUMX258,00001BF -19-16FEB16-3/9

•2 Code Check Is DTC 000051.03 stored? YES: See DTC 000051.03.

NO: Go to next step.

OUMX258,00001BF -19-16FEB16-4/9

•3 Code Check Is DTC 000051.04 active? YES: Go to next step.

NO: Go to “Circuit Check”.

OUMX258,00001BF -19-16FEB16-5/9

•4 Terminal Check 1. Ignition OFF, Engine OFF.

2. Disconnect air throttle actuator connector Y5401.

3. Perform Terminal Test on air throttle actuator and Y5401 connector. YES: Repair problem.
Check codes.
Were any problems found? NO: Go to next step.

OUMX258,00001BF -19-16FEB16-6/9

•5 Terminal Check 1. Ignition OFF, Engine OFF.

2. Disconnect ECU connector A5502.

3. Perform Terminal Test on A5502 connector female sockets 20, 23, and 52. And YES: Repair problem.
corresponding ECU male pins. Check codes.
Were any problems found? NO: Go to next step.

OUMX258,00001BF -19-16FEB16-7/9

•6 Continuity Check 1. Disconnect connector Y5401.

2. Measure resistance between A5502 connector female socket 20 and Y5401 YES: Repair short to signal
connector female socket F. wire in harness.
Is resistance measurement less than 5 ohms? NO: Repair open wire or
mis-pin in harness. .

Continued on next page OUMX258,00001BF -19-16FEB16-8/9

TM130419 (24FEB16) 235-50-8 PN=924

030916
 Diagnose—DTCs, ECU 000001—000199

•7 Circuit Check 1. In Service ADVISOR, monitor Air Throttle Actuator Position Input Voltage.
Data Point Normal Range
Air Throttle Actuator Position Input Voltage 2.0—4.75 V

2. Perform Wiggle Test. YES: Repair harness

problem.
Does voltage ever go below 0.2 V? NO: See engine CTM.
OUMX258,00001BF -19-16FEB16-9/9

TM130419 (24FEB16) 235-50-9 030916

PN=925
 Diagnose—DTCs, ECU 000001—000199

ECU 000100.01 — Engine Oil Pressure Signal

Extremely Low The engine oil pressure signal is much lower
than expected.
OUMX258,00001C2 -19-16FEB16-1/6

Diagnostic Procedure
Troubleshooting Sequence:
000100.01
When DTC is Displayed:
When the engine is running and the error is active.
Related Information:
The engine oil pressure is lower than the oil pressure switch threshold.
Alarm Level:
Stop
Control Unit Response:
The ECU derates the engine.
Additional references:
For sensor location, and more information on how to use Diagnostic Test Box, see engine CTM.
For complete wiring information:
- see Main Schematic, T4
located in Section 230, Group 20.

A5502

28 50 72 94
27 49 71 93
26 48 70 92
25 47 69 91
24 46 68 90
23 45 67 89
22 44 66 88
21 43 65 87
20 42 64 86
19 41 63 85
18 40 62 84 MT-1
17 39 61 83
16 38 60 82 15 Tan 620
15 37 59 81
14 36 58 80
13 35 57 79
12 34 56 78
11 33 55 77

TCT009804 —UN—19MAR14
10 32 54 76
9 31 53 75
8 30 52 74
7 29 51 73
2 4 6

1 3 5

Engine Oil Pressure Switch Wiring Diagram

A5502—15—Signal
Continued on next page OUMX258,00001C2 -19-16FEB16-2/6

TM130419 (24FEB16) 235-50-10 030916

PN=926
 Diagnose—DTCs, ECU 000001—000199

•1 Check Engine Oil Is level between the “Add” and “Full” marks? YES: Go to next step.

NO: Check that oil is

correct type. Add oil to
correct level.
OUMX258,00001C2 -19-16FEB16-3/6

•2 Read DTCs and Store

Snapshot Information
1. Connect to Service ADVISOR.

NOTE: When DTCs are cleared Snapshot information for ALL DTCs is cleared.
YES: Stop engine. Go to
next step.

2. Run engine and check for error code. Does code appear? NO: End of checks.
OUMX258,00001C2 -19-16FEB16-4/6

•3 Verify Engine Has

Oil Pressure
1. Remove oil pressure switch from the engine and install a pressure gauge in engine
block. See Test Oil Pressure—3TNV82A, 3TNV88.

2. Run engine at rated engine speed and slow idle engine speed. YES: Reinstall oil pressure
switch. Go to next step.
Was the gauge readings within specification? NO: Investigate other
potential mechanical
problems:
• Incorrect Oil
• Plugged Oil Filter
• Excessive Oil Temperature
• Sticky Oil Pressure
Regulating Valve
• Plugged Oil Pump Screen
• Cracked Pick-up Tube
• Worn or Dirty Oil Pump
• Faulty or Missing Piston
Cooling Orifice
• Excessive Main Bearing
Clearance
• Excessive Rod Bearing
Clearance
OUMX258,00001C2 -19-16FEB16-5/6

•4 Terminal Check 1. Ignition OFF, Engine OFF.

2. Disconnect engine oil pressure switch connector T-19.

3. Measure the resistance between A5502 connector female socket 15 and T-19
connector.
4. Perform Terminal Test on switch and B19 connector. YES: Repair problem.
Perform Verification
Procedure.
Were any problems found? NO: See engine CTM.

OUMX258,00001C2 -19-16FEB16-6/6

TM130419 (24FEB16) 235-50-11 PN=927

030916
 Diagnose—DTCs, ECU 000001—000199

ECU 000100.04 — Engine Oil Pressure Signal

Out of Range Low The engine oil pressure signal is lower than expected.
OUMX258,00001C3 -19-16FEB16-1/5

Diagnostic Procedure
Troubleshooting Sequence:
000100.01
000100.04
When DTC is Displayed:
When the ignition is ON, the engine is OFF, and the fault is active.
Related Information:
This fault detects an open circuit in the oil pressure switch circuit approximately 1 second after the ignition is switched
from OFF to ON and the starter is not immediately engaged.
Alarm Level:
Stop
Control Unit Response:
The ECU derates the engine.
Additional references:
For sensor location, and more information on how to use Diagnostic Test Box, see engine CTM.
For complete wiring information:
- see Main Schematic, T4
located in Section 230, Group 20.

A5502

28 50 72 94
27 49 71 93
26 48 70 92
25 47 69 91
24 46 68 90
23 45 67 89
22 44 66 88
21 43 65 87
20 42 64 86
19 41 63 85
18 40 62 84 MT-1
17 39 61 83
16 38 60 82 15 Tan 620
15 37 59 81
14 36 58 80
13 35 57 79
12 34 56 78
11 33 55 77 TCT009804 —UN—19MAR14
10 32 54 76
9 31 53 75
8 30 52 74
7 29 51 73
2 4 6

1 3 5

Engine Oil Pressure Switch Wiring Diagram

A5502—15—Signal
Continued on next page OUMX258,00001C3 -19-16FEB16-2/5

TM130419 (24FEB16) 235-50-12 030916

PN=928
 Diagnose—DTCs, ECU 000001—000199

•1 Read DTCs and Store

Snapshot Information
1. Connect Service ADVISOR.
NOTE: When DTCs are cleared, Snapshot Information for ALL DTCs is cleared.

2. Ignition ON, Engine OFF.

3. Refresh codes. YES: Go to next step.
Is DTC 000100.04 active? NO: See DTC 000100.01.
OUMX258,00001C3 -19-16FEB16-3/5

•2 Terminal Check 1. Ignition OFF, Engine OFF.

2. Disconnect engine oil pressure switch connector T-19.

3. Perform Terminal Test on sensor and B19 connector. YES: Repair problem.
Perform Verification
Procedure.
Were any problems found? NO: Go to next step.
OUMX258,00001C3 -19-16FEB16-4/5

•3 Switch Check 1. Disconnect connector T-19.

NOTE: Ignore any oil pressure codes that set once the connector has been removed.

2. Ignition ON, engine running.

3. Measure the resistance between switch male pin and single point ground YES: See engine CTM.
Is resistance greater than 100K Ohms? NO: Replace engine oil
pressure switch. Perform
Verification Procedure.
OUMX258,00001C3 -19-16FEB16-5/5

TM130419 (24FEB16) 235-50-13 030916

PN=929
 Diagnose—DTCs, ECU 000001—000199

ECU 000102.03 — Manifold Air Pressure

Signal Out of Range High The manifold air pressure signal exceeds the sensor
high voltage specification.
Continued on next page OUMX258,00001DC -19-16FEB16-1/7

TM130419 (24FEB16) 235-50-14 030916

PN=930
 Diagnose—DTCs, ECU 000001—000199

Diagnostic Procedure
Troubleshooting Sequence:
522591.12
000102.03
When DTC is Displayed:
When the ignition is on, engine is running, and the fault is active.
Related Information:
The manifold air pressure signal voltage to the ECU corresponds to a pressure higher than what is physically possible
for the manifold air pressure sensor.
Alarm Level:
Stop
Control Unit Response:
The ECU derates the engine.
The ECU commands the EGR Valve fully closed.
The ECU will command an engine stop after 15 minutes of continuous operation with the fault active.
Additional references:
For sensor location, more pressure sensor information, and information on how to use Diagnostic Test Box, see
engine CTM.
For complete wiring information:
- see Main Schematic, T4
- see Engine Connector X5057 Schematic
located in Section 230, Group 20.

A5502

28 50 72 94
27 49 71 93
26 48 70 92
25 47 69 91
24 46 68 90 X5057
23 45 67 89
22 44 66 88
21 43 65 87
20 42 64 86
19 41 63 85
18 40 62 84 74 Brn 404 4 4 3 2 1
17 39 61 83
16 38 60 82 39 Wht 403 3
15 37 59 81 85 Pur 402 2 B5114
14 36 58 80 45 Pnk 401 1 8 7 6 5
13 35 57 79
12 34 56 78
11 33 55 77
10 32 54 76
TCT009799 —UN—09JAN14

9 31 53 75 2
8 30 52 74 3
7 29 51 73 4 4
8 7 6 5 3 5 6 5 4 3 2 1
2 4 6
4 3 2 1 2
1
1 3 5

Manifold Air and Exhaust Pressure Sensor Wiring Diagram

A5502—45—Supply A5502—39—Manifold Air A5502—85—Exhaust Pressure
A5502—74—Return Pressure Signal Signal
Continued on next page OUMX258,00001DC -19-16FEB16-2/7

TM130419 (24FEB16) 235-50-15 030916

PN=931
 Diagnose—DTCs, ECU 000001—000199

•1 Read DTCs and Store

Snapshot Information
1. Connect Service ADVISOR.
NOTE: When DTCs are cleared, Snapshot information for ALL DTCs is cleared.

2. Ignition ON, Engine OFF.

3. Refresh codes. YES: See DTC 522591.12
Is DTC 522591.12 active or stored? NO: Go to next step.
OUMX258,00001DC -19-16FEB16-3/7

•2 Code Check Is DTC 000102.03 active? YES: Go to next step.

NO: See engine CTM.

OUMX258,00001DC -19-16FEB16-4/7

•3 Circuit Check 1. Ignition ON, Engine OFF.

2. In Service ADVISOR, monitor Manifold Air Pressure Input Voltage.

Data Point Normal Range
Manifold Air Pressure Input Voltage 2.0—3.2 V

3. Perform Wiggle Test. YES: Repair harness

problem. Perform
Verification Procedure.
Does sensor input voltage ever read greater than 4.9 V? NO: Go to next step.
OUMX258,00001DC -19-16FEB16-5/7

•4 Terminal Check 1. Ignition OFF, Engine OFF.

2. Disconnect Manifold Air and Exhaust Pressure sensor connector B5114.

3. Perform Terminal Test on sensor and B5114 connector. YES: Repair problem.
Perform Verification
Procedure.
Were any problems found? NO: Go to next step.

OUMX258,00001DC -19-16FEB16-6/7

•5 Continuity Check 1. Measure the resistance between A5502 connector female socket 74 and B5114
connector female socket 2.

2. Measure the resistance between A5502 connector female socket 39 and B5114 YES: See engine CTM.
connector female socket 5.
Are both resistance measurements less than 5 ohms? NO: Repair mis-pin.
Perform Verification
Procedure.

OUMX258,00001DC -19-16FEB16-7/7

TM130419 (24FEB16) 235-50-16 030916

PN=932
 Diagnose—DTCs, ECU 000001—000199

ECU 000102.04 — Manifold Air Pressure

Signal Out of Range Low The manifold air pressure signal is lower than the
sensor low voltage specification.
Continued on next page OUMX258,00001DD -19-16FEB16-1/8

TM130419 (24FEB16) 235-50-17 030916

PN=933
 Diagnose—DTCs, ECU 000001—000199

Diagnostic Procedure
Troubleshooting Sequence:
522591.12
000102.03
000102.04
When DTC is Displayed:
When the ignition is on, engine is running, and the fault is active.
Related Information:
The manifold air pressure signal voltage to the ECU corresponds to a pressure lower than what is physically possible
for the manifold air pressure sensor.
Alarm Level:
Stop
Control Unit Response:
The ECU derates the engine.
The ECU commands the EGR Valve fully closed.
The ECU will command an engine stop after 15 minutes of continuous operation with the fault active.
Additional references:
For sensor location, more pressure sensor information, and information on how to use Diagnostic Test Box, see
engine CTM.
For complete wiring information:
- see Main Schematic, T4
- see Engine Connector X5057 Schematic
located in Section 230, Group 20.

A5502

28 50 72 94
27 49 71 93
26 48 70 92
25 47 69 91
24 46 68 90 X5057
23 45 67 89
22 44 66 88
21 43 65 87
20 42 64 86
19 41 63 85
18 40 62 84 74 Brn 404 4 4 3 2 1
17 39 61 83
16 38 60 82 39 Wht 403 3
15 37 59 81 85 Pur 402 2 B5114
14 36 58 80 45 Pnk 401 1 8 7 6 5
13 35 57 79
12 34 56 78
11 33 55 77
10 32 54 76
TCT009799 —UN—09JAN14

9 31 53 75 2
8 30 52 74 3
7 29 51 73 4 4
8 7 6 5 3 5 6 5 4 3 2 1
2 4 6
4 3 2 1 2
1
1 3 5

Manifold Air and Exhaust Pressure Sensor Wiring Diagram

A5502—45—Supply A5502—39—Manifold Air A5502—85—Exhaust Pressure
A5502—74—Return Pressure Signal Signal
Continued on next page OUMX258,00001DD -19-16FEB16-2/8

TM130419 (24FEB16) 235-50-18 030916

PN=934
 Diagnose—DTCs, ECU 000001—000199

•1 Read DTCs and Store

Snapshot Information
1. Connect Service ADVISOR.
NOTE: When DTCs are cleared, Snapshot Information for ALL DTCs is cleared.

2. Ignition ON, Engine OFF.

3. Refresh codes. YES: See DTC 522591.12
Is DTC 522591.12 stored? NO: Go to next step.
OUMX258,00001DD -19-16FEB16-3/8

•2 Code Check Is DTC 000102.03 stored? YES: See DTC 000102.03.

NO: Go to next step.

OUMX258,00001DD -19-16FEB16-4/8

•3 Code Check 1. Ignition ON, engine running.

2. Refresh codes. YES: Go to next step.

Is DTC 000102.04 active? NO: See engine CTM.
OUMX258,00001DD -19-16FEB16-5/8

•4 Circuit Check 1. In Service ADVISOR, monitor Manifold Air Pressure Input Voltage.
Data Point Normal Range
Manifold Air Pressure Input Voltage 2.0—3.2 V

2. Perform Wiggle Test. YES: Repair harness

problem. Perform
Verification Procedure.
Does voltage ever go below 0.2 V? NO: Go to next step.

OUMX258,00001DD -19-16FEB16-6/8

•5 Terminal Check 1. Ignition OFF, Engine OFF.

2. Disconnect Manifold Air and Exhaust Pressure sensor connector B5114.

3. Perform Terminal Test on sensor and B5114 connector. YES: Repair problem.
Perform Verification
Procedure.
Were any problems found? NO: Go to next step.

OUMX258,00001DD -19-16FEB16-7/8

•6 Continuity Check Measure resistance between A5502 connector female socket 39 and B5114 connector
female socket 5.
YES: Repair short to signal
wire in harness. Perform
Verification Procedure. See
engine CTM.
Is resistance less than 5 ohms? NO: Repair open or
mis-pin in harness. Perform
Verification Procedure. See
engine CTM.

OUMX258,00001DD -19-16FEB16-8/8

TM130419 (24FEB16) 235-50-19 030916

PN=935
 Diagnose—DTCs, ECU 000001—000199

ECU 000102.13 — Manifold Air Pressure

Signal Calibration Fault The manifold air pressure signal is lower than the
sensor low voltage specification.
Continued on next page OUMX258,00001DE -19-16FEB16-1/9

TM130419 (24FEB16) 235-50-20 030916

PN=936
 Diagnose—DTCs, ECU 000001—000199

Diagnostic Procedure
Troubleshooting Sequence:522591.12
000102.03
000102.04
000102.07
When DTC is Displayed:When the ignition is on, and the fault is active.
Related Information:
At ignition on, engine off, the ECU performs a comparison of multiple pressure sensors on the engine.
The manifold air pressure sensor signal voltage to the ECU is higher or lower than the other sensors being compared
at ignition on, engine off.
Alarm Level:Stop
Control Unit Response:
The ECU derates the engine.
The ECU will command an engine stop after 15 minutes of continuous operation with the fault active.
Additional references:
For sensor location, more pressure sensor information, and information on how to use Diagnostic Test Box, see
engine CTM.
For complete wiring information:
- see Main Schematic, T4
- see Engine Connector X5057 Schematic
located in Section 230, Group 20.

A5502

28 50 72 94
27 49 71 93
26 48 70 92
25 47 69 91
24 46 68 90 X5057
23 45 67 89
22 44 66 88
21 43 65 87
20 42 64 86
19 41 63 85
18 40 62 84 74 Brn 404 4 4 3 2 1
17 39 61 83
16 38 60 82 39 Wht 403 3
15 37 59 81 85 Pur 402 2 B5114
14 36 58 80 45 Pnk 401 1 8 7 6 5
13 35 57 79
12 34 56 78
11 33 55 77
10 32 54 76

TCT009799 —UN—09JAN14
9 31 53 75 2
8 30 52 74 3
7 29 51 73 4 4
8 7 6 5 3 5 6 5 4 3 2 1
2 4 6
4 3 2 1 2
1
1 3 5

Manifold Air and Exhaust Pressure Sensor Wiring Diagram

A5502—45—Supply A5502—39—Manifold Air A5502—85—Exhaust Pressure
A5502—74—Return Pressure Signal Signal
Continued on next page OUMX258,00001DE -19-16FEB16-2/9

TM130419 (24FEB16) 235-50-21 030916

PN=937
 Diagnose—DTCs, ECU 000001—000199

•1 Read DTCs and Store

Snapshot Information
1. Connect Service ADVISOR.
NOTE: When DTCs are cleared, Snapshot Information for ALL DTCs is cleared.

2. Ignition ON, Engine OFF.

3. Refresh codes. YES: See DTC 522591.12.
Is DTC 522591.12 stored? NO: Go to next step.
OUMX258,00001DE -19-16FEB16-3/9

•2 Code Check Is DTC 000102.03 stored? YES: See DTC000102.03

procedure.

NO: Go to next step.

OUMX258,00001DE -19-16FEB16-4/9

•3 Code Check Is DTC 000102.04 stored? YES: See DTC 000102.04.

NO: Go to next step.

OUMX258,00001DE -19-16FEB16-5/9

•4 Code Check Is DTC 000102.07 active? YES: Go to next step.

NO: See engine CTM.

OUMX258,00001DE -19-16FEB16-6/9

•5 Terminal Check 1. Ignition OFF, Engine OFF.

2. Disconnect Manifold Air and Exhaust Pressure sensor connector B5114.

3. Perform Terminal Test on sensor and B5114 connector. YES: Repair problem.
Perform Verification
Procedure.
Were any problems found? NO: Go to next step.

OUMX258,00001DE -19-16FEB16-7/9

•6 Terminal Check 1. Ignition OFF, Engine OFF.

2. Disconnect ECU connector A5502.

3. Perform Terminal Test on A5502 connector female sockets 39, 45, 74, and 85. And YES: Repair problem.
corresponding ECU male pins. Perform Verification
Procedure.
Were any problems found? NO: Go to next step.

OUMX258,00001DE -19-16FEB16-8/9

•7 Continuity Check Measure the resistance between A5502 connector female socket 39 and B5114
connector female socket 5.
YES: Repair short
in harness. Perform
Verification Procedure.
Is resistance measurement less than 5 ohms? NO: Repair open, high
resistance, or mis-pin
in harness. Perform
Verification Procedure.

OUMX258,00001DE -19-16FEB16-9/9

TM130419 (24FEB16) 235-50-22 030916

PN=938
 Diagnose—DTCs, ECU 000001—000199

ECU 000105.03 — Manifold Air Temperature Control Unit Response:

Signal Out of Range High
The ECU derates the engine.The ECU commands the Air
The manifold air temperature signal exceeds the Throttle Actuator fully open.
sensor high voltage specification. The ECU commands the EGR Valve fully closed.
Troubleshooting Sequence: The ECU will command an engine stop after 15 minutes
000105.03 of continuous operation with the fault active.

When DTC is Displayed: Additional references:

When the ignition is on, and the fault is active. For sensor location, more temperature sensor information,
and information on how to use Diagnostic Test Box, see
Related Information: engine CTM.
The manifold air temperature sensor signal voltage to the For complete wiring information:
ECU corresponds to a temperature higher than what is - see Main Schematic, T4
physically possible for the manifold air temperature sensor.
- see Engine Connector X5058 Schematic
Alarm Level:
located in Section 230, Group 20.
Stop

A5502

28 50 72 94
27 49 71 93
26 48 70 92
25 47 69 91
24 46 68 90 X5058
23 45 67 89
22 44 66 88
21 43 65 87
20 42 64 86
19 41 63 85
18 40 62 84
17 39 61 83 6 5 4 3 2 1
16 38 60 82 52 Brn 423 7
15 37 59 81 10
14 36 58 80
13 35 57 79 12 11 10 9 8 7
12
11
34
33
56
55
78
77
B5206
10 32 54 76
9 31 53 75
8 30 52 74
7 29 51 73
2 4 6 12 11 10 9 8 7
7 A
10 B B A
1 3 5 6 5 4 3 2 1

A5501

15 30 45 60
14 29 44 59
13 28 43 58
12 27 42 57
11 26 41 56
10 25 40 55
9 24 39 54
59 Pur 426
8 23 38 53
7 22 37 52
TCT009800 —UN—09JAN14

6 21 36 51
5 20 35 50
4 19 34 49
3 18 33 48
2 17 32 47
1 16 31 46

Manifold Air Temperature Sensor Wiring Diagram

A5501—59—Signal A5502—52—Return
Continued on next page OUMX258,00001C4 -19-16FEB16-1/6

TM130419 (24FEB16) 235-50-23 030916

PN=939
 Diagnose—DTCs, ECU 000001—000199

Diagnostic Procedure
OUMX258,00001C4 -19-16FEB16-2/6

•1 Read DTCs and Store

Snapshot Information
1. Connect Service ADVISOR.
NOTE: When DTCs are cleared, Snapshot information for ALL DTCs is cleared.

2. Ignition ON, Engine OFF.

3. Refresh codes. YES: Go to next step.
Is DTC 000105.03 active? NO: Skip next step, go to
following step.
OUMX258,00001C4 -19-16FEB16-3/6

•2 Terminal Check 1. Ignition OFF, Engine OFF.

2. Disconnect manifold air temperature sensor connector B5206.

3. Perform Terminal Test on sensor and B5206 connector. YES: Repair problem.
Perform Verification
Procedure.
Were any problems found? NO: Go to next step.
OUMX258,00001C4 -19-16FEB16-4/6

•3 Sensor Check In Service ADVISOR, monitor Manifold Air Temperature Input Voltage.

Data Point Normal Range YES: Replace sensor.

Perform Verification
Manifold Air Temperature Input Voltage 2.4—2.8 V
Procedure.
Is voltage between 2.4 and 2.8 V? NO: Go to next step.

OUMX258,00001C4 -19-16FEB16-5/6

•4 Circuit Check Perform Wiggle Test while monitoring manifold sensor input voltage. YES: Repair harness
problem. Perform
Verification Procedure.
Does sensor input voltage ever read greater than 4.9 V? NO: See CTM124019.

OUMX258,00001C4 -19-16FEB16-6/6

TM130419 (24FEB16) 235-50-24 030916

PN=940
 Diagnose—DTCs, ECU 000001—000199

ECU 000105.04 — Manifold Air Temperature Control Unit Response:

Signal Out of Range Low
The ECU derates the engine.
The manifold air temperature signal is lower than The ECU commands the Air Throttle Actuator fully open.
the sensor low voltage specification.
The ECU commands the EGR Valve fully closed.
Troubleshooting Sequence:
The ECU commands an engine stop after 15 minutes of
000105.03 continuous operation with the fault active.
000105.04 Additional references:
When DTC is Displayed: For sensor location, more temperature sensor information,
When the ignition is on, and the fault is active. and information on how to use Diagnostic Test Box, see
engine CTM.
Related Information:
For complete wiring information:
The manifold air temperature sensor signal voltage to the
ECU corresponds to a temperature lower than what is - see Main Schematic, T4
physically possible for the manifold air temperature sensor. - see Engine Connector X5058 Schematic
Alarm Level: located in Section 230, Group 20.
Stop

A5502

28 50 72 94
27 49 71 93
26 48 70 92
25 47 69 91
24 46 68 90 X5058
23 45 67 89
22 44 66 88
21 43 65 87
20 42 64 86
19 41 63 85
18 40 62 84
17 39 61 83 6 5 4 3 2 1
16 38 60 82 52 Brn 423 7
15 37 59 81 10
14 36 58 80
13 35 57 79 12 11 10 9 8 7
12
11
34
33
56
55
78
77
B5206
10 32 54 76
9 31 53 75
8 30 52 74
7 29 51 73
2 4 6 12 11 10 9 8 7
7 A
10 B B A
1 3 5 6 5 4 3 2 1

A5501

15 30 45 60
14 29 44 59
13 28 43 58
12 27 42 57
11 26 41 56
10 25 40 55
9 24 39 54
59 Pur 426
8 23 38 53
7 22 37 52
TCT009800 —UN—09JAN14

6 21 36 51
5 20 35 50
4 19 34 49
3 18 33 48
2 17 32 47
1 16 31 46

Manifold Air Temperature Sensor Wiring Diagram

A5501—59—Signal A5502—52—Return
Continued on next page OUMX258,00001C5 -19-16FEB16-1/6

TM130419 (24FEB16) 235-50-25 030916

PN=941
 Diagnose—DTCs, ECU 000001—000199

Diagnostic Procedure
OUMX258,00001C5 -19-16FEB16-2/6

•1 Read DTCs and Store

Snapshot Information
1. Connect Service ADVISOR.
NOTE: When DTCs are cleared, Snapshot Information for ALL DTCs is cleared.

2. Ignition ON, Engine OFF.

3. If any DTCs have snapshot capture or snapshot recording information, save the
information.
4. Refresh codes. YES: See DTC 000105.03
procedure.
Is DTC 000105.03 a stored code? NO: Go to next step.
OUMX258,00001C5 -19-16FEB16-3/6

•2 Code Check Is DTC 000105.04 active? YES: Go to next step.

NO: Go to “Circuit Check”

step.
OUMX258,00001C5 -19-16FEB16-4/6

•3 Terminal Check 1. Ignition OFF, Engine OFF.

2. Disconnect manifold air temperature sensor connector B5206.

3. Perform Terminal Test on sensor and B5206 connector. YES: Repair problem.
Perform Verification
Procedure.
Were any problems found? NO: Go to next step.

OUMX258,00001C5 -19-16FEB16-5/6

•4 Circuit Check 1. Ignition ON, Engine OFF.

2. In Service ADVISOR, monitor Manifold Air Temperature Input Voltage.

Data Point Normal Range
Manifold Air Temperature Input Voltage 2.4—2.8 V

3. Perform Wiggle Test. YES: Replace sensor.

Perform Verification
Procedure.
Is voltage between 2.4 and 2.8 V? NO: See engine CTM.

OUMX258,00001C5 -19-16FEB16-6/6

TM130419 (24FEB16) 235-50-26 030916

PN=942
 Diagnose—DTCs, ECU 000001—000199

ECU 000108.03 — Barometric Pressure

Signal Out of Range High The barometric pressure sensor signal exceeds the
sensor high voltage specification.
OUMX258,00001C6 -19-16FEB16-1/5

Diagnostic Procedure
Troubleshooting Sequence:
000108.03
When DTC is Displayed:
When the ignition is on, and the fault is active.
Related Information:
The barometric pressure sensor signal voltage to the ECU corresponds to a pressure higher than what is physically
possible for the barometric pressure sensor. The barometric air pressure sensor is an internal ECU sensor and
cannot be repaired.
Alarm Level:
Warning
Control Unit Response:
The ECU derates the engine.
The ECU commands the EGR Valve fully closed.
Additional References:
For more information see engine CTM.
OUMX258,00001C6 -19-16FEB16-2/5

•1 Read DTCs and Store

Snapshot Information
1. Connect Service ADVISOR.

NOTE: When DTCs are cleared, Snapshot information for ALL DTCs is cleared.

2. Ignition ON, Engine OFF.

3. Refresh DTCs. YES: Go to next step.
Is DTC 000108.03 active? NO: Perform Verification
Procedure..
OUMX258,00001C6 -19-16FEB16-3/5

•2 Air Vent Check 1. Ignition OFF, Engine OFF.

2. Inspect the air vent located on the side of the ECU. YES: See engine CTM.
Is vent free from debris? NO: Clear debris from air
vent. Go to next step.

OUMX258,00001C6 -19-16FEB16-4/5

•3 Check Codes Ignition ON, Engine OFF. YES: See engine CTM.

Is DTC 000108.03 active? NO: Perform Verification

Procedure.

OUMX258,00001C6 -19-16FEB16-5/5

TM130419 (24FEB16) 235-50-27 030916

PN=943
 Diagnose—DTCs, ECU 000001—000199

ECU 000108.04 — Barometric Pressure

Signal Out of Range Low The barometric pressure sensor signal exceeds the
sensor low voltage specification.
OUMX258,00001C7 -19-16FEB16-1/5

Diagnostic Procedure
Troubleshooting Sequence:
000108.04
When DTC is Displayed:
When the ignition is on, and the fault is active.
Related Information:
The barometric pressure sensor signal voltage to the ECU corresponds to a pressure lower than what is physically
possible for the barometric pressure sensor. The barometric air pressure sensor is an internal ECU sensor and
cannot be repaired.
Alarm Level:
Warning
Control Unit Response:
The ECU derates the engine.
The ECU commands the EGR Valve fully closed.
Additional References:
For more information see engine CTM.
OUMX258,00001C7 -19-16FEB16-2/5

•1 Read DTCs and Store

Snapshot Information
1. Connect Service ADVISOR.

NOTE: When DTCs are cleared, Snapshot information for ALL DTCs is cleared.

2. Ignition ON, Engine OFF.

3. Refresh DTCs. YES: Go to next step.
Is DTC 000108.04 active? NO: Perform Verification
Procedure.
OUMX258,00001C7 -19-16FEB16-3/5

•2 Air Vent Check 1. Ignition OFF, Engine OFF.

2. Inspect the air vent located on the side of the ECU. YES: See engine CTM.
Is vent free from debris? NO: Clear debris from air
vent. Go to next step.

OUMX258,00001C7 -19-16FEB16-4/5

•3 Check Codes Ignition ON, Engine OFF. YES: See engine CTM.

Is DTC 000108.04 active? NO: Perform Verification

Procedure.

OUMX258,00001C7 -19-16FEB16-5/5

TM130419 (24FEB16) 235-50-28 030916

PN=944
 Diagnose—DTCs, ECU 000001—000199

ECU 000108.10 — Barometric Pressure

Signal Abnormal The barometric pressure sensor signal is abnormal.
OUMX258,00001C8 -19-16FEB16-1/5

Diagnostic Procedure
Troubleshooting Sequence:
000108.04
When DTC is Displayed:
When the ignition is on and the fault is active.
Related Information:
The barometric pressure sensor signal voltage to the ECU corresponds to a pressure that is significantly different than
the exhaust manifold pressure and manifold air pressure. The barometric air pressure sensor is an internal ECU sensor
and cannot be repaired. The ECU performs a cross check of the three pressure sensors at Ignition ON, Engine OFF.
Alarm Level:
Warning
Control Unit Response:
The ECU derates the engine.
The ECU commands the EGR Valve fully closed.
Additional References:
For more information on the Control Unit Information and Overview Test, see engine CTM.
OUMX258,00001C8 -19-16FEB16-2/5

•1 Read DTCs and Store

Snapshot Information
1. Connect Service ADVISOR.

2. Ignition ON, Engine OFF.

3. Refresh DTCs. YES: Go to next step.
Is DTC 000108.10 active? NO: Perform Verification
Procedure.
OUMX258,00001C8 -19-16FEB16-3/5

•2 Air Vent Check 1. Ignition OFF, Engine OFF.

2. Inspect the air vent located on the rear of the ECU. YES: See engine CTM.
Is vent free from debris? NO: Clear debris from air
vent. Go to next step.

OUMX258,00001C8 -19-16FEB16-4/5

•3 Check Codes 1. Ignition ON, Engine OFF.

2. Clear DTCs
3. Refresh codes. YES: See engine CTM.
Is DTC 000108.10 active? NO: Perform Verification
Procedure.

OUMX258,00001C8 -19-16FEB16-5/5

TM130419 (24FEB16) 235-50-29 030916

PN=945
 Diagnose—DTCs, ECU 000001—000199

ECU 000110.00 — Engine Coolant

The engine coolant temperature sensor signal is much
Temperature Signal Extremely High higher than expected at the operating conditions that set
the DTC.
The engine coolant temperature signal is much
higher than expected Alarm Level:
Preliminary Checks: Stop

• Leaks around hoses and clamps Control Unit Response:

• Indication of spraying coolant The ECU derates the engine.
• Leaks around water pump housing
• Blockage of air flow through radiator The ECU commands the EGR Valve fully closed.
• Overall cooling fan operation
• Fan damage Additional references:
• Damaged shrouds and shutters For sensor location, more temperature sensor information,
• Low coolant level and information on how to use Diagnostic Test Box, see
Troubleshooting Sequence: engine CTM.

000110.03 For complete wiring information:

000110.00 - see Main Schematic, T4

When DTC is Displayed: - see Engine Connector X5057 Schematic

When the engine is running and the fault is active. located in Section 230, Group 20.

Related Information:

A5501
X5057
15 30 45 60
14 29 44 59
13 28 43 58
12 27 42 57
11 26 41 56
10 25 40 55 4 3 2 1
9 24 39 54 28 Grn 407 7
8 23 38 53 29 Blu 408 8
7 22 37 52 8 7 6 5
6 21 36 51 B5208
5 20 35 50

TCT009797 —UN—08JAN14
4 19 34 49
3 18 33 48
2 17 32 47
1 16 31 46
8 7 6 5 7 1 1 2
4 3 2 1 8 2

Engine Coolant Temperature Sensor Wiring Diagram

A5501—28—Signal A5501—29—Return
OUMX258,00001C9 -19-16FEB16-1/6

Diagnostic Procedure
Continued on next page OUMX258,00001C9 -19-16FEB16-2/6

TM130419 (24FEB16) 235-50-30 030916

PN=946
 Diagnose—DTCs, ECU 000001—000199

•1 Read DTCs and Store

Snapshot Information
1. Connect Service ADVISOR.
NOTE: When DTCs are cleared Snapshot information for ALL DTCs is cleared.

2. Ignition ON, Engine OFF.

3. Ignition OFF, Engine OFF. YES: Repair problem.
Perform Verification
Procedure.
Are any problems found? NO: Go to next step.
OUMX258,00001C9 -19-16FEB16-3/6

•2 Verify Sensor
Operation
1. Ignition ON, engine running.

2. Operate engine at fast idle for 15 minutes.

3. Ignition OFF, Engine OFF.
4. Let engine cool for 10 minutes.
5. Ignition ON, Engine OFF.
6. Monitor Engine Coolant Temperature in Service ADVISOR.
7. Measure temperature of thermostat housing with JT07253 infrared temperature gun.
8. Compare the readings. YES: Perform Verification
Procedure.
Data Point Live Reading Normal Range
Engine Coolant 71—88 °C
Temperature 160—190 °F

Were the readings within 5 °C (9 °F) of each other? NO: Go to next step.
OUMX258,00001C9 -19-16FEB16-4/6

•3 Terminal Check 1. Ignition OFF, Engine OFF.

2. Disconnect engine coolant temperature sensor connector B5208.

3. Perform Terminal Test on sensor and B5208 connector. YES: Repair problem.
Perform Verification
Procedure.
Were any problems found? NO: Go to next step.
OUMX258,00001C9 -19-16FEB16-5/6

•4 Sensor Check In Service ADVISOR, monitor Engine Coolant Temperature Input Voltage.

Data Point Normal Range YES: Replace thermostat.

Engine Coolant Temperature Input Voltage 3.0—3.4 V

Is voltage between 3.0 and 3.4 V? NO: See engine CTM.

OUMX258,00001C9 -19-16FEB16-6/6

TM130419 (24FEB16) 235-50-31 030916

PN=947
 Diagnose—DTCs, ECU 000001—000199

ECU 000110.03 — Engine Coolant

Warning
Temperature Signal Out of Range High
Control Unit Response:
The engine coolant temperature signal exceeds the
The ECU derates the engine.
sensor high voltage specification.
The ECU commands the EGR Valve fully closed.
Troubleshooting Sequence:
Additional references:
000110.03
For sensor location, more temperature sensor information,
When DTC is Displayed:
and information on how to use Diagnostic Test Box, see
When the ignition is on, and the fault is active. engine CTM.
Related Information: For complete wiring information:
- see Main Schematic, T4
The engine coolant temperature sensor signal voltage to
the ECU corresponds to a temperature higher than what - see Engine Connector X5057 Schematic
is physically possible for the engine coolant temperature
located in Section 230, Group 20.
sensor.
Alarm Level:

A5501
X5057
15 30 45 60
14 29 44 59
13 28 43 58
12 27 42 57
11 26 41 56
10 25 40 55 4 3 2 1
9 24 39 54 28 Grn 407 7
8 23 38 53 29 Blu 408 8
7 22 37 52 8 7 6 5
6 21 36 51 B5208
5 20 35 50

TCT009797 —UN—08JAN14
4 19 34 49
3 18 33 48
2 17 32 47
1 16 31 46
8 7 6 5 7 1 1 2
4 3 2 1 8 2

Engine Coolant Temperature Sensor Wiring Diagram

A5501—28—Signal A5501—29—Return
OUMX258,00001CA -19-16FEB16-1/5

Diagnostic Procedure
OUMX258,00001CA -19-16FEB16-2/5

•1 Read DTCs and Store

Snapshot Information
1. Connect Service ADVISOR.

NOTE: When DTCs are cleared Snapshot information for ALL DTCs is cleared.

2. Ignition ON, Engine OFF.

3. Refresh Codes. YES: Go to next step.
Is DTC 000110.03 active? NO: Go to “Circuit Check”
step.
Continued on next page OUMX258,00001CA -19-16FEB16-3/5

TM130419 (24FEB16) 235-50-32 030916

PN=948
 Diagnose—DTCs, ECU 000001—000199

•2 Sensor Check In Service ADVISOR, monitor Engine Coolant Temperature Input Voltage.

Data Point Normal Range YES: Replace sensor.

Perform Verification
Engine Coolant Temperature Input Voltage 3.0—3.4 V
Procedure.
Is voltage between 3.0 and 3.4 V? NO: Go to next step.
OUMX258,00001CA -19-16FEB16-4/5

•3 Terminal Check 1. Ignition OFF, Engine OFF.

2. Disconnect engine coolant temperature sensor connector B5208.

3. Perform Terminal Test on sensor and B5208 connector. YES: Repair problem.
Perform Verification
Procedure.
Were any problems found? NO: See engine CTM.
OUMX258,00001CA -19-16FEB16-5/5

TM130419 (24FEB16) 235-50-33 030916

PN=949
 Diagnose—DTCs, ECU 000001—000199

ECU 000110.04 — Engine Coolant

Alarm Level:
Temperature Signal Out of Range Low
Warning
The engine coolant temperature signal is lower than
Control Unit Response:
the sensor low voltage specification.
The ECU derates the engine.
Troubleshooting Sequence:
The ECU commands the EGR Valve fully closed.
000110.03
Additional references:
000110.04
For sensor location, more temperature sensor information,
When DTC is Displayed:
and information on how to use Diagnostic Test Box, see
When the ignition is on, and the fault is active. engine CTM.
Related Information: For complete wiring information:
The engine coolant temperature sensor signal voltage to - see Main Schematic, T4
the ECU corresponds to a temperature lower than what
- see Engine Connector X5057 Schematic
is physically possible for the engine coolant temperature
sensor. located in Section 230, Group 20.

A5501
X5057
15 30 45 60
14 29 44 59
13 28 43 58
12 27 42 57
11 26 41 56
10 25 40 55 4 3 2 1
9 24 39 54 28 Grn 407 7
8 23 38 53 29 Blu 408 8
7 22 37 52 8 7 6 5
6 21 36 51 B5208
5 20 35 50

TCT009797 —UN—08JAN14
4 19 34 49
3 18 33 48
2 17 32 47
1 16 31 46
8 7 6 5 7 1 1 2
4 3 2 1 8 2

Engine Coolant Temperature Sensor Wiring Diagram

A5501—28—Signal A5501—29—Return
OUMX258,00001CB -19-16FEB16-1/6

Diagnostic Procedure
OUMX258,00001CB -19-16FEB16-2/6

•1 Read DTCs and Store

Snapshot Information
1. Connect Service ADVISOR.
NOTE: When DTCs are cleared, Snapshot Information for ALL DTCs is cleared.

2. Ignition ON, Engine OFF.

3. Refresh codes. YES: See DTC 000110.03.
Is DTC 000110.03 a stored code? NO: Go to next step.
Continued on next page OUMX258,00001CB -19-16FEB16-3/6

TM130419 (24FEB16) 235-50-34 030916

PN=950
 Diagnose—DTCs, ECU 000001—000199

•2 Code Check Is DTC 000110.04 active? YES: Go to next step.

NO: Go to “Terminal
Check” step.
OUMX258,00001CB -19-16FEB16-4/6

•3 Sensor Check In Service ADVISOR, monitor Engine Coolant Temperature Input Voltage.

Data Point Normal Range YES: Replace sensor.

Perform Verification
Engine Coolant Temperature Input Voltage 3.0—3.4 V
Procedure.
Is voltage between 3.0 and 3.4 V? NO: Go to next step.
OUMX258,00001CB -19-16FEB16-5/6

•4 Terminal Check 1. Ignition OFF, Engine OFF.

2. Disconnect engine coolant temperature sensor connector B5208.

3. Perform Terminal Test on sensor and B5208 connector. YES: Repair problem.
Perform Verification
Procedure.
Were any problems found? NO: See engine CTM.
OUMX258,00001CB -19-16FEB16-6/6

TM130419 (24FEB16) 235-50-35 030916

PN=951
 Diagnose—DTCs, ECU 000001—000199

ECU 000157.00 — Fuel Rail Pressure Signal

Extremely High The fuel rail pressure signal is extremely high.
Continued on next page OUMX258,00001CC -19-16FEB16-1/3

TM130419 (24FEB16) 235-50-36 030916

PN=952
 Diagnose—DTCs, ECU 000001—000199

Diagnostic Procedure
Troubleshooting Sequence:
522592.12
000633.03
000633.05
000633.06
000157.00
When DTC is Displayed:
When the ignition is on, engine running, and the error is active.
Related Information:
The fuel rail pressure sensor signal voltage to the ECU corresponds to a pressure higher than an ECU defined threshold.
Alarm Level:
STOP
Control Unit Response:
The ECU commands the engine to stop.
The ECU commands the EGR Valve fully closed.
Additional References:
For sensor location, more pressure sensor information, more high-pressure fuel system information, information
on how to use Diagnostic Test Box, see engine CTM.
For complete wiring information:
- see Main Schematic, T4
- see Engine Connector X5059 Schematic
located in Section 230, Group 20.

A5501
X5059
15 30 45 60
14 29 44 59
13 28 43 58
12 27 42 57
11 26 41 56 6 5 4 3 2 1
10 25 40 55 25 Wht 442 3
9 24 39 54 26 Grn 441 2
8 23 38 53 07 Pnk 440 1
7 22 37 52 12 11 10 9 8 7
6 21 36 51
5 20 35 50
B5100
TCT009789 —UN—07JAN14

4 19 34 49
3 18 33 48
2 17 32 47
1 16 31 46
12 11 10 9 8 7 3 1
2 2 1 2 3
6 5 4 3 2 1 1 3

Fuel Rail Pressure Sensor Wiring Diagram

A5501—07 —Supply A5501—25 —Return A5501—26 —Signal
Continued on next page OUMX258,00001CC -19-16FEB16-2/3

TM130419 (24FEB16) 235-50-37 030916

PN=953
 Diagnose—DTCs, ECU 000001—000199

•1 Read DTCs and Store

Snapshot Information
1. Connect Service ADVISOR.
NOTE: When DTCs are cleared, Snapshot information for ALL DTCs is cleared.

2. Ignition ON, Engine OFF.

3. Ignition ON, engine running.
4. Wait 90 seconds. Refresh DTCs. YES: See engine CTM,
“High-Pressure Fuel
System Check”.
Is DTC 000157.00 active? NO: See Problem Not
Found Procedure.
OUMX258,00001CC -19-16FEB16-3/3

TM130419 (24FEB16) 235-50-38 030916

PN=954
 Diagnose—DTCs, ECU 000001—000199

ECU 000157.03 — Fuel Rail Pressure Signal

Out of Range High The fuel rail pressure signal is higher than the
sensor high voltage specification.
OUMX258,00001CD -19-16FEB16-1/6

Diagnostic Procedure
Troubleshooting Sequence:
522592.12
000157.03
When DTC is Displayed:When the ignition is on, and the error is active.
Related Information:
The fuel rail pressure sensor signal voltage to the ECU corresponds to a pressure higher than what is physically
possible for the fuel rail pressure.
Alarm Level:
STOP
Control Unit Response:
The ECU commands the engine to stop.
Additional References:
For sensor location, more pressure sensor information, more high-pressure fuel system information, information
on how to use Diagnostic Test Box, see engine CTM.
For complete wiring information:
- see Main Schematic, T4
- see Engine Connector X5059 Schematic
located in Section 230, Group 20.

A5501
X5059
15 30 45 60
14 29 44 59
13 28 43 58
12 27 42 57
11 26 41 56 6 5 4 3 2 1
10 25 40 55 25 Wht 442 3
9 24 39 54 26 Grn 441 2
8 23 38 53 07 Pnk 440 1
7 22 37 52 12 11 10 9 8 7
6 21 36 51
5 20 35 50
4 19 34 49
B5100 TCT009789 —UN—07JAN14

3 18 33 48
2 17 32 47
1 16 31 46
12 11 10 9 8 7 3 1
2 2 1 2 3
6 5 4 3 2 1 1 3

Fuel Rail Pressure Sensor Wiring Diagram

A5501—07 —Supply A5501—25 —Return A5501—26 —Signal
Continued on next page OUMX258,00001CD -19-16FEB16-2/6

TM130419 (24FEB16) 235-50-39 030916

PN=955
 Diagnose—DTCs, ECU 000001—000199

•1 Read DTCs and Store

Snapshot Information
1. Connect Service ADVISOR.
NOTE: When DTCs are cleared, Snapshot information for ALL DTCs is cleared.

2. Ignition ON, Engine OFF.

3. Refresh Codes. YES: See DTC 522592.12.
Is DTC 522592.12 active or stored? NO: Go to next step.
OUMX258,00001CD -19-16FEB16-3/6

•2 Code Check Is DTC 000157.03 active? YES: Go to next step.

NO: Go to “Sensor Check”

step.
OUMX258,00001CD -19-16FEB16-4/6

•3 Terminal Check 1. Ignition OFF, Engine OFF.

2. Disconnect fuel rail pressure sensor connector B5100.

3. Perform Terminal Test on sensor and B5100 connector. YES: Repair problem.
Check codes.
Were any problems found? NO: Go to next step.
OUMX258,00001CD -19-16FEB16-5/6

•4 Sensor Check In Service ADVISOR, monitor Fuel Rail Pressure Input Voltage.

Data Point Normal Range YES: Replace sensor.

Check codes.
Fuel Rail Pressure Input Voltage 1.6—2.0 V

Is voltage between 1.6 and 2.0 V? NO: See engine CTM.

OUMX258,00001CD -19-16FEB16-6/6

TM130419 (24FEB16) 235-50-40 030916

PN=956
 Diagnose—DTCs, ECU 000001—000199

ECU 000157.04 — Fuel Rail Pressure Signal

Out of Range Low The fuel rail pressure signal is lower than the
sensor low voltage specification.
OUMX258,00001CE -19-16FEB16-1/6

Diagnostic Procedure
Troubleshooting Sequence:522592.12
000157.03
000157.04
When DTC is Displayed:
When the ignition is on, and the error is active.
Related Information:
The fuel rail pressure sensor signal voltage to the ECU corresponds to a pressure lower than what is physically
possible for the fuel rail pressure.
Alarm Level:
STOP
Control Unit Response:
The ECU commands the engine to stop.
Additional References:
For sensor location, more pressure sensor information, more high-pressure fuel system information, information
on how to use Diagnostic Test Box, see engine CTM.
For complete wiring information:
- see Main Schematic, T4
- see Engine Connector X5059 Schematic
located in Section 230, Group 20.

A5501
X5059
15 30 45 60
14 29 44 59
13 28 43 58
12 27 42 57
11 26 41 56 6 5 4 3 2 1
10 25 40 55 25 Wht 442 3
9 24 39 54 26 Grn 441 2
8 23 38 53 07 Pnk 440 1
7 22 37 52 12 11 10 9 8 7
6 21 36 51
5 20 35 50
B5100
TCT009789 —UN—07JAN14

4 19 34 49
3 18 33 48
2 17 32 47
1 16 31 46
12 11 10 9 8 7 3 1
2 2 1 2 3
6 5 4 3 2 1 1 3

Fuel Rail Pressure Sensor Wiring Diagram

A5501—07 —Supply A5501—25 —Return A5501—26 —Signal
Continued on next page OUMX258,00001CE -19-16FEB16-2/6

TM130419 (24FEB16) 235-50-41 030916

PN=957
 Diagnose—DTCs, ECU 000001—000199

•1 Read DTCs and Store

Snapshot Information
1. Connect Service ADVISOR.
NOTE: When DTCs are cleared, Snapshot information for ALL DTCs is cleared.

2. Ignition ON, Engine OFF.

3. Refresh codes. YES: See DTC 000157.03.
Is DTC 000157.03 stored? NO: Go to next step.
OUMX258,00001CE -19-16FEB16-3/6

•2 Code Check Is DTC 000157.04 active? YES: Go to next step.

NO: Go to “Sensor Check”

step.
OUMX258,00001CE -19-16FEB16-4/6

•3 Terminal Check 1. Ignition OFF, Engine OFF.

2. Disconnect fuel rail pressure sensor connector B5100.

3. Perform Terminal Test on sensor and B5100 connector. YES: Repair problem.
Check codes.
Were any problems found? NO: Go to next step.
OUMX258,00001CE -19-16FEB16-5/6

•4 Sensor Check In Service ADVISOR, monitor Fuel Rail Pressure Input Voltage.

Data Point Normal Range YES: Replace sensor.

Check codes.
Fuel Rail Pressure Input Voltage 1.6—2.0 V

Is voltage between 1.6 and 2.0 V? NO: See engine CTM.

OUMX258,00001CE -19-16FEB16-6/6

TM130419 (24FEB16) 235-50-42 030916

PN=958
 Diagnose—DTCs, ECU 000001—000199

ECU 000157.15 — Fuel Rail Pressure Signal

Slightly High The fuel rail pressure signal is slightly higher than desired.
Continued on next page OUMX258,00001CF -19-16FEB16-1/3

TM130419 (24FEB16) 235-50-43 030916

PN=959
 Diagnose—DTCs, ECU 000001—000199

Diagnostic Procedure
Troubleshooting Sequence:
522592.12
000633.03
000633.05
000633.06
000157.15
When DTC is Displayed:
When the ignition is on, engine running, and the error is active.
Related Information:
The fuel rail pressure sensor signal voltage to the ECU corresponds to a pressure slightly higher than an ECU
defined threshold.
Alarm Level:
STOP
Control Unit Response:
The ECU commands the engine to stop.
The ECU commands the EGR Valve fully closed.
Additional References:
For sensor location, more pressure sensor information, more high-pressure fuel system information, information
on how to use Diagnostic Test Box, see engine CTM.
For complete wiring information:
- see Main Schematic, T4
- see Engine Connector X5059 Schematic
located in Section 230, Group 20.

A5501
X5059
15 30 45 60
14 29 44 59
13 28 43 58
12 27 42 57
11 26 41 56 6 5 4 3 2 1
10 25 40 55 25 Wht 442 3
9 24 39 54 26 Grn 441 2
8 23 38 53 07 Pnk 440 1
7 22 37 52 12 11 10 9 8 7
6 21 36 51
5 20 35 50
B5100
TCT009789 —UN—07JAN14

4 19 34 49
3 18 33 48
2 17 32 47
1 16 31 46
12 11 10 9 8 7 3 1
2 2 1 2 3
6 5 4 3 2 1 1 3

Fuel Rail Pressure Sensor Wiring Diagram

A5501—07 —Supply A5501—25 —Return A5501—26 —Signal
Continued on next page OUMX258,00001CF -19-16FEB16-2/3

TM130419 (24FEB16) 235-50-44 030916

PN=960
 Diagnose—DTCs, ECU 000001—000199

•1 Read DTCs and Store

Snapshot Information
1. Connect Service ADVISOR.
NOTE: When DTCs are cleared, Snapshot information for ALL DTCs is cleared.

2. Ignition ON, Engine OFF.

3. Ignition ON, engine running.
4. Wait 90 seconds. Refresh DTCs YES: See DTC 000157.00
for troubleshooting
procedure.
Is DTC 000157.15 active? NO: Problem Not Found
Procedure
OUMX258,00001CF -19-16FEB16-3/3

TM130419 (24FEB16) 235-50-45 030916

PN=961
 Diagnose—DTCs, ECU 000001—000199

ECU 000157.16 — Fuel Rail Pressure Limiter

Open The fuel rail pressure signal is moderately
lower than desired.
Continued on next page OUMX258,00001D0 -19-16FEB16-1/4

TM130419 (24FEB16) 235-50-46 030916

PN=962
 Diagnose—DTCs, ECU 000001—000199

Diagnostic Procedure
Troubleshooting Sequence:
522592.12
000633.03
000633.05
000633.06
000157.00
000157.03
000157.04
000157.15
000157.18
523469.00
000157.16
When DTC is Displayed:
When the ignition is on, engine running, and the error is active.
Related Information:
The fuel rail pressure sensor signal voltage to the ECU corresponds to a pressure lower than an ECU defined threshold.
Alarm Level:
STOP
Control Unit Response:
The ECU commands the engine to stop.
Additional References:For sensor location, more pressure sensor information, more high-pressure fuel system
information, information on how to use Diagnostic Test Box, see engine CTM.
For complete wiring information:
- see Main Schematic, T4
- see Engine Connector X5059 Schematic
located in Section 230, Group 20.

Continued on next page OUMX258,00001D0 -19-16FEB16-2/4

TM130419 (24FEB16) 235-50-47 030916

PN=963
 Diagnose—DTCs, ECU 000001—000199

A5501
X5059
15 30 45 60
14 29 44 59
13 28 43 58
12 27 42 57
11 26 41 56 6 5 4 3 2 1
10 25 40 55 25 Wht 442 3
9 24 39 54 26 Grn 441 2
8 23 38 53 07 Pnk 440 1
7 22 37 52 12 11 10 9 8 7
6 21 36 51
5 20 35 50
B5100

TCT009789 —UN—07JAN14
4 19 34 49
3 18 33 48
2 17 32 47
1 16 31 46
12 11 10 9 8 7 3 1
2 2 1 2 3
6 5 4 3 2 1 1 3

Fuel Rail Pressure Sensor Wiring Diagram

A5501—07 —Supply A5501—25 —Return A5501—26 —Signal
OUMX258,00001D0 -19-16FEB16-3/4

•1 Read DTCs and Store

Snapshot Information
1. Connect Service ADVISOR.
NOTE: When DTCs are cleared, Snapshot information for ALL DTCs is cleared.

2. Ignition ON, Engine OFF.

3. Refresh DTCs YES: Refer to engine CTM.
Replace Fuel Rail Pressure
Limiter.
Is DTC 523469.00 active or stored? NO: See CTM1240,
“High-Pressure Fuel
System Check”.
OUMX258,00001D0 -19-16FEB16-4/4

TM130419 (24FEB16) 235-50-48 030916

PN=964
 Diagnose—DTCs, ECU 000001—000199

ECU 000157.18 — Fuel Rail Pressure Signal

Moderately Low The fuel rail pressure signal is moderately
lower than desired.
Continued on next page OUMX258,00001D1 -19-16FEB16-1/4

TM130419 (24FEB16) 235-50-49 030916

PN=965
 Diagnose—DTCs, ECU 000001—000199

Diagnostic Procedure
Troubleshooting Sequence:
522592.12
000633.03
000633.05
000633.06
000157.18
When DTC is Displayed:
When the ignition is on, engine running, and the error is active.
Related Information:
The fuel rail pressure sensor signal voltage to the ECU corresponds to a pressure lower than an ECU defined threshold.
Alarm Level:
STOP
Control Unit Response:
The ECU commands the engine to stop.
The ECU commands the EGR Valve fully closed.
Additional References:
For sensor location, more pressure sensor information, more high-pressure fuel system information, information
on how to use Diagnostic Test Box, see engine CTM.
For complete wiring information:
- see Main Schematic, T4
located in Section 230, Group 20.

A5501
X5059
15 30 45 60
14 29 44 59
13 28 43 58
12 27 42 57
11 26 41 56 6 5 4 3 2 1
10 25 40 55 25 Wht 442 3
9 24 39 54 26 Grn 441 2
8 23 38 53 07 Pnk 440 1
7 22 37 52 12 11 10 9 8 7
6 21 36 51
5 20 35 50
4 19 34 49
B5100 TCT009789 —UN—07JAN14
3 18 33 48
2 17 32 47
1 16 31 46
12 11 10 9 8 7 3 1
2 2 1 2 3
6 5 4 3 2 1 1 3

Fuel Rail Pressure Sensor Wiring Diagram

A5501—07 —Supply A5501—25 —Return A5501—26 —Signal
Continued on next page OUMX258,00001D1 -19-16FEB16-2/4

TM130419 (24FEB16) 235-50-50 030916

PN=966
 Diagnose—DTCs, ECU 000001—000199

•1 Read DTCs and Store

Snapshot Information
1. Connect Service ADVISOR.
NOTE: When DTCs are cleared, Snapshot information for ALL DTCs is cleared.

2. Ignition ON, Engine OFF.

3. Ignition ON, engine running.
4. Wait 90 seconds. Refresh DTCs YES: Go to next step.
Is DTC 000157.18 active? NO: See engine CTM,
“Problem Not Found
Procedure”.
OUMX258,00001D1 -19-16FEB16-3/4

•2 Low-Pressure Fuel
Supply System Check
Check for fuel pump DTC codes: VCU 000931.3, VCU000931.4 YES: Go to VCU DTC
diagnostics section.

Are codes present? NO: Check fuel

pump pressure. See
Test Fuel Pump
Pressure—3TNV82A,
3TNV88.
OUMX258,00001D1 -19-16FEB16-4/4

TM130419 (24FEB16) 235-50-51 030916

PN=967
 Diagnose—DTCs, ECU 000001—000199

ECU 000167.01 — Charging System Voltage

When DTC is Displayed:
Extremely Low
When the ignition is on, engine running, and the error is
The charging system voltage is extremely low. active.
Related Troubleshooting Codes Additional References:
000158.01 For electrical voltage tests - see Electrical Tests and
Adjustments Section 230, Group 40.
Code Caused By:
For alternator tests - see engine CTM.
Battery voltage (VBAT), critical low voltage (below normal
operating range). For complete wiring information:
Alarm Level: - see Main Schematic, T4
Stop located in Section 230, Group 20.
SAE Lamp:
Red
OUMX258,00001D2 -19-16FEB16-1/4

Diagnostic Procedure
OUMX258,00001D2 -19-16FEB16-2/4

•1 Read DTCs and Store

Snapshot Information
1. Connect Service ADVISOR.

NOTE: When DTCs are cleared Snapshot information for ALL DTCs is cleared.

2. Ignition ON, Engine OFF.

3. Refresh Codes. YES: Go to next step.
Is DTC 000167.01 active? NO: Perform Verification
Procedure
OUMX258,00001D2 -19-16FEB16-3/4

•2 Alternator Test alternator output and system voltage. See Regulated Voltage Output Test. Is
voltage okay?
YES: Perform Verification
Procedure

NO: Repair or replace

alternator. See alternator
repair in Section 30, Group
30.

OUMX258,00001D2 -19-16FEB16-4/4

TM130419 (24FEB16) 235-50-52 PN=968

030916
 Diagnose—DTCs, ECU 000001—000199

ECU 000167.05 — Charging System Circuit When the ignition is on, engine running, and the error is
Out of Range Low active.

The charging system has high resistance. Additional References:

Code Caused By: For electrical voltage tests - see Electrical Tests and
Adjustments Section 230, Group 40.
Battery voltage (VBAT), critical low voltage (below normal
operating range). For alternator tests - see engine CTM.

Alarm Level: For complete wiring information:

Stop - see Main Schematic, T4

SAE Lamp: located in Section 230, Group 20.

Red
When DTC is Displayed:
OUMX258,00001D3 -19-16FEB16-1/4

Diagnostic Procedure
OUMX258,00001D3 -19-16FEB16-2/4

•1 Read DTCs and Store

Snapshot Information
1. Connect Service ADVISOR.
NOTE: When DTCs are cleared Snapshot information for ALL DTCs is cleared.

2. Ignition ON, Engine OFF.

3. Refresh Codes. YES: Go to next step.
Is DTC 000167.05 active? NO: Perform Verification
Procedure
OUMX258,00001D3 -19-16FEB16-3/4

•2 Alternator Test alternator output and system voltage. See Regulated Voltage Output Test. Is
voltage okay?
YES: Perform Verification
Procedure

NO: Repair or replace

alternator. See alternator
repair in Section 30, Group
30.

OUMX258,00001D3 -19-16FEB16-4/4

TM130419 (24FEB16) 235-50-53 PN=969

030916
 Diagnose—DTCs, ECU 000001—000199

ECU 000173.03 — Exhaust Manifold

Warning
Temperature Signal Out Of Range High
Control Unit Response:
The exhaust manifold temperature signal exceeds
The ECU derates the engine.
the sensor high voltage specification.
The ECU commands the EGR Valve fully closed.
Troubleshooting Sequence:
Additional references:
000173.03
For sensor location, more temperature sensor information,
When DTC is Displayed:
and information on how to use Diagnostic Test Box, see
When the ignition is on, and the fault is active. engine CTM.
Related Information: For complete wiring information:
The exhaust manifold temperature sensor signal voltage - see Main Schematic, T4
to the ECU corresponds to a temperature higher than
- see Engine Connector X5059 Schematic
what is physically possible for the exhaust manifold
temperature sensor. located in Section 230, Group 20.
Alarm Level:

A5501

15 30 45 60 X5059
14 29 44 59
13 28 43 58
12 27 42 57
11 26 41 56
10 25 40 55 6 5 4 3 2 1
9 24 39 54
8 23 38 53 51 Brn 423 12
7 22 37 52 10
6 21 36 51 12 11 10 9 8 7
5 20 35 50
B5216
4 19 34 49
3 18 33 48
2 17 32 47
1 16 31 46
12 11 10 9 8 7
12 1
2 1
A5502 6 5 4 3 2 1 10 2

28 50 72 94
27 49 71 93
26 48 70 92
25 47 69 91
24 46 68 90
23 45 67 89
22 44 66 88
21 43 65 87
20 42 64 86
19 41 63 85
18 40 62 84
17 39 61 83
16 38 60 82 56 Pur 451
15 37 59 81
14 36 58 80
13 35 57 79
12 34 56 78
11 33 55 77
10 32 54 76
TCT009801 —UN—09JAN14
9 31 53 75
8 30 52 74
7 29 51 73
2 4 6

1 3 5

Exhaust Manifold Temperature Sensor Wiring Diagram

A5502—56 —Signal A5501—51 —Return
Continued on next page OUMX258,00001D6 -19-16FEB16-1/6

TM130419 (24FEB16) 235-50-54 030916

PN=970
 Diagnose—DTCs, ECU 000001—000199

Diagnostic Procedure
OUMX258,00001D6 -19-16FEB16-2/6

•1 Read DTCs and Store

Snapshot Information
1. Connect Service ADVISOR.
NOTE: When DTCs are cleared, Snapshot information for ALL DTCs is cleared.

2. Ignition ON, Engine OFF.

3. Refresh Codes. YES: Go to next step.
Is DTC 000173.03 active? NO: Go to “Circuit Check”
step.
OUMX258,00001D6 -19-16FEB16-3/6

•2 Terminal Check 1. Ignition OFF, Engine OFF.

2. Disconnect exhaust manifold temperature sensor connector B5216.

3. Perform Terminal Test on sensor and B5216 connector. YES: Repair problem.
Perform Verification
Procedure.
Were any problems found? NO: Go to next step.
OUMX258,00001D6 -19-16FEB16-4/6

•3 Sensor Check 1. In Service ADVISOR, monitor Exhaust Manifold Temperature Input Voltage.
Data Point Normal Range
Exhaust Manifold Temperature Input 1.8—2.4 V
Voltage

2. Perform Wiggle Test. YES: Repair harness

problem. Perform
Verification Procedure.
Does sensor input voltage ever read greater than 4.9 V? NO: Go to next step.

OUMX258,00001D6 -19-16FEB16-5/6

•4 Sensor Check Is voltage between 1.8 and 2.2 V? YES: Replace sensor.
Perform Verification
Procedure.
NO: See engine CTM.

OUMX258,00001D6 -19-16FEB16-6/6

TM130419 (24FEB16) 235-50-55 030916

PN=971
 Diagnose—DTCs, ECU 000001—000199

ECU 000173.04 — Exhaust Manifold Alarm Level:Warning

Temperature Signal Out Of Range Low
Control Unit Response:
The exhaust manifold temperature signal is lower than The ECU derates the engine.
the sensor low voltage specification.
The ECU commands the EGR Valve fully closed.
Troubleshooting Sequence:
Additional references:
000173.03
For sensor location, more temperature sensor information,
000173.04 and information on how to use Diagnostic Test Box, see
When DTC is Displayed: engine CTM.

When the ignition is on, and the fault is active. For complete wiring information:

Related Information:The exhaust manifold temperature - see Main Schematic, T4

sensor signal voltage to the ECU corresponds to a - see Engine Connector X5059 Schematic
temperature lower than what is physically possible for the
exhaust manifold temperature sensor. located in Section 230, Group 20.

A5501

15 30 45 60 X5059
14 29 44 59
13 28 43 58
12 27 42 57
11 26 41 56
10 25 40 55 6 5 4 3 2 1
9 24 39 54
8 23 38 53 51 Brn 423 12
7 22 37 52 10
6 21 36 51 12 11 10 9 8 7
5 20 35 50
B5216
4 19 34 49
3 18 33 48
2 17 32 47
1 16 31 46
12 11 10 9 8 7
12 1
2 1
A5502 6 5 4 3 2 1 10 2

28 50 72 94
27 49 71 93
26 48 70 92
25 47 69 91
24 46 68 90
23 45 67 89
22 44 66 88
21 43 65 87
20 42 64 86
19 41 63 85
18 40 62 84
17 39 61 83
16 38 60 82 56 Pur 451
15 37 59 81
14 36 58 80
13 35 57 79
12 34 56 78
11 33 55 77
10 32 54 76

TCT009801 —UN—09JAN14
9 31 53 75
8 30 52 74
7 29 51 73
2 4 6

1 3 5

Exhaust Manifold Temperature Sensor Wiring Diagram

A5502—56 —Signal A5501—51 —Return
OUMX258,00001D7 -19-16FEB16-1/6

Diagnostic Procedure
Continued on next page OUMX258,00001D7 -19-16FEB16-2/6

TM130419 (24FEB16) 235-50-56 030916

PN=972
 Diagnose—DTCs, ECU 000001—000199

•1 Read DTCs and Store

Snapshot Information
1. Connect Service ADVISOR.
NOTE: When DTCs are cleared, Snapshot information for ALL DTCs is cleared.

2. Ignition ON, Engine OFF.

3. Refresh codes. YES: See DTC 000173.03
procedure.
Is DTC 000173.03 a stored code? NO: Go to next step.
OUMX258,00001D7 -19-16FEB16-3/6

•2 Code Check 1. Ignition ON, Engine OFF

2. Refresh codes. YES: Go to next step.

Is DTC 000173.04 active? NO: Go to “Circuit Check”
step.
OUMX258,00001D7 -19-16FEB16-4/6

•3 Sensor Check 1. Ignition ON, Engine OFF.

2. In Service ADVISOR, monitor Exhaust Manifold Temperature Input Voltage.

Data Point Normal Range
Exhaust Manifold Temperature Input 1.8—2.4 V
Voltage

3. Perform Wiggle Test. YES: Repair short to

ground on signal wire.
Perform Verification
Procedure.
Does voltage ever go below 0.2 V? NO: Go to next step.
OUMX258,00001D7 -19-16FEB16-5/6

•4 Circuit Check Is voltage between 1.8 and 2.4 V? YES: Replace sensor.
Perform Verification
Procedure.
NO: See engine CTM.

OUMX258,00001D7 -19-16FEB16-6/6

TM130419 (24FEB16) 235-50-57 030916

PN=973
 Diagnose—DTCs, ECU 000001—000199

ECU 000174.00 — Fuel Temperature Signal

Extremely High The ECU has detected that the fuel temperature
signal is much higher than specification.
OUMX258,00001D8 -19-16FEB16-1/5

Diagnostic Procedure
Trouble Shooting Sequence:
000110.00
000174.00
When DTC is Displayed:
When the engine has been running for a minimum length of time and the fuel temperature is greater than a
predetermined threshold for a minimum length of time.
Related Information:
The ECU has detected that the fuel temperature signal is much higher than specification.
Alarm Level:
Warning
Control Unit Response:
The ECU will attempt to operate engine as normal.
Additional references:
For sensor location, more temperature sensor information, and information on how to use Diagnostic Test Box,
see engine CTM.
For complete wiring information:
- see Main Schematic, T4
- see Engine Connector X5059 Schematic
located in Section 230, Group 20.

A5501
X5059
15 30 45 60
14 29 44 59
13 28 43 58
12 27 42 57
11 26 41 56 6 5 4 3 2 1
10 25 40 55
9 24 39 54
8 23 38 53 51 Brn 450 12
7 22 37 52 11 Blu 449 11 12 11 10 9 8 7
6 21 36 51
5 20 35 50 B5209
TCT009792 —UN—07JAN14

4 19 34 49
3 18 33 48
2 17 32 47
1 16 31 46
12 11 10 9 8 7 11 1
1 2
6 5 4 3 2 1 12 2

Fuel Temperature Sensor Wiring Diagram

A5501—11 —Signal A5501—51 —Return
Continued on next page OUMX258,00001D8 -19-16FEB16-2/5

TM130419 (24FEB16) 235-50-58 030916

PN=974
 Diagnose—DTCs, ECU 000001—000199

•1 Read DTCs and Store

Snapshot Information
1. Connect Service ADVISOR.

2. Allow engine to sit for 5 minutes.

NOTE: When DTCs are cleared, Snapshot information for ALL DTCs is cleared.
3. Ignition ON, Engine OFF.
4. Visually inspect fuel cooler (if equipped) for plugging, debris, or damage.
5. Visually inspect for low fuel level in the fuel tank. YES: Repair Problem.
Perform Verification
Procedure.
Were any problems found? NO: Go to next step.
OUMX258,00001D8 -19-16FEB16-3/5

•2 Sensor Check 1. Ignition ON, engine running.

2. In Service ADVISOR, monitor Fuel Temperature until temperature stabilizes.

Data Point Normal Range
Fuel Temperature -18—49 °C
0—120 °F

3. Measure temperature of the fuel near the fuel temperature sensor with JT07253
infrared temperature gun.
4. Compare the readings. YES: See engine CTM.
Are the readings within 5 °C (9 °F) of each other? NO: Go to next step.
OUMX258,00001D8 -19-16FEB16-4/5

•3 Terminal Check 1. Ignition OFF, Engine OFF.

2. Disconnect fuel temperature sensor connector B5209.

3. Perform Terminal Test on sensor and B5209 connector. YES: Repair problem.
Perform Verification
Procedure.
Were any problems found? NO: See engine CTM.
OUMX258,00001D8 -19-16FEB16-5/5

TM130419 (24FEB16) 235-50-59 030916

PN=975
 Diagnose—DTCs, ECU 000001—000199

ECU 000174.03 — Fuel Temperature Signal

Warning
Out Of Range High
Control Unit Response:
The fuel temperature signal exceeds the sensor
The ECU derates the engine.
high voltage specification.
Additional references:
Troubleshooting Sequence:
For sensor location, more temperature sensor information,
000174.03
and information on how to use Diagnostic Test Box, see
When DTC is Displayed: engine CTM.
When the ignition is on, and the fault is active. For complete wiring information:
Related Information: - see Main Schematic, T4
The fuel temperature sensor signal voltage to the - see Engine Connector X5059 Schematic
ECU corresponds to a temperature higher than what is
located in Section 230, Group 20.
physically possible for the fuel temperature sensor.
Alarm Level:

A5501
X5059
15 30 45 60
14 29 44 59
13 28 43 58
12 27 42 57
11 26 41 56 6 5 4 3 2 1
10 25 40 55
9 24 39 54
8 23 38 53 51 Brn 450 12
7 22 37 52 11 Blu 449 11 12 11 10 9 8 7
6 21 36 51
5 20 35 50 B5209

TCT009792 —UN—07JAN14
4 19 34 49
3 18 33 48
2 17 32 47
1 16 31 46
12 11 10 9 8 7 11 1
1 2
6 5 4 3 2 1 12 2

Fuel Temperature Sensor Wiring Diagram

A5501—11 —Signal A5501—51 —Return
OUMX258,00001D9 -19-16FEB16-1/6

Diagnostic Procedure
OUMX258,00001D9 -19-16FEB16-2/6

•1 Read DTCs and Store

Snapshot Information
1. Connect Service ADVISOR.
NOTE: When DTCs are cleared, Snapshot information for ALL DTCs is cleared.

2. Ignition ON, Engine OFF.

3. Refresh Codes. YES: Go to next step.
Is DTC 000174.03 active? NO: Go to “Sensor Check”
step.
Continued on next page OUMX258,00001D9 -19-16FEB16-3/6

TM130419 (24FEB16) 235-50-60 030916

PN=976
 Diagnose—DTCs, ECU 000001—000199

•2 Terminal Check 1. Ignition OFF, Engine OFF.

2. Disconnect fuel temperature sensor connector B5209.

3. Perform Terminal Test on sensor and B5209 connector. YES: Repair problem.
Perform Verification
Procedure.
Were any problems found? NO: Go to next step.
OUMX258,00001D9 -19-16FEB16-4/6

•3 Sensor Check 1. In Service ADVISOR, monitor Fuel Temperature Input Voltage.

Data Point Normal Range
Fuel Temperature Input Voltage 2.0—2.4 V

2. Perform Wiggle Test. YES: Repair harness

problem. Perform
Verification Procedure.
Does sensor input voltage ever read greater than 4.9 V? NO: Go to next step.
OUMX258,00001D9 -19-16FEB16-5/6

•4 Circuit Check Is voltage between 2.0 and 2.4 V? YES: Replace sensor.
Perform Verification
Procedure.
NO: See engine CTM.
OUMX258,00001D9 -19-16FEB16-6/6

TM130419 (24FEB16) 235-50-61 030916

PN=977
 Diagnose—DTCs, ECU 000001—000199

ECU 000174.04 — Fuel Temperature Signal

Out Of Range Low The fuel temperature signal is lower than the sensor
low voltage specification.
OUMX258,00001DA -19-16FEB16-1/7

Diagnostic Procedure
Troubleshooting Sequence:
000174.03
000174.04
When DTC is Displayed:
When the ignition is on, and the fault is active.
Related Information:
The fuel temperature sensor signal voltage to the ECU corresponds to a temperature lower than what is physically
possible for the fuel temperature sensor.
Alarm Level:
Warning
Control Unit Response:
The ECU derates the engine.
Additional references:
For sensor location, more temperature sensor information, and information on how to use Diagnostic Test Box,
see engine CTM.
For complete wiring information:
- see Main Schematic, T4
- see Engine Connector X5059 Schematic
located in Section 230, Group 20.

A5501
X5059
15 30 45 60
14 29 44 59
13 28 43 58
12 27 42 57
11 26 41 56 6 5 4 3 2 1
10 25 40 55
9 24 39 54
8 23 38 53 51 Brn 450 12
7 22 37 52 11 Blu 449 11 12 11 10 9 8 7
6 21 36 51
5 20 35 50 B5209
TCT009792 —UN—07JAN14

4 19 34 49
3 18 33 48
2 17 32 47
1 16 31 46
12 11 10 9 8 7 11 1
1 2
6 5 4 3 2 1 12 2

Fuel Temperature Sensor Wiring Diagram

A5501—11 —Signal A5501—51 —Return
Continued on next page OUMX258,00001DA -19-16FEB16-2/7

TM130419 (24FEB16) 235-50-62 030916

PN=978
 Diagnose—DTCs, ECU 000001—000199

•1 Read DTCs and Store

Snapshot Information
1. Connect Service ADVISOR.
NOTE: When DTCs are cleared, Snapshot information for ALL DTCs is cleared.

2. Ignition ON, Engine OFF.

3. Refresh codes. YES: See DTC 000174.03
procedure.
Is DTC 000174.03 a stored code? NO: Go to next step.
OUMX258,00001DA -19-16FEB16-3/7

•2 Code Check 1. Ignition ON, Engine OFF

2. Refresh codes. YES: Go to next step.

Is DTC 000174.04 active? NO: Go to “Check Circuit”
step.
OUMX258,00001DA -19-16FEB16-4/7

•3 Terminal Check 1. Ignition OFF, Engine OFF.

2. Disconnect fuel temperature sensor connector B5209.

3. Perform Terminal Test on sensor and B5209 connector. YES: Repair problem.
Perform Verification
Procedure
Were any problems found? NO: Go to next step.
OUMX258,00001DA -19-16FEB16-5/7

•4 Sensor Check 1. Ignition ON, Engine OFF.

2. In Service ADVISOR, monitor Fuel Temperature Input Voltage.

Data Point Normal Range
Fuel Temperature Input Voltage 2.0—2.4 V

3. Perform Wiggle Test. YES: Repair short to

ground on signal wire.
Perform Verification
Procedure.
Does voltage ever go below 0.2 V? NO: Go to next step.

OUMX258,00001DA -19-16FEB16-6/7

•5 Circuit Check Is voltage between 2.0 and 2.4 V? YES: Replace sensor.
Perform Verification
Procedure.
NO: See engine CTM.

OUMX258,00001DA -19-16FEB16-7/7

TM130419 (24FEB16) 235-50-63 030916

PN=979
 Diagnose—DTCs, ECU 000001—000199

ECU 000190.00 — Engine Speed Extremely

High The ECU detects that the engine speed exceeds
the maximum RPM.
OUMX258,00001DB -19-16FEB16-1/3

Diagnostic Procedure
Troubleshooting Sequence:
522400.02
522400.05
522401.02
522401.05
522401.07
000190.00
When DTC is Displayed:
When the ignition is on and the engine is running.
Related Information:
The ECU detects that the engine speed exceeds the maximum RPM.
Alarm Level:
Stop
Control Unit Response:
The ECU stops fuel flow to the high-pressure common-rail (HPCR), by turning off the suction control valve on the
high-pressure fuel pump.
Additional references:
For more high-pressure fuel system information, speed sensors, and information on how to use Diagnostic Test Box,
see engine CTM.
For complete wiring information:
- see Main Schematic, T4
located in Section 230, Group 20.
Continued on next page OUMX258,00001DB -19-16FEB16-2/3

TM130419 (24FEB16) 235-50-64 030916

PN=980
 Diagnose—DTCs, ECU 000001—000199

•1 Read DTCs and Store

Snapshot Information
1. Connect Service ADVISOR.
NOTE: When DTCs are cleared, Snapshot information for ALL DTCs is cleared.

2. Ignition ON, Engine OFF.

3. If any DTCs have snapshot capture or snapshot recording information, save the
information.
4. Obtain information about operating conditions from the operator that observed
this code being set.
5. Inspect for possible conditions that may possibly cause this code:
• Unintended fuel in intake.
• Stuck ether relay
• Application driving the engine to an excessive speed. Example: Going down a hill YES: Repair problem.
and using the engine as a brake. Perform Verification
Procedure.
Have any of these conditions occurred? NO: See engine CTM,
“Problem Not Found
Procedure”.
OUMX258,00001DB -19-16FEB16-3/3

TM130419 (24FEB16) 235-50-65 030916

PN=981
 Diagnose—DTCs, ECU 000001—000199

TM130419 (24FEB16) 235-50-66 030916

PN=982
 Group 51
Diagnose—DTCs, ECU 000200—000699
ECU 000412.03 — EGR Temperature Signal Control Unit Response:
Out of Range High
The ECU derates the engine.
The EGR temperature signal exceeds the sensor The ECU commands the EGR Valve fully closed.
high voltage specification.
Additional references:
Troubleshooting Sequence:
For sensor location, more temperature sensor information,
000412.03 and information on how to use Diagnostic Test Box, see
When DTC is Displayed: engine CTM.

When the ignition is on, and the fault is active. For complete wiring information:
- see Main Schematic, T4
Related Information:
- see Engine Connector X5058 Schematic
The EGR temperature sensor signal voltage to the
ECU corresponds to a temperature higher than what is located in Section 230, Group 20.
physically possible for the EGR temperature sensor.
Alarm Level:Warning

A5502

28 50 72 94
27 49 71 93
26 48 70 92
25 47 69 91 X5058
24 46 68 90
23 45 67 89
22 44 66 88
21 43 65 87
20 42 64 86
19 41 63 85
18 40 62 84 6 5 4 3 2 1
17 39 61 83 52 Brn 423 7
16 38 60 82 33 Pnk 427 11
15 37 59 81
14 36 58 80 12 11 10 9 8 7
13
12
35
34
57
56
79
78
B5207
11 33 55 77
10 32 54 76

TCT009798 —UN—08JAN14
9 31 53 75
8 30 52 74
7 29 51 73
12 11 10 9 8 7
2 4 6 7 A
11 B B A
6 5 4 3 2 1
1 3 5

EGR Temperature Sensor Wiring Diagram

A5501—33—Signal A5502—52—Return

OUMX258,00001E1 -19-16FEB16-1/5

Diagnostic Procedure
OUMX258,00001E1 -19-16FEB16-2/5

•1 Read DTCs and Store

Snapshot Information
1. Connect Service ADVISOR.

NOTE: When DTCs are cleared Snapshot information for ALL DTCs is cleared.

2. Ignition ON, Engine OFF.

3. Refresh Codes. YES: Go to next step.
Is DTC 000412.03 active? NO: Go to “Circuit Check”
step.

Continued on next page OUMX258,00001E1 -19-16FEB16-3/5

TM130419 (24FEB16) 235-51-1 030916

PN=983
 Diagnose—DTCs, ECU 000200—000699

•2 Terminal Check 1. Ignition OFF, Engine OFF.

2. Disconnect EGR temperature sensor connector B5207.

3. Perform Terminal Test on sensor and B5207 connector. YES: Repair problem.
Perform Verification
Procedure.
Were any problems found? NO: Go to next step.
OUMX258,00001E1 -19-16FEB16-4/5

•3 Sensor Check In Service ADVISOR, monitor EGR Temperature Input Voltage.

Data Point Normal Range YES: Replace sensor.

Perform Verification
EGR Temperature Input Voltage 2.0—3.2 V
Procedure.
Is voltage between 2.4 and 2.8 V? NO: See engine CTM.
OUMX258,00001E1 -19-16FEB16-5/5

TM130419 (24FEB16) 235-51-2 030916

PN=984
 Diagnose—DTCs, ECU 000200—000699

ECU 000412.04 — EGR Temperature Signal

Out Of Range Low The EGR temperature signal is lower than the
sensor low voltage specification.
OUMX258,00001E2 -19-16FEB16-1/7

Diagnostic Procedure
Troubleshooting Sequence:000412.03000412.04
When DTC is Displayed:
When the ignition is on, and the fault is active.
Related Information:The EGR temperature sensor signal voltage to the ECU corresponds to a temperature lower
than what is physically possible for the EGR temperature sensor.
Alarm Level:Warning
Control Unit Response:
The ECU derates the engine.
The ECU commands the EGR Valve fully closed.
Additional references:
For sensor location, more temperature sensor information, and information on how to use Diagnostic Test Box,
see engine CTM.
For complete wiring information:
- see Main Schematic, T4
- see Engine Connector X5058 Schematic
located in Section 230, Group 20.

A5502

28 50 72 94
27 49 71 93
26 48 70 92
25 47 69 91 X5058
24 46 68 90
23 45 67 89
22 44 66 88
21 43 65 87
20 42 64 86
19 41 63 85
18 40 62 84 6 5 4 3 2 1
17 39 61 83 52 Brn 423 7
16 38 60 82 33 Pnk 427 11
15 37 59 81
14 36 58 80 12 11 10 9 8 7
13
12
35
34
57
56
79
78
B5207
11 33 55 77
10 32 54 76

TCT009798 —UN—08JAN14
9 31 53 75
8 30 52 74
7 29 51 73
12 11 10 9 8 7
2 4 6 7 A
11 B B A
6 5 4 3 2 1
1 3 5

EGR Temperature Sensor Wiring Diagram

A5501—33—Signal A5502—52—Return
Continued on next page OUMX258,00001E2 -19-16FEB16-2/7

TM130419 (24FEB16) 235-51-3 030916

PN=985
 Diagnose—DTCs, ECU 000200—000699

•1 Read DTCs and Store

Snapshot Information
1. Connect Service ADVISOR.
NOTE: When DTCs are cleared, Snapshot Information for ALL DTCs is cleared.

2. Ignition ON, Engine OFF.

3. Refresh codes. YES: See DTC 000412.03
procedure.
Is DTC 000412.03 a stored code? NO: Go to next step.
OUMX258,00001E2 -19-16FEB16-3/7

•2 Code Check 1. Ignition ON, Engine OFF

2. Refresh codes. YES: Go to next step.

Is DTC 000412.04 active? NO: Go to “Circuit Check”
step.
OUMX258,00001E2 -19-16FEB16-4/7

•3 Terminal Check 1. Ignition OFF, Engine OFF.

2. Disconnect EGR temperature sensor connector B5207.

3. Perform Terminal Test on sensor and B5207 connector. YES: Repair problem.
Perform Verification
Procedure.
Were any problems found? NO: Go to next step.
OUMX258,00001E2 -19-16FEB16-5/7

•4 Circuit Check 1. Ignition ON, Engine OFF.

2. In Service ADVISOR, monitor EGR Temperature Input Voltage.

3. Perform Wiggle Test.
Data Point Normal Range YES: Repair short to
ground on signal wire.
EGR Temperature Input Voltage 2.0—4.75 V
Perform Verification
Procedure.
Does voltage ever go below 0.2 V? NO: Go to next step.

OUMX258,00001E2 -19-16FEB16-6/7

•5 Circuit Check In Service ADVISOR, monitor EGR Temperature Input Voltage. YES: Replace sensor.
Perform Verification
Procedure.
Is voltage between 2.4 and 2.8 V? NO: See engine CTM.

OUMX258,00001E2 -19-16FEB16-7/7

TM130419 (24FEB16) 235-51-4 030916

PN=986
 Diagnose—DTCs, ECU 000200—000699

ECU 000630.12 — ECU EEPROM Error

The ECU detects an internal error.
OUMX258,00001E3 -19-16FEB16-1/3

Diagnostic Procedure
Troubleshooting Sequence:
000630.12
When DTC is Displayed:
The ECU detects an internal error.
Related Information:
This DTC will be present if the ECU has not been programmed or may be present if there is an internal error.
Alarm Level:
Warning
Control Unit Response:
The ECU derates the engine.
OUMX258,00001E3 -19-16FEB16-2/3

•1 Read DTCs 1. Ignition ON, engine OFF

2. Connect Service ADVISOR.

3. Refresh codes. YES: See engine CTM.
Is DTC 000630.12 active? NO: Perform Verification
Procedure.
OUMX258,00001E3 -19-16FEB16-3/3

TM130419 (24FEB16) 235-51-5 030916

PN=987
 Diagnose—DTCs, ECU 000200—000699

ECU 000633.03 — Suction Control Valve

Circuit Out of Range High The ECU has detected the suction control valve drive
voltage is greater than the specified value.
OUMX258,00001E4 -19-16FEB16-1/11

Diagnostic Procedure
Troubleshooting Sequence:
000633.03
When DTC is Displayed:When the ignition is on, and the fault is active.
Related Information:
The ECU has detected the voltage to the suction control valve is greater than expected.
Alarm Level:
Stop
Control Unit Response:
The ECU derates the engine.
The ECU commands the EGR Valve fully closed.
Additional references:
For component location, more suction control information, and information on how to use Diagnostic Test Box, see
engine CTM.
For complete wiring information:
- see Main Schematic, T4
- see Engine Connector X5060 Schematic
located in Section 230, Group 20.

A5501
X5060
15 30 45 60
14 29 44 59
13 28 43 58
12 27 42 57
11 26 41 56 6 5 4 3 2 1
10 25 40 55 Grn 466 9
9 24 39 54 04 Grn 468 Grn 467 10
8 23 38 53 05 Wht 471 Wht 469 11
7 22 37 52 Wht 470 12 12 11 10 9 8 7
6 21 36 51
5 20 35 50 Y5002
TCT009796 —UN—08JAN14
4 19 34 49
3 18 33 48
2 17 32 47
1 16 31 46 9
12 11 10 9 8 7 10 1
11 1 2
6 5 4 3 2 1 2
12

Suction Control Valve Wiring Diagram

A5501—5—Drive - A5501—4—Drive +
Continued on next page OUMX258,00001E4 -19-16FEB16-2/11

TM130419 (24FEB16) 235-51-6 030916

PN=988
 Diagnose—DTCs, ECU 000200—000699

•1 Read DTCs and Store

Snapshot Information
1. Connect Service ADVISOR.
NOTE: When DTCs are cleared, Snapshot information for ALL DTCs is cleared.

2. Ignition ON, Engine OFF.

3. Refresh codes. YES: Go to next step.
Is DTC 000633.03 active? NO: Perform Verification
Procedure.
OUMX258,00001E4 -19-16FEB16-3/11

•2 Terminal Check 1. Ignition OFF, Engine OFF.

2. Disconnect suction control valve connector Y5002.

3. Perform Terminal Test on suction control valve and Y5002 connector. YES: Repair problem.
Perform Verification
Procedure.
Were any problems found? NO: Go to next step.
OUMX258,00001E4 -19-16FEB16-4/11

•3 Terminal Check 1. Disconnect ECU connector A5501.

2. Perform Terminal Test on A5501 connector female sockets 4 and 5. And YES: Repair problem.
corresponding ECU male pins. Perform Verification
Procedure.
Were any problems found? NO: Go to next step.
OUMX258,00001E4 -19-16FEB16-5/11

•4 Wire to Wire Check On Y5002 connector, measure resistance between female sockets 1 and 2. YES: Go to next step.

Is resistance greater than 100k Ohms? NO: Repair short in

wiring harness. Perform
Verification Procedure.

OUMX258,00001E4 -19-16FEB16-6/11

•5 Continuity Check 1. Measure the resistance between A5501 connector female socket 4 and Y5002
connector female socket 1.

2. Measure the resistance between A5501 connector female socket 5 and Y5002 YES: Go to next step.
connector female socket 2.
Are all resistance measurements less than 5 Ohms? NO: Repair high resistance
or mis-pin in harness.
Perform Verification
Procedure.

Continued on next page OUMX258,00001E4 -19-16FEB16-7/11

TM130419 (24FEB16) 235-51-7 030916

PN=989
 Diagnose—DTCs, ECU 000200—000699

•6 Short to Ground Check 1. On A5501 connector, measure resistance between female socket 4 and single
point ground.

2. On A5501 connector, measure resistance between female socket 5 and single YES: Go to next step.
point ground.
Are both resistances greater than 100k Ohms? NO: Repair short in
harness. Perform
Verification Procedure.
OUMX258,00001E4 -19-16FEB16-8/11

•7 Check Wiring Harness 1. On A5501 connector, measure resistance between female socket 4 and all other
sockets in A5501 connector.

2. On A5501 connector, measure resistance between female socket 5 and all other YES: Go to next step.
sockets in A5501 connector.
Are all resistances greater than 100k Ohms? NO: Repair short in
harness. Perform
Verification Procedure.
OUMX258,00001E4 -19-16FEB16-9/11

•8 Terminal Check 1. Disconnect ECU connector A5502.

2. Measure the resistance between A5501 connector female socket 4 and all sockets
in A5502 connector.
3. Measure the resistance between A5501 connector female socket 5 and all sockets YES: Go to next step.
in A5502 connector.
Are all resistances greater than 100k Ohms? NO: Repair short in
harness. Perform
Verification Procedure.
OUMX258,00001E4 -19-16FEB16-10/11

•9 Replace Suction
Control Valve
1. Ignition OFF, Engine OFF

2. Replace suction control valve.

3. Reconnect all connectors and components.
4. Ignition ON, engine running.
5. Refresh codes. YES: See engine CTM.
Is DTC 000633.03 active? NO: Perform Verification
Procedure

OUMX258,00001E4 -19-16FEB16-11/11

TM130419 (24FEB16) 235-51-8 030916

PN=990
 Diagnose—DTCs, ECU 000200—000699

ECU 000633.05 — Suction Control Valve

Circuit Has High Resistance The ECU has detected high resistance on the
suction control valve drive circuit.
OUMX258,00001E5 -19-16FEB16-1/10

Diagnostic Procedure
Troubleshooting Sequence: 000633.05
When DTC is Displayed:
When the ignition is on, and the fault is active.
Related Information:
The ECU has detected that the current to the suction control valve is lower than expected, indicating high resistance
in the drive circuit.
Alarm Level:Stop
Control Unit Response:
The ECU derates the engine.
The ECU commands the EGR Valve fully closed.
Additional references:
For component location, more suction control information, and information on how to use Diagnostic Test Box, see
engine CTM.
For complete wiring information:
- see Main Schematic, T4
- see Engine Connector X5060 Schematic
located in Section 230, Group 20.

A5501
X5060
15 30 45 60
14 29 44 59
13 28 43 58
12 27 42 57
11 26 41 56 6 5 4 3 2 1
10 25 40 55 Grn 466 9
9 24 39 54 04 Grn 468 Grn 467 10
8 23 38 53 05 Wht 471 Wht 469 11
7 22 37 52 Wht 470 12 12 11 10 9 8 7
6 21 36 51
5 20 35 50 Y5002

TCT009796 —UN—08JAN14
4 19 34 49
3 18 33 48
2 17 32 47
1 16 31 46 9
12 11 10 9 8 7 10 1
11 1 2
6 5 4 3 2 1 2
12

Suction Control Valve Wiring Diagram

A5501—5—Drive - A5501—4—Drive +
Continued on next page OUMX258,00001E5 -19-16FEB16-2/10

TM130419 (24FEB16) 235-51-9 030916

PN=991
 Diagnose—DTCs, ECU 000200—000699

•1 Read DTCs and Store

Snapshot Information
1. Connect Service ADVISOR.
NOTE: When DTCs are cleared, Snapshot information for ALL DTCs is cleared.

2. Ignition ON, Engine OFF.

3. Ignition ON, Engine OFF.
4. Refresh codes. YES: Go to next step.
Is DTC 000633.05 active? NO: Perform Verification
Procedure.
OUMX258,00001E5 -19-16FEB16-3/10

•2 Terminal Check 1. Ignition OFF, Engine OFF.

2. Disconnect suction control valve connector Y5002.

3. Perform Terminal Test on suction control valve and Y5002 connector. YES: Repair problem.
Perform Verification
Procedure.
Were any problems found? NO: Go to next step.
OUMX258,00001E5 -19-16FEB16-4/10

•3 Terminal Check 1. Disconnect ECU connector A5501.

2. Perform Terminal Test on A5501 connector female sockets 4 and 5. And YES: Repair problem.
corresponding ECU male pins. Perform Verification
Procedure.
Were any problems found? NO: Go to next step.
OUMX258,00001E5 -19-16FEB16-5/10

•4 Wire to Wire Check On Y5002 connector, measure resistance between female sockets 1 and 2. YES: Go to next step.

Is resistance greater than 100k Ohms? NO: Repair short in

wiring harness. Perform
Verification Procedure.

OUMX258,00001E5 -19-16FEB16-6/10

•5 Continuity Check 1. Measure the resistance between A5501 connector female socket 4 and Y5002
connector female socket 1.

2. Measure the resistance between A5501 connector female socket 5 and Y5002 YES: Go to next step.
connector female socket 2.
Are all resistance measurements less than 5 Ohms? NO: Repair high resistance
or mis-pin in harness.
Perform Verification
Procedure.

Continued on next page OUMX258,00001E5 -19-16FEB16-7/10

TM130419 (24FEB16) 235-51-10 030916

PN=992
 Diagnose—DTCs, ECU 000200—000699

•6 Short to Ground Check 1. On A5501 connector, measure resistance between female socket 4 and single
point ground.

2. On A5501 connector, measure resistance between female socket 5 and single YES: Go to next step.
point ground.
Are both resistances greater than 100k Ohms? NO: Repair short in
harness. Perform
Verification Procedure.
OUMX258,00001E5 -19-16FEB16-8/10

•7 Check Wiring Harness 1. On A5501 connector, measure resistance between female socket 4 and all other
sockets in A5501 connector.

2. On A5501 connector, measure resistance between female socket 5 and all other YES: Go to next step.
sockets in A5501 connector.
Are all resistances greater than 100k Ohms? NO: Repair short in
harness. Perform
Verification Procedure.
OUMX258,00001E5 -19-16FEB16-9/10

•8 Replace Suction
Control Valve
1. Ignition OFF, Engine OFF

2. Replace suction control valve.

3. Reconnect all connectors and components.
4. Ignition ON, engine running.
5. Refresh codes. YES: See engine CTM.
Is DTC 000633.05 active? NO: Perform Verification
Procedure
OUMX258,00001E5 -19-16FEB16-10/10

TM130419 (24FEB16) 235-51-11 030916

PN=993
 Diagnose—DTCs, ECU 000200—000699

ECU 000633.06 — Suction Control Valve

Circuit Has Low Resistance The ECU has detected low resistance on the suction
control valve drive circuit.
OUMX258,00001E6 -19-16FEB16-1/11

Diagnostic Procedure
Troubleshooting Sequence:
000633.06
When DTC is Displayed:
When the ignition is ON, and the fault is active.
Related Information:The ECU has detected that the current to the suction control valve is higher than expected,
indicating low resistance in the drive circuit.
Alarm Level:Stop
Control Unit Response:
The ECU derates the engine.
The ECU commands the EGR Valve fully closed.
Additional references:
For component location, more suction control information, and information on how to use Diagnostic Test Box, see
engine CTM.
For complete wiring information:
- see Main Schematic, T4
- see Engine Connector X5060 Schematic
located in Section 230, Group 20.

A5501
X5060
15 30 45 60
14 29 44 59
13 28 43 58
12 27 42 57
11 26 41 56 6 5 4 3 2 1
10 25 40 55 Grn 466 9
9 24 39 54 04 Grn 468 Grn 467 10
8 23 38 53 05 Wht 471 Wht 469 11
7 22 37 52 Wht 470 12 12 11 10 9 8 7
6 21 36 51
5 20 35 50 Y5002

TCT009796 —UN—08JAN14
4 19 34 49
3 18 33 48
2 17 32 47
1 16 31 46 9
12 11 10 9 8 7 10 1
11 1 2
6 5 4 3 2 1 2
12

Suction Control Valve Wiring Diagram

A5501—5—Drive - A5501—4—Drive +
Continued on next page OUMX258,00001E6 -19-16FEB16-2/11

TM130419 (24FEB16) 235-51-12 030916

PN=994
 Diagnose—DTCs, ECU 000200—000699

•1 Read DTCs and Store

Snapshot Information
1. Connect Service ADVISOR.
NOTE: When DTCs are cleared, Snapshot information for ALL DTCs is cleared.

2. Ignition ON, Engine OFF.

3. Refresh codes. YES: Go to next step.
Is DTC 000633.03 active? NO: Perform Verification
Procedure.
OUMX258,00001E6 -19-16FEB16-3/11

•2 Terminal Check 1. Ignition OFF, Engine OFF.

2. Disconnect suction control valve connector Y5002.

3. Perform Terminal Test on suction control valve and Y5002 connector. YES: Repair problem.
Perform Verification
Procedure.
Were any problems found? NO: Go to next step.
OUMX258,00001E6 -19-16FEB16-4/11

•3 Terminal Check 1. Disconnect ECU connector A5501.

2. Perform Terminal Test on A5501 connector female sockets 4 and 5. And YES: Repair problem.
corresponding ECU male pins. Perform Verification
Procedure.
Were any problems found? NO: Go to next step.
OUMX258,00001E6 -19-16FEB16-5/11

•4 Wire to Wire Check On Y5002 connector, measure resistance between female sockets 1 and 2. YES: Go to next step.

Is resistance greater than 100k Ohms? NO: Repair short in

wiring harness. Perform
Verification Procedure.

OUMX258,00001E6 -19-16FEB16-6/11

•5 Continuity Check 1. Measure the resistance between A5501 connector female socket 4 and Y5002
connector female socket 1.

2. Measure the resistance between A5501 connector female socket 5 and Y5002 YES: Go to next step.
connector female socket 2.
Are all resistance measurements less than 5 Ohms? NO: Repair high resistance
or mis-pin in harness.
Perform Verification
Procedure.

Continued on next page OUMX258,00001E6 -19-16FEB16-7/11

TM130419 (24FEB16) 235-51-13 030916

PN=995
 Diagnose—DTCs, ECU 000200—000699

•6 Short to Ground Check 1. On A5501 connector, measure resistance between female socket 4 and single
point ground.

2. On A5501 connector, measure resistance between female socket 5 and single YES: Go to next step.
point ground.
Are both resistances greater than 100k Ohms? NO: Repair short in
harness. Perform
Verification Procedure.
OUMX258,00001E6 -19-16FEB16-8/11

•7 Check Wiring Harness 1. On A5501 connector, measure resistance between female socket 4 and all other
sockets in A5501 connector.

2. On A5501 connector, measure resistance between female socket 5 and all other YES: Go to next step.
sockets in A5501 connector.
Are all resistances greater than 100k Ohms? NO: Repair short in
harness. Perform
Verification Procedure.
OUMX258,00001E6 -19-16FEB16-9/11

•8 Terminal Check 1. Disconnect ECU connector A5502.

2. Measure the resistance between A5501 connector female socket 4 and all sockets
in A5502 connector.
3. Measure the resistance between A5501 connector female socket 5 and all sockets YES: Go to next step.
in A5502 connector.
Are all resistances greater than 100k Ohms? NO: Repair short in
harness. Perform
Verification Procedure.
OUMX258,00001E6 -19-16FEB16-10/11

•9 Replace Suction
Control Valve
1. Ignition OFF, Engine OFF

2. Replace suction control valve.

3. Reconnect all connectors and components.
4. Ignition ON, engine running.
5. Refresh codes. YES: See engine CTM.
Is DTC 000633.03 active? NO: Perform Verification
Procedure

OUMX258,00001E6 -19-16FEB16-11/11

TM130419 (24FEB16) 235-51-14 030916

PN=996
 Diagnose—DTCs, ECU 000200—000699

ECU 000652.03 — Injector #3 Circuit Out of

Range High The ECU detected high voltage on the injector #3 circuit.
Continued on next page OUMX258,00001EA -19-16FEB16-1/5

TM130419 (24FEB16) 235-51-15 030916

PN=997
 Diagnose—DTCs, ECU 000200—000699

Diagnostic Procedure
Troubleshooting Sequence:
002798.06
000652.03
When DTC is Displayed:
When the engine is cranking or running.
Related Information:
The ECU detected high voltage on the injector #3 circuit.
The ECU supplies injectors #1, #2, and #3 from one common high voltage driver on three cylinder engines.
The ECU switches the low side (ground) to control each individual injector.
Alarm Level:
Warning
Control Unit Response:
The ECU derates the engine.
The ECU commands the EGR Valve fully closed.
The ECU commands the faulty injector to stop injecting fuel.
Additional References:For more Electronic Injector (EI) information, and information on how to use Diagnostic
Test Box, see engine CTM.
For complete wiring information:
- see Main Schematic, T4
- see Engine Connector X5060 Schematic
located in Section 230, Group 20.

A5501
X5060
15 30 45 60
14 29 44 59
13 28 43 58
12 27 42 57
11 26 41 56 6 5 4 3 2 1
10 25 40 55
9 24 39 54 33 Gry 464 7
8 23 38 53 16 Brn 465 8
7 22 37 52 12 11 10 9 8 7
6 21 36 51
5 20 35 50 Y5008
4 19 34 49 TCT009795 —UN—08JAN14
3 18 33 48
2 17 32 47
1 16 31 46
12 11 10 9 8 7 7 1
1 2
6 5 4 3 2 1 8 2

Injector #3 Circuit, Three Cylinder Engine

A5501—33—Injector #3 Drive A5501—16—Injector #3 Drive Low
High
Continued on next page OUMX258,00001EA -19-16FEB16-2/5

TM130419 (24FEB16) 235-51-16 030916

PN=998
 Diagnose—DTCs, ECU 000200—000699

•1 Read DTCs and Store

Snapshot Information
1. Connect Service ADVISOR.
NOTE: When DTCs are cleared Snapshot information for ALL DTCs is cleared.

2. Ignition ON, engine running. YES: Go to next step.

Is DTC 000652.03 active? NO: Go to “Terminal
Check” step 3.
OUMX258,00001EA -19-16FEB16-3/5

•2 Terminal Check 1. Ignition OFF, Engine OFF.

2. Disconnect injector #3 connector Y5008.

3. Perform Terminal Test on engine and injector harness sides of connector. YES: Repair problem.
Perform Verification
Procedure.
Were any problems found? NO: Go to next step.
OUMX258,00001EA -19-16FEB16-4/5

•3 Terminal Check 1. Disconnect ECU connector A5501. YES: Repair problem.

Perform Verification
Procedure.
2. Perform Terminal Test on A5501 connector female sockets 16 and 33. And NO: See Problem Not
corresponding ECU male pins. Found Procedure.
Were any problems found? NO: See engine CTM.
OUMX258,00001EA -19-16FEB16-5/5

TM130419 (24FEB16) 235-51-17 030916

PN=999
 Diagnose—DTCs, ECU 000200—000699

ECU 000652.05 — Injector #3 Circuit Has

High Resistance The ECU detected high resistance in the injector #3 circuit.
OUMX258,00001EB -19-16FEB16-1/4

Diagnostic Procedure
Troubleshooting Sequence:
002798.06
000652.05
When DTC is Displayed:
When the engine is cranking or running.
Related Information:
The ECU detected high resistance on the injector #3 circuit.
The ECU supplies injectors #1, #2, and #3 from one common high voltage driver on three cylinder engines.
The ECU switches the low side (ground) to control each individual injector.
Alarm Level:Warning
Control Unit Response:
The ECU derates the engine.
The ECU commands the EGR Valve fully closed.
The ECU commands the faulty injector to stop injecting fuel.
Additional References:For more Electronic Injector (EI) information, and information on how to use Diagnostic
Test Box, see engine CTM.
For complete wiring information:- see Main Schematic, T4
- see Engine Connector X5060 Schematic
located in Section 230, Group 20.

A5501
X5060
15 30 45 60
14 29 44 59
13 28 43 58
12 27 42 57
11 26 41 56 6 5 4 3 2 1
10 25 40 55
9 24 39 54 33 Gry 464 7
8 23 38 53 16 Brn 465 8
7 22 37 52 12 11 10 9 8 7
6 21 36 51
5 20 35 50 Y5008
TCT009795 —UN—08JAN14

4 19 34 49
3 18 33 48
2 17 32 47
1 16 31 46
12 11 10 9 8 7 7 1
1 2
6 5 4 3 2 1 8 2

Injector #3 Circuit, Three Cylinder Engine

A5501—33—Injector #3 Drive A5501—16—Injector #3 Drive Low
High
Continued on next page OUMX258,00001EB -19-16FEB16-2/4

TM130419 (24FEB16) 235-51-18 030916

PN=1000
 Diagnose—DTCs, ECU 000200—000699

•1 Read DTCs and Store

Snapshot Information
1. Connect Service ADVISOR.
NOTE: When DTCs are cleared Snapshot information for ALL DTCs is cleared.

2. Ignition ON, engine running. YES: Go to next step.

Is DTC 000652.05 active? NO: Perform Verification
Procedure.
OUMX258,00001EB -19-16FEB16-3/4

•2 Terminal Check 1. Ignition OFF, Engine OFF.

2. Disconnect injector #3 connector Y5008.

3. Perform Terminal Test on engine and injector harness sides of connector. YES: Repair problem.
Perform Verification
Procedure.
Were any problems found? NO: See engine CTM.
OUMX258,00001EB -19-16FEB16-4/4

TM130419 (24FEB16) 235-51-19 030916

PN=1001
 Diagnose—DTCs, ECU 000200—000699

ECU 000652.06 — Injector #3 Circuit Has Low

Resistance The ECU detected low resistance in the injector #1 circuit.
Continued on next page OUMX258,00001EC -19-16FEB16-1/5

TM130419 (24FEB16) 235-51-20 030916

PN=1002
 Diagnose—DTCs, ECU 000200—000699

Diagnostic Procedure
Troubleshooting Sequence:
002798.06
000652.06
When DTC is Displayed:
When the engine is cranking or running.
Related Information:
The ECU detected low resistance on the injector #3 circuit.
The ECU supplies injectors #1, #2, and #3 from one common high voltage driver on three cylinder engines.
The ECU switches the low side (ground) to control each individual injector.
Alarm Level:
Warning
Control Unit Response:
The ECU derates the engine.
The ECU commands the EGR Valve fully closed.
The ECU commands the faulty injector to stop injecting fuel.
Additional References:
For more Electronic Injector (EI) information, and information on how to use Diagnostic Test Box, see engine CTM.
For complete wiring information:
- see Main Schematic, T4
- see Engine Connector X5060 Schematic
located in Section 230, Group 20.

A5501
X5060
15 30 45 60
14 29 44 59
13 28 43 58
12 27 42 57
11 26 41 56 6 5 4 3 2 1
10 25 40 55
9 24 39 54 33 Gry 464 7
8 23 38 53 16 Brn 465 8
7 22 37 52 12 11 10 9 8 7
6 21 36 51
5 20 35 50 Y5008 TCT009795 —UN—08JAN14
4 19 34 49
3 18 33 48
2 17 32 47
1 16 31 46
12 11 10 9 8 7 7 1
1 2
6 5 4 3 2 1 8 2

Injector #3 Circuit, Three Cylinder Engine

A5501—33—Injector #3 Drive A5501—16—Injector #3 Drive Low
High
Continued on next page OUMX258,00001EC -19-16FEB16-2/5

TM130419 (24FEB16) 235-51-21 030916

PN=1003
 Diagnose—DTCs, ECU 000200—000699

•1 Read DTCs and Store

Snapshot Information
1. Connect Service ADVISOR.
NOTE: When DTCs are cleared Snapshot information for ALL DTCs is cleared.

2. Ignition ON, engine running. YES: Go to next step.

Is DTC 000652.06 active? NO: Go to “Short Circuit
Check” step.
OUMX258,00001EC -19-16FEB16-3/5

•2 Terminal Check 1. Ignition OFF, Engine OFF.

2. Disconnect injector #3 connector Y5008.

3. Perform Terminal Test on engine and injector harness sides of connector. YES: Repair problem.
Perform Verification
Procedure.
Were any problems found? NO: Go to next step.
OUMX258,00001EC -19-16FEB16-4/5

•3 Short Circuit Check 1. Ignition ON, engine running.

2. Refresh codes. YES: See engine CTM.

NOTE: DTC 652.05 may become active in this step. Please disregard.
Is DTC 000652.06 active? NO: Replace #3 fuel
injector. Perform
Verification Procedure.
OUMX258,00001EC -19-16FEB16-5/5

TM130419 (24FEB16) 235-51-22 030916

PN=1004
 Diagnose—DTCs, ECU 000200—000699

ECU 000653.03 — Injector #2 Circuit Out of

Range High The ECU detected high voltage on the injector #2 circuit.
Continued on next page OUMX258,00001ED -19-16FEB16-1/5

TM130419 (24FEB16) 235-51-23 030916

PN=1005
 Diagnose—DTCs, ECU 000200—000699

Diagnostic Procedure
Troubleshooting Sequence:
002798.06
000653.03
When DTC is Displayed:
When the engine is cranking or running.
Related Information:
The ECU detected high voltage on the injector #2 circuit.
The ECU supplies injectors #1, #2, and #3 from one common high voltage driver on three cylinder engines.
The ECU switches the low side (ground) to control each individual injector.
Alarm Level:
Warning
Control Unit Response:
The ECU derates the engine.
The ECU commands the EGR Valve fully closed.
The ECU commands the faulty injector to stop injecting fuel.
Additional References:
For more Electronic Injector (EI) information, and information on how to use Diagnostic Test Box, see engine CTM.
For complete wiring information:
- see Main Schematic, T4
- see Engine Connector X5060 Schematic
located in Section 230, Group 20.

A5501
X5060
15 30 45 60
14 29 44 59
13 28 43 58
12 27 42 57
11 26 41 56 6 5 4 3 2 1
10 25 40 55
9 24 39 54 47 Wht 462 5
8 23 38 53 17 Blu 463 6
7 22 37 52 12 11 10 9 8 7
6 21 36 51
5 20 35 50 Y5007 TCT009794 —UN—08JAN14
4 19 34 49
3 18 33 48
2 17 32 47
1 16 31 46
12 11 10 9 8 7 5 1
1 2
6 5 4 3 2 1 6 2

Injector #2 Circuit, Three Cylinder Engine

A5501—47—Injector #2 Drive A5501—17—Injector #2 Drive Low
High
Continued on next page OUMX258,00001ED -19-16FEB16-2/5

TM130419 (24FEB16) 235-51-24 030916

PN=1006
 Diagnose—DTCs, ECU 000200—000699

•1 Read DTCs and Store

Snapshot Information
1. Connect Service ADVISOR.
NOTE: When DTCs are cleared Snapshot information for ALL DTCs is cleared.

2. Ignition ON, engine running. YES: Go to next step.

Is DTC 000653.03 active? NO: Go to “Terminal
Check” step 3.
OUMX258,00001ED -19-16FEB16-3/5

•2 Terminal Check 1. Ignition OFF, Engine OFF.

2. Disconnect injector #2 connector Y5007.

3. Perform Terminal Test on engine and injector harness sides of connector. YES: Repair problem.
Perform Verification
Procedure.
Were any problems found? NO: Go to next step.
OUMX258,00001ED -19-16FEB16-4/5

•3 Terminal Check 1. Disconnect ECU connector A5501. YES: Repair problem.

Perform Verification
Procedure.
2. Perform Terminal Test on A5501 connector female sockets 17 and 47. And NO: See Problem Not
corresponding ECU male pins. Found Procedure.
Were any problems found? NO: See engine CTM.
OUMX258,00001ED -19-16FEB16-5/5

TM130419 (24FEB16) 235-51-25 030916

PN=1007
 Diagnose—DTCs, ECU 000200—000699

ECU 000653.05 — Injector #2 Circuit Has

High Resistance The ECU detected high resistance in the injector #2 circuit.
Continued on next page OUMX258,00001EE -19-16FEB16-1/4

TM130419 (24FEB16) 235-51-26 030916

PN=1008
 Diagnose—DTCs, ECU 000200—000699

Diagnostic Procedure
Troubleshooting Sequence:
002798.06
000653.05
When DTC is Displayed:
When the engine is cranking or running.
Related Information:
The ECU detected high resistance on the injector #2 circuit.
The ECU supplies injectors #1, #2, and #3 from one common high voltage driver on three cylinder engines.
The ECU switches the low side (ground) to control each individual injector.
Alarm Level:
Warning
Control Unit Response:
The ECU derates the engine.
The ECU commands the EGR Valve fully closed.
The ECU commands the faulty injector to stop injecting fuel.
Additional References:
For more Electronic Injector (EI) information, and information on how to use Diagnostic Test Box, see engine CTM.
For complete wiring information:
- see Main Schematic, T4
- see Engine Connector X5060 Schematic
located in Section 230, Group 20.

A5501
X5060
15 30 45 60
14 29 44 59
13 28 43 58
12 27 42 57
11 26 41 56 6 5 4 3 2 1
10 25 40 55
9 24 39 54 47 Wht 462 5
8 23 38 53 17 Blu 463 6
7 22 37 52 12 11 10 9 8 7
6 21 36 51
5 20 35 50 Y5007 TCT009794 —UN—08JAN14
4 19 34 49
3 18 33 48
2 17 32 47
1 16 31 46
12 11 10 9 8 7 5 1
1 2
6 5 4 3 2 1 6 2

Injector #2 Circuit, Three Cylinder Enigne

A5501—47—Injector #2 Drive A5501—17—Injector #2 Drive Low
High
Continued on next page OUMX258,00001EE -19-16FEB16-2/4

TM130419 (24FEB16) 235-51-27 030916

PN=1009
 Diagnose—DTCs, ECU 000200—000699

•1 Read DTCs and Store

Snapshot Information
1. Connect Service ADVISOR.
NOTE: When DTCs are cleared Snapshot information for ALL DTCs is cleared.

2. Ignition ON, engine running. YES: Go to next step.

Is DTC 000653.05 active? NO: Perform Verification
Procedure.
OUMX258,00001EE -19-16FEB16-3/4

•2 Terminal Check 1. Ignition OFF, Engine OFF.

2. Disconnect injector #2 connector Y5007.

3. Perform Terminal Test on engine and injector harness sides of connector. YES: Repair problem.
Perform Verification
Procedure.
Were any problems found? NO: See engine CTM.
OUMX258,00001EE -19-16FEB16-4/4

TM130419 (24FEB16) 235-51-28 030916

PN=1010
 Diagnose—DTCs, ECU 000200—000699

ECU 000653.06 — Injector #2 Circuit Has Low

Resistance The ECU detected low resistance in the injector #2 circuit.
Continued on next page OUMX258,00001EF -19-16FEB16-1/5

TM130419 (24FEB16) 235-51-29 030916

PN=1011
 Diagnose—DTCs, ECU 000200—000699

Diagnostic Procedure
Troubleshooting Sequence:
002798.06
000653.06
When DTC is Displayed:
When the engine is cranking or running.
Related Information:
The ECU detected low resistance on the injector #2 circuit.
The ECU supplies injectors #1, #2, and #3 from one common high voltage driver on three cylinder engines.
The ECU switches the low side (ground) to control each individual injector.
Alarm Level:
Warning
Control Unit Response:
The ECU derates the engine.
The ECU commands the EGR Valve fully closed.
The ECU commands the faulty injector to stop injecting fuel.
Additional References:
For more Electronic Injector (EI) information, and information on how to use Diagnostic Test Box, see engine CTM.
For complete wiring information:
- see Main Schematic, T4
- see Engine Connector X5060 Schematic
located in Section 230, Group 20.

A5501
X5060
15 30 45 60
14 29 44 59
13 28 43 58
12 27 42 57
11 26 41 56 6 5 4 3 2 1
10 25 40 55
9 24 39 54 47 Wht 462 5
8 23 38 53 17 Blu 463 6
7 22 37 52 12 11 10 9 8 7
6 21 36 51
5 20 35 50 Y5007 TCT009794 —UN—08JAN14
4 19 34 49
3 18 33 48
2 17 32 47
1 16 31 46
12 11 10 9 8 7 5 1
1 2
6 5 4 3 2 1 6 2

Injector #2 Circuit, Three Cylinder Enigne

A5501—47—Injector #2 Drive A5501—17—Injector #2 Drive Low
High
Continued on next page OUMX258,00001EF -19-16FEB16-2/5

TM130419 (24FEB16) 235-51-30 030916

PN=1012
 Diagnose—DTCs, ECU 000200—000699

•1 Read DTCs and Store

Snapshot Information
1. Connect Service ADVISOR.
NOTE: When DTCs are cleared Snapshot information for ALL DTCs is cleared.

2. Ignition ON, engine running. YES: Go to next step.

Is DTC 000653.06 active? NO: Go to “Short Circuit
Check” step.
OUMX258,00001EF -19-16FEB16-3/5

•2 Terminal Check 1. Ignition OFF, Engine OFF.

2. Disconnect injector #2 connector Y5007.

3. Perform Terminal Test on engine and injector harness sides of connector. YES: Repair problem.
Perform Verification
Procedure.
Were any problems found? NO: Go to next step.
OUMX258,00001EF -19-16FEB16-4/5

•3 Short Circuit Check 1. Ignition ON, engine running.

2. Refresh codes. YES: See engine CTM.

NOTE: DTC 653.05 may become active in this step. Please disregard.
Is DTC 000653.06 active? NO: Replace #2 fuel
injector. Perform
Verification Procedure.
OUMX258,00001EF -19-16FEB16-5/5

TM130419 (24FEB16) 235-51-31 030916

PN=1013
 Diagnose—DTCs, ECU 000200—000699

ECU 000654.03 — Injector #1 Circuit Out of

Range High The ECU detected high voltage on the injector #1 circuit.
OUMX258,00001F0 -19-16FEB16-1/5

Diagnostic Procedure
Troubleshooting Sequence:
002797.06
000654.03
When DTC is Displayed:When the engine is cranking or running.
Related Information:
The ECU detected high voltage on the injector #1 circuit.The ECU supplies injectors #1, #2, and #3 from one common
high voltage driver on three cylinder engines.
The ECU switches the low side (ground) to control each individual injector.
Alarm Level:
Warning
Control Unit Response:
The ECU derates the engine.
The ECU commands the EGR Valve fully closed.
The ECU commands the faulty injector to stop injecting fuel.
Additional References:
For more Electronic Injector (EI) information, and information on how to use Diagnostic Test Box, see engine CTM.
For complete wiring information:
- see Main Schematic, T4
- see Engine Connector X5060 Schematic
located in Section 230, Group 20.

A5501
X5060
15 30 45 60
14 29 44 59
13 28 43 58
12 27 42 57
11 26 41 56 6 5 4 3 2 1
10 25 40 55
9 24 39 54
8 23 38 53 48 Grn 460 3
7 22 37 52 18 Org 461 4 12 11 10 9 8 7
6 21 36 51
5 20 35 50 Y5006
TCT009793 —UN—08JAN14

4 19 34 49
3 18 33 48
2 17 32 47
1 16 31 46
12 11 10 9 8 7 3 1
1 2
6 5 4 3 2 1 4 2

Injector #1 Circuit Three Cylinder Engine

A5501—48—Injector #1 Drive A5501—18—Injector #1 Drive Low
High
Continued on next page OUMX258,00001F0 -19-16FEB16-2/5

TM130419 (24FEB16) 235-51-32 030916

PN=1014
 Diagnose—DTCs, ECU 000200—000699

•1 Read DTCs and Store

Snapshot Information
1. Connect Service ADVISOR.
NOTE: When DTCs are cleared Snapshot information for ALL DTCs is cleared.

2. Ignition ON, engine running. YES: Go to next step.

Is DTC 000654.03 active? NO: Go to “Terminal
Check” step 3.
OUMX258,00001F0 -19-16FEB16-3/5

•2 Terminal Check 1. Ignition OFF, Engine OFF.

2. Disconnect injector #1 connector Y5006.

3. Perform Terminal Test on engine and injector harness sides of connector. YES: Repair problem.
Perform Verification
Procedure.
Were any problems found? NO: Go to next step.
OUMX258,00001F0 -19-16FEB16-4/5

•3 Terminal Check 1. Disconnect ECU connector A5501. YES: Repair problem.

Perform Verification
Procedure.
2. Perform Terminal Test on A5501 connector female sockets 18 and 48. And NO: See Problem Not
corresponding ECU male pins. Found Procedure.
Were any problems found? NO: See engine CTM.
OUMX258,00001F0 -19-16FEB16-5/5

TM130419 (24FEB16) 235-51-33 030916

PN=1015
 Diagnose—DTCs, ECU 000200—000699

ECU 000654.05 — Injector #1 Circuit Has

High Resistance The ECU detected high resistance in the injector #1 circuit.
Continued on next page OUMX258,00001F1 -19-16FEB16-1/4

TM130419 (24FEB16) 235-51-34 030916

PN=1016
 Diagnose—DTCs, ECU 000200—000699

Diagnostic Procedure
When DTC is Displayed:
Troubleshooting Sequence:
002797.06
000654.05
When the engine is cranking or running.
Related Information:
The ECU detected high resistance in the injector #1 circuit.
The ECU supplies injectors #1, #2, and #3 from one common high voltage driver on three cylinder engines.
The ECU switches the low side (ground) to control each individual injector.
Alarm Level:
Warning
Control Unit Response:
The ECU derates the engine.
The ECU commands the EGR Valve fully closed.
The ECU commands the faulty injector to stop injecting fuel.
Additional References:
For more Electronic Injector (EI) information, and information on how to use Diagnostic Test Box, see engine CTM.
For complete wiring information:
- see Main Schematic, T4
- see Engine Connector X5060 Schematic
located in Section 230, Group 20.

A5501
X5060
15 30 45 60
14 29 44 59
13 28 43 58
12 27 42 57
11 26 41 56 6 5 4 3 2 1
10 25 40 55
9 24 39 54
8 23 38 53 48 Grn 460 3
7 22 37 52 18 Org 461 4 12 11 10 9 8 7
6 21 36 51
5 20 35 50 Y5006 TCT009793 —UN—08JAN14
4 19 34 49
3 18 33 48
2 17 32 47
1 16 31 46
12 11 10 9 8 7 3 1
1 2
6 5 4 3 2 1 4 2

Injector #1 Circuit Three Cylinder Engine

A5501—48—Injector #1 Drive A5501—18—Injector #1 Drive Low
High
Continued on next page OUMX258,00001F1 -19-16FEB16-2/4

TM130419 (24FEB16) 235-51-35 030916

PN=1017
 Diagnose—DTCs, ECU 000200—000699

•1 Read DTCs and Store

Snapshot Information
1. Connect Service ADVISOR.
NOTE: When DTCs are cleared Snapshot information for ALL DTCs is cleared.

2. Ignition ON, engine running. YES: Go to next step.

Is DTC 000654.05 active? NO: Perform Verification
Procedure
OUMX258,00001F1 -19-16FEB16-3/4

•2 Terminal Check 1. Ignition OFF, Engine OFF.

2. Disconnect injector #1 connector Y5006.

3. Perform Terminal Test on engine and injector harness sides of connector. YES: Repair problem.
Perform Verification
Procedure.
Were any problems found? NO: See engine CTM.
OUMX258,00001F1 -19-16FEB16-4/4

TM130419 (24FEB16) 235-51-36 030916

PN=1018
 Diagnose—DTCs, ECU 000200—000699

ECU 000654.06 — Injector #1 Circuit Has Low

Resistance The ECU detected low resistance in the injector #1 circuit.
Continued on next page OUMX258,00001F2 -19-16FEB16-1/5

TM130419 (24FEB16) 235-51-37 030916

PN=1019
 Diagnose—DTCs, ECU 000200—000699

Diagnostic Procedure
Troubleshooting Sequence:
002797.06
000654.06
When DTC is Displayed:
When the engine is cranking or running.
Related Information:
The ECU detected low resistance in the injector #1 circuit.
The ECU supplies injectors #1, #2, and #3 from one common high voltage driver on three cylinder engines.
The ECU switches the low side (ground) to control each individual injector.
Alarm Level:
Warning
Control Unit Response:
The ECU derates the engine.
The ECU commands the EGR Valve fully closed.
The ECU commands the faulty injector to stop injecting fuel.
Additional References:
For more Electronic Injector (EI) information, and information on how to use Diagnostic Test Box, see engine CTM.
For complete wiring information:
- see Main Schematic, T4
- see Engine Connector X5060 Schematic
located in Section 230, Group 20.

A5501
X5060
15 30 45 60
14 29 44 59
13 28 43 58
12 27 42 57
11 26 41 56 6 5 4 3 2 1
10 25 40 55
9 24 39 54
8 23 38 53 48 Grn 460 3
7 22 37 52 18 Org 461 4 12 11 10 9 8 7
6 21 36 51
5 20 35 50 Y5006 TCT009793 —UN—08JAN14
4 19 34 49
3 18 33 48
2 17 32 47
1 16 31 46
12 11 10 9 8 7 3 1
1 2
6 5 4 3 2 1 4 2

Injector #1 Circuit Three Cylinder Engine

A5501—48—Injector #1 Drive A5501—18—Injector #1 Drive Low
High
Continued on next page OUMX258,00001F2 -19-16FEB16-2/5

TM130419 (24FEB16) 235-51-38 030916

PN=1020
 Diagnose—DTCs, ECU 000200—000699

•1 Read DTCs and Store

Snapshot Information
1. Connect Service ADVISOR.
NOTE: When DTCs are cleared Snapshot information for ALL DTCs is cleared.

2. Ignition ON, engine running. YES: Go to next step.

Is DTC 000654.06 active? NO: Go to “Short Circuit
Check” step.
OUMX258,00001F2 -19-16FEB16-3/5

•2 Terminal Check 1. Ignition OFF, Engine OFF.

2. Disconnect injector #1 connector Y5006.

3. Perform Terminal Test on engine and injector harness sides of connector. YES: Repair problem.
Perform Verification
Procedure.
Were any problems found? NO: Go to next step.
OUMX258,00001F2 -19-16FEB16-4/5

•3 Short Circuit Check 1. Ignition ON, engine running.

2. Refresh codes. YES: See engine CTM.

NOTE: DTC 654.05 may become active in this step. Please disregard.
Is DTC 000654.06 active? NO: Replace #1 fuel
injector. Perform
Verification Procedure.
OUMX258,00001F2 -19-16FEB16-5/5

TM130419 (24FEB16) 235-51-39 030916

PN=1021
 Diagnose—DTCs, ECU 000200—000699

TM130419 (24FEB16) 235-51-40 030916

PN=1022
 Group 52
Diagnose—DTCs, ECU 000700—001999
ECU 001209.03 — Exhaust Manifold Pressure
Signal Out of Range High The exhaust manifold pressure signal exceeds the
sensor high voltage specification.
OUMX258,00001F3 -19-16FEB16-1/6

Diagnostic Procedure
Troubleshooting Sequence:
001209.03
When DTC is Displayed:
When the ignition is ON, the engine is running, and the fault is active.
Related Information:
The exhaust pressure signal voltage to the ECU corresponds to a pressure higher than what is physically possible
for the exhaust pressure sensor.
Alarm Level:
Stop
Control Unit Response:
The ECU derates the engine.
The ECU commands the EGR Valve fully closed.
The ECU will prohibit a service regeneration.
Additional references:
For sensor location, more pressure sensor information, and information on how to use Diagnostic Test Box, see
engine CTM.
For complete wiring information:
- see Main Schematic, T4
- see Engine Connector X5057 Schematic

A5502

28 50 72 94
27 49 71 93
26 48 70 92
25 47 69 91
24 46 68 90 X5057
23 45 67 89
22 44 66 88
21 43 65 87
20 42 64 86
19 41 63 85
18 40 62 84 74 Brn 404 4 4 3 2 1
17 39 61 83
16 38 60 82 39 Wht 403 3
15 37 59 81 85 Pur 402 2 B5114
14 36 58 80 45 Pnk 401 1 8 7 6 5
13 35 57 79
12 34 56 78
11 33 55 77
10 32 54 76

TCT009799 —UN—09JAN14
9 31 53 75 2
8 30 52 74 3
7 29 51 73 4 4
8 7 6 5 3 5 6 5 4 3 2 1
2 4 6
4 3 2 1 2
1
1 3 5

Manifold Air and Exhaust Pressure Sensor Wiring Diagram

A5502 – 39—Manifold Air A5502 – 45—Supply A5502 – 85—Exhaust Pressure
Pressure Sensor Signal A5502 – 74—Return Sensor Signal
Continued on next page OUMX258,00001F3 -19-16FEB16-2/6

TM130419 (24FEB16) 235-52-1 030916

PN=1023
 Diagnose—DTCs, ECU 000700—001999

•1 Read DTCs and Store

Snapshot Information
1. Connect Service ADVISOR.
NOTE: When DTCs are cleared Snapshot information for ALL DTCs is cleared.

2. Ignition ON, Engine OFF.

3. If any DTCs have snapshot capture or snapshot recording information, save the
information.
4. Refresh codes. YES: Go to next step.
Is DTC 001209.03 active? NO: Go to “Circuit Check”
step.
OUMX258,00001F3 -19-16FEB16-3/6

•2 Terminal Check 1. Ignition OFF, Engine OFF.

2. Disconnect manifold air and exhaust pressure sensor connector B5114.

3. Check terminals on sensor and B5114 connector. YES: Repair problem.
Perform Verification
Procedure.
Were any problems found? NO: Go to next step.
OUMX258,00001F3 -19-16FEB16-4/6

•3 Continuity Check 1. Measure the resistance between A5502 connector female socket 74 and B5114
connector female socket 2.

2. Measure the resistance between A5502 connector female socket 85 and B5114 YES: See CTM201419.
connector female socket 4.
Are both resistance measurements less than 5 ohms? NO: Repair mis-pin.
Perform Verification
Procedure.
OUMX258,00001F3 -19-16FEB16-5/6

•4 Terminal Check 1. Disconnect ECU connector A5502.

2. Perform Terminal Test on A5502 connector female sockets 39, 45, 74, and 85. And YES: Repair problem.
corresponding ECU male pins. Perform Verification
Procedure
Were any problems found? NO: See CTM201419.

OUMX258,00001F3 -19-16FEB16-6/6

TM130419 (24FEB16) 235-52-2 030916

PN=1024
 Diagnose—DTCs, ECU 000700—001999

ECU 001209.04 — Exhaust Manifold Pressure

Signal Out of Range Low The exhaust manifold pressure signal is lower than
the sensor low voltage specification.
OUMX258,00001F4 -19-16FEB16-1/8

Diagnostic Procedure
Troubleshooting Sequence:
001209.03
001209.04
When DTC is Displayed:
When the ignition is ON, the engine is running, and the fault is active.
Related Information:
The exhaust pressure sensor signal voltage to the ECU corresponds to a pressure lower than what is physically
possible for the exhaust pressure sensor.
Alarm Level:
Stop
Control Unit Response:
The ECU derates the engine.
The ECU commands the EGR Valve fully closed.
The ECU will prohibit a service regeneration.
Additional references:
For sensor location, more pressure sensor information, and information on how to use Diagnostic Test Box, see
engine CTM.
For complete wiring information:
- see Main Schematic, T4
- see Engine Connector X5057 Schematic

A5502

28 50 72 94
27 49 71 93
26 48 70 92
25 47 69 91
24 46 68 90 X5057
23 45 67 89
22 44 66 88
21 43 65 87
20 42 64 86
19 41 63 85
18 40 62 84 74 Brn 404 4 4 3 2 1
17 39 61 83
16 38 60 82 39 Wht 403 3
15 37 59 81 85 Pur 402 2 B5114
14 36 58 80 45 Pnk 401 1 8 7 6 5
13 35 57 79
12 34 56 78
11 33 55 77
10 32 54 76

TCT009799 —UN—09JAN14
9 31 53 75 2
8 30 52 74 3
7 29 51 73 4 4
8 7 6 5 3 5 6 5 4 3 2 1
2 4 6
4 3 2 1 2
1
1 3 5

Manifold Air and Exhaust Pressure Sensor Wiring Diagram

A5502 – 39—Manifold Air A5502 – 45—Supply A5502 – 85—Exhaust Pressure
Pressure Sensor Signal A5502 – 74—Return Sensor Signal
Continued on next page OUMX258,00001F4 -19-16FEB16-2/8

TM130419 (24FEB16) 235-52-3 030916

PN=1025
 Diagnose—DTCs, ECU 000700—001999

•1 Read DTCs and Store

Snapshot Information
1. Connect Service ADVISOR.
NOTE: When DTCs are cleared, Snapshot Information for ALL DTCs is cleared.

2. Ignition ON, Engine OFF.

3. If any DTCs have snapshot capture or snapshot recording information, save the
information.
4. Refresh codes. YES: See DTC 001209.03
diagnostics.
Is DTC 001209.03 stored? NO: Go to next step.
OUMX258,00001F4 -19-16FEB16-3/8

•2 Terminal Check 1. Ignition OFF, Engine OFF.

2. Disconnect manifold air and exhaust pressure sensor connector B5114.

3. Perform Terminal Test on sensor and B5114 connector. YES: Repair problem.
Perform Verification
Procedure.
Were any problems found? NO: Go to next step.
OUMX258,00001F4 -19-16FEB16-4/8

•3 Continuity Check Measure the resistance between A5502 connector female socket 85 and B5114
connector female socket 4.
YES: Repair short to signal
wire in harness. Perform
Verification Procedure.
Is resistance less than 5 ohms? NO: Repair open, high
resistance, or mis-pin
in harness. Perform
Verification Procedure.
OUMX258,00001F4 -19-16FEB16-5/8

•4 Circuit Check 1. Ignition ON, Engine OFF.

2. Monitor Exhaust Manifold Pressure Sensor Input Voltage in Service ADVISOR.

3. Perform Wiggle Test. YES: Repair harness
problem. Perform
Verification Procedure.
Does voltage ever go below 0.2 V? NO: Go to next step.

OUMX258,00001F4 -19-16FEB16-6/8

•5 Terminal Check 1. Ignition OFF, Engine OFF.

2. Disconnect exhaust manifold pressure sensor connector B5114.

3. Perform Terminal Test on sensor and B5114 connector. YES: Repair problem.
Perform Verification
Procedure.
Were any problems found? NO: Go to next step.

Continued on next page OUMX258,00001F4 -19-16FEB16-7/8

TM130419 (24FEB16) 235-52-4 PN=1026

030916
 Diagnose—DTCs, ECU 000700—001999

•6 Terminal Check 1. Disconnect ECU connector A5502.

2. Perform Terminal Test on A5502 connector female sockets 39, 45, 74, and 85. And YES: Repair problem.
corresponding ECU male pins. Perform Verification
Procedure.
Were any problems found? NO: See CTM201419.
OUMX258,00001F4 -19-16FEB16-8/8

TM130419 (24FEB16) 235-52-5 030916

PN=1027
 Diagnose—DTCs, ECU 000700—001999

ECU 001209.13 — Exhaust Manifold Pressure

Signal Calibration Fault The ECU detects an exhaust manifold pressure mismatch.
OUMX258,00001F5 -19-16FEB16-1/7

Diagnostic Procedure
Troubleshooting Sequence:
001209.03
001209.04
001209.13
When DTC is Displayed:
When the ignition is ON, the engine is OFF, and the fault is active.
When the ignition is ON, engine is running, and the actual exhaust manifold pressure is not within an estimated range
the ECU expects, based from engine operating conditions.
Related Information:
The ECU compares the exhaust manifold pressure to the manifold air pressure sensor and the barometric pressure
sensor at ignition on, engine off.
Alarm Level:
Stop
Control Unit Response:
The ECU derates the engine.
The ECU commands the EGR Valve fully closed.
The ECU will prohibit a service regeneration.
Additional references:
For sensor location, more pressure sensor information, and information on how to use Diagnostic Test Box, see
engine CTM.
For complete wiring information:
- see Main Schematic, T4
- see Engine Connector X5057 Schematic

A5502

28 50 72 94
27 49 71 93
26 48 70 92
25 47 69 91
24 46 68 90 X5057
23 45 67 89
22 44 66 88
21 43 65 87
20 42 64 86
19 41 63 85
18 40 62 84 74 Brn 404 4 4 3 2 1
17 39 61 83
16 38 60 82 39 Wht 403 3
15 37 59 81 85 Pur 402 2 B5114
14 36 58 80 45 Pnk 401 1 8 7 6 5
13 35 57 79
12 34 56 78
11 33 55 77
10 32 54 76
TCT009799 —UN—09JAN14

9 31 53 75 2
8 30 52 74 3
7 29 51 73 4 4
8 7 6 5 3 5 6 5 4 3 2 1
2 4 6
4 3 2 1 2
1
1 3 5

Manifold Air and Exhaust Pressure Sensor Wiring Diagram

A5502 – 39—Manifold Air A5502 – 45—Supply A5502 – 85—Exhaust Pressure
Pressure Sensor Signal A5502 – 74—Return Sensor Signal
Continued on next page OUMX258,00001F5 -19-16FEB16-2/7

TM130419 (24FEB16) 235-52-6 030916

PN=1028
 Diagnose—DTCs, ECU 000700—001999

•1 Read DTCs and Store

Snapshot Information
1. Connect Service ADVISOR.
NOTE: When DTCs are cleared, Snapshot Information for ALL DTCs is cleared.

2. Ignition ON, Engine OFF.

3. If any DTCs have snapshot capture or snapshot recording information, save the
information.
4. Refresh codes. YES: See 001209.03
diagnostics.
Is DTC 001209.03 stored? NO: Go to next step.
OUMX258,00001F5 -19-16FEB16-3/7

•2 Code Check Is DTC 001209.04 stored? YES: See 001209.04

diagnostics.

NO: Go to next step.

OUMX258,00001F5 -19-16FEB16-4/7

•3 Code Check 1. Ignition ON, engine running.

2. Wait a minimum of 20 seconds.

3. Refresh codes. YES: Go to “Terminal
Check” step.
Is DTC 001209.13 active? NO: Go to next step.
OUMX258,00001F5 -19-16FEB16-5/7

•4 Code Check 1. Review Snapshot Information stored from step 1 or speak with operator to
determine conditions where DTC became active.

2. Operate engine under condition where the DTC became active.

3. Refresh codes. YES: Go to next step.
Is DTC 001209.13 active? NO: See diagnostics
section in CTM201419.

OUMX258,00001F5 -19-16FEB16-6/7

•5 Terminal Check 1. Ignition OFF, Engine OFF.

2. Disconnect manifold air and exhaust pressure sensor connector B5114.

3. Perform Terminal Test on sensor and B5114 connector. YES: Repair problem.
Perform Verification
Procedure.
Were any problems found? NO: See engine CTM.

OUMX258,00001F5 -19-16FEB16-7/7

TM130419 (24FEB16) 235-52-7 030916

PN=1029
 Diagnose—DTCs, ECU 000700—001999

TM130419 (24FEB16) 235-52-8 030916

PN=1030
 Group 53
Diagnose—DTCs, ECU 002000—002999
ECU 002791.00 — EGR Valve Drive Circuit Control Unit Response:
Voltage Extremely High
The ECU derates the engine.
The EGR Valve has detected its supply voltage The ECU commands the EGR Valve fully closed.
is out of range high.
Additional References:
Trouble Shooting Sequence:
For EGR actuator location, information on how to use
002791.00 Diagnostic Test Box, and for more information on the
When DTC is Displayed: control unit information and overview test, see engine
CTM.
When the ignition is on, or engine is running, and the EGR
valve reports the fault is active. For complete wiring information:

Related Information: - see Main Schematic, T4

- see Engine Connector X5058 Schematic
This code is set when the EGR valve detects that its - see Engine Controls and Sensors Schematic
supply voltage from the ECU is out of range high .
located in Section 230, Group 20.
Alarm Level:
Warning
A5502
K2
28 50 72 94
27 49 71 93 V13
26 48 70 92 Blu 671
X5058
25 47 69 91 68 Blu 670
24 46 68 90
23 45 67 89 01 Red 213 Red 212
22 44 66 88 03 Red 214
21 43 65 87
20 42 64 86 05 Red 215 Red 211 (B+) Org 420 1 6 5 4 3 2 1
19 41 63 85 54 Yel F250 Yel F250 2
18 40 62 84
17 39 61 83 76 Grn F150 Grn F150 3
16 38 60 82 4
02 Blk 128 Blk 122 12 11 10 9 8 7
15 37 59 81
14 36 58 80 04 Blk 124
13 35 57 79 06 Blk 125
12 34 56 78
11 33 55 77
Blk 121

10 32 54 76

TCT009803 —UN—13JAN14
9 31 53 75 A
8 30 52 74 B 4
7 29 51 73 A B C D 12 11 10 9 8 7
C 3
2 4 6 D 2 6 5 4 3 2 1
1
1 3 5 Y5400
R5606

EGR Valve Wiring Diagram

A5502 – 01—Supply A5502 – 05—Supply A5502 – 68—Relay Coil Control V13— Diode
A5502 – 02—Return A5502 – 06—Return K2—EGR Valve Power Relay
A5502 – 03—Supply A5502 – 54—CAN High R5606—Resistor
A5502 – 04—Return A5502 – 76—CAN Low

OUMX258,00001F6 -19-16FEB16-1/6

Diagnostic Procedure
Continued on next page OUMX258,00001F6 -19-16FEB16-2/6

TM130419 (24FEB16) 235-53-1 030916

PN=1031
 Diagnose—DTCs, ECU 002000—002999

•1 Read DTCs and Store

Snapshot Information
1. Connect Service ADVISOR.
NOTE: When DTCs are cleared, Snapshot information for ALL DTCs is cleared.

2. Ignition ON, Engine OFF.

3. If any DTCs have snapshot capture or snapshot recording information, save the
information.
4. Ignition ON, Engine running.
5. Refresh codes. YES: Go to next step.
Is DTC 002791.00 active? NO: See Problem Not
Found Procedure.
OUMX258,00001F6 -19-16FEB16-3/6

•2 Charging System
Check
1. Check battery terminals and battery state of charge.

2. Ignition ON, engine running.

3. Check charging system for proper operation. YES: Repair problem. Go
to “Check Codes” step.
Were any problems found? NO: Go to next step.
OUMX258,00001F6 -19-16FEB16-4/6

•3 Terminal Check 1. Ignition OFF, Engine OFF.

2. Disconnect EGR valve connector Y5400.

3. Perform Terminal Test on EGR valve and Y5400 connector. YES: Repair problem. Go
to “Check Codes” step.
Were any problems found? NO: Go to next step.
OUMX258,00001F6 -19-16FEB16-5/6

•4 Circuit Check 1. Connect multimeter :

• to Y5400 connector female socket A (+).

• to Y5400 connector female socket B (-).
2. Ignition ON, Engine OFF.
3. In Service ADVISOR, monitor Unswitched Battery Voltage.
4. Monitor voltage on multimeter. YES: Replace EGR
valve. Perform Verification
Data Point Normal Range
Procedure.
Battery Voltage 10.8—14.4 V

Is reading on multimeter within +/- 0.5 V of unswitched battery voltage? NO: See engine CTM.

OUMX258,00001F6 -19-16FEB16-6/6

TM130419 (24FEB16) 235-53-2 PN=1032

030916
 Diagnose—DTCs, ECU 002000—002999

ECU 002791.01 — EGR Valve Drive Circuit Control Unit Response:

Voltage Extremely Low
The ECU derates the engine.
The EGR Valve has detected its supply voltage The ECU commands the EGR Valve fully closed.
is out of range low.
Additional References:
Trouble Shooting Sequence:
For EGR actuator location, information on how to use
002791.01 Diagnostic Test Box, and for more information on the
When DTC is Displayed: control unit information and overview test, see engine
CTM.
When the ignition is on, or engine is running, and the EGR
valve reports the fault is active. For complete wiring information:

Related Information: - see Main Schematic, T4

- see Engine Connector X5058 Schematic
This code is set when the EGR valve detects that its - see Engine Controls and Sensors Schematic
supply voltage from the ECU is out of range low.
located in Section 230, Group 20.
Alarm Level:Warning
A5502
K2
28 50 72 94
27 49 71 93 V13
26 48 70 92 Blu 671
X5058
25 47 69 91 68 Blu 670
24 46 68 90
23 45 67 89 01 Red 213 Red 212
22 44 66 88 03 Red 214
21 43 65 87
20 42 64 86 05 Red 215 Red 211 (B+) Org 420 1 6 5 4 3 2 1
19 41 63 85 54 Yel F250 Yel F250 2
18 40 62 84
17 39 61 83 76 Grn F150 Grn F150 3
16 38 60 82 4
02 Blk 128 Blk 122 12 11 10 9 8 7
15 37 59 81
14 36 58 80 04 Blk 124
13 35 57 79 06 Blk 125
12 34 56 78
11 33 55 77
Blk 121

10 32 54 76

TCT009803 —UN—13JAN14
9 31 53 75 A
8 30 52 74 B 4
7 29 51 73 A B C D 12 11 10 9 8 7
C 3
2 4 6 D 2 6 5 4 3 2 1
1
1 3 5 Y5400
R5606

EGR Valve Wiring Diagram

A5502 – 01—Supply A5502 – 05—Supply A5502 – 68—Relay Coil Control V13— Diode
A5502 – 02—Return A5502 – 06—Return K2—EGR Valve Power Relay
A5502 – 03—Supply A5502 – 54—CAN High R5606—Resistor
A5502 – 04—Return A5502 – 76—CAN Low
OUMX258,00001F7 -19-16FEB16-1/8

Diagnostic Procedure
Continued on next page OUMX258,00001F7 -19-16FEB16-2/8

TM130419 (24FEB16) 235-53-3 030916

PN=1033
 Diagnose—DTCs, ECU 002000—002999

•1 Read DTCs and Store

Snapshot Information
1. Connect Service ADVISOR.
NOTE: When DTCs are cleared, Snapshot information for ALL DTCs is cleared.

2. Ignition ON, Engine OFF.

3. If any DTCs have snapshot capture or snapshot recording information.
4. Ignition ON, Engine running.
5. Refresh codes. YES: Go to next step.
Is DTC 002791.01 active? NO: See Problem Not
Found Procedure.
OUMX258,00001F7 -19-16FEB16-3/8

•2 Charging System
Check
1. Check battery terminals and battery state of charge.

2. Ignition ON, engine running.

3. Check charging system for proper operation. YES: Repair problem. Go
to “Check Codes” step.
Were any problems found? NO: Go to next step.
OUMX258,00001F7 -19-16FEB16-4/8

•3 Continuity Check 1. Remove K2 relay from socket.

2. Measure resistance between A5502 connector female socket 1 and K2 female

socket pin 30.
3. Measure resistance between K2 female socket pin 87 and Y5400 connector
female socket A.
4. Measure resistance between A5502 connector female socket 2 and Y5400 YES: Test K2 relay. See
connector female socket B. Relay Test. Replace relay
as necessary. Perform
Verification Procedure. Go
to next step.
Are both resistances less than 5 ohms? NO: Repair high resistance
or open in harness. Perform
Verification Procedure. Go
to next step.
OUMX258,00001F7 -19-16FEB16-5/8

•4 Diode Check 1. Set multimeter to diode test.

2. Check continuity between A5502 connector female socket 68 and K2 female

socket pin 85.
3. Reverse leads and measure continuity. YES: Go to next step.
Does continuity check okay for diode test in both directions? NO: Replace diode as
necessary. Perform
Verification Procedure. Go
to next step.

Continued on next page OUMX258,00001F7 -19-16FEB16-6/8

TM130419 (24FEB16) 235-53-4 PN=1034

030916
 Diagnose—DTCs, ECU 002000—002999

•5 Terminal Check 1. Ignition OFF, Engine OFF.

2. Disconnect EGR valve connector Y5400.

3. Perform Terminal Test on EGR valve and Y5400 connector. YES: Repair problem. Go
to “Check Codes” step.
Were any problems found? NO: Go to next step.
OUMX258,00001F7 -19-16FEB16-7/8

•6 Circuit Check 1. Connect multimeter :

• to Y5400 connector female socket A (+).

• to Y5400 connector female socket B (-).
2. Ignition ON, Engine OFF.
3. In Service ADVISOR, monitor Unswitched Battery Voltage.
4. Monitor voltage on multimeter. YES: Replace EGR
valve. Perform Verification
Data Point Normal Range
Procedure.
Battery Voltage 10.8—14.4 V

Is reading on multimeter within +/- 0.5 V of unswitched battery voltage? NO: See engine CTM.
OUMX258,00001F7 -19-16FEB16-8/8

TM130419 (24FEB16) 235-53-5 PN=1035

030916
 Diagnose—DTCs, ECU 002000—002999

ECU 002791.07 — EGR Valve Position Error

The EGR valve actuator has detected an
internal feedback error.
OUMX258,00001F8 -19-16FEB16-1/3

Diagnostic Procedure
Trouble Shooting Sequence:
002791.07
When DTC is Displayed:
When the ignition is on and the EGR actuator reports the fault is active.
Related Information:
This code is set when the EGR actuator detects an internal feedback error. The EGR actuator sends a message via the
CAN communication system to the ECU stating that it has detected an internal feedback error and the ECU sets the fault.
Alarm Level:
Warning
Control Unit Response:
The ECU derates the engine.
The ECU commands the EGR Valve fully closed.
Additional References:
For EGR actuator location, information on how to use Diagnostic Test Box, and for more information on the control
unit information and overview test, see engine CTM.
For complete wiring information:
- see Main Schematic, T4
- see Engine Connector X5058 Schematic
located in Section 230, Group 20.
OUMX258,00001F8 -19-16FEB16-2/3

•1 Read DTCs and Store

Snapshot Information
1. Connect Service ADVISOR.

NOTE: When DTCs are cleared, Snapshot information for ALL DTCs is cleared.

2. Ignition ON, Engine OFF.

3. If any DTCs have snapshot capture or snapshot recording information, save the
information.
4. Ignition ON, Engine OFF.
5. Refresh codes. YES: Replace EGR
valve actuator. Perform
Verification Procedure.
Is DTC 002791.07 active? NO: See engine CTM,
“Problem Not Found
Procedure”.
OUMX258,00001F8 -19-16FEB16-3/3

TM130419 (24FEB16) 235-53-6 030916

PN=1036
 Diagnose—DTCs, ECU 002000—002999

ECU 002791.09 — EGR Valve Communication

Error The EGR valve actuator has detected an
internal data error.
OUMX258,00001F9 -19-16FEB16-1/3

Diagnostic Procedure
Trouble Shooting Sequence:
002791.09
When DTC is Displayed:
When the ignition is on and the EGR actuator reports the fault is active.
Related Information:
This code is set when the EGR actuator detects an internal data error. The EGR actuator sends a message via the
CAN communication system to the ECU stating that it has detected an internal data error and the ECU sets the fault.
Alarm Level:
Warning
Control Unit Response:
The ECU derates the engine.
The ECU commands the EGR Valve fully closed.
Additional References:
For EGR actuator location, information on how to use Diagnostic Test Box, and for more information on the control
unit information and overview test, see engine CTM.
For complete wiring information:
- see Main Schematic, T4
- see Engine Connector X5058 Schematic
located in Section 230, Group 20.
OUMX258,00001F9 -19-16FEB16-2/3

•1 Read DTCs and Store

Snapshot Information
1. Connect Service ADVISOR.

NOTE: When DTCs are cleared, Snapshot information for ALL DTCs is cleared.

2. Ignition ON, Engine OFF.

3. If any DTCs have snapshot capture or snapshot recording information, save the
information.
4. Ignition ON, Engine OFF.
5. Refresh codes. YES: Replace EGR
valve actuator. Perform
Verification Procedure.
Is DTC 002791.09 active? NO: See engine CTM,
“Problem Not Found
Procedure”.
OUMX258,00001F9 -19-16FEB16-3/3

TM130419 (24FEB16) 235-53-7 030916

PN=1037
 Diagnose—DTCs, ECU 002000—002999

ECU 002791.12 — EGR Valve Actuator

Internal Error The EGR valve actuator has detected an internal error.
OUMX258,00001FA -19-16FEB16-1/3

Diagnostic Procedure
Trouble Shooting Sequence:
002791.12
When DTC is Displayed:
When the ignition is on, or engine is running, and the EGR actuator reports the fault is active.
Related Information:
This code is set when the EGR actuator detects an internal error. The EGR actuator sends a message via the CAN
communication system to the ECU stating that it has detected an internal error and the ECU sets the fault.
Alarm Level:
Warning
Control Unit Response:
The ECU derates the engine.
The ECU commands the EGR Valve fully closed.
Additional References:
For EGR actuator location, information on how to use Diagnostic Test Box, and for more information on the control
unit information and overview test, see engine CTM.
For complete wiring information:
- see Main Schematic, T4
- see Engine Connector X5058 Schematic
located in Section 230, Group 20.
OUMX258,00001FA -19-16FEB16-2/3

•1 Read DTCs and Store

Snapshot Information
1. Connect Service ADVISOR.

NOTE: When DTCs are cleared, Snapshot information for ALL DTCs is cleared.

2. Ignition ON, Engine OFF.

3. If any DTCs have snapshot capture or snapshot recording information, save the
information.
4. Ignition ON, engine running.
5. Refresh codes. YES: Replace EGR
valve actuator. Perform
Verification Procedure.
Is DTC 002791.12 active? NO: See engine CTM,
“Problem Not Found
Procedure”.
OUMX258,00001FA -19-16FEB16-3/3

TM130419 (24FEB16) 235-53-8 030916

PN=1038
 Diagnose—DTCs, ECU 002000—002999

ECU 002797.06 — Injector High Voltage

Supply #1 Circuit Has Low Resistance The ECU has detected a problem with injector
high voltage supply #1.
OUMX258,00001FB -19-16FEB16-1/3

Diagnostic Procedure
Troubleshooting Sequence:
002797.06
When DTC is Displayed:
When the ignition is on, engine running, or cranking, and the fault is active.
Related Information:
The ECU has detected an internal problem with the injector high voltage supply #1 circuit.
The ECU supplies injectors from one common high voltage driver on three cylinder engines.
The ECU switches the low side (ground) to control each individual injector.
Alarm Level:
Warning
Control Unit Response:
The ECU tries to maintain proper operating conditions.
The ECU derates the engine.
The ECU commands the EGR Valve fully closed.
The ECU commands injection to stop for injectors.
The engine may not run when this fault is present.
The ECU will command an engine stop after two hours of continuous operation with the fault active.
Additional references:
For more electronic injector information, and for more information on the control unit information and overview test,
see engine CTM.
NOTE: The wiring diagrams provided are a basic schematic. For detailed schematics, please
refer to your applications technical manual.

For complete wiring information:

- see Main Schematic, T4
- see Engine Connector X5060 Schematic
OUMX258,00001FB -19-16FEB16-2/3

•1 Read DTCs and Store

Snapshot Information
1. Connect Service ADVISOR.

NOTE: When DTCs are cleared, Snapshot information for ALL DTCs is cleared.

2. Ignition ON, Engine OFF.

3. If any DTCs have snapshot capture or snapshot recording information, save the
information.
4. Ignition ON, cranking or engine running.
5. Refresh codes. YES: See engine CTM.
Is DTC 002797.06 active? NO: See Problem Not
Found Procedure.
OUMX258,00001FB -19-16FEB16-3/3

TM130419 (24FEB16) 235-53-9 030916

PN=1039
 Diagnose—DTCs, ECU 002000—002999

ECU 002798.06 — Injector High Voltage

Supply #2 Circuit Has Low Resistance The ECU has detected a problem with injector
high voltage supply #2.
OUMX258,00001FC -19-16FEB16-1/3

Diagnostic Procedure
Troubleshooting Sequence:
002798.06
When DTC is Displayed:
When the ignition is on, engine running, and the fault is active.
Related Information:
The ECU has detected an internal problem with the injector high voltage supply #2 circuit.
The ECU supplies injectors from one common high voltage driver on three cylinder engines.
The ECU switches the low side (ground) to control each individual injector.
Alarm Level:
Warning
Control Unit Response:
The ECU tries to maintain proper operating conditions.
The ECU derates the engine.
The ECU commands the EGR Valve fully closed.
The ECU commands injection to stop for injectors #2 and #3.
The ECU will command an engine stop after two hours of continuous operation with the fault active.
Additional references:
For more electronic injector information, and for more information on the control unit information and overview test,
see engine CTM.
NOTE: The wiring diagrams provided are a basic schematic. For detailed schematics, please
refer to your applications technical manual.

For complete wiring information:

- see Main Schematic, T4
- see Engine Connector X5060 Schematic
OUMX258,00001FC -19-16FEB16-2/3

•1 Read DTCs and Store

Snapshot Information
1. Connect Service ADVISOR.

NOTE: When DTCs are cleared, Snapshot information for ALL DTCs is cleared.

2. Ignition ON, Engine OFF.

3. If any DTCs have snapshot capture or snapshot recording information, save the
information.
4. Ignition ON, engine running.
5. Refresh codes. YES: Go engine CTM.
Is DTC 002798.06 active? NO: See Problem Not
Found Procedure.
OUMX258,00001FC -19-16FEB16-3/3

TM130419 (24FEB16) 235-53-10 030916

PN=1040
 Diagnose—DTCs, ECU 002000—002999

ECU 002950.03 — Air Throttle Actuator Drive Warning

Circuit 1 Out of Range High Control Unit Response:
The ECU derates the engine.
The ECU has detected high voltage on the air The ECU commands the air throttle actuator fully open.
throttle actuator drive circuit 1. The ECU commands the EGR Valve fully closed.
Troubleshooting Sequence: The ECU will abort an active regeneration.
002950.03 Additional references:
When DTC is Displayed: For component location, more air throttle actuator
When the ignition is on, engine is running, and the fault information, and information on how to use Diagnostic
is active. Test Box, see engine CTM.

Related Information: For complete wiring information:

The ECU has detected the air throttle actuator drive circuit - see Main Schematic, T4
1 is out of range high. - see Engine Connector X5058 Schematic

Alarm Level:

A5502

28 50 72 94
27 49 71 93
26 48 70 92
25 47 69 91
24
23
46
45
68
67
90
89
X5058
22 44 66 88
21 43 65 87
20 42 64 86
19 41 63 85
18 40 62 84 23 Pnk 421 5
17 39 61 83 6 6 5 4 3 2 1
20 Grn 422
16 38 60 82 52 Brn 423 7
15 37 59 81 8
14 36 58 80
13 35 57 79 9 12 11 10 9 8 7
12 34 56 78
11 33 55 77
10 32 54 76
9 31 53 75
8 30 52 74
7 29 51 73 Y5401
9
2 4 6 12 11 10 9 8 7 8 A
7 B
6 5 4 3 2 1 A B C D E F
1 3 5 6 C
5 E
F
A5501

15 30 45 60
14 29 44 59
13 28 43 58
12 27 42 57
11 26 41 56
10 25 40 55
9 24 39 54 19 Org 424
8 23 38 53 20 Wht 425
7 22 37 52

TCT009802 —UN—13JAN14
6 21 36 51
5 20 35 50
4 19 34 49
3 18 33 48
2 17 32 47
1 16 31 46

Air Throttle Actuator Wiring Diagram

A5501—19—Drive (+) A5502—20—Signal A5502—52—Return
A5501—20—Drive (-) A5502—23—Supply
OUMX258,00001FD -19-16FEB16-1/7

Diagnostic Procedure
Continued on next page OUMX258,00001FD -19-16FEB16-2/7

TM130419 (24FEB16) 235-53-11 030916

PN=1041
 Diagnose—DTCs, ECU 002000—002999

•1 Read DTCs and Store

Snapshot Information
1. Connect Service ADVISOR.
NOTE: When DTCs are cleared, Snapshot information for ALL DTCs is cleared.

2. Ignition ON, Engine OFF.

3. If any DTCs have snapshot capture or snapshot recording information, save the
information.
4. Refresh codes. YES: Go to next step.
Is DTC 002950.03 active? NO: Perform Verification
Procedure.
OUMX258,00001FD -19-16FEB16-3/7

•2 Terminal Check 1. Ignition OFF, Engine OFF.

2. Disconnect air throttle actuator connector Y5401.

3. Perform Terminal Test on air throttle actuator and Y5401 connector. YES: Repair problem.
Perform Verification
Procedure.
Were any problems found? NO: Go to next step.
OUMX258,00001FD -19-16FEB16-4/7

•3 Terminal Check 1. Disconnect ECU connectors A5501 and A5502.

2. Perform Terminal Test on A5501 connector female sockets 19, 20, and A5502 YES: Repair problem.
connector female sockets 20, 23, 52. And corresponding ECU male pins. Perform Verification
Procedure.
Were any problems found? NO: Go to next step.
OUMX258,00001FD -19-16FEB16-5/7

•4 Wire to Wire Check On A5501 connector, measure resistance between female sockets 19 and 20 while
performing Wiggle Test.
YES: Go to next step.

Is resistance always greater than 100k ohms? NO: Repair short in

wiring harness. Perform
Verification Procedure.

OUMX258,00001FD -19-16FEB16-6/7

•5 Replace Air Throttle

Actuator
1. Replace air throttle actuator.

2. Ignition ON, Engine OFF.

NOTE: Ignore any air throttle actuator codes except for DTC 002950.03.
3. Refresh codes. YES: See engine CTM.
Is DTC 002950.03 active? NO: Perform Verification
Procedure.

OUMX258,00001FD -19-16FEB16-7/7

TM130419 (24FEB16) 235-53-12 030916

PN=1042
 Diagnose—DTCs, ECU 002000—002999

ECU 002950.04 — Air Throttle Actuator Drive Warning

Circuit 1 Out of Range Low Control Unit Response:
The ECU derates the engine.
The ECU has detected low voltage on the air The ECU commands the Air Throttle Actuator fully open.
throttle actuator drive circuit 1. The ECU commands the EGR valve fully closed.
Troubleshooting Sequence: The ECU will abort an active regeneration.
002950.04 Additional references:
When DTC is Displayed: For component location, more air throttle actuator
When the ignition is ON, engine is running, and the fault information, and information on how to use Diagnostic
is active. Test Box, see engine CTM.

Related Information: For complete wiring information:

The ECU has detected the air throttle actuator drive circuit - see Main Schematic, T4
1 is out of range low. - see Engine Connector X5058 Schematic

Alarm Level:

A5502

28 50 72 94
27 49 71 93
26 48 70 92
25 47 69 91
24
23
46
45
68
67
90
89
X5058
22 44 66 88
21 43 65 87
20 42 64 86
19 41 63 85
18 40 62 84 23 Pnk 421 5
17 39 61 83 6 6 5 4 3 2 1
20 Grn 422
16 38 60 82 52 Brn 423 7
15 37 59 81 8
14 36 58 80
13 35 57 79 9 12 11 10 9 8 7
12 34 56 78
11 33 55 77
10 32 54 76
9 31 53 75
8 30 52 74
7 29 51 73 Y5401
9
2 4 6 12 11 10 9 8 7 8 A
7 B
6 5 4 3 2 1 A B C D E F
1 3 5 6 C
5 E
F
A5501

15 30 45 60
14 29 44 59
13 28 43 58
12 27 42 57
11 26 41 56
10 25 40 55
9 24 39 54 19 Org 424
8 23 38 53 20 Wht 425
7 22 37 52

TCT009802 —UN—13JAN14
6 21 36 51
5 20 35 50
4 19 34 49
3 18 33 48
2 17 32 47
1 16 31 46

Air Throttle Actuator Wiring Diagram

A5501—19—Drive (+) A5502—20—Signal A5502—52—Return
A5501—20—Drive (-) A5502—23—Supply
OUMX258,00001FE -19-16FEB16-1/7

Diagnostic Procedure
Continued on next page OUMX258,00001FE -19-16FEB16-2/7

TM130419 (24FEB16) 235-53-13 030916

PN=1043
 Diagnose—DTCs, ECU 002000—002999

•1 Read DTCs and Store

Snapshot Information
1. Connect Service ADVISOR.
NOTE: When DTCs are cleared, Snapshot information for ALL DTCs is cleared.

2. Ignition ON, Engine OFF.

3. If any DTCs have snapshot capture or snapshot recording information, save the
information.
4. Refresh codes. YES: Go to next step.
Is DTC 002950.04 active? NO: Perform Verification
Procedure.
OUMX258,00001FE -19-16FEB16-3/7

•2 Terminal Check 1. Ignition OFF, Engine OFF.

2. Disconnect air throttle actuator connector Y5401.

3. Perform Terminal Test on air throttle actuator and Y5401 connector. YES: Repair problem.
Perform Verification
Procedure.
Were any problems found? NO: Go to next step.
OUMX258,00001FE -19-16FEB16-4/7

•3 Terminal Check 1. Disconnect ECU connectors A5501 and A5502.

2. Perform Terminal Test on A5501 connector female sockets 19, 20, and A5502 YES: Repair problem.
connector female sockets 20, 23, and 52. And corresponding ECU male pins. Perform Verification
Procedure.
Were any problems found? NO: Go to next step.
OUMX258,00001FE -19-16FEB16-5/7

•4 Wire to Wire Check On A5501 connector, measure resistance between female sockets 19 and 20 while
performing Wiggle Test.
YES: Go to next step.

Is resistance always greater than 100k ohms? NO: Repair short in

wiring harness. Perform
Verification Procedure.

OUMX258,00001FE -19-16FEB16-6/7

•5 Replace Air Throttle

Actuator
1. Replace air throttle actuator.

2. Ignition ON, Engine OFF.

NOTE: Ignore any air throttle actuator codes except for DTC 002950.04.
3. Refresh codes. YES: See engine CTM.
Is DTC 002950.04 active? NO: Perform Verification
Procedure.

OUMX258,00001FE -19-16FEB16-7/7

TM130419 (24FEB16) 235-53-14 030916

PN=1044
 Diagnose—DTCs, ECU 002000—002999

ECU 002950.05 — Air Throttle Actuator Drive Warning

Circuit Has High Resistance Control Unit Response:
The ECU derates the engine.
The ECU has detected high resistance on the air The ECU commands the Air Throttle Actuator fully open.
throttle actuator drive circuit. The ECU commands the EGR Valve fully closed.
Troubleshooting Sequence: The ECU will abort an active regeneration.
002950.05 Additional references:
When DTC is Displayed: For component location, more air throttle actuator
When the ignition is on and the fault is active. information, and information on how to use Diagnostic
Test Box, see engine CTM.
Related Information:
The ECU has detected that there is a fault on the air For complete wiring information:
throttle actuator drive circuit. - see Main Schematic, T4
- see Engine Connector X5058 Schematic
Alarm Level:

A5502

28 50 72 94
27 49 71 93
26 48 70 92
25 47 69 91
24
23
46
45
68
67
90
89
X5058
22 44 66 88
21 43 65 87
20 42 64 86
19 41 63 85
18 40 62 84 23 Pnk 421 5
17 39 61 83 6 6 5 4 3 2 1
20 Grn 422
16 38 60 82 52 Brn 423 7
15 37 59 81 8
14 36 58 80
13 35 57 79 9 12 11 10 9 8 7
12 34 56 78
11 33 55 77
10 32 54 76
9 31 53 75
8 30 52 74
7 29 51 73 Y5401
9
2 4 6 12 11 10 9 8 7 8 A
7 B
6 5 4 3 2 1 A B C D E F
1 3 5 6 C
5 E
F
A5501

15 30 45 60
14 29 44 59
13 28 43 58
12 27 42 57
11 26 41 56
10 25 40 55
9 24 39 54 19 Org 424
8 23 38 53 20 Wht 425
7 22 37 52

TCT009802 —UN—13JAN14
6 21 36 51
5 20 35 50
4 19 34 49
3 18 33 48
2 17 32 47
1 16 31 46

Air Throttle Actuator Wiring Diagram

A5501—19—Drive (+) A5502—20—Signal A5502—52—Return
A5501—20—Drive (-) A5502—23—Supply
OUMX258,00001FF -19-16FEB16-1/10

Diagnostic Procedure
Continued on next page OUMX258,00001FF -19-16FEB16-2/10

TM130419 (24FEB16) 235-53-15 030916

PN=1045
 Diagnose—DTCs, ECU 002000—002999

•1 Read DTCs and Store

Snapshot Information
1. Connect Service ADVISOR.
NOTE: When DTCs are cleared Snapshot information for ALL DTCs is cleared.

2. Ignition ON, Engine OFF.

3. If any DTCs have snapshot capture or snapshot recording information, save the YES: Go to next step.
information.
Is DTC 002950.05.05 active? NO: Perform Verification
Procedure.
OUMX258,00001FF -19-16FEB16-3/10

•2 Terminal Check 1. Ignition OFF, Engine OFF.

2. Disconnect Air Throttle Actuator connector Y5401.

3. Perform Terminal Test on Air Throttle Actuator and Y5401 connector. YES: Repair problem.
Perform Verification
Procedure.
Were any problems found? NO: Go to next step.
OUMX258,00001FF -19-16FEB16-4/10

•3 Terminal Check 1. Disconnect ECU connector A5501.

2. Perform Terminal Test on A5501 connector female sockets 19, 20, and A5502 YES: Repair problem.
connector female sockets 20, 23, and 52. And corresponding ECU male pins. Perform Verification
Procedure.
Were any problems found? NO: Go to next step.
OUMX258,00001FF -19-16FEB16-5/10

•4 Short to Voltage Check 1. Ignition ON, Engine OFF

2. Measure the voltage between Y5401 connector female socket A (+) and single
point ground.
3. Measure the voltage between Y5401 connector female socket B (+) and single YES: See Short to Voltage
point ground. Procedure
Is either measurement greater than 0.5 V? NO: Go to next step.

OUMX258,00001FF -19-16FEB16-6/10

•5 Continuity Check 1. Ignition OFF, Engine OFF

2. Measure resistance between A5501 connector female socket 20 and Y5401

connector female socket A.
3. Measure resistance between A5501 connector female socket 19 and Y5401 YES: Go to next step.
connector female socket B.
Are both resistance measurements less than 5 Ohms? NO: Repair open, high
resistance, or mis-pin
in harness. Perform
Verification Procedure.

Continued on next page OUMX258,00001FF -19-16FEB16-7/10

TM130419 (24FEB16) 235-53-16 030916

PN=1046
 Diagnose—DTCs, ECU 002000—002999

•6 Short to Ground Check 1. Reconnect ECU connector A5501.

2. Measure resistance between Y5401 connector female socket A and single point
ground.
3. Measure resistance between Y5401 connector female socket B and single point YES: Repair drive wire
ground. short to ground in harness.
Perform Verification
Procedure.
Is either measurement less than 100 Ohms? NO: Go to next step.
OUMX258,00001FF -19-16FEB16-8/10

•7 Wire to Wire Check 1. Measure resistance between A5501 connector female socket 19 and all other
sockets in A5501.

2. Measure resistance between A5501 connector female socket 20 and all other YES: Repair drive wire
sockets in A5501. short in harness. Perform
Verification Procedure.
Is any measurement less than 100k Ohms? NO: Go to next step.
OUMX258,00001FF -19-16FEB16-9/10

•8 Replace Air Throttle

Actuator
1. Ignition OFF, Engine OFF.

2. Replace air throttle actuator.

3. Reconnect all components.
4. Ignition ON, Engine Running.
5. Wait 90 seconds. Refresh DTCs. YES: See engine CTM.
Is DTC 002950.05 active? NO: Perform Verification
Procedure.
OUMX258,00001FF -19-16FEB16-10/10

TM130419 (24FEB16) 235-53-17 PN=1047

030916
 Diagnose—DTCs, ECU 002000—002999

ECU 002950.06 — Air Throttle Actuator Drive Warning

Circuit Has Low Resistance Control Unit Response:
The ECU derates the engine.
The ECU has detected low resistance on the air The ECU commands the Air Throttle Actuator fully open.
throttle actuator drive circuit. The ECU commands the EGR Valve fully closed.
Troubleshooting Sequence: The ECU will abort an active regeneration.
002950.06 Additional references:
When DTC is Displayed: For component location, more air throttle actuator
When the ignition is on and the fault is active. information, and information on how to use Diagnostic
Test Box, see engine CTM.
Related Information:
The ECU has detected that there is a fault on the air For complete wiring information:
throttle actuator drive circuit. - see Main Schematic, T4
- see Engine Connector X5058 Schematic
Alarm Level:

A5502

28 50 72 94
27 49 71 93
26 48 70 92
25 47 69 91
24
23
46
45
68
67
90
89
X5058
22 44 66 88
21 43 65 87
20 42 64 86
19 41 63 85
18 40 62 84 23 Pnk 421 5
17 39 61 83 6 6 5 4 3 2 1
20 Grn 422
16 38 60 82 52 Brn 423 7
15 37 59 81 8
14 36 58 80
13 35 57 79 9 12 11 10 9 8 7
12 34 56 78
11 33 55 77
10 32 54 76
9 31 53 75
8 30 52 74
7 29 51 73 Y5401
9
2 4 6 12 11 10 9 8 7 8 A
7 B
6 5 4 3 2 1 A B C D E F
1 3 5 6 C
5 E
F
A5501

15 30 45 60
14 29 44 59
13 28 43 58
12 27 42 57
11 26 41 56
10 25 40 55
9 24 39 54 19 Org 424
8 23 38 53 20 Wht 425
7 22 37 52

TCT009802 —UN—13JAN14
6 21 36 51
5 20 35 50
4 19 34 49
3 18 33 48
2 17 32 47
1 16 31 46

Air Throttle Actuator Wiring Diagram

A5501—19—Drive (+) A5502—20—Signal A5502—52—Return
A5501—20—Drive (-) A5502—23—Supply
OUMX258,0000200 -19-16FEB16-1/10

Diagnostic Procedure
Continued on next page OUMX258,0000200 -19-16FEB16-2/10

TM130419 (24FEB16) 235-53-18 030916

PN=1048
 Diagnose—DTCs, ECU 002000—002999

•1 Read DTCs and Store

Snapshot Information
1. Connect Service ADVISOR.
NOTE: When DTCs are cleared Snapshot information for ALL DTCs is cleared.

2. Ignition ON, Engine OFF.

3. If any DTCs have snapshot capture or snapshot recording information, save the YES: Go to next step.
information.
Is DTC 002950.06 active? NO: Perform Verification
Procedure.
OUMX258,0000200 -19-16FEB16-3/10

•2 Terminal Check 1. Ignition OFF, Engine OFF.

2. Disconnect air throttle actuator connector Y5401.

3. Perform Terminal Test on air throttle actuator and Y5401 connector. YES: Repair problem.
Perform Verification
Procedure.
Were any problems found? NO: Go to next step.
OUMX258,0000200 -19-16FEB16-4/10

•3 Terminal Check 1. Disconnect ECU connector A5501.

2. Perform Terminal Test on A5501 connector female sockets 19, 20, and A5502 YES: Repair problem.
connector female sockets 20, 23, and 52. And corresponding ECU male pins. Perform Verification
Procedure.
Were any problems found? NO: Go to next step.
OUMX258,0000200 -19-16FEB16-5/10

•4 Short to Voltage Check 1. Ignition ON, Engine OFF

2. Measure the voltage between Y5401 connector female socket A (+) and single
point ground.
3. Measure the voltage between Y5401 connector female socket B (+) and single YES: See Short to Voltage
point ground. Procedure.
Is either measurement greater than 0.5 V? NO: Go to next step.

OUMX258,0000200 -19-16FEB16-6/10

•5 Continuity Check 1. Ignition OFF, Engine OFF

2. Measure resistance between A5501 connector female socket 20 and Y5401

connector female socket A.
3. Measure resistance between A5501 connector female socket 19 and Y5401 YES: Go to next step.
connector female socket B.
Are both resistance measurements less than 5 Ohms? NO: Repair open, high
resistance, or mis-pin
in harness. Perform
Verification Procedure.

Continued on next page OUMX258,0000200 -19-16FEB16-7/10

TM130419 (24FEB16) 235-53-19 030916

PN=1049
 Diagnose—DTCs, ECU 002000—002999

•6 Short to Ground Check 1. Reconnect ECU connector A5501.

2. Measure resistance between Y5401 connector female socket A and single point
ground.
3. Measure resistance between Y5401 connector female socket B and single point YES: Repair drive wire
ground. short to ground in harness.
Perform Verification
Procedure.
Is either measurement less than 100 Ohms? NO: Go to next step.
OUMX258,0000200 -19-16FEB16-8/10

•7 Wire to Wire Check 1. Measure resistance between A5501 connector female socket 19 and all other
sockets in A5501.

2. Measure resistance between A5501 connector female socket 20 and all other YES: Repair drive wire
sockets in A5501. short in harness. Perform
Verification Procedure.
Is any measurement less than 100k Ohms? NO: Go to next step.
OUMX258,0000200 -19-16FEB16-9/10

•8 Replace Air Throttle

Actuator
1. Ignition OFF, Engine OFF.

2. Replace air throttle actuator.

3. Reconnect all components.
4. Ignition ON, engine running.
5. Wait 90 seconds. Refresh DTCs. YES: See engine CTM.
Is DTC 002950.05 active? NO: Perform Verification
Procedure.
OUMX258,0000200 -19-16FEB16-10/10

TM130419 (24FEB16) 235-53-20 PN=1050

030916
 Diagnose—DTCs, ECU 002000—002999

ECU 002951.03 — Air Throttle Actuator Drive Control Unit Response:

Circuit 2 Out of Range High The ECU derates the engine.
The ECU commands the Air Throttle Actuator fully open.
The ECU has detected high voltage on the air The ECU commands the EGR valve fully closed.
throttle actuator drive circuit 2. The ECU will abort an active regeneration.
The ECU will command an engine stop after two hours of
Troubleshooting Sequence: continuous operation with the fault active.
002951.03
Additional references:
When DTC is Displayed: For component location, more air throttle actuator
When the ignition is on and the fault is active. information, and information on how to use Diagnostic
Related Information: Test Box, see engine CTM.
The ECU has detected the air throttle actuator drive circuit For complete wiring information:
2 is out of range high. - see Main Schematic, T4
Alarm Level: - see Engine Connector X5058 Schematic
Warning

A5502

28 50 72 94
27 49 71 93
26 48 70 92
25 47 69 91
24
23
46
45
68
67
90
89
X5058
22 44 66 88
21 43 65 87
20 42 64 86
19 41 63 85
18 40 62 84 23 Pnk 421 5
17 39 61 83 6 6 5 4 3 2 1
20 Grn 422
16 38 60 82 52 Brn 423 7
15 37 59 81 8
14 36 58 80
13 35 57 79 9 12 11 10 9 8 7
12 34 56 78
11 33 55 77
10 32 54 76
9 31 53 75
8 30 52 74
7 29 51 73 Y5401
9
2 4 6 12 11 10 9 8 7 8 A
7 B
6 5 4 3 2 1 A B C D E F
1 3 5 6 C
5 E
F
A5501

15 30 45 60
14 29 44 59
13 28 43 58
12 27 42 57
11 26 41 56
10 25 40 55
9 24 39 54 19 Org 424
8 23 38 53 20 Wht 425
7 22 37 52

TCT009802 —UN—13JAN14
6 21 36 51
5 20 35 50
4 19 34 49
3 18 33 48
2 17 32 47
1 16 31 46

Air Throttle Actuator Wiring Diagram

A5501—19—Drive (+) A5502—20—Signal A5502—52—Return
A5501—20—Drive (-) A5502—23—Supply
OUMX258,0000201 -19-16FEB16-1/10

Diagnostic Procedure
Continued on next page OUMX258,0000201 -19-16FEB16-2/10

TM130419 (24FEB16) 235-53-21 030916

PN=1051
 Diagnose—DTCs, ECU 002000—002999

•1 Read DTCs and Store

Snapshot Information
1. Connect Service ADVISOR.
NOTE: When DTCs are cleared Snapshot information for ALL DTCs is cleared.

2. Ignition ON, Engine OFF.

3. If any DTCs have snapshot capture or snapshot recording information, save the YES: Go to next step.
information.
Is DTC 002951.03 active? NO: Perform Verification
Procedure.
OUMX258,0000201 -19-16FEB16-3/10

•2 Terminal Check 1. Ignition OFF, Engine OFF.

2. Disconnect air throttle actuator connector Y5401.

3. Perform Terminal Test on air throttle actuator and Y5401 connector. YES: Repair problem.
Perform Verification
Procedure.
Were any problems found? NO: Go to next step.
OUMX258,0000201 -19-16FEB16-4/10

•3 Terminal Check 1. Disconnect ECU connector A5501.

2. Perform Terminal Test on A5501 connector female sockets 19, 20, and A5502 YES: Repair problem.
connector female sockets 20, 23, and 52. And corresponding ECU male pins. Perform Verification
Procedure.
Were any problems found? NO: Go to next step.
OUMX258,0000201 -19-16FEB16-5/10

•4 Short to Voltage Check 1. Ignition ON, Engine OFF

2. Measure the voltage between Y5401 connector female socket A (+) and single
point ground.
3. Measure the voltage between Y5401 connector female socket B (+) and single YES: See Short to Voltage
point ground. Procedure.
Is either measurement greater than 0.5 V? NO: Go to next step.

OUMX258,0000201 -19-16FEB16-6/10

•5 Continuity Check 1. Ignition OFF, Engine OFF

2. Measure resistance between A5501 connector female socket 20 and Y5401

connector female socket A.
3. Measure resistance between A5501 connector female socket 19 and Y5401 YES: Go to next step.
connector female socket B.
Are both resistance measurements less than 5 Ohms? NO: Repair open, high
resistance, or mis-pin
in harness. Perform
Verification Procedure.

Continued on next page OUMX258,0000201 -19-16FEB16-7/10

TM130419 (24FEB16) 235-53-22 030916

PN=1052
 Diagnose—DTCs, ECU 002000—002999

•6 Short to Ground Check 1. Reconnect ECU connector A5501.

2. Measure resistance between Y5401 connector female socket A and single point
ground.
3. Measure resistance between Y5401 connector female socket B and single point YES: Repair drive wire
ground. short to ground in harness.
Perform Verification
Procedure.
Is either measurement less than 100 Ohms? NO: Go to next step.
OUMX258,0000201 -19-16FEB16-8/10

•7 Wire to Wire Check 1. Measure resistance between A5501 connector female socket 19 and all other
sockets in A5501.

2. Measure resistance between A5501 connector female socket 20 and all other YES: Repair drive wire
sockets in A5501. short in harness. Perform
Verification Procedure.
Is any measurement less than 100k Ohms? NO: Go to next step.
OUMX258,0000201 -19-16FEB16-9/10

•8 Replace Air Throttle

Actuator
1. Ignition OFF, Engine OFF.

2. Replace air throttle actuator.

3. Reconnect all components.
4. Ignition ON, Engine Running.
5. Wait 90 seconds. Refresh DTCs. YES: See engine CTM.
Is DTC 002950.05 active? NO: Perform Verification
Procedure.
OUMX258,0000201 -19-16FEB16-10/10

TM130419 (24FEB16) 235-53-23 PN=1053

030916
 Diagnose—DTCs, ECU 002000—002999

ECU 002951.04 — Air Throttle Actuator Drive Warning

Circuit 2 Out of Range Low Control Unit Response:
The ECU derates the engine.
The ECU has detected low voltage on the air The ECU commands the Air Throttle Actuator fully open.
throttle actuator drive circuit. The ECU commands the EGR Valve fully closed.
Troubleshooting Sequence: The ECU will abort an active regeneration.
002951.04 Additional references:
When DTC is Displayed: For component location, more air throttle actuator
When the ignition is on and the fault is active. information, and information on how to use Diagnostic
Test Box, see engine CTM.
Related Information:
The ECU has detected the air throttle actuator drive circuit For complete wiring information:
2 is out of range low. - see Main Schematic, T4
- see Engine Connector X5058 Schematic
Alarm Level:

A5502

28 50 72 94
27 49 71 93
26 48 70 92
25 47 69 91
24
23
46
45
68
67
90
89
X5058
22 44 66 88
21 43 65 87
20 42 64 86
19 41 63 85
18 40 62 84 23 Pnk 421 5
17 39 61 83 6 6 5 4 3 2 1
20 Grn 422
16 38 60 82 52 Brn 423 7
15 37 59 81 8
14 36 58 80
13 35 57 79 9 12 11 10 9 8 7
12 34 56 78
11 33 55 77
10 32 54 76
9 31 53 75
8 30 52 74
7 29 51 73 Y5401
9
2 4 6 12 11 10 9 8 7 8 A
7 B
6 5 4 3 2 1 A B C D E F
1 3 5 6 C
5 E
F
A5501

15 30 45 60
14 29 44 59
13 28 43 58
12 27 42 57
11 26 41 56
10 25 40 55
9 24 39 54 19 Org 424
8 23 38 53 20 Wht 425
7 22 37 52

TCT009802 —UN—13JAN14
6 21 36 51
5 20 35 50
4 19 34 49
3 18 33 48
2 17 32 47
1 16 31 46

Air Throttle Actuator Wiring Diagram

A5501—19—Drive (+) A5502—20—Signal A5502—52—Return
A5501—20—Drive (-) A5502—23—Supply
OUMX258,0000202 -19-16FEB16-1/10

Diagnostic Procedure
Continued on next page OUMX258,0000202 -19-16FEB16-2/10

TM130419 (24FEB16) 235-53-24 030916

PN=1054
 Diagnose—DTCs, ECU 002000—002999

•1 Read DTCs and Store

Snapshot Information
1. Connect Service ADVISOR.
NOTE: When DTCs are cleared Snapshot information for ALL DTCs is cleared.

2. Ignition ON, Engine OFF.

3. If any DTCs have snapshot capture or snapshot recording information, save the YES: Go to next step.
information..
Is DTC 002951.04 active? NO: Perform Verification
Procedure.
OUMX258,0000202 -19-16FEB16-3/10

•2 Terminal Check 1. Ignition OFF, Engine OFF.

2. Disconnect air throttle actuator connector Y5401.

3. Perform Terminal Test on air throttle actuator and Y5401 connector. YES: Repair problem.
Perform Verification
Procedure.
Were any problems found? NO: Go to next step.
OUMX258,0000202 -19-16FEB16-4/10

•3 Terminal Check 1. Disconnect ECU connector A5501.

2. Perform Terminal Test on A5501 connector female sockets 19, 20, and A5502 YES: Repair problem.
connector female sockets 20, 23, and 52. And corresponding ECU male pins. Perform Verification
Procedure.
Were any problems found? NO: Go to next step.
OUMX258,0000202 -19-16FEB16-5/10

•4 Short to Voltage Check 1. Ignition ON, Engine OFF

2. Measure the voltage between Y5401 connector female socket A (+) and single
point ground.
3. Measure the voltage between Y5401 connector female socket B (+) and single YES: See Short to Voltage
point ground. Procedure.
Is either measurement greater than 0.5 V? NO: Go to next step.

OUMX258,0000202 -19-16FEB16-6/10

•5 Continuity Check 1. Ignition OFF, Engine OFF

2. Measure resistance between A5501 connector female socket 20 and Y5401

connector female socket A.
3. Measure resistance between A5501 connector female socket 19 and Y5401 YES: Go to next step.
connector female socket B.
Are both resistance measurements less than 5 Ohms? NO: Repair open, high
resistance, or mis-pin
in harness. Perform
Verification Procedure.

Continued on next page OUMX258,0000202 -19-16FEB16-7/10

TM130419 (24FEB16) 235-53-25 030916

PN=1055
 Diagnose—DTCs, ECU 002000—002999

•6 Short to Ground Check 1. Reconnect ECU connector A5501.

2. Measure resistance between Y5401 connector female socket A and single point
ground.
3. Measure resistance between Y5401 connector female socket B and single point YES: Repair drive wire
ground. short to ground in harness.
Perform Verification
Procedure.
Is either measurement less than 100 Ohms? NO: Go to next step.
OUMX258,0000202 -19-16FEB16-8/10

•7 Wire to Wire Check 1. Measure resistance between A5501 connector female socket 19 and all other
sockets in A5501.

2. Measure resistance between A5501 connector female socket 20 and all other YES: Repair drive wire
sockets in A5501. short in harness. Perform
Verification Procedure.
Is any measurement less than 100k Ohms? NO: Go to next step.
OUMX258,0000202 -19-16FEB16-9/10

•8 Replace Air Throttle

Actuator
1. Ignition OFF, Engine OFF.

2. Replace air throttle actuator.

3. Reconnect all components.
4. Ignition ON, engine running.
5. Wait 90 seconds. Refresh DTCs. YES: See engine CTM.
Is DTC 002950.05 active? NO: Perform Verification
Procedure.
OUMX258,0000202 -19-16FEB16-10/10

TM130419 (24FEB16) 235-53-26 PN=1056

030916
 Group 54
Diagnose—DTCs, ECU 003000—003999
ECU 003242.00 — DOC Inlet Temperature Alarm Level:
Extremely High
Warning
The ECU has detected that the DOC inlet temperature Control Unit Response:
is less than the specification.
The ECU derates the engine.
Troubleshooting Sequence:
Additional References:For sensor location, more
Any DTC temperature sensor information, information on how
003242.00 to use Diagnostic Test Box, more information on
the Aftertreatment Verification Procedure, and more
When DTC is Displayed: information on the Service Regeneration test, see engine
CTM.
When the ignition is on, the engine is running, and the
fault is active. For complete wiring information:
Related Information: - see Main Schematic, T4
The DOC inlet temperature sensor signal voltage to the - see Engine Controls and Sensors Schematic
ECU corresponds to a temperature greater than what is
physically possible for the DOC inlet temperature sensor. located in Section 230, Group 20.

A5502

28 50 72 94
27 49 71 93
26 48 70 92
25
24
47
46
69
68
91
90
B5201
23 45 67 89
22 44 66 88
21 43 65 87
20 42 64 86
19 41 63 85
18 40 62 84
17 39 61 83 81 Wht 910 1
16 38 60 82 2 1
77 Brn 360 Brn 363 2
15 37 59 81
14 36 58 80
13 35 57 79
12 34 56 78
11 33 55 77
10 32 54 76

TCT010217 —UN—20JAN14
9 31 53 75
8 30 52 74
7 29 51 73
2 4 6

1 3 5

DOC Inlet Temperature Sensor Wiring Diagram

A5502—77—Return A5502—81—Signal

OUMX258,0000203 -19-16FEB16-1/5

Diagnostic Procedure
Continued on next page OUMX258,0000203 -19-16FEB16-2/5

TM130419 (24FEB16) 235-54-1 030916

PN=1057
 Diagnose—DTCs, ECU 003000—003999

•1 Read DTCs and Store

Snapshot Information
1. Connect Service ADVISOR.

2. Ignition ON, Engine OFF.

3. Ignition OFF, Engine OFF.
4. Disconnect DOC inlet temperature sensor connector B5201.
5. Perform Terminal Test on sensor and B5201 connector. YES: Repair problem.
Perform Aftertreatment
Verification Procedure.
Were any problems found? NO: Go to next step.
OUMX258,0000203 -19-16FEB16-3/5

•2 Circuit Check 1. Ignition ON, Engine OFF.

2. In Service ADVISOR, monitor DOC Inlet Temperature Input Voltage.

3. Perform Wiggle Test.
Data Point Normal Range YES: Go to next step.
DOC Inlet Temperature Input Voltage 2.8—3.2 V

Is voltage between 2.8 and 3.2 V? NO: See engine CTM.

OUMX258,0000203 -19-16FEB16-4/5

•3 Condition Check 1. Ignition OFF, Engine OFF.

2. Reconnect all connectors and components.

3. Inspect for possible causes of high exhaust temperatures such as: YES: Repair problem.
Perform Verification
• Fuel injection system problems
• Turbocharger compressor inlet restrictions (if applicable) Procedure.
• DOC inlet piping damage
• Excessive blow-by
• Turbocharger system problems (if applicable)
• EGR system problems
Were any problems found? NO: Replace sensor.
Perform Verification
Procedure.
OUMX258,0000203 -19-16FEB16-5/5

TM130419 (24FEB16) 235-54-2 030916

PN=1058
 Diagnose—DTCs, ECU 003000—003999

ECU 003242.03 — DOC Inlet Temperature Control Unit Response:

Signal Out of Range High
The ECU derates the engine.
The DOC inlet temperature sensor signal exceeds The ECU commands the EGR Valve fully closed.
the sensor high voltage specification.
The ECU aborts an active regeneration.
Troubleshooting Sequence:
Additional References:
003242.03
For sensor location, more temperature sensor information,
When DTC is Displayed: information on how to use Diagnostic Test Box, more
When the ignition is on, the engine is running, and the information on the Aftertreatment Verification Procedure,
fault is active. and more information on the Service Regeneration test,
see engine CTM.
Related Information:
For complete wiring information:
The DOC inlet temperature sensor signal voltage to the
ECU corresponds to a temperature higher than what is - see Main Schematic, T4
physically possible for the DOC inlet temperature sensor. - see Engine Controls and Sensors Schematic
Alarm Level: located in Section 230, Group 20.
Stop

A5502

28 50 72 94
27 49 71 93
26 48 70 92
25
24
47
46
69
68
91
90
B5201
23 45 67 89
22 44 66 88
21 43 65 87
20 42 64 86
19 41 63 85
18 40 62 84
17 39 61 83 81 Wht 910 1
16 38 60 82 2 1
77 Brn 360 Brn 363 2
15 37 59 81
14 36 58 80
13 35 57 79
12 34 56 78
11 33 55 77
10 32 54 76

TCT010217 —UN—20JAN14
9 31 53 75
8 30 52 74
7 29 51 73
2 4 6

1 3 5

DOC Inlet Temperature Sensor Wiring Diagram

A5502— 77—Return A5502— 81—Signal
OUMX258,0000204 -19-16FEB16-1/5

Diagnostic Procedure
Continued on next page OUMX258,0000204 -19-16FEB16-2/5

TM130419 (24FEB16) 235-54-3 030916

PN=1059
 Diagnose—DTCs, ECU 003000—003999

•1 Read DTCs and Store

Snapshot Information
1. Connect Service ADVISOR.
NOTE: When DTCs are cleared, Snapshot information for ALL DTCs is cleared.

2. Ignition ON, Engine OFF.

3. If any DTCs have snapshot capture or snapshot recording information, save the
information.
4. Ignition ON, engine running.
5. Refresh Codes. YES: Go to next step.
Is DTC 003242.03 active? NO: Perform
Aftertreatment Verification
Procedure.
OUMX258,0000204 -19-16FEB16-3/5

•2 Terminal Check 1. Ignition OFF, Engine OFF.

2. Disconnect DOC inlet temperature sensor connector B5201.

3. Perform Terminal Test on sensor and B5201 connector. YES: Repair problem.
Perform Aftertreatment
Verification Procedure.
Were any problems found? NO: Go to next step.
OUMX258,0000204 -19-16FEB16-4/5

•3 Sensor Check 1. Ignition ON, Engine OFF.

2. In Service ADVISOR, monitor DOC Inlet Temperature Input Voltage.

3. Perform Wiggle Test.
Data Point Normal Range YES: Replace sensor.
Perform Verification
DOC Inlet Temperature Input Voltage 2.8—3.2 V
Procedure.
Is voltage between 2.8 and 3.2 V? NO: See engine CTM.
OUMX258,0000204 -19-16FEB16-5/5

TM130419 (24FEB16) 235-54-4 PN=1060

030916
 Diagnose—DTCs, ECU 003000—003999

ECU 003242.04 — DOC Inlet Temperature Control Unit Response:

Signal Out of Range Low
The ECU derates the engine.
The DOC inlet temperature sensor signal exceeds The ECU commands the EGR Valve fully closed.
the sensor low voltage specification.
The ECU aborts an active regeneration.
Troubleshooting Sequence:
Additional References:
003242.03
For sensor location, more temperature sensor information,
003242.04 information on how to use Diagnostic Test Box, more
When DTC is Displayed: information on the Aftertreatment Verification Procedure,
and more information on the Service Regeneration test,
When the ignition is on, the engine is running, and the see engine CTM.
fault is active.
For complete wiring information:
Related Information:
- see Main Schematic, T4
The DOC inlet temperature sensor signal voltage to the
ECU corresponds to a temperature lower than what is - see Engine Controls and Sensors Schematic
physically possible for the DOC inlet temperature sensor. located in Section 230, Group 20.
Alarm Level:
Stop

A5502

28 50 72 94
27 49 71 93
26 48 70 92
25
24
47
46
69
68
91
90
B5201
23 45 67 89
22 44 66 88
21 43 65 87
20 42 64 86
19 41 63 85
18 40 62 84
17 39 61 83 81 Wht 910 1
16 38 60 82 2 1
77 Brn 360 Brn 363 2
15 37 59 81
14 36 58 80
13 35 57 79
12 34 56 78
11 33 55 77
10 32 54 76

TCT010217 —UN—20JAN14
9 31 53 75
8 30 52 74
7 29 51 73
2 4 6

1 3 5

DOC Inlet Temperature Sensor Wiring Diagram

A5502—77—Return A5502—81—Signal
OUMX258,0000205 -19-16FEB16-1/6

Diagnostic Procedure
Continued on next page OUMX258,0000205 -19-16FEB16-2/6

TM130419 (24FEB16) 235-54-5 030916

PN=1061
 Diagnose—DTCs, ECU 003000—003999

•1 Read DTCs and Store

Snapshot Information
1. Connect Service ADVISOR.
NOTE: When DTCs are cleared, Snapshot Information for ALL DTCs is cleared.

2. Ignition ON, Engine OFF.

3. If any DTCs have snapshot capture or snapshot recording information, save the
information.
4. Refresh codes. YES: See DTC 003242.03.
Is DTC 003242.03 a stored code? NO: Go to next step.
OUMX258,0000205 -19-16FEB16-3/6

•2 Code Check Is DTC 003242.04 active? YES: Go to next step.

NO: Perform
OUMX258,0000205 -19-16FEB16-4/6

•3 Terminal Check 1. Ignition OFF, Engine OFF.

2. Disconnect DOC inlet temperature sensor connector B5201.

3. Perform Terminal Test on sensor and B5201 connector. YES: Repair problem.
Perform Aftertreatment
Verification Procedure.
Were any problems found? NO: Go to next step.
OUMX258,0000205 -19-16FEB16-5/6

•4 Sensor Check 1. Ignition ON, Engine OFF.

2. In Service ADVISOR, monitor DOC Inlet Temperature Input Voltage.

3. Perform Wiggle Test.
Data Point Normal Range YES: Replace sensor.
Perform Verification
DOC Inlet Temperature Input Voltage 2.8—3.2 V
Procedure.
Is voltage between 2.8 and 3.2 V? NO: See engine CTM.

OUMX258,0000205 -19-16FEB16-6/6

TM130419 (24FEB16) 235-54-6 030916

PN=1062
 Diagnose—DTCs, ECU 003000—003999

ECU 003250.00 — DOC Outlet Temperature Unintended hydrocarbons in the DOC

Extremely High
Alarm Level:
The ECU has detected that the DOC outlet temperature Stop
is greater than the specification.
Control Unit Response:
Troubleshooting Sequence:
The ECU derates the engine.
003250.00
The ECU commands the EGR Valve fully closed.
When DTC is Displayed:
The ECU aborts an active regeneration.
When the ignition is on, the engine is running, active
regeneration is occurring, and the fault is active. Additional References:
Related Information: For sensor location, more temperature sensor information,
information on how to use Diagnostic Test Box, more
The DOC outlet temperature sensor signal voltage to the information on the Aftertreatment Verification Procedure,
ECU corresponds to a temperature greater than what is and more information on the Service Regeneration test,
expected by the ECU. see engine CTM.
The DOC inlet temperature sensor B5201, DOC outlet For more information on the Exhaust Condition Check,
temperature sensor B5202, and aftertreatment pressure see engine CTM Section 04, Group 155.
sensor B5109 utilize a common 5 V sensor return circuit
from ECU A5502 connector, pin 77. A failure on this For complete wiring information:
common circuit may result in fault codes for more than
one of the components listed. - see Main Schematic, T4

This DTC can indicate: - see Engine Controls and Sensors Schematic

A faulty DOC outlet temperature sensor located in Section 230, Group 20.

A DOC outlet temperature sensor circuit issue

A5502

28 50 72 94
27 49 71 93
26 48 70 92
25 47 69 91 B5202
24 46 68 90
23 45 67 89
22 44 66 88
21 43 65 87
20 42 64 86
19 41 63 85
18 40 62 84
17 39 61 83 80 Pur 710 1
16 38 60 82 2 1
77 Brn 360 Brn 362 2
15 37 59 81
14 36 58 80
13 35 57 79
12 34 56 78
11 33 55 77
10 32 54 76

TCT010216 —UN—20JAN14
9 31 53 75
8 30 52 74
7 29 51 73
2 4 6

1 3 5

DOC Outlet Temperature Sensor Wiring Diagram

A5502—77—Return A5502—80—Signal
OUMX258,0000206 -19-16FEB16-1/5

Diagnostic Procedure
Continued on next page OUMX258,0000206 -19-16FEB16-2/5

TM130419 (24FEB16) 235-54-7 030916

PN=1063
 Diagnose—DTCs, ECU 003000—003999

•1 Read DTCs and Store

Snapshot Information
1. Connect Service ADVISOR.

2. Ignition OFF, Engine OFF.

CAUTION: Wait until exhaust filter is cool enough to touch

to avoid burning injury.
3. Disconnect DOC Outlet temperature sensor connector B5202.
4. Perform Terminal Test on sensor and B5202 connector. YES: Repair problem.
Were any problems found? NO: Go to next step.
OUMX258,0000206 -19-16FEB16-3/5

•2 Circuit Check 1. Ignition ON, Engine OFF.

2. In Service ADVISOR, monitor DOC Outlet Temperature Input Voltage.

3. Perform Wiggle Test.
Data Point Normal Range YES: Go to next step.
DOC Outlet Temperature Input Voltage 2.8—3.2 V

Does voltage remain between 2.8 and 3.2 V? NO: Repair harness
problem. Perform “Exhaust
Condition Check”. See
engine CTM Section 04,
Group 155.
OUMX258,0000206 -19-16FEB16-4/5

•3 Replace Sensor 1. Replace DOC Outlet temperature sensor.

2. If possible, run engine under operating conditions that set code.

3. Refresh codes. YES: See engine CTM.
Did DTC 003250.00 reappear? NO: Perform “Exhaust
Condition Check”. See
engine CTM Section 04,
Group 155.
OUMX258,0000206 -19-16FEB16-5/5

TM130419 (24FEB16) 235-54-8 030916

PN=1064
 Diagnose—DTCs, ECU 003000—003999

ECU 003250.01 — DOC Outlet Temperature NOTE: The fault can be caused by running fuel with too
Extremely Low high of sulfur content. Refer to your operators
manual to ensure that the correct fuel is being used.
The ECU has detected that the DOC outlet temperature
is less than the specification. Alarm Level:
Troubleshooting Sequence: Warning
003250.01 Control Unit Response:
When DTC is Displayed: The ECU derates the engine.
When the ignition is on, the engine is running, active The ECU commands the EGR Valve fully closed.
regeneration is occurring, and the fault is active.
The ECU aborts an active regeneration.
Related Information:
Additional References:
The DOC outlet temperature sensor signal voltage to the
ECU corresponds to a temperature less than what is For sensor location, more temperature sensor information,
expected by the ECU. information on how to use Diagnostic Test Box, more
information on the Aftertreatment Verification Procedure,
The DOC inlet temperature sensor B5201, DOC outlet and more information on the Service Regeneration test,
temperature sensor B5202, and aftertreatment pressure see engine CTM.
sensor B5109 utilize a common 5 V sensor return circuit
from ECU A5502 connector, pin 77. A failure on this For more information on the Service Regeneration, see
common circuit may result in fault codes for more than engine CTM Section 04, Group 160.
one of the components listed. For complete wiring information:
This DTC can indicate: - see Main Schematic, T4
A faulty DOC outlet temperature sensor; - see Engine Controls and Sensors Schematic
A DOC outlet temperature sensor circuit issue;
Unintended hydrocarbons in the DOC located in Section 230, Group 20.

A5502

28 50 72 94
27 49 71 93
26 48 70 92
25 47 69 91 B5202
24 46 68 90
23 45 67 89
22 44 66 88
21 43 65 87
20 42 64 86
19 41 63 85
18 40 62 84
17 39 61 83 80 Pur 710 1
16 38 60 82 2 1
77 Brn 360 Brn 362 2
15 37 59 81
14 36 58 80
13 35 57 79
12 34 56 78
11 33 55 77
10 32 54 76

TCT010216 —UN—20JAN14
9 31 53 75
8 30 52 74
7 29 51 73
2 4 6

1 3 5

DOC Outlet Temperature Sensor Wiring Diagram

A5502—77—Return A5502—80—Signal
OUMX258,0000207 -19-16FEB16-1/6

Diagnostic Procedure
Continued on next page OUMX258,0000207 -19-16FEB16-2/6

TM130419 (24FEB16) 235-54-9 030916

PN=1065
 Diagnose—DTCs, ECU 003000—003999

•1 Read DTCs and Store

Snapshot Information
1. Connect Service ADVISOR.
NOTE: When DTCs are cleared, Snapshot Information for ALL DTCs is cleared.

2. Ignition ON, Engine OFF.

3. If any DTCs have snapshot capture or snapshot recording information, save the
information.
4. Review snapshot data for code 003250.01. YES: Go to next step.
Was ambient temperature below -20 °C (-4 °F) when DTC 003250.01 was active? NO: Go to step 3..
OUMX258,0000207 -19-16FEB16-3/6

•2 Service Regeneration
Check
1. Ignition ON, engine running.

2. In Service ADVISOR, monitor Engine Coolant Temperature.

3. Run engine until Engine Coolant Temperature rises above 75 °C (167 °F).
4. In Service ADVISOR, perform Service Regeneration, see engine CTM Section YES: Go to next step.
04, Group 160 for instructions.
Does DTC 003250.01 become active? NO: Perform “Exhaust
Condition Check”. See
engine CTM Section 04,
Group 155.
OUMX258,0000207 -19-16FEB16-4/6

•3 Terminal Check 1. Ignition OFF, Engine OFF.

2. Disconnect B5202 DOC Outlet Temperature Sensor connector.

3. Perform Terminal Test on sensor and B5202 connector. YES: Repair Problem.
Perform “Exhaust Condition
Check”. See engine CTM
Section 04, Group 155.
Were any problems found? NO: Go to next step.
OUMX258,0000207 -19-16FEB16-5/6

•4 Sensor Check 1. Ignition ON, Engine OFF.

2. In Service ADVISOR, monitor DOC Outlet Temperature Input Voltage.

3. Perform Wiggle Test.
Data Point Normal Range YES: Replace sensor.
Perform “Exhaust Condition
DOC Outlet Temperature Input Voltage 2.8—3.2 V
Check”. See engine CTM
Section 04, Group 155.
Does voltage remain between 2.8 and 3.2 V? NO: See engine CTM.

OUMX258,0000207 -19-16FEB16-6/6

TM130419 (24FEB16) 235-54-10 030916

PN=1066
 Diagnose—DTCs, ECU 003000—003999

ECU 003250.03 — DOC Outlet Temperature Control Unit Response:

Signal Out of Range High
The ECU derates the engine.
The DOC outlet temperature sensor signal exceeds The ECU commands the EGR Valve fully closed.
the sensor high voltage specification.
The ECU aborts an active regeneration.
Troubleshooting Sequence:
The ECU will command an engine stop after 15 minutes
003250.03 of continuous operation with the fault active.
When DTC is Displayed: Additional References:
When the ignition is on, the engine is running, and the For sensor location, more temperature sensor information,
fault is active. information on how to use Diagnostic Test Box, more
Related Information: information on the Aftertreatment Verification Procedure,
and more information on the Service Regeneration test,
The DOC outlet temperature sensor signal voltage to the see engine CTM.
ECU corresponds to a temperature higher than what is
physically possible for the DOC outlet temperature sensor. For more information on the Exhaust Condition Check,
see engine CTM Section 04, Group 155.
The DOC inlet temperature sensor B5201, DOC outlet
temperature sensor B5202, and aftertreatment pressure For complete wiring information:
sensor B5109 utilize a common 5 V sensor return circuit - see Main Schematic, T4
from ECU A5502 connector, pin 77. A failure on this
common circuit may result in fault codes for more than - see Engine Controls and Sensors Schematic
one of the components listed.
located in Section 230, Group 20.
Alarm Level:
Stop

A5502

28 50 72 94
27 49 71 93
26 48 70 92
25 47 69 91 B5202
24 46 68 90
23 45 67 89
22 44 66 88
21 43 65 87
20 42 64 86
19 41 63 85
18 40 62 84
17 39 61 83 80 Pur 710 1
16 38 60 82 2 1
77 Brn 360 Brn 362 2
15 37 59 81
14 36 58 80
13 35 57 79
12 34 56 78
11 33 55 77
10 32 54 76

TCT010216 —UN—20JAN14
9 31 53 75
8 30 52 74
7 29 51 73
2 4 6

1 3 5

DOC Outlet Temperature Sensor Wiring Diagram

A5502—77—Return A5502—80—Signal
OUMX258,0000208 -19-16FEB16-1/5

Diagnostic Procedure
Continued on next page OUMX258,0000208 -19-16FEB16-2/5

TM130419 (24FEB16) 235-54-11 030916

PN=1067
 Diagnose—DTCs, ECU 003000—003999

•1 Read DTCs and Store

Snapshot Information
1. Connect Service ADVISOR.
NOTE: When DTCs are cleared, Snapshot information for ALL DTCs is cleared.

2. Ignition ON, Engine OFF.

3. Ignition ON, engine running.
4. Refresh codes. YES: Go to next step.
Is DTC 003250.03 active? NO: Perform “Aftertreat-
ment Verification Proce-
dure”. See engine CTM.
OUMX258,0000208 -19-16FEB16-3/5

•2 Terminal Check 1. Ignition OFF, Engine OFF.

2. Disconnect DOC outlet temperature sensor connector B5202.

3. Perform Terminal Test on sensor and B5202 connector. YES: Repair problem.
Perform “Aftertreatment
Verification Procedure”.
See engine CTM.
Were any problems found? NO: Go to next step.
OUMX258,0000208 -19-16FEB16-4/5

•3 Circuit Check 1. Ignition ON, Engine OFF.

2. In Service ADVISOR, monitor DOC Outlet Temperature Input Voltage.

3. Perform Wiggle Test.
Data Point Normal Range YES: Replace sensor.
Perform “Aftertreatment
DOC Outlet Temperature Input Voltage 2.8—3.2 V
Verification Procedure”.
See engine CTM.
Does voltage remain between 2.8 and 3.2 V? NO: See engine CTM.
OUMX258,0000208 -19-16FEB16-5/5

TM130419 (24FEB16) 235-54-12 030916

PN=1068
 Diagnose—DTCs, ECU 003000—003999

ECU 003250.04 — DOC Outlet Temperature Alarm Level:

Signal Out of Range Low
Stop
The DOC outlet temperature sensor signal exceeds Control Unit Response:
the sensor low voltage specification.
The ECU derates the engine.
Troubleshooting Sequence:
The ECU commands the EGR Valve fully closed.
003250.03
The ECU aborts an active regeneration.
003250.04
Additional References:
When DTC is Displayed:
For sensor location, more temperature sensor information,
When the ignition is on, the engine is running, and the information on how to use Diagnostic Test Box, more
fault is active. information on the Aftertreatment Verification Procedure,
Related Information: and more information on the Service Regeneration test,
see engine CTM.
The DOC outlet temperature sensor signal voltage to the
ECU corresponds to a temperature lower than what is For more information on the Exhaust Condition Check,
physically possible for the DOC outlet temperature sensor. see engine CTM Section 04, Group 155.

The DOC inlet temperature sensor B5201, DOC outlet For complete wiring information:
temperature sensor B5202, and aftertreatment pressure - see Main Schematic, T4
sensor B5109 utilize a common 5 V sensor return circuit
from ECU A5502 connector, pin 77. A failure on this - see Engine Controls and Sensors Schematic
common circuit may result in fault codes for more than
one of the components listed. located in Section 230, Group 20.

A5502

28 50 72 94
27 49 71 93
26 48 70 92
25 47 69 91 B5202
24 46 68 90
23 45 67 89
22 44 66 88
21 43 65 87
20 42 64 86
19 41 63 85
18 40 62 84
17 39 61 83 80 Pur 710 1
16 38 60 82 2 1
77 Brn 360 Brn 362 2
15 37 59 81
14 36 58 80
13 35 57 79
12 34 56 78
11 33 55 77
10 32 54 76

TCT010216 —UN—20JAN14
9 31 53 75
8 30 52 74
7 29 51 73
2 4 6

1 3 5

DOC Outlet Temperature Sensor Wiring Diagram

A5502—77—Return A5502—80—Signal
OUMX258,0000209 -19-16FEB16-1/6

Diagnostic Procedure
Continued on next page OUMX258,0000209 -19-16FEB16-2/6

TM130419 (24FEB16) 235-54-13 030916

PN=1069
 Diagnose—DTCs, ECU 003000—003999

•1 Read DTCs and Store

Snapshot Information
1. Connect Service ADVISOR.
NOTE: When DTCs are cleared, Snapshot Information for ALL DTCs is cleared.

2. Ignition ON, Engine OFF.

3. If any DTCs have snapshot capture or snapshot recording information, save the
information.
4. Ignition ON, engine running.
5. Refresh codes. YES: See engine CTM.
Is DTC 003250.03 a stored code? NO: Go to next step.
OUMX258,0000209 -19-16FEB16-3/6

•2 Code Check Is DTC 003250.04 active? YES: Go to next step.

NO: Perform “Aftertreat-

ment Verification Proce-
dure”. See engine CTM.
OUMX258,0000209 -19-16FEB16-4/6

•3 Terminal Check 1. Ignition OFF, Engine OFF.

2. Disconnect DOC outlet temperature sensor connector B5202.

3. Perform Terminal Test on sensor and B5202 connector. YES: Repair problem.
Perform “Aftertreatment
Verification Procedure”.
See engine CTM.
Were any problems found? NO: Go to next step.
OUMX258,0000209 -19-16FEB16-5/6

•4 Circuit Check 1. Ignition ON, Engine OFF.

2. In Service ADVISOR, monitor DOC Outlet Temperature Input Voltage.

3. Perform Wiggle Test.
Data Point Normal Range YES: Replace sensor.
Perform “Aftertreatment
DOC Outlet Temperature Input Voltage 2.8—3.2 V
Verification Procedure”.
See engine CTM.
Does voltage remain between 2.8 and 3.2 V? NO: See engine CTM.

OUMX258,0000209 -19-16FEB16-6/6

TM130419 (24FEB16) 235-54-14 030916

PN=1070
 Diagnose—DTCs, ECU 003000—003999

ECU 003251.00 — DPF Differential Pressure

Alarm Level:
Extremely High
Stop
The DPF Differential Pressure Sensor is not responding
Control Unit Response:
or the ECU has detected an exhaust flow and DPF
differential pressure correlation problem. The ECU derates the engine.
Troubleshooting Sequence: The ECU commands the EGR Valve fully closed.
003251.03 The ECU aborts an active regeneration.
003251.04 Additional References:
003251.00 For sensor location, more pressure sensor information,
and information on how to use Diagnostic Test Box, see
When DTC is Displayed:
engine CTM.
When the ignition is ON, the engine is running, and the
For more information on the control unit information and
fault is active.
overview test, see engine CTM Section 04, Group 160.
Related Information:
For complete wiring information:
The DPF Differential Pressure Sensor is reporting a
- see Main Schematic, T4
pressure greater than specifications allow.
- see Engine Controls and Sensors Schematic
NOTE: This DTC can be caused by extreme cold
conditions where moisture has frozen in a line. located in Section 230, Group 20.
DTC clears once line thaws.
A5502

28 50 72 94
27 49 71 93
26 48 70 92
25 47 69 91
24 46 68 90
23 45 67 89
22 44 66 88 B5109
21 43 65 87
20 42 64 86
19 41 63 85
18 40 62 84 77 Brn 360 Brn 361 2
17 39 61 83
16 38 60 82 24 Pnk 631 2-24 3
15 37 59 81 1-12 4
14 36 58 80 63 Blu 415 2-63 5 6 5 4 3 2 1
13 35 57 79
12 34 56 78
11 33 55 77 A5501
10 32 54 76
9 31 53 75
8 30 52 74
7 29 51 73 15 30 45 60
2 4 6 14 29 44 59
13 28 43 58
12 27 42 57
1 3 5
11 26 41 56
10 25 40 55
9 24 39 54

TCT010843 —UN—08MAR14
12 Grn 661
8 23 38 53
7 22 37 52
6 21 36 51
5 20 35 50
4 19 34 49
3 18 33 48
2 17 32 47
1 16 31 46

Aftertreatment Pressure Sensor

A5501—12—DPF Inlet Pressure A5502—24—Supply A5502—77—Return
Sensor Signal A5502—63—DPF Differential
Pressure Signal
OUMX258,000020A -19-16FEB16-1/8

Diagnostic Procedure
Continued on next page OUMX258,000020A -19-16FEB16-2/8

TM130419 (24FEB16) 235-54-15 030916

PN=1071
 Diagnose—DTCs, ECU 003000—003999

•1 Read DTCs and Store

Snapshot Information
1. Connect Service ADVISOR.
NOTE: When DTCs are cleared, Snapshot information for ALL DTCs is cleared.

2. Ignition ON, Engine OFF.

3. Refresh codes. YES: See DTC 003251.03
procedure.
Is DTC 003251.03 stored? NO: Go to next step.
OUMX258,000020A -19-16FEB16-3/8

•2 Code Check Is DTC 003251.04 stored? YES: See DTC 003251.04

procedure.

NO: Go to next step.

OUMX258,000020A -19-16FEB16-4/8

•3 Line Check 1. Ignition OFF, Engine OFF

2. Remove lines from DPF to the aftertreatment pressure sensor.

3. Inspect lines for obstructions. YES: Repair problem.
Perform Verification
Procedure.
Are obstructions found? NO: Go to next step.
OUMX258,000020A -19-16FEB16-5/8

•4 Terminal Check 1. Ignition OFF, Engine OFF.

2. Disconnect aftertreatment pressure sensor connector B5109.

3. Perform Terminal Test on sensor and B5109 connector. YES: Repair problem.
Perform Verification
Procedure.
Were any problems found? NO: Go to next step.

OUMX258,000020A -19-16FEB16-6/8

•5 Continuity Check Measure resistance between A5501 connector female socket 63 and B5109 connector
female socket 5.
YES: Repair short on signal
wire in harness. Perform
Verification Procedure.
Is resistance measurement less than 5 Ohms? NO: Repair high resistance
or mis-pin on signal wire
in harness. Perform
Verification Procedure.

OUMX258,000020A -19-16FEB16-7/8

•6 Circuit Check 1. In Service ADVISOR, monitor DPF Differential Pressure Input Voltage.

2. Perform Wiggle Test.

Data Point Normal Range YES: Replace
aftertreatment pressure
DPF Differential Pressure Input Voltage 2.7—3.1 V
sensor. Perform Verification
Procedure.
Is voltage between 2.7 and 3.1 V? NO: See engine CTM.

OUMX258,000020A -19-16FEB16-8/8

TM130419 (24FEB16) 235-54-16 PN=1072

030916
 Diagnose—DTCs, ECU 003000—003999

ECU 003251.03 — DPF Differential Pressure

Stop
Signal Out of Range High
Control Unit Response:
The DPF Differential pressure signal exceeds the
The ECU derates the engine.
sensor high-voltage specification.
The ECU commands the EGR Valve fully closed.
Troubleshooting Sequence:
The ECU aborts an active regeneration.
003251.03
Additional References:
When DTC is Displayed:
For sensor location, more pressure sensor information,
When the ignition is ON, the engine is running, and the
and information on how to use Diagnostic Test Box, see
fault is active.
engine CTM.
Related Information:
For complete wiring information:
The DPF Differential pressure signal voltage to the ECU
- see Main Schematic, T4
corresponds to a pressure higher than what is physically
possible for the DPF Differential pressure sensor. - see Engine Controls and Sensors Schematic
Alarm Level: located in Section 230, Group 20.
A5502

28 50 72 94
27 49 71 93
26 48 70 92
25 47 69 91
24 46 68 90
23 45 67 89
22 44 66 88 B5109
21 43 65 87
20 42 64 86
19 41 63 85
18 40 62 84 77 Brn 360 Brn 361 2
17 39 61 83
16 38 60 82 24 Pnk 631 2-24 3
15 37 59 81 1-12 4
14 36 58 80 63 Blu 415 2-63 5 6 5 4 3 2 1
13 35 57 79
12 34 56 78
11 33 55 77 A5501
10 32 54 76
9 31 53 75
8 30 52 74
7 29 51 73 15 30 45 60
2 4 6 14 29 44 59
13 28 43 58
12 27 42 57
1 3 5
11 26 41 56
10 25 40 55
9 24 39 54

TCT010843 —UN—08MAR14
12 Grn 661
8 23 38 53
7 22 37 52
6 21 36 51
5 20 35 50
4 19 34 49
3 18 33 48
2 17 32 47
1 16 31 46

Aftertreatment Pressure Sensor

A5501—12—DPF Inlet Pressure A5502—24—Supply A5502—77—Return
Sensor Signal A5502—63—DPF Differential
Pressure Signal
OUMX258,000020B -19-16FEB16-1/7

Diagnostic Procedure
Continued on next page OUMX258,000020B -19-16FEB16-2/7

TM130419 (24FEB16) 235-54-17 030916

PN=1073
 Diagnose—DTCs, ECU 003000—003999

•1 Read DTCs and Store

Snapshot Information
1. Connect Service ADVISOR.
NOTE: When DTCs are cleared Snapshot information for ALL DTCs is cleared.

2. Ignition ON, Engine OFF.

3. Ignition ON, Engine OFF.
4. Refresh codes. YES: Go to next step.
Is DTC 003251.03 active or stored? NO: Go to “Circuit Check”
step.
OUMX258,000020B -19-16FEB16-3/7

•2 Terminal Check 1. Ignition OFF, Engine OFF.

2. Disconnect aftertreatment pressure sensor connector B5109.

3. Perform Terminal Test on sensor and B5109 connector. YES: Repair problem.
Perform Verification
Procedure.
Were any problems found? NO: Go to next step.
OUMX258,000020B -19-16FEB16-4/7

•3 Terminal Check 1. Ignition OFF, Engine OFF.

2. Disconnect ECU connectors A5501 and A5502.

3. Perform Terminal Test on A5501 connector female socket 12 and A5502 connector YES: Repair problem.
female sockets 24, 63, and 77. And corresponding ECU male pins. Perform Verification
Procedure.
Were any problems found? NO: Go to next step.
OUMX258,000020B -19-16FEB16-5/7

•4 Continuity Check 1. Measure the resistance between A5502 connector female socket 77 and B5109
connector female socket 2.

2. Measure the resistance between A5502 connector female socket 63 and B5109 YES: See Problem Not
connector female socket 5. Found Procedure.
Are both resistance measurements less than 5 ohms? NO: Repair mis-pin.
Perform Verification
Procedure.

OUMX258,000020B -19-16FEB16-6/7

•5 Circuit Check 1. Ignition ON, Engine OFF.

2. Monitor DPF Differential Pressure Input Voltage in Service ADVISOR.

3. Perform Wiggle Test.
Data Point Normal Range YES: Repair harness
problem. Perform
DPF Differential Pressure Input Voltage 2.7—3.1 V
Verification Procedure
Does sensor input voltage ever read greater than 4.8 V? NO: See engine CTM

OUMX258,000020B -19-16FEB16-7/7

TM130419 (24FEB16) 235-54-18 030916

PN=1074
 Diagnose—DTCs, ECU 003000—003999

ECU 003251.04 — DPF Differential Pressure

Stop
Signal Out of Range Low
Control Unit Response:
The DPF differential pressure signal is lower than
The ECU derates the engine.
the sensor low voltage specification.
The ECU commands the EGR Valve fully closed.
Troubleshooting Sequence:
The ECU aborts an active regeneration.
003251.03
Additional References:
003251.04
For sensor location, more pressure sensor information,
When DTC is Displayed:
and information on how to use Diagnostic Test Box, see
When the ignition is ON, the engine is running, and the engine CTM.
fault is active.
For complete wiring information:
Related Information:
- see Main Schematic, T4
The DPF differential pressure sensor signal voltage to
- see Engine Controls and Sensors Schematic
the ECU corresponds to a pressure lower than what
is physically possible for the DPF differential pressure located in Section 230, Group 20.
sensor.
Alarm Level:
A5502

28 50 72 94
27 49 71 93
26 48 70 92
25 47 69 91
24 46 68 90
23 45 67 89
22 44 66 88 B5109
21 43 65 87
20 42 64 86
19 41 63 85
18 40 62 84 77 Brn 360 Brn 361 2
17 39 61 83
16 38 60 82 24 Pnk 631 2-24 3
15 37 59 81 1-12 4
14 36 58 80 63 Blu 415 2-63 5 6 5 4 3 2 1
13 35 57 79
12 34 56 78
11 33 55 77 A5501
10 32 54 76
9 31 53 75
8 30 52 74
7 29 51 73 15 30 45 60
2 4 6 14 29 44 59
13 28 43 58
12 27 42 57
1 3 5
11 26 41 56
10 25 40 55
9 24 39 54

TCT010843 —UN—08MAR14
12 Grn 661
8 23 38 53
7 22 37 52
6 21 36 51
5 20 35 50
4 19 34 49
3 18 33 48
2 17 32 47
1 16 31 46

Aftertreatment Pressure Sensor

A5501—12—DPF Inlet Pressure A5502—24—Supply A5502—77—Return
Sensor Signal A5502—63—DPF Differential
Pressure Signal
OUMX258,000020C -19-16FEB16-1/6

Diagnostic Procedure
Continued on next page OUMX258,000020C -19-16FEB16-2/6

TM130419 (24FEB16) 235-54-19 030916

PN=1075
 Diagnose—DTCs, ECU 003000—003999

•1 Read DTCs and Store

Snapshot Information
1. Connect Service ADVISOR.
NOTE: When DTCs are cleared, Snapshot Information for ALL DTCs is cleared.

2. Ignition ON, Engine OFF.

3. If any DTCs have snapshot capture or snapshot recording information, save the
information.
4. Refresh codes. YES: See DTC 003251.03
procedure.
Is DTC 003251.03 stored? NO: Go to next step.
OUMX258,000020C -19-16FEB16-3/6

•2 Code Check Is DTC 003251.04 active? YES: Go to next step.

NO: Go to “Circuit Check”

step.
OUMX258,000020C -19-16FEB16-4/6

•3 Terminal Check 1. Ignition OFF, Engine OFF.

2. Disconnect aftertreatment pressure sensor connector B5109.

3. Perform Terminal Test on sensor and B5109 connector. YES: Repair problem.
Perform Verification
Procedure.
Were any problems found? NO: Go to next step.
OUMX258,000020C -19-16FEB16-5/6

•4 Circuit Check 1. In Service ADVISOR, monitor DPF Differential Pressure Input Voltage.

2. Perform Wiggle Test.

Data Point Normal Range YES: Replace sensor.
Perform Verification
DPF Differential Pressure Input Voltage 2.7—3.1 V
Procedure.
Is voltage between 2.7 and 3.1 V? NO: See engine CTM.

OUMX258,000020C -19-16FEB16-6/6

TM130419 (24FEB16) 235-54-20 030916

PN=1076
 Diagnose—DTCs, ECU 003000—003999

ECU 003251.13 — DPF Differential Pressure Alarm Level:

Sensor Calibration Fault
Stop
The ECU detects a difference in the DPF differential Control Unit Response:
pressure signal compared to other pressure
sensors prior to startup. The ECU derates the engine.
Troubleshooting Sequence: The ECU commands the EGR Valve fully closed.
003251.03 The ECU aborts an active regeneration.
003251.04 Additional References:
003251.13 For sensor location, more pressure sensor information,
information on how to measure pressures, and information
When DTC is Displayed: on how to use Diagnostic Test Box, see engine CTM.
When the ignition is ON, engine OFF, and the fault is active. For complete wiring information:
Related Information: - see Main Schematic, T4
At ignition ON, engine OFF prior to starting the engine, - see Engine Controls and Sensors Schematic
the ECU compares pressure sensor values to detect
abnormal sensor values. located in Section 230, Group 20.
This fault is set when the DPF differential pressure sensor
value is not within a predetermined range compared to
the other pressure sensors.
A5502

28 50 72 94
27 49 71 93
26 48 70 92
25 47 69 91
24 46 68 90
23 45 67 89
22 44 66 88 B5109
21 43 65 87
20 42 64 86
19 41 63 85
18 40 62 84 77 Brn 360 Brn 361 2
17 39 61 83
16 38 60 82 24 Pnk 631 2-24 3
15 37 59 81 1-12 4
14 36 58 80 63 Blu 415 2-63 5 6 5 4 3 2 1
13 35 57 79
12 34 56 78
11 33 55 77 A5501
10 32 54 76
9 31 53 75
8 30 52 74
7 29 51 73 15 30 45 60
2 4 6 14 29 44 59
13 28 43 58
12 27 42 57
1 3 5
11 26 41 56
10 25 40 55
9 24 39 54

TCT010843 —UN—08MAR14
12 Grn 661
8 23 38 53
7 22 37 52
6 21 36 51
5 20 35 50
4 19 34 49
3 18 33 48
2 17 32 47
1 16 31 46

Aftertreatment Pressure Sensor

A5501—12—DPF Inlet Pressure A5502—24—Supply A5502—77—Return
Sensor Signal A5502—63—DPF Differential
Pressure Signal
OUMX258,000020D -19-16FEB16-1/6

Diagnostic Procedure
Continued on next page OUMX258,000020D -19-16FEB16-2/6

TM130419 (24FEB16) 235-54-21 030916

PN=1077
 Diagnose—DTCs, ECU 003000—003999

•1 Read DTCs and Store

Snapshot Information
1. Connect Service ADVISOR.
NOTE: When DTCs are cleared, Snapshot Information for ALL DTCs is cleared.

2. Ignition ON, Engine OFF.

3. If any DTCs have snapshot capture or snapshot recording information, save the
information.
4. Refresh codes. YES: See DTC 003251.03
procedure.
Is DTC 003251.03 active or stored? NO: Go to next step.
OUMX258,000020D -19-16FEB16-3/6

•2 Code Check Is DTC 003251.04 active or stored? YES: See DTC 003251.04
procedure.

NO: Go to next step.

OUMX258,000020D -19-16FEB16-4/6

•3 Terminal Check 1. Ignition OFF, Engine OFF.

2. Disconnect aftertreatment pressure sensor connector B5109.

3. Perform Terminal Test on sensor and B5109 connector. YES: Repair problem.
Perform Verification
Procedure.
Were any problems found? NO: Go to next step.
OUMX258,000020D -19-16FEB16-5/6

•4 Circuit Check 1. In Service ADVISOR, monitor DPF Differential Pressure Input Voltage.

2. Perform Wiggle Test.

Data Point Normal Range YES: Replace sensor.
Perform Verification
DPF Differential Pressure Input Voltage 2.7—3.1 V
Procedure.
Is voltage between 2.7 and 3.1 V? NO: See engine CTM.

OUMX258,000020D -19-16FEB16-6/6

TM130419 (24FEB16) 235-54-22 030916

PN=1078
 Diagnose—DTCs, ECU 003000—003999

ECU 003609.03 — DPF Inlet Pressure Signal

Stop
Out of Range High
Control Unit Response:
The DPF inlet pressure signal exceeds the sensor
The ECU derates the engine.
high-voltage specification.
The ECU commands the EGR Valve fully closed.
Troubleshooting Sequence:
The ECU aborts an active regeneration.
003609.03
Additional References:
When DTC is Displayed:
For sensor location, more pressure sensor information,
When the ignition is ON, the engine is running, and the
information on how to measure pressures, and information
fault is active.
on how to use Diagnostic Test Box, see engine CTM.
Related Information:
For complete wiring information:
The DPF inlet pressure signal voltage to the ECU
- see Main Schematic, T4
corresponds to a pressure higher than what is physically
possible for the DPF inlet pressure sensor. - see Engine Controls and Sensors Schematic
Alarm Level: located in Section 230, Group 20.
A5502

28 50 72 94
27 49 71 93
26 48 70 92
25 47 69 91
24 46 68 90
23 45 67 89
22 44 66 88 B5109
21 43 65 87
20 42 64 86
19 41 63 85
18 40 62 84 77 Brn 360 Brn 361 2
17 39 61 83
16 38 60 82 24 Pnk 631 2-24 3
15 37 59 81 1-12 4
14 36 58 80 63 Blu 415 2-63 5 6 5 4 3 2 1
13 35 57 79
12 34 56 78
11 33 55 77 A5501
10 32 54 76
9 31 53 75
8 30 52 74
7 29 51 73 15 30 45 60
2 4 6 14 29 44 59
13 28 43 58
12 27 42 57
1 3 5
11 26 41 56
10 25 40 55
9 24 39 54

TCT010843 —UN—08MAR14
12 Grn 661
8 23 38 53
7 22 37 52
6 21 36 51
5 20 35 50
4 19 34 49
3 18 33 48
2 17 32 47
1 16 31 46

Aftertreatment Pressure Sensor

A5501—12—DPF Inlet Pressure A5502—24—Supply A5502—77—Return
Sensor Signal A5502—63—DPF Differential
Pressure Signal
OUMX258,000020E -19-16FEB16-1/7

Diagnostic Procedure
Continued on next page OUMX258,000020E -19-16FEB16-2/7

TM130419 (24FEB16) 235-54-23 030916

PN=1079
 Diagnose—DTCs, ECU 003000—003999

•1 Read DTCs and Store

Snapshot Information
1. Connect Service ADVISOR.
NOTE: When DTCs are cleared Snapshot information for ALL DTCs is cleared.

2. Ignition ON, Engine OFF.

3. If any DTCs have snapshot capture or snapshot recording information, save the
information.
4. Ignition ON, engine running.
5. Refresh codes. YES: Go to next step.
Is DTC 003609.03 active or stored? NO: Go to “Circuit Check”
procedure.
OUMX258,000020E -19-16FEB16-3/7

•2 Terminal Check 1. Ignition OFF, Engine OFF.

2. Disconnect aftertreatment pressure sensor connector B5109.

3. Perform Terminal Test on sensor and B5109 connector. YES: Repair problem.
Perform Verification
Procedure.
Were any problems found? NO: Go to next step.
OUMX258,000020E -19-16FEB16-4/7

•3 Terminal Check 1. Ignition OFF, Engine OFF.

2. Disconnect ECU connectors A5501 and A5502.

3. Perform Terminal Test on ECU connectors A5501 and A5502. YES: Repair problem.
Perform Verification
Procedure.
Were any problems found? NO: Go to next step.
OUMX258,000020E -19-16FEB16-5/7

•4 Continuity Check 1. Measure the resistance between A5502 connector female socket 77 and B5109
connector female socket 2.

2. Measure the resistance between A5501 connector female socket 12 and B5109 YES: Go to next step.
connector female socket 4.
Are both resistance measurements less than 5 ohms? NO: Repair mis-pin.
Perform Verification
Procedure.

OUMX258,000020E -19-16FEB16-6/7

•5 Circuit Check 1. In Service ADVISOR, monitor DPF Inlet Pressure Input Voltage.

2. Perform Wiggle Test.

Data Point Normal Range YES: Replace sensor.
Perform Verification
DPF Inlet Pressure Input Voltage 1.9—2.3 V
Procedure.
Is voltage between 1.9 and 2.3 V? NO: See engine CTM.

OUMX258,000020E -19-16FEB16-7/7

TM130419 (24FEB16) 235-54-24 030916

PN=1080
 Diagnose—DTCs, ECU 003000—003999

ECU 003609.04 — DPF Inlet Pressure Signal

Stop
Out of Range Low
Control Unit Response:
The DPF inlet pressure signal is lower than the
The ECU derates the engine.
sensor low voltage specification.
The ECU commands the EGR Valve fully closed.
Troubleshooting Sequence:
The ECU aborts an active regeneration.
003609.03
Additional References:
003609.04
For sensor location, more pressure sensor information,
When DTC is Displayed:
information on how to measure pressures, and information
When the ignition is ON, the engine is running, and the on how to use Diagnostic Test Box, see engine CTM.
fault is active.
For complete wiring information:
Related Information:
- see Main Schematic, T4
The DPF inlet pressure sensor signal voltage to the ECU
- see Engine Controls and Sensors Schematic
corresponds to a pressure lower than what is physically
possible for the DPF inlet pressure sensor. located in Section 230, Group 20.
Alarm Level:
A5502

28 50 72 94
27 49 71 93
26 48 70 92
25 47 69 91
24 46 68 90
23 45 67 89
22 44 66 88 B5109
21 43 65 87
20 42 64 86
19 41 63 85
18 40 62 84 77 Brn 360 Brn 361 2
17 39 61 83
16 38 60 82 24 Pnk 631 2-24 3
15 37 59 81 1-12 4
14 36 58 80 63 Blu 415 2-63 5 6 5 4 3 2 1
13 35 57 79
12 34 56 78
11 33 55 77 A5501
10 32 54 76
9 31 53 75
8 30 52 74
7 29 51 73 15 30 45 60
2 4 6 14 29 44 59
13 28 43 58
12 27 42 57
1 3 5
11 26 41 56
10 25 40 55
9 24 39 54

TCT010843 —UN—08MAR14
12 Grn 661
8 23 38 53
7 22 37 52
6 21 36 51
5 20 35 50
4 19 34 49
3 18 33 48
2 17 32 47
1 16 31 46

Aftertreatment Pressure Sensor

A5501—12—DPF Inlet Pressure A5502—24—Supply A5502—77—Return
Sensor Signal A5502—63—DPF Differential
Pressure Signal
OUMX258,000020F -19-16FEB16-1/7

Diagnostic Procedure
Continued on next page OUMX258,000020F -19-16FEB16-2/7

TM130419 (24FEB16) 235-54-25 030916

PN=1081
 Diagnose—DTCs, ECU 003000—003999

•1 Read DTCs and Store

Snapshot Information
1. Connect Service ADVISOR.
NOTE: When DTCs are cleared, Snapshot Information for ALL DTCs is cleared.

2. Ignition ON, Engine OFF.

3. If any DTCs have snapshot capture or snapshot recording information.
4. Refresh codes. YES: See DTC 003609.03
procedure.
Is DTC 003609.03 stored? NO: Go to next step.
OUMX258,000020F -19-16FEB16-3/7

•2 Code Check Is DTC 003609.04 active? YES: Go to next step.

NO: See engine CTM.

OUMX258,000020F -19-16FEB16-4/7

•3 Terminal Check 1. Ignition OFF, Engine OFF.

2. Disconnect aftertreatment pressure sensor connector B5109.

3. Perform Terminal Test on sensor and B5109 connector. YES: Repair problem.
Perform Verification
Procedure.
Were any problems found? NO: Go to next step.
OUMX258,000020F -19-16FEB16-5/7

•4 Open or High
Resistance Circuit
Check
1. Press and hold both S2 and S3 buttons on Diagnostic Test Box.

2. Monitor voltage on multimeter. YES: Repair open or

high resistance in return
wire. Perform Verification
Procedure.
Does voltage now remain between 4.8 and 5.2 V? NO: Repair open or
high resistance in supply
wire. Perform Verification
Procedure.

OUMX258,000020F -19-16FEB16-6/7

•5 Circuit Check 1. In Service ADVISOR, monitor DPF Inlet Pressure Input Voltage.

2. Perform Wiggle Test.

Data Point Normal Range YES: Replace sensor.
Perform Verification
DPF Inlet Pressure Input Voltage 1.9—2.3 V
Procedure.
Is voltage between 1.9 and 2.3 V? NO: See engine CTM.

OUMX258,000020F -19-16FEB16-7/7

TM130419 (24FEB16) 235-54-26 030916

PN=1082
 Diagnose—DTCs, ECU 003000—003999

ECU 003695.14 — Exhaust Filter Cleaning

Preliminary Checks:
Inhibited by Operator Interface (PDU)
See Inhibiting Active Regeneration.
Code Caused By:
See Accessing Diesel Particulate Filter Displays.
Operator manually turned off DPF functions.
Refer to Primary Display Unit (PDU) Section 235, Group
Alarm Level: 10.
Service alert Diagnosis:
To Clear Display: • Recall, record (Snapshot test under Interactive Tests)
and clear codes.
Set Auto Regeneration button to ‘Enabled’. See Active Service ADVISOR™ : This procedure can be performed
Regeneration and Inhibiting Active Regeneration. by making a connection to the machine and using
Control Unit Response: the ”Diagnostics” tab to view and clear codes. Use
Snapshot Test under Interactive Test tab for specific
None control unit to record fault.
Snapshot Recorded:
• Clear codes using Diagnostic tab
• Recall codes again and check for return of this code.
Yes • Recreate operating conditions that caused code.
• End of tests if code does not return.
Required Tools:
None
Service ADVISOR is a trademark of Deere & Company
CB12260,000008B -19-30MAR15-1/1

TM130419 (24FEB16) 235-54-27 030916

PN=1083
 Diagnose—DTCs, ECU 003000—003999

ECU 003719.00 — Calculated Soot Level

Extremely High The DPF soot level indicates that the soot level
in the DPF is extremely high.
OUMX258,0000210 -19-16FEB16-1/5

Diagnostic Procedure
Troubleshooting Sequence:
Any active or stored DTC.
003719.00
When DTC is Displayed:
When the ignition is ON, the engine is running, and the fault is active.
Related Information:
There are two different soot models used to calculate soot level within the DPF. There is a calculated base model, and
a DPF pressure differential-based model. One or more of these models is indicating that the soot level within the DPF
is extremely high. This fault sets with either the 522573.00 or 522574.00 DTC. These faults are for information only.
This fault can be caused by other factors such as, regenerations being inhibited via the operator interface, improper
sulfur content in the fuel, poor engine condition causing high blow-by, or electronic fuel injector fueling problems.
Using Service ADVISOR or the vehicle operator interface, a DPF Service Recovery procedure is required when the
soot level within the DPF is extremely high.
See Recovery Regeneration.
Alarm Level:
Stop
Control Unit Response:
The ECU derates the engine.
Additional references:
See Accessing Diesel Particulate Filter Displays.
See Parked Regeneration.
For more information on the Control Unit Information and Overview Test, and more information on DPF Service
Recovery test, see engine CTM.
OUMX258,0000210 -19-16FEB16-2/5

•1 Read DTCs and Store

Snapshot Information
1. Connect Service ADVISOR.

2. Ignition ON, Engine OFF.

3. On the vehicle operator interface, view the Exhaust Filter Clean status. YES: Go to next step.
Does status read “Auto Clean Disabled”? NO: Go to “Monitor DTCs”
step.
OUMX258,0000210 -19-16FEB16-3/5

•2 DPF Recovery 1. On the vehicle operator interface, change the Exhaust Filter Clean status to read
“Auto Clean Enabled”.

2. Ignition ON, Engine Running.

3. In Service ADVISOR, perform Service Regeneration. See Recovery Regeneration. YES: Talk to operator
about application usage
and Exhaust Filter Cleaning
process.
Does DPF Service Recovery complete successfully? NO: Go to next step.

Continued on next page OUMX258,0000210 -19-16FEB16-4/5

TM130419 (24FEB16) 235-54-28 030916

PN=1084
 Diagnose—DTCs, ECU 003000—003999

•3 Monitor DTCs Refresh DTCs. YES: Troubleshoot those

DTCs.

Are any DTCs other than 003719.00, 003719.16, 522573.00, or 522574.00 active NO: Contact DTAC for
or stored? support.
OUMX258,0000210 -19-16FEB16-5/5

TM130419 (24FEB16) 235-54-29 030916

PN=1085
 Diagnose—DTCs, ECU 003000—003999

ECU 003719.07 — DPF Recovery Prohibited

The DPF soot level indicates that the soot level
in the DPF is extremely high.
OUMX258,0000211 -19-16FEB16-1/5

Diagnostic Procedure
Troubleshooting Sequence:
Any active or stored DTC.
003719.07
When DTC is Displayed:
When the engine is running and the fault is active.
Related Information:
There are two different soot models used to calculate soot level within the DPF. There is a calculated base model,
and a DPF pressure differential based model. One or more of these models is indicating that the soot level within
the DPF is extremely high.
This fault will set in conjunction with either the 522573.00 or 522574.00 DTC. These faults are for information only.
This fault can be caused by other factors, such as, regenerations being inhibited via the operator interface, improper
sulfur content in the fuel, poor engine condition causing high blow-by, or electronic fuel injector fueling problems.
Using Service ADVISOR or the vehicle operator interface, a DPF Service Recovery procedure is required when the
soot level within the DPF is extremely high.
See Recovery Regeneration.
Alarm Level:
Stop
Control Unit Response:
The ECU derates the engine.
Additional references:
For more information on the Control Unit Information and Overview Test, see engine CTM.
For more information on DPF Service Recovery test, see “DPF Functions and DTCs”, Section 235, Group 15.
OUMX258,0000211 -19-16FEB16-2/5

•1 Read DTCs and Store

Snapshot Information
1. Connect Service ADVISOR, see engine CTM in Section 04, Group 160.

2. Ignition ON, Engine OFF.

3. On the vehicle operator interface, view the Exhaust Filter Clean status. See YES: Go to next step.
Accessing Diesel Particulate Filter Displays.
Does status read “Auto Clean Disabled”? NO: Go to step 3.
OUMX258,0000211 -19-16FEB16-3/5

•2 DPF Recovery 1. On the vehicle operator interface, change the Exhaust Filter Clean status to read
“Auto Clean Enabled”. See Active Regeneration. If the Parked Regeneration icon
appears, perform a parked regeneration. See Parked Regeneration.
2. Ignition ON, Engine Running.
3. In Service ADVISOR, perform Service Regeneration. YES: Talk to operator
about application usage
and Exhaust Filter Cleaning
process.
Does DPF Service Recovery complete successfully? NO: Go to next step.

Continued on next page OUMX258,0000211 -19-16FEB16-4/5

TM130419 (24FEB16) 235-54-30 PN=1086

030916
 Diagnose—DTCs, ECU 003000—003999

•3 Monitor DTCs 1. Ignition OFF, engine OFF for 60 seconds.

2. Ignition ON, engine OFF.

3. Refresh DTCs. YES: Troubleshoot those
DTCs.
Are any DTCs other than 003719.00, 003719.16, 522573.00, or 522574.00 active NO: Contact DTAC for
or stored? support.
OUMX258,0000211 -19-16FEB16-5/5

TM130419 (24FEB16) 235-54-31 030916

PN=1087
 Diagnose—DTCs, ECU 003000—003999

ECU 003719.09 — DPF Recovery Failed

The ECU has detected the DPF regeneration has failed.
OUMX258,0000212 -19-16FEB16-1/5

Diagnostic Procedure
Troubleshooting Sequence:
Any active or stored DTC.
003250.01
003719.09
When DTC is Displayed:
When the ignition is ON and the fault is active.
Related Information:
The fault can be caused by other factors such as, regenerations being inhibited, improper sulfur content in the fuel, or
electronic fuel injector fuel problems.
A DPF Service Recovery procedure is required when the soot level within the DPF is extremely high. Using the vehicle
operator interface, perform a DPF Parked Regeneration procedure. See Parked Regeneration.
Using Service ADVISOR, perform DPF Service Recovery.
Alarm Level:
Stop
Control Unit Response:
The ECU commands the engine to stop.
Additional references:
For more information on the Control Unit Information and Overview Test, more information on DPF Service Recovery
test, see engine CTM.
OUMX258,0000212 -19-16FEB16-2/5

•1 Read DTCs and Store

Snapshot Information
1. Connect Service ADVISOR.

2. Ignition ON, Engine OFF.

3. On the vehicle operator interface, view the Exhaust Filter Clean status. See YES: Go to next step.
Accessing Diesel Particulate Filter Displays.
Does status read “Auto Clean Disabled”? NO: Go to “Monitor DTCs”
step.
OUMX258,0000212 -19-16FEB16-3/5

•2 DPF Recovery 1. On the vehicle operator interface, change the Exhaust Filter Clean status to read
“Auto Clean Enabled”. See Active Regeneration. If the Parked Regeneration icon
appears, perform a parked regeneration. SeeParked Regeneration.
2. Ignition ON, Engine Running.
3. In Service ADVISOR, perform DPF Service Recovery. YES: Talk to operator
about application usage
and Exhaust Filter Cleaning
process.
Does DPF Service Recovery complete successfully? NO: Go to next step.

Continued on next page OUMX258,0000212 -19-16FEB16-4/5

TM130419 (24FEB16) 235-54-32 PN=1088

030916
 Diagnose—DTCs, ECU 003000—003999

•3 Monitor DTCs Refresh DTCs. YES: Troubleshoot those

DTCs.

Are any DTCs active or stored? NO: Contact DTAC for

support.
OUMX258,0000212 -19-16FEB16-5/5

TM130419 (24FEB16) 235-54-33 030916

PN=1089
 Diagnose—DTCs, ECU 003000—003999

ECU 003719.16 — Calculated Soot Level

Moderately High The DPF soot level indicates that the soot level
in the DPF is moderately high.
OUMX258,0000213 -19-16FEB16-1/6

Diagnostic Procedure
Troubleshooting Sequence:
Any active or stored DTC.
003719.16
When DTC is Displayed:
When the ignition is ON, the engine is running, and the fault is active.
Related Information:
There are two different soot models used to calculate soot level within the DPF. There is a calculated base model,
and a DPF pressure differential-based model. One or more of these models is indicating that the soot level within the
DPF is moderately high.
This fault will set with either the 522573.00 or 522574.00 DTC. These faults are for information only.
This fault can be caused by other factors, such as, regenerations being inhibited via the operator interface, improper
sulfur content in the fuel, poor engine condition causing high blow-by, or electronic fuel injector fueling problems.
Using Service ADVISOR or the vehicle operator interface, a Service Regeneration procedure is required when the soot
level within the DPF is moderately high. See Parked Regeneration.
Alarm Level:
Warning
Control Unit Response:
The ECU derates the engine.
Additional references:
For more information on the Control Unit Information and Overview Test, and more information on Service
Regeneration test, see engine CTM.
OUMX258,0000213 -19-16FEB16-2/6

•1 Regeneration Perform Service Regeneration. On the vehicle operator interface, if the Parked YES: Check for related
Regeneration icon appears, perform a parked regeneration. See Parked Regeneration. codes.
Does the regeneration complete and the code clear?
NO: Go to next step.
OUMX258,0000213 -19-16FEB16-3/6

•2 Read DTCs and Store

Snapshot Information
1. Connect Service ADVISOR.

2. Ignition ON, Engine OFF.

3. On the vehicle operator interface, view the Exhaust Filter Clean status. YES: Go to next step.
Does status read “Auto Clean Disabled”? NO: On the vehicle
operator interface, change
the Exhaust Filter Clean
status to read “Auto Clean
Enabled”. See Active
Regeneration.

Continued on next page OUMX258,0000213 -19-16FEB16-4/6

TM130419 (24FEB16) 235-54-34 030916

PN=1090
 Diagnose—DTCs, ECU 003000—003999

•3 Service Regeneration 1. If the Parked Regeneration icon appears, perform a parked regeneration. See
Parked Regeneration.

2. Ignition ON, Engine Running.

3. In Service ADVISOR, perform Service Regeneration. YES: Talk to operator
about application usage
and Exhaust Filter Cleaning
process.
Does regeneration complete successfully? NO: Go to next step.
OUMX258,0000213 -19-16FEB16-5/6

•4 Monitor DTCs Refresh DTCs. YES: Troubleshoot those

DTCs.

Are any DTCs other than 003719.00, 003719.16, 522573.00, or 522574.00 active NO: Contact DTAC for
or stored? support.
OUMX258,0000213 -19-16FEB16-6/6

TM130419 (24FEB16) 235-54-35 PN=1091

030916
 Diagnose—DTCs, ECU 003000—003999

ECU 003720.00 — Calculated Ash Level

The calculated ash level is extremely high. This is the
Extremely High second notification to the operator that the DPF ash load
is getting too high.
The calculated ash level is extremely higher than expected.
Alarm Level:
Troubleshooting Sequence:
Stop
003251.04
003251.03 Control Unit Response:
003251.00
The ECU derates the engine.
003720.00
The PDU flashes an Ash Cleaning Required icon each
When DTC is Displayed:
second.
When the ignition is ON, the engine is running, and the
Additional References:
fault is active.
For more DPF ash information, see “Exhaust Filter
Related Information:
Operation” in CTM12041, in Section 03, Group 137.
OUMX258,0000214 -19-30MAR15-1/3

Diagnostic Procedure
OUMX258,0000214 -19-30MAR15-2/3

•1 Read DTCs 1. Connect to Service ADVISOR.

2. Ignition ON, Engine OFF.

3. Refresh codes. YES: Work stored codes
in order of Troubleshooting
Sequence.
Are any of the DTCs in the Troubleshooting Sequence active or stored? NO: Replace DPF. Perform
Verification Procedure.
OUMX258,0000214 -19-30MAR15-3/3

TM130419 (24FEB16) 235-54-36 PN=1092

030916
 Diagnose—DTCs, ECU 003000—003999

ECU 003720.16 — Calculated Ash Level

The calculated ash level is moderately high. This is the
Moderately High first notification to the operator that the DPF ash load is
getting too high.
The calculated ash level is moderately higher
than expected. Alarm Level:
Troubleshooting Sequence: Warning
003251.04 Control Unit Response:
003251.03
The ECU derates the engine.
003251.00
003720.00 The PDU displays an Engine Fault - Warning
003720.16
Additional References:
When DTC is Displayed:
For more DPF ash information, see “Exhaust Filter
When the ignition is ON, the engine is running, and the Operation” in engine CTM, Section 03, Group 137.
fault is active.
Related Information:
OUMX258,0000215 -19-16FEB16-1/3

Diagnostic Procedure
OUMX258,0000215 -19-16FEB16-2/3

•1 Read DTCs 1. Connect to Service ADVISOR.

2. Ignition ON, Engine OFF.

3. Refresh codes. YES: Work stored codes
in order of Troubleshooting
Sequence.
Are any of the DTCs in the Troubleshooting Sequence active or stored? NO: Replace DPF. Perform
Verification Procedure.
OUMX258,0000215 -19-16FEB16-3/3

TM130419 (24FEB16) 235-54-37 030916

PN=1093
 Diagnose—DTCs, ECU 003000—003999

TM130419 (24FEB16) 235-54-38 030916

PN=1094
 Group 55
Diagnose—DTCs, ECU 004000—529999
ECU 004257.12 — Injector High Voltage
Supply Internal Failure The ECU detects an internal fault in the injector
high voltage supply.
OUMX258,00001A6 -19-16FEB16-1/3

Diagnostic Procedure
Troubleshooting Sequence:
004257.12
When DTC is Displayed:
The ECU detects an internal fault in the injector high voltage supply when the ignition is on, engine running, and
the fault is active.
Related Information:
This DTC may be present if the ECU has not been programmed and will be present if there is an internal fault.
Alarm Level:
Warning
Control Unit Response:
The ECU derates the engine.
The ECU commands the EGR Valve fully closed.
OUMX258,00001A6 -19-16FEB16-2/3

•1 Read DTCs 1. Ignition ON, engine OFF

2. Connect Service ADVISOR.

3. Ignition ON, engine running.
4. Refresh codes. YES: See engine CTM.
Is DTC 004257.12 active? NO: Perform Verification
Procedure.

OUMX258,00001A6 -19-16FEB16-3/3

TM130419 (24FEB16) 235-55-1 030916

PN=1095
 Diagnose—DTCs, ECU 004000—529999

ECU 522243.05 — Glow Plug Relay Driver

Preliminary Checks:
Circuit Has High Resistance
Ensure that key switch is not in start position.
Glow plug relay driver circuit has high resistance
Diagnosis:
Code Caused By:
• Recall, record (Snapshot test under Interactive Tests)
Engine glow plug relay request shorted to high and clear codes.
Service ADVISOR™ : This procedure can be performed
Alarm Level: by making a connection to the machine and using
Alarm the ”Diagnostics” tab to view and clear codes. Use
Snapshot Test under Interactive Test tab for specific
Alarm Frequency: controller to record fault.
Continuous
• Clear codes using Diagnostic tab
• Recall codes again and check for return of this code.
Control Unit Response: • Recreate operating conditions that caused code.
• End of tests if code does not return.
Alarm
NOTE: Common conditions to cause code.
Snapshot Recorded:
• Faulty key switch
Yes • Faulty wiring
Required Tools:
• Faulty starter relay
Multimeter

Service ADVISOR is a trademark of Deere & Company

OUMX258,000025A -19-20SEP14-1/5

Procedure
OUMX258,000025A -19-20SEP14-2/5

•1 Signal Check Using Service ADVISOR, determine if “Glow plug request” signal is active. Is signal
active?
YES: Go to next step.

NO: End of tests.

OUMX258,000025A -19-20SEP14-3/5

•2 Wiring Check glow plug relay wires for shorts to battery voltage. Is wiring ok? YES: Reinstall controller
payload. Check Approved
Software for Control Units.
NO: Repair wiring as
required.

OUMX258,000025A -19-20SEP14-4/5

•3 Check relay Check operation of the relay. Does the relay click when the key switch is in the start
position? When the relay is activated is there 12 volts coming out of pin 87?
YES: Check wiring from
relay to starter.

NO: Check for signals

coming in on pins 85 and
86, if they are good replace
relay. Perform verification
procedure.
Verification Procedure

OUMX258,000025A -19-20SEP14-5/5

TM130419 (24FEB16) 235-55-2 030916

PN=1096
 Diagnose—DTCs, ECU 004000—529999

ECU 522243.06 — Glow Plug Relay Driver

Preliminary Checks:
Circuit Has Low Resistance
Ensure that key switch is not in start position.
Glow plug relay driver circuit has low resistance.
Diagnosis:
Code Caused By:
• Recall, record (Snapshot test under Interactive Tests)
Engine glow plug relay request shorted to low and clear codes.
Service ADVISOR™ : This procedure can be performed
Alarm Level: by making a connection to the machine and using
Alarm the ”Diagnostics” tab to view and clear codes. Use
Snapshot Test under Interactive Test tab for specific
Alarm Frequency: controller to record fault.
Continuous
• Clear codes using Diagnostic tab
• Recall codes again and check for return of this code.
Control Unit Response: • Recreate operating conditions that caused code.
• End of tests if code does not return.
Shutdown
NOTE: Common conditions to cause code.
Snapshot Recorded:
• Faulty key switch
Yes • Faulty wiring
Required Tools:
• Faulty starter relay
Multimeter

Service ADVISOR is a trademark of Deere & Company

OUMX258,000025B -19-20SEP14-1/5

Procedure
OUMX258,000025B -19-20SEP14-2/5

•1 Signal Check Using Service ADVISOR, determine if “Glow plug request” signal is active. Is signal
active?
YES: Go to next step.

NO: End of tests.

OUMX258,000025B -19-20SEP14-3/5

•2 Wiring Check glow plug relay wires for shorts to battery voltage. Is wiring ok? YES: Reinstall controller
payload. Check Approved
Software for Control Units.
NO: Repair wiring as
required.

OUMX258,000025B -19-20SEP14-4/5

•3 Check relay Check operation of the relay. Does the relay click when the key switch is in the start
position? When the relay is activated is there 12 volts coming out of pin 87?
YES: Check wiring from
relay to starter.

NO: Check for signals

coming in on pins 85 and
86, if they are good replace
relay. Perform verification
procedure.
Verification Procedure

OUMX258,000025B -19-20SEP14-5/5

TM130419 (24FEB16) 235-55-3 030916

PN=1097
 Diagnose—DTCs, ECU 004000—529999

ECU 522329.00 — Water-In-Fuel Level

Extremely High The ECU has detected an excessive amount
of water in the fuel.
OUMX258,000025D -19-16FEB16-1/9

Diagnostic Procedure
Troubleshooting Sequence:
522329.00
When DTC is Displayed:
When the ignition is on, and the fault is active.
Related Information:
The ECU has detected that the amount of water in the fuel is much higher than specification.
Alarm Level:
Warning
Control Unit Response:
The ECU tries to maintain normal operating conditions.
Additional References:
For sensor location see engine CTM in Section 03, Group 140.
For more information on the Control Unit Information and Overview Test, see engine CTM in Section 04, Group 160.
NOTE: The wiring diagrams provided are a basic schematic. For detailed schematics, please
refer to your applications technical manual.

For connector repair or complete wiring information:

- see engine CTM.
located in Section 06, Group 190.

A5502

28 50 72 94
27 49 71 93
26 48 70 92
25 47 69 91
24 46 68 90
23 45 67 89
22 44 66 88
21 43 65 87
20 42 64 86 B5600
19 41 63 85
18 40 62 84
17 39 61 83
16 38 60 82 88 OG 2-88 A
A B
15 37 59 81 40 GY 2-40 B
14 36 58 80
13 35 57 79

RG21809 —UN—06MAY13
12 34 56 78
11 33 55 77
10 32 54 76
9 31 53 75
8 30 52 74
7 29 51 73
2 4 6

1 3 5

Water-In-Fuel Sensor
A5502—40—Signal A5502—88—Ignition Switched
Voltage
Continued on next page OUMX258,000025D -19-16FEB16-2/9

TM130419 (24FEB16) 235-55-4 030916

PN=1098
 Diagnose—DTCs, ECU 004000—529999

•1 Read DTCs and Store

Snapshot Information
1. Connect Service ADVISOR.
NOTE: When DTCs are cleared, Snapshot information for ALL DTCs is cleared.

2. Ignition ON, Engine OFF for three minutes.

3. Clear all codes.
4. Refresh Codes. YES: Go to next step.
Is DTC 522329.00 active? NO: Refer to your
application technical
manual for fuel filter service
information.
OUMX258,000025D -19-16FEB16-3/9

•2 Water in Fuel Check 1. Ignition OFF, Engine OFF.

2. Drain water from primary fuel filter assembly water separator bowl.
3. Disconnect low-pressure fuel pump connector.
4. Ignition ON, Engine OFF for three minutes. YES: Go to next step.
Is DTC 522329.00 active? NO: Perform Verification
Procedure.
OUMX258,000025D -19-16FEB16-4/9

•3 Switch Check 1. Ignition ON, Engine OFF.

2. Clear all codes.

3. Refresh codes. YES: Go to next step.
Is DTC 522329.00 active? NO: Replace primary fuel
filter. Perform Verification
Procedure.
OUMX258,000025D -19-16FEB16-5/9

•4 Terminal Check 1. Ignition OFF, Engine OFF.

2. Disconnected water-in-fuel switch connector B5600.

3. Perform Terminal Test on switch and B5600 connector. YES: Repair problem.
Perform Verification
Procedure.
Were any problems found? NO: Go to next step.

OUMX258,000025D -19-16FEB16-6/9

•5 Switch Check 1. Ignition ON, Engine OFF.

2. Clear all codes.

3. Refresh codes. YES: Go to next step.
Is DTC 522329.00 active? NO: Replace primary fuel
filter assembly. Perform
Verification Procedure.

Continued on next page OUMX258,000025D -19-16FEB16-7/9

TM130419 (24FEB16) 235-55-5 PN=1099

030916
 Diagnose—DTCs, ECU 004000—529999

•6 Terminal Check 1. Ignition OFF, Engine OFF.

2. Disconnect ECU connector A5502.

3. Perform Terminal Test on A5502 connector female socket 40 and 88. And YES: Repair problem.
corresponding ECU male pin. Perform Verification
Procedure.
Were any problems found? NO: Go to next step.
OUMX258,000025D -19-16FEB16-8/9

•7 Continuity Check Measure the resistance between A5502 connector female socket 40 and B5600
connector female socket A.
Is resistance less than 5 Ohms?
YES: See engine CTM..

NO: Repair open or

mis-pin in harness. Perform
Verification Procedure.
OUMX258,000025D -19-16FEB16-9/9

TM130419 (24FEB16) 235-55-6 PN=1100

030916
 Diagnose—DTCs, ECU 004000—529999

ECU 522400.02 — Crankshaft Position Signal Warning

Invalid Control Unit Response:
The ECU derates the engine.
The ECU detects excessive noise (extra pulses) The ECU tries to maintain proper operating conditions
on the crankshaft position signal. and uses the camshaft position sensor for engine speed.
Troubleshooting Sequence: Additional References:
522400.02 For more crankshaft position sensor information, see
When DTC is Displayed: engine CTM, Section 03, Group 140.
When the engine is running and the fault is active. For connector repair or complete wiring information:
Related Information: - see Main Schematic, T4
The ECU has detected abnormal pulses or excessive - see Engine Connector X5059 Schematic
noise (extra pulses) on the crankshaft position signal. located in Section 06, Group 190.

Alarm Level:

A5501
X5059
15 30 45 60
14 29 44 59
13 28 43 58
12 27 42 57
11 26 41 56 6 5 4 3 2 1
10 25 40 55 8 Blk 448 9
9 24 39 54
8 23 38 53 4 Org 447 8
7 22 37 52 9 Pnk 446 7 12 11 10 9 8 7
6 21 36 51
5 20 35 50 B5301

TCT009791 —UN—07JAN14
4 19 34 49
3 18 33 48
2 17 32 47
1 16 31 46
12 11 10 9 8 7 8 1
1 2
6 5 4 3 2 1 7 2

Crankshaft Position Sensor Wiring Diagram

A5501—54—Return A5501—39—Signal A5501—38—Shield
OUMX258,000025E -19-16FEB16-1/6

Diagnostic Procedure
OUMX258,000025E -19-16FEB16-2/6

•1 Read DTCs and Store

Snapshot Information
1. Connect Service ADVISOR.

NOTE: When DTCs are cleared, Snapshot Information for ALL DTCs is cleared.

2. Ignition ON, Engine OFF.

3. Ignition ON, engine running.
4. Refresh codes. YES: Go to next step.
Is DTC 522400.02 active? NO: See engine CTM.
Continued on next page OUMX258,000025E -19-16FEB16-3/6

TM130419 (24FEB16) 235-55-7 030916

PN=1101
 Diagnose—DTCs, ECU 004000—529999

•2 Terminal Check 1. Ignition OFF, Engine OFF.

2. Disconnect crankshaft position sensor B5301.

3. Perform Terminal Test on crankshaft position sensor and B5301 connector. YES: Repair problem.
Perform Verification
Procedure.
Were any problems found? NO: Go to next step.
OUMX258,000025E -19-16FEB16-4/6

•3 Sensor Check On crankshaft position sensor, measure resistance between female sockets 1 and 2. YES: Go to next step.

Is resistance between 945 and 1155 Ohms? NO: Replace sensor.

Perform Verification
Procedure.
OUMX258,000025E -19-16FEB16-5/6

•4 Physical Damage
Inspection
1. Remove crankshaft position sensor.

2. Visually inspect crankshaft position sensor for damage. YES: Replace sensor.
Perform Verification
Procedure.
Any damage found? NO: See engine CTM.
OUMX258,000025E -19-16FEB16-6/6

TM130419 (24FEB16) 235-55-8 030916

PN=1102
 Diagnose—DTCs, ECU 004000—529999

ECU 522400.05 — Crankshaft Position Signal Warning

Missing Control Unit Response:
The ECU derates the engine.
The ECU has not detected the crankshaft position signal. The ECU tries to maintain proper operating conditions
Troubleshooting Sequence: and uses the camshaft position sensor for engine speed.
522400.05 Additional References:
When DTC is Displayed: For more crankshaft position sensor information, see
When the engine is running and the fault is active. engine CTM, Section 03, Group 140.

Related Information: For connector repair or complete wiring information:

The ECU has not detected the crankshaft position signal. - see Main Schematic, T4
- see Engine Connector X5059 Schematic
Alarm Level: located in Section 06, Group 190.

A5501
X5059
15 30 45 60
14 29 44 59
13 28 43 58
12 27 42 57
11 26 41 56 6 5 4 3 2 1
10 25 40 55 8 Blk 448 9
9 24 39 54
8 23 38 53 4 Org 447 8
7 22 37 52 9 Pnk 446 7 12 11 10 9 8 7
6 21 36 51
5 20 35 50 B5301

TCT009791 —UN—07JAN14
4 19 34 49
3 18 33 48
2 17 32 47
1 16 31 46
12 11 10 9 8 7 8 1
1 2
6 5 4 3 2 1 7 2

Crankshaft Position Sensor Wiring Diagram

A5501—54—Return A5501—39—Signal A5501—38—Shield
OUMX258,000025F -19-16FEB16-1/6

Diagnostic Procedure
OUMX258,000025F -19-16FEB16-2/6

•1 Read DTCs and Store

Snapshot Information
1. Connect Service ADVISOR.

NOTE: When DTCs are cleared, Snapshot Information for ALL DTCs is cleared.

2. Ignition ON, Engine OFF.

3. Ignition ON, engine running.
4. Refresh codes. YES: Go to next step.
Is DTC 522400.05 active? NO: See engine CTM.
Continued on next page OUMX258,000025F -19-16FEB16-3/6

TM130419 (24FEB16) 235-55-9 030916

PN=1103
 Diagnose—DTCs, ECU 004000—529999

•2 Terminal Check 1. Ignition OFF, Engine OFF.

2. Disconnect crankshaft position sensor B5301.

3. Perform Terminal Test on crankshaft position sensor and B5301 connector. YES: Repair problem.
Perform Verification
Procedure.
Were any problems found? NO: Go to next step.
OUMX258,000025F -19-16FEB16-4/6

•3 Sensor Check On crankshaft position sensor, measure resistance between female sockets 1 and 2. YES: Go to next step.

Is resistance between 945 and 1155 Ohms? NO: Replace sensor.

Perform Verification
Procedure.
OUMX258,000025F -19-16FEB16-5/6

•4 Physical Damage
Inspection
1. Remove crankshaft position sensor.

2. Visually inspect crankshaft position sensor for damage. YES: Replace sensor.
Perform Verification
Procedure.
Any damage found? NO: See engine CTM.
OUMX258,000025F -19-16FEB16-6/6

TM130419 (24FEB16) 235-55-10 030916

PN=1104
 Diagnose—DTCs, ECU 004000—529999

ECU 522401.02 — Camshaft Position Signal Alarm Level:

Invalid Warning

The ECU detects excessive noise (extra pulses) Control Unit Response:
on the camshaft position signal. The ECU tries to maintain proper operating conditions
and uses the crankshaft position sensor for engine speed.
Troubleshooting Sequence:
522401.02 Additional References:
For more camshaft position sensor information, see
When DTC is Displayed: engine CTM, Section 03, Group 140.
When the engine is running and the fault is active.
For connector repair or complete wiring information:
Related Information: - see Main Schematic, T4
The ECU has detected abnormal pulses or excessive - see Engine Connector X5059 Schematic
noise (extra pulses) on the camshaft position signal. located in Section 06, Group 190.

A5501
X5059
15 30 45 60
14 29 44 59
13 28 43 58
12 27 42 57
11 26 41 56 6 5 4 3 2 1
10 25 40 55 52 Wht 445 6
9 24 39 54 37 Blu 444 5
8 23 38 53 08 Pnk 443 4
7 22 37 52 12 11 10 9 8 7
6 21 36 51
5 20 35 50
B5302

TCT009790 —UN—08JAN14
4 19 34 49
3 18 33 48
2 17 32 47
1 16 31 46
12 11 10 9 8 7 6 1
5 2 1 2 3
6 5 4 3 2 1 4 3

Camshaft Position Sensor Wiring Diagram

A5501—08—Supply A5501—52—Return A5501—37—Signal
OUMX258,0000260 -19-16FEB16-1/11

Diagnostic Procedure
OUMX258,0000260 -19-16FEB16-2/11

•1 Read DTCs and Store

Snapshot Information
1. Connect Service ADVISOR.

NOTE: When DTCs are cleared, Snapshot Information for ALL DTCs is cleared.

2. Ignition ON, Engine OFF.

3. Ignition ON, engine running.
4. Refresh codes. YES: Go to next step.
Is DTC 522401.02 active? NO: See engine CTM.
Continued on next page OUMX258,0000260 -19-16FEB16-3/11

TM130419 (24FEB16) 235-55-11 030916

PN=1105
 Diagnose—DTCs, ECU 004000—529999

•2 Terminal Check 1. Ignition OFF, Engine OFF.

2. Disconnect camshaft position sensor B5302.

3. Perform Terminal Test on camshaft position sensor and B5302 connector. YES: Repair problem.
Perform Verification
Procedure.
Were any problems found? NO: Go to next step.
OUMX258,0000260 -19-16FEB16-4/11

•3 Terminal Check 1. Ignition OFF, Engine OFF.

2. Disconnect ECU connector A5501.

3. Perform Terminal Test on A5501 connector female sockets 8, 37, and 52. And YES: Repair problem.
corresponding ECU male pins. Perform Verification
Procedure.
Any damage found? NO: Go to next step.
OUMX258,0000260 -19-16FEB16-5/11

•4 Wire to Wire Check On B5302 connector, measure resistance between female sockets 1 and 2. YES: Go to next step.

Is resistance greater than 100k Ohms? NO: Repair short in

wiring harness. Perform
Verification Procedure.
OUMX258,0000260 -19-16FEB16-6/11

•5 Continuity Check 1. Measure the resistance between A5501 connector female socket 37 and B5302
connector female socket 2.

2. Measure the resistance between A5501 connector female socket 52 and B5302 YES: Go to next step.
connector female socket 1.
Are all resistance measurements less than 5 Ohms? NO: Repair high resistance
or mis-pin in harness.
Perform Verification
Procedure.

OUMX258,0000260 -19-16FEB16-7/11

•6 Short to Ground Check 1. On A5501 connector, measure resistance between female socket 37 and single
point ground.

2. On A5501 connector, measure resistance between female socket 52 and single YES: Go to next step.
point ground.
Are both resistances greater than 100k Ohms? NO: Repair short in
harness. Perform
Verification Procedure.

Continued on next page OUMX258,0000260 -19-16FEB16-8/11

TM130419 (24FEB16) 235-55-12 030916

PN=1106
 Diagnose—DTCs, ECU 004000—529999

•7 Check Wiring Harness 1. On A5501 connector, measure resistance between female socket 37 and all other
sockets in A5501 connector.

2. On A5501 connector, measure resistance between female socket 52 and all other YES: Go to next step.
sockets in A5501 connector.
Are all resistances greater than 100k Ohms? NO: Repair short in
harness. Perform
Verification Procedure.
OUMX258,0000260 -19-16FEB16-9/11

•8 Physical Damage
Inspection
1. Remove camshaft position sensor.

2. Visually inspect camshaft position sensor for damage. YES: Replace sensor.
Perform Verification
Procedure.
Any damage found? NO: Go to next step.
OUMX258,0000260 -19-16FEB16-10/11

•9 Physical Damage
Inspection
1. Remove high-pressure fuel pump gear cover.

2. Visually inspect camshaft timing wheel for damage. YES: Replace camshaft
timing wheel. Perform
Verification Procedure.
Any damage found? NO: Contact DTAC for
support.
OUMX258,0000260 -19-16FEB16-11/11

TM130419 (24FEB16) 235-55-13 030916

PN=1107
 Diagnose—DTCs, ECU 004000—529999

ECU 522401.05 — Camshaft Position Signal Warning

Missing Control Unit Response:
The ECU derates the engine.
The ECU has not detected the camshaft position signal. The ECU tries to maintain proper operating conditions
Troubleshooting Sequence: and uses the crankshaft position sensor for engine speed.
522401.05 Additional References:
When DTC is Displayed: For more camshaft position sensor information, see
When the engine is running and the fault is active. engine CTM, Section 03, Group 140.

Related Information: For connector repair or complete wiring information:

The ECU has not detected the camshaft position signal. - see Main Schematic, T4
- see Engine Connector X5059 Schematic
Alarm Level: located in Section 06, Group 190.

A5501
X5059
15 30 45 60
14 29 44 59
13 28 43 58
12 27 42 57
11 26 41 56 6 5 4 3 2 1
10 25 40 55 52 Wht 445 6
9 24 39 54 37 Blu 444 5
8 23 38 53 08 Pnk 443 4
7 22 37 52 12 11 10 9 8 7
6 21 36 51
5 20 35 50
B5302

TCT009790 —UN—08JAN14
4 19 34 49
3 18 33 48
2 17 32 47
1 16 31 46
12 11 10 9 8 7 6 1
5 2 1 2 3
6 5 4 3 2 1 4 3

Camshaft Position Sensor Wiring Diagram

A5501—08—Supply A5501—52—Return A5501—37—Signal
OUMX258,0000261 -19-16FEB16-1/11

Diagnostic Procedure
OUMX258,0000261 -19-16FEB16-2/11

•1 Read DTCs and Store

Snapshot Information
1. Connect Service ADVISOR.

NOTE: When DTCs are cleared, Snapshot Information for ALL DTCs is cleared.

2. Ignition ON, Engine OFF.

3. Ignition ON, engine running.
4. Refresh codes. YES: Go to next step.
Is DTC 522401.05 active? NO: See engine CTM.
Continued on next page OUMX258,0000261 -19-16FEB16-3/11

TM130419 (24FEB16) 235-55-14 030916

PN=1108
 Diagnose—DTCs, ECU 004000—529999

•2 Terminal Check 1. Ignition OFF, Engine OFF.

2. Disconnect camshaft position sensor B5302.

3. Perform Terminal Test on camshaft position sensor and B5302 connector. YES: Repair problem.
Perform Verification
Procedure.
Were any problems found? NO: See engine CTM.
OUMX258,0000261 -19-16FEB16-4/11

•3 Terminal Check 1. Ignition OFF, Engine OFF.

2. Disconnect ECU connector A5501.

3. Perform Terminal Test on A5501 connector female sockets 8, 37, and 52. And YES: Repair problem.
corresponding ECU male pins. Perform Verification
Procedure.
Any damage found? NO: Go to next step.
OUMX258,0000261 -19-16FEB16-5/11

•4 Wire to Wire Check On B5302 connector, measure resistance between female sockets 1 and 2. YES: Go to next step.

Is resistance greater than 100k Ohms? NO: Repair short in

wiring harness. Perform
Verification Procedure.
OUMX258,0000261 -19-16FEB16-6/11

•5 Continuity Check 1. Measure the resistance between A5501 connector female socket 37 and B5301
connector female socket 2.

2. Measure the resistance between A5501 connector female socket 52 and B5301 YES: Go to next step.
connector female socket 1.
Are all resistance measurements less than 5 Ohms? NO: Repair high resistance
or mis-pin in harness.
Perform Verification
Procedure.

OUMX258,0000261 -19-16FEB16-7/11

•6 Short to Ground Check 1. On A5501 connector, measure resistance between female socket 37 and single
point ground.

2. On A5501 connector, measure resistance between female socket 52 and single YES: Go to next step.
point ground.
Are both resistances greater than 100k Ohms? NO: Repair short in
harness. Perform
Verification Procedure.

Continued on next page OUMX258,0000261 -19-16FEB16-8/11

TM130419 (24FEB16) 235-55-15 030916

PN=1109
 Diagnose—DTCs, ECU 004000—529999

•7 Check Wiring Harness 1. On A5501 connector, measure resistance between female socket 37 and all other
sockets in A5501 connector.

2. On A5501 connector, measure resistance between female socket 52 and all other YES: Go to next step.
sockets in A5501 connector.
Are all resistances greater than 100k Ohms? NO: Repair short in
harness. Perform
Verification Procedure.
OUMX258,0000261 -19-16FEB16-9/11

•8 Physical Damage
Inspection
1. Remove camshaft position sensor.

2. Visually inspect camshaft position sensor for damage. YES: Replace sensor.
Perform Verification
Procedure.
Any damage found? NO: Go to next step.
OUMX258,0000261 -19-16FEB16-10/11

•9 Physical Damage
Inspection
1. Remove high-pressure fuel pump timing cover.

2. Visually inspect camshaft timing wheel for damage. YES: Replace camshaft
timing wheel. Perform
Verification Procedure.
Any damage found? NO: Contact DTAC for
support.
OUMX258,0000261 -19-16FEB16-11/11

TM130419 (24FEB16) 235-55-16 030916

PN=1110
 Diagnose—DTCs, ECU 004000—529999

ECU 522401.07 — Camshaft Position and Alarm Level:

Crankshaft Position Signals Out of Sync Warning

The ECU has not detected the camshaft position signal. Control Unit Response:
The ECU tries to maintain proper operating conditions
Troubleshooting Sequence: and uses the crankshaft position sensor for engine speed.
522401.02
522401.05 Additional References:
522401.07 For more camshaft position sensor and crankshaft
position sensor information, see engine CTM, Section 03,
When DTC is Displayed: Group 140.
When the engine is running and the fault is active.
For connector repair or complete wiring information:
Related Information: - see Main Schematic, T4
The ECU the camshaft position sensor signal is not - see Engine Connector X5059 Schematic
correctly timed relative to the crankshaft position sensor located in Section 06, Group 190.
signal.

A5501
X5059
15 30 45 60
14 29 44 59
13 28 43 58
12 27 42 57
11 26 41 56 6 5 4 3 2 1
10 25 40 55 52 Wht 445 6
9 24 39 54 37 Blu 444 5
8 23 38 53 08 Pnk 443 4
7 22 37 52 12 11 10 9 8 7
6 21 36 51
5 20 35 50
B5302

TCT009790 —UN—08JAN14
4 19 34 49
3 18 33 48
2 17 32 47
1 16 31 46
12 11 10 9 8 7 6 1
5 2 1 2 3
6 5 4 3 2 1 4 3

Camshaft Position Sensor Wiring Diagram

A5501—08—Supply A5501—52—Return A5501—37—Signal
OUMX258,0000262 -19-16FEB16-1/11

Diagnostic Procedure
OUMX258,0000262 -19-16FEB16-2/11

•1 Read DTCs and Store

Snapshot Information
1. Connect Service ADVISOR.

NOTE: When DTCs are cleared, Snapshot Information for ALL DTCs is cleared.

2. Ignition ON, Engine OFF.

3. Ignition ON, engine running.
4. Refresh codes. YES: Go to next step.
Is DTC 522401.07 active? NO: See engine CTM.
OUMX258,0000262 -19-16FEB16-3/11

•2 Service Check Have repairs for camshaft or crankshaft timing gears been perform recently? YES: Inspect for proper
camshaft to crankshaft
timing. See engine CTM for
proper timing information.
NO: Go to next step.

Continued on next page OUMX258,0000262 -19-16FEB16-4/11

TM130419 (24FEB16) 235-55-17 030916

PN=1111
 Diagnose—DTCs, ECU 004000—529999

•3 Terminal Check 1. Ignition OFF, Engine OFF.

2. Disconnect camshaft position sensor B5302.

3. Perform Terminal Test on camshaft position sensor and B5302 connector. YES: Repair problem.
Perform Verification
Procedure.
Were any problems found? NO: Go to next step.
OUMX258,0000262 -19-16FEB16-5/11

•4 Terminal Check 1. Ignition OFF, Engine OFF.

2. Disconnect ECU connector A5501.

3. Perform Terminal Test on A5501 connector female sockets 8, 37, and 52. And YES: Repair problem.
corresponding ECU male pins. Perform Verification
Procedure.
Any damage found? NO: Go to next step.
OUMX258,0000262 -19-16FEB16-6/11

•5 Wire to Wire Check On B5302 connector, measure resistance between female sockets 1 and 2. YES: Go to next step.

Is resistance greater than 100k Ohms? NO: Repair short in

wiring harness. Perform
Verification Procedure.
OUMX258,0000262 -19-16FEB16-7/11

•6 Continuity Check 1. Measure the resistance between A5501 connector female socket 37 and B5302
connector female socket 2.

2. Measure the resistance between A5501 connector female socket 52 and B5302 YES: Go to next step.
connector female socket 1.
Are all resistance measurements less than 5 Ohms? NO: Repair high resistance
or mis-pin in harness.
Perform Verification
Procedure.

OUMX258,0000262 -19-16FEB16-8/11

•7 Short to Ground Check 1. On A5501 connector, measure resistance between female socket 37 and single
point ground.

2. On A5501 connector, measure resistance between female socket 52 and single YES: Go to next step.
point ground.
Are both resistances greater than 100k Ohms? NO: Repair short in
harness. Perform
Verification Procedure.

Continued on next page OUMX258,0000262 -19-16FEB16-9/11

TM130419 (24FEB16) 235-55-18 030916

PN=1112
 Diagnose—DTCs, ECU 004000—529999

•8 Check Wiring Harness 1. On A5501 connector, measure resistance between female socket 37 and all other
sockets in A5501 connector.

2. On A5501 connector, measure resistance between female socket 52 and all other YES: Go to next step.
sockets in A5501 connector.
Are all resistances greater than 100k Ohms? NO: Repair short in
harness. Perform
Verification Procedure.
OUMX258,0000262 -19-16FEB16-10/11

•9 Physical Damage
Inspection
1. Remove camshaft position sensor.

2. Visually inspect camshaft position sensor for damage. YES: Replace sensor.
Perform Verification
Procedure.
Any damage found? NO: Contact DTAC for
support.
OUMX258,0000262 -19-16FEB16-11/11

TM130419 (24FEB16) 235-55-19 030916

PN=1113
 Diagnose—DTCs, ECU 004000—529999

ECU 522571.03 — Suction Control Valve Low Stop

Side Drive Circuit Out of Range High Control Unit Response:
The ECU derates the engine.
The ECU has detected the suction control valve low side The ECU commands the EGR Valve fully closed.
drive circuit voltage is greater than the specified value. DPF regeneration will be aborted and inhibited while the
Troubleshooting Sequence: fault is active.
522571.03 Additional References:
When DTC is Displayed: For suction control valve information, see engine CTM,
When the ignition is on, and the fault is active. Section 03, Group 130.

Related Information: For component location, connector repair or complete

The ECU has detected the voltage on the suction control wiring information:
valve low side drive circuit is greater than expected. - see Main Schematic, T4
- see Engine Connector X5060 Schematic
Alarm Level: located in Section 06, Group 190.

A5501
X5060
15 30 45 60
14 29 44 59
13 28 43 58
12 27 42 57
11 26 41 56 6 5 4 3 2 1
10 25 40 55 Grn 466 9
9 24 39 54 04 Grn 468 Grn 467 10
8 23 38 53 05 Wht 471 Wht 469 11
7 22 37 52 Wht 470 12 12 11 10 9 8 7
6 21 36 51
5 20 35 50 Y5002

TCT009796 —UN—08JAN14
4 19 34 49
3 18 33 48
2 17 32 47
1 16 31 46 9
12 11 10 9 8 7 10 1
11 1 2
6 5 4 3 2 1 2
12

Suction Control Valve Wiring Diagram

A5501—5—Drive - A5501—4—Drive +
OUMX258,0000263 -19-16FEB16-1/11

Diagnostic Procedure
OUMX258,0000263 -19-16FEB16-2/11

•1 Read DTCs and Store

Snapshot Information
1. Connect Service ADVISOR.

NOTE: When DTCs are cleared, Snapshot information for ALL DTCs is cleared.

2. Ignition ON, Engine OFF.

3. Refresh codes. YES: Go to next step.
Is DTC 522571.03 active? NO: See engine CTM.
Continued on next page OUMX258,0000263 -19-16FEB16-3/11

TM130419 (24FEB16) 235-55-20 030916

PN=1114
 Diagnose—DTCs, ECU 004000—529999

•2 Terminal Check 1. Ignition OFF, Engine OFF.

2. Disconnect suction control valve connector Y5002.

3. Perform Terminal Test on suction control valve and Y5002 connector. YES: Repair problem.
Perform Verification
Procedure.
Were any problems found? NO: Go to next step.
OUMX258,0000263 -19-16FEB16-4/11

•3 Terminal Check 1. Disconnect ECU connector A5501.

2. Perform Terminal Test on A5501 connector female sockets 4 and 5. And YES: Repair problem.
corresponding ECU male pins. Perform Verification
Procedure.
Were any problems found? NO: Go to next step.
OUMX258,0000263 -19-16FEB16-5/11

•4 Wire to Wire Check On Y5002 connector, measure resistance between female sockets 1 and 2. YES: Go to next step.

Is resistance greater than 100k Ohms? NO: Repair short in

wiring harness. Perform
Verification Procedure.
OUMX258,0000263 -19-16FEB16-6/11

•5 Continuity Check 1. Measure the resistance between A5501 connector female socket 4 and Y5002
connector female socket 1.

2. Measure the resistance between A5501 connector female socket 5 and Y5002 YES: Go to next step.
connector female socket 2.
Are all resistance measurements less than 5 Ohms? NO: Repair high resistance
or mis-pin in harness.
Perform Verification
Procedure.

OUMX258,0000263 -19-16FEB16-7/11

•6 Short to Ground Check 1. On A5501 connector, measure resistance between female socket 4 and single
point ground.

2. On A5501 connector, measure resistance between female socket 5 and single YES: Go to next step.
point ground.
Are both resistances greater than 100k Ohms? NO: Repair short in
harness. Perform
Verification Procedure.

Continued on next page OUMX258,0000263 -19-16FEB16-8/11

TM130419 (24FEB16) 235-55-21 030916

PN=1115
 Diagnose—DTCs, ECU 004000—529999

•7 Check Wiring Harness 1. On A5501 connector, measure resistance between female socket 4 and all other
sockets in A5501 connector.

2. On A5501 connector, measure resistance between female socket 5 and all other YES: Go to next step.
sockets in A5501 connector.
Are all resistances greater than 100k Ohms? NO: Repair short in
harness. Perform
Verification Procedure.
OUMX258,0000263 -19-16FEB16-9/11

•8 Resistance Check 1. Disconnect ECU connector A5502.

2. Measure the resistance between A5501 connector female socket 4 and all sockets
in A5502 connector.
3. Measure the resistance between A5501 connector female socket 5 and all sockets YES: Go to next step.
in A5502 connector.
Are all resistances greater than 100k Ohms? NO: Repair short in
harness. Perform
Verification Procedure.
OUMX258,0000263 -19-16FEB16-10/11

•9 Replace Suction
Control Valve
1. Ignition OFF, Engine OFF

2. Replace suction control valve.

3. Reconnect all connectors and components.
4. Ignition ON, engine running.
5. Refresh codes. YES: Contact DTAC for
support.
Is DTC 522571.03 active? NO: Perform Verification
Procedure
OUMX258,0000263 -19-16FEB16-11/11

TM130419 (24FEB16) 235-55-22 030916

PN=1116
 Diagnose—DTCs, ECU 004000—529999

ECU 522571.06 — Suction Control Valve Low Stop

Side Drive Circuit Has Low Resistance Control Unit Response:
The ECU derates the engine.
The ECU has detected low resistance on the suction The ECU commands the EGR Valve fully closed.
control valve drive circuit. DPF regeneration will be aborted and inhibited while the
Troubleshooting Sequence: fault is active.
522571.06 Additional References:
When DTC is Displayed: For suction control valve information, see engine CTM,
When the ignition is on, and the fault is active. Section 03, Group 130.

Related Information: For component location, connector repair or complete

The ECU has detected that the current to the suction wiring information:
control valve is higher than expected, indicating low - see Main Schematic, T4
resistance in the drive circuit. - see Engine Connector X5060 Schematic
located in Section 06, Group 190.
Alarm Level:

A5501
X5060
15 30 45 60
14 29 44 59
13 28 43 58
12 27 42 57
11 26 41 56 6 5 4 3 2 1
10 25 40 55 Grn 466 9
9 24 39 54 04 Grn 468 Grn 467 10
8 23 38 53 05 Wht 471 Wht 469 11
7 22 37 52 Wht 470 12 12 11 10 9 8 7
6 21 36 51
5 20 35 50 Y5002

TCT009796 —UN—08JAN14
4 19 34 49
3 18 33 48
2 17 32 47
1 16 31 46 9
12 11 10 9 8 7 10 1
11 1 2
6 5 4 3 2 1 2
12

Suction Control Valve Wiring Diagram

A5501—5—Drive - A5501—4—Drive +
OUMX258,0000264 -19-16FEB16-1/10

Diagnostic Procedure
OUMX258,0000264 -19-16FEB16-2/10

•1 Read DTCs 1. Connect Service ADVISOR.

NOTE: When DTCs are cleared, Snapshot information for ALL DTCs is cleared.

2. Ignition ON, Engine OFF.

3. Refresh codes. YES: Go to next step.
Is DTC 522571.06 active? NO: See engine CTM.
Continued on next page OUMX258,0000264 -19-16FEB16-3/10

TM130419 (24FEB16) 235-55-23 030916

PN=1117
 Diagnose—DTCs, ECU 004000—529999

•2 Terminal Check 1. Ignition OFF, Engine OFF.

2. Disconnect suction control valve connector Y5002.

3. Perform Terminal Test on suction control valve and Y5002 connector. YES: Repair problem.
Perform Verification
Procedure.
Were any problems found? NO: Go to next step.
OUMX258,0000264 -19-16FEB16-4/10

•3 Terminal Check 1. Disconnect ECU connector A5501.

2. Perform Terminal Test on A5501 connector female sockets 4 and 5. And YES: Repair problem.
corresponding ECU male pins. Perform Verification
Procedure.
Were any problems found? NO: Go to next step.
OUMX258,0000264 -19-16FEB16-5/10

•4 Wire to Wire Check On Y5002 connector, measure resistance between female sockets 1 and 2. YES: Go to next step.

Is resistance greater than 100k Ohms? NO: Repair short in

wiring harness. Perform
Verification Procedure.
OUMX258,0000264 -19-16FEB16-6/10

•5 Continuity Check 1. Measure the resistance between A5501 connector female socket 4 and Y5002
connector female socket 1.

2. Measure the resistance between A5501 connector female socket 5 and Y5002 YES: Go to next step.
connector female socket 2.
Are all resistance measurements less than 5 Ohms? NO: Repair high resistance
or mis-pin in harness.
Perform Verification
Procedure.

OUMX258,0000264 -19-16FEB16-7/10

•6 Short to Ground Check 1. On A5501 connector, measure resistance between female socket 4 and single
point ground.

2. On A5501 connector, measure resistance between female socket 5 and single YES: Go to next step.
point ground.
Are both resistances greater than 100k Ohms? NO: Repair short in
harness. Perform
Verification Procedure.

Continued on next page OUMX258,0000264 -19-16FEB16-8/10

TM130419 (24FEB16) 235-55-24 030916

PN=1118
 Diagnose—DTCs, ECU 004000—529999

•7 Check Wiring Harness 1. On A5501 connector, measure resistance between female socket 4 and all other
sockets in A5501 connector.

2. On A5501 connector, measure resistance between female socket 5 and all other YES: Go to next step.
sockets in A5501 connector.
Are all resistances greater than 100k Ohms? NO: Repair short in
harness. Perform
Verification Procedure.
OUMX258,0000264 -19-16FEB16-9/10

•8 Replace Suction
Control Valve
1. Ignition OFF, Engine OFF

2. Replace suction control valve.

3. Reconnect all connectors and components.
4. Ignition ON, engine running.
5. Refresh codes. YES: Contact DTAC for
support.
Is DTC 522571.06 active? NO: Perform Verification
Procedure
OUMX258,0000264 -19-16FEB16-10/10

TM130419 (24FEB16) 235-55-25 030916

PN=1119
 Diagnose—DTCs, ECU 004000—529999

ECU 522572.06 — Suction Control Valve High Stop

Side Drive Circuit Has Low Resistance Control Unit Response:
The ECU derates the engine.
The ECU has detected low resistance on the suction The ECU commands the EGR Valve fully closed.
control valve drive circuit. DPF regeneration will be aborted and inhibited while the
Troubleshooting Sequence: fault is active.
522572.06 Additional References:
When DTC is Displayed: For suction control valve information, see engine CTM,
When the ignition is on, and the fault is active. Section 03, Group 130.

Related Information: For component location, connector repair or complete

The ECU has detected that the current to the suction wiring information:
control valve is higher than expected, indicating low - see Main Schematic, T4
resistance in the drive circuit. - see Engine Connector X5060 Schematic
located in Section 06, Group 190.
Alarm Level:

A5501
X5060
15 30 45 60
14 29 44 59
13 28 43 58
12 27 42 57
11 26 41 56 6 5 4 3 2 1
10 25 40 55 Grn 466 9
9 24 39 54 04 Grn 468 Grn 467 10
8 23 38 53 05 Wht 471 Wht 469 11
7 22 37 52 Wht 470 12 12 11 10 9 8 7
6 21 36 51
5 20 35 50 Y5002

TCT009796 —UN—08JAN14
4 19 34 49
3 18 33 48
2 17 32 47
1 16 31 46 9
12 11 10 9 8 7 10 1
11 1 2
6 5 4 3 2 1 2
12

Suction Control Valve Wiring Diagram

A5501—5—Drive - A5501—4—Drive +
OUMX258,0000265 -19-16FEB16-1/10

Diagnostic Procedure
OUMX258,0000265 -19-16FEB16-2/10

•1 Read DTCs 1. Connect Service ADVISOR.

NOTE: When DTCs are cleared, Snapshot information for ALL DTCs is cleared.

2. Ignition ON, Engine OFF.

3. Refresh codes. YES: Go to next step.
Is DTC 522572.06 active? NO: See engine CTM.
Continued on next page OUMX258,0000265 -19-16FEB16-3/10

TM130419 (24FEB16) 235-55-26 030916

PN=1120
 Diagnose—DTCs, ECU 004000—529999

•2 Terminal Check 1. Ignition OFF, Engine OFF.

2. Disconnect suction control valve connector Y5002.

3. Perform Terminal Test on suction control valve and Y5002 connector. YES: Repair problem.
Perform Verification
Procedure.
Were any problems found? NO: Go to next step.
OUMX258,0000265 -19-16FEB16-4/10

•3 Terminal Check 1. Disconnect ECU connector A5501.

2. Perform Terminal Test on A5501 connector female sockets 4 and 5. And YES: Repair problem.
corresponding ECU male pins. Perform Verification
Procedure.
Were any problems found? NO: Go to next step.
OUMX258,0000265 -19-16FEB16-5/10

•4 Wire to Wire Check On Y5002 connector, measure resistance between female sockets 1 and 2. YES: Go to next step.

Is resistance greater than 100k Ohms? NO: Repair short in

wiring harness. Perform
Verification Procedure.
OUMX258,0000265 -19-16FEB16-6/10

•5 Continuity Check 1. Measure the resistance between A5501 connector female socket 4 and Y5002
connector female socket 1.

2. Measure the resistance between A5501 connector female socket 5 and Y5002 YES: Go to next step.
connector female socket 2.
Are all resistance measurements less than 5 Ohms? NO: Repair high resistance
or mis-pin in harness.
Perform Verification
Procedure.

OUMX258,0000265 -19-16FEB16-7/10

•6 Short to Ground Check 1. On A5501 connector, measure resistance between female socket 4 and single
point ground.

2. On A5501 connector, measure resistance between female socket 5 and single YES: Go to next step.
point ground.
Are both resistances greater than 100k Ohms? NO: Repair short in
harness. Perform
Verification Procedure.

Continued on next page OUMX258,0000265 -19-16FEB16-8/10

TM130419 (24FEB16) 235-55-27 030916

PN=1121
 Diagnose—DTCs, ECU 004000—529999

•7 Check Wiring Harness 1. On A5501 connector, measure resistance between female socket 4 and all other
sockets in A5501 connector.

2. On A5501 connector, measure resistance between female socket 5 and all other YES: Go to next step.
sockets in A5501 connector.
Are all resistances greater than 100k Ohms? NO: Repair short in
harness. Perform
Verification Procedure.
OUMX258,0000265 -19-16FEB16-9/10

•8 Replace Suction
Control Valve
1. Ignition OFF, Engine OFF

2. Replace suction control valve.

3. Reconnect all connectors and components.
4. Ignition ON, engine running.
5. Refresh codes. YES: Contact DTAC for
support.
Is DTC 522572.06 active? NO: Perform Verification
Procedure
OUMX258,0000265 -19-16FEB16-10/10

TM130419 (24FEB16) 235-55-28 030916

PN=1122
 Diagnose—DTCs, ECU 004000—529999

ECU 522572.11 — Suction Control Valve High Stop

Side Drive Circuit Current Fault Control Unit Response:
The ECU derates the engine.
The ECU has detected a current fault on the suction The ECU commands the EGR Valve fully closed.
control valve drive circuit. The ECU will abort and inhibit DPF regenerations.
Troubleshooting Sequence: Additional References:
522572.11 For suction control valve information, see engine CTM,
When DTC is Displayed: Section 03, Group 130.
When the ignition is on, and the fault is active. For component location, connector repair or complete
Related Information: wiring information:
The ECU has detected that the current to the suction - see Main Schematic, T4
control valve is higher than expected, and overheating - see Engine Connector X5060 Schematic
has occurred in the drive circuit. located in Section 06, Group 190.

Alarm Level:

A5501
X5060
15 30 45 60
14 29 44 59
13 28 43 58
12 27 42 57
11 26 41 56 6 5 4 3 2 1
10 25 40 55 Grn 466 9
9 24 39 54 04 Grn 468 Grn 467 10
8 23 38 53 05 Wht 471 Wht 469 11
7 22 37 52 Wht 470 12 12 11 10 9 8 7
6 21 36 51
5 20 35 50 Y5002

TCT009796 —UN—08JAN14
4 19 34 49
3 18 33 48
2 17 32 47
1 16 31 46 9
12 11 10 9 8 7 10 1
11 1 2
6 5 4 3 2 1 2
12

Suction Control Valve Wiring Diagram

A5501—5—Drive - A5501—4—Drive +
OUMX258,0000266 -19-16FEB16-1/11

Diagnostic Procedure
OUMX258,0000266 -19-16FEB16-2/11

•1 Read DTCs and Store

Snapshot Information
1. Connect Service ADVISOR.

NOTE: When DTCs are cleared, Snapshot information for ALL DTCs is cleared.

2. Ignition ON, Engine OFF.

3. Refresh codes. YES: Go to next step.
Is DTC 522572.11 active? NO: See engine CTM.
Continued on next page OUMX258,0000266 -19-16FEB16-3/11

TM130419 (24FEB16) 235-55-29 030916

PN=1123
 Diagnose—DTCs, ECU 004000—529999

•2 Terminal Check 1. Ignition OFF, Engine OFF.

2. Disconnect suction control valve connector Y5002.

3. Perform Terminal Test on suction control valve and Y5002 connector. YES: Repair problem.
Perform Verification
Procedure.
Were any problems found? NO: Go to next step.
OUMX258,0000266 -19-16FEB16-4/11

•3 Terminal Check 1. Disconnect ECU connector A5501.

2. Perform Terminal Test on A5501 connector female sockets 4 and 5. And YES: Repair problem.
corresponding ECU male pins. Perform Verification
Procedure.
Were any problems found? NO: Go to next step.
OUMX258,0000266 -19-16FEB16-5/11

•4 Wire to Wire Check On Y5002 connector, measure resistance between female sockets 1 and 2. YES: Go to next step.

Is resistance greater than 100k Ohms? NO: Repair short in

wiring harness. Perform
Verification Procedure.
OUMX258,0000266 -19-16FEB16-6/11

•5 Continuity Check 1. Measure the resistance between A5501 connector female socket 4 and Y5002
connector female socket 1.

2. Measure the resistance between A5501 connector female socket 5 and Y5002 YES: Go to next step.
connector female socket 2.
Are all resistance measurements less than 5 Ohms? NO: Repair high resistance
or mis-pin in harness.
Perform Verification
Procedure.

OUMX258,0000266 -19-16FEB16-7/11

•6 Short to Ground Check 1. On A5501 connector, measure resistance between female socket 4 and single
point ground.

2. On A5501 connector, measure resistance between female socket 5 and single YES: Go to next step.
point ground.
Are both resistances greater than 100k Ohms? NO: Repair short in
harness. Perform
Verification Procedure.

Continued on next page OUMX258,0000266 -19-16FEB16-8/11

TM130419 (24FEB16) 235-55-30 030916

PN=1124
 Diagnose—DTCs, ECU 004000—529999

•7 Check Wiring Harness 1. On A5501 connector, measure resistance between female socket 4 and all other
sockets in A5501 connector.

2. On A5501 connector, measure resistance between female socket 5 and all other YES: Go to next step.
sockets in A5501 connector.
Are all resistances greater than 100k Ohms? NO: Repair short in
harness. Perform
Verification Procedure.
OUMX258,0000266 -19-16FEB16-9/11

•8 Resistance Check 1. Disconnect ECU connector A5502.

2. Measure the resistance between A5501 connector female socket 4 and all sockets
in A5502 connector.
3. Measure the resistance between A5501 connector female socket 5 and all sockets YES: Go to next step.
in A5502 connector.
Are all resistances greater than 100k Ohms? NO: Repair short in
harness. Perform
Verification Procedure.
OUMX258,0000266 -19-16FEB16-10/11

•9 Replace Suction
Control Valve
1. Ignition OFF, Engine OFF

2. Replace suction control valve.

3. Reconnect all connectors and components.
4. Ignition ON, engine running.
5. Refresh codes. YES: Contact DTAC for
support.
Is DTC 522572.11 active? NO: Perform Verification
Procedure
OUMX258,0000266 -19-16FEB16-11/11

TM130419 (24FEB16) 235-55-31 030916

PN=1125
 Diagnose—DTCs, ECU 004000—529999

ECU 522573.00 — Calculated Soot Level High

The ECU has calculated that the soot level in the
diesel particulate filter is high.
OUMX258,0000267 -19-20JAN14-1/4

Diagnostic Procedure
Troubleshooting Sequence:
003719.00
003719.16
When DTC is Displayed:
When the ignition is on, the engine is running, and the fault is active.
Alarm Level:
None
Control Unit Response:
This DTC is an information only fault code. It will be accompanied by either a 003719.00 or 003719.16 DTC.
This fault indicates that the soot level is high based upon calculations performed in the ECU.
This DTC does not indicate that a problem has occurred.
It does indicate the method the ECU used to determine the soot level is high in the DPF.
The 522573.00 DTC is resolved by performing the diagnostic steps for the accompanying DTC 003719.00 or 003719.16
NOTE: Any fault with the DOC outlet temperature sensor or circuit can contribute to errors in the ECU calculation
for soot level. If any DTC with the SPN of 003250 are present, it is critical to diagnose those first.
OUMX258,0000267 -19-20JAN14-2/4

•1 Read DTCs 1. Connect Service ADVISOR.

2. Ignition ON, Engine OFF.

3. Refresh codes. YES: See DTC 003719.00
procedure.
Is DTC 003719.00 active or stored? NO: Go to next step.
OUMX258,0000267 -19-20JAN14-3/4

•2 Read DTCs Is DTC 003719.16 active or stored? YES: See DTC 003719.16
procedure.

NO: Contact DTAC.

OUMX258,0000267 -19-20JAN14-4/4

TM130419 (24FEB16) 235-55-32 030916

PN=1126
 Diagnose—DTCs, ECU 004000—529999

ECU 522574.00 — DPF Differential Pressure

Soot Level High The ECU has determined that the DPF Differential
Pressure sensor is indicating that the soot level in
the diesel particulate filter is high.
OUMX258,0000268 -19-20JAN14-1/4

Diagnostic Procedure
Troubleshooting Sequence:
003719.00
003719.16
When DTC is Displayed:
When the ignition is on, the engine is running, and the fault is active.
Alarm Level:
None
Control Unit Response:
This DTC is an information only fault code. It will be accompanied by either a 003719.00 or 003719.16 DTC.
This fault indicates that the soot level is high based upon the DPF differential pressure sensor reading.
This DTC does not indicate that a problem has occurred.
It does indicate the method the ECU used to determine the soot level is high in the DPF.
The 522574.00 DTC is resolved by performing the diagnostic steps for the accompanying DTC 003719.00 or 003719.16
NOTE: Any fault with the DPF differential pressure sensor or circuit can contribute to errors in the ECU determination
of soot level. If any DTC with the SPN of 003251 are present, it is critical to diagnose those first.
OUMX258,0000268 -19-20JAN14-2/4

•1 Read DTCs and Store

Snapshot Information
1. Connect Service ADVISOR.

2. Ignition ON, Engine OFF.

3. Refresh codes. YES: See DTC 003719.00
procedure.
Is DTC 003719.00 active or stored? NO: Go to next step.
OUMX258,0000268 -19-20JAN14-3/4

•2 Read DTCs Is DTC 003719.16 active or stored? YES: See DTC 003719.16
procedure.

NO: Contact DTAC.

OUMX258,0000268 -19-20JAN14-4/4

TM130419 (24FEB16) 235-55-33 030916

PN=1127
 Diagnose—DTCs, ECU 004000—529999

ECU 522575.07 — Parked Regeneration

Failed The ECU detects that the parked regeneration has
not completed within the required time.
OUMX258,0000269 -19-16FEB16-1/3

Diagnostic Procedure
Troubleshooting Sequence:
Any active or stored DTCs
003250.01
522575.07
When DTC is Displayed:
When the engine is running and the fault is active.
Related Information:
The ECU detects that the parked regeneration has not completed within the required time.
DTC 003719.16 becomes active when this fault becomes active.
Other Possible Causes of this DTC:
Aftertreatment temperature sensors error.
DOC deterioration.
DOC sulfur poisoning or contamination.
Alarm Level:
Warning
Control Unit Response:
The ECU tries to maintain proper operating conditions.
Additional References:
For more aftertreatment system operation information, see engine CTM, Section 03, Group 137.
OUMX258,0000269 -19-16FEB16-2/3

•1 Read DTCs 1. Connect Service ADVISOR.

NOTE: When DTCs are cleared, Snapshot information for ALL DTCs is cleared.

2. Ignition ON, Engine OFF.

3. Refresh Codes. YES: Perform diagnostics
on the active or stored
DTCs.
Are any other active or stored DTCs present? NO: Investigate other
possible causes of the
parked regeneration failure.
OUMX258,0000269 -19-16FEB16-3/3

TM130419 (24FEB16) 235-55-34 PN=1128

030916
 Diagnose—DTCs, ECU 004000—529999

ECU 522576.12 — ECU EEPROM Read Error

The ECU detects an internal fault.
OUMX258,000026A -19-16FEB16-1/3

Diagnostic Procedure
Troubleshooting Sequence:
522576.12
When DTC is Displayed:
The ECU detects an internal fault.
Related Information:
This DTC will be present if the ECU has not been programmed or may be present if there is an internal fault.
Alarm Level:
Warning
Control Unit Response:
The ECU derates the engine.
The ECU will command the EGR Valve fully closed.
OUMX258,000026A -19-16FEB16-2/3

•1 Read DTCs 1. Ignition ON, engine OFF

2. Connect Service ADVISOR.

3. Refresh codes. YES: See engine CTM.
Is DTC 522576.12 active? NO: Perform Verification
Procedure.
OUMX258,000026A -19-16FEB16-3/3

TM130419 (24FEB16) 235-55-35 030916

PN=1129
 Diagnose—DTCs, ECU 004000—529999

ECU 522577.11 — Parked Regeneration Not Warning

Performed Control Unit Response:
The ECU tries to maintain proper operating conditions.
The ECU detects the parked regeneration has not been
performed within the required time since requested. Additional References:
For more aftertreatment system operation information,
Troubleshooting Sequence: see engine CTM, Section 03, Group 137.
Any active or stored DTCs
522577.11 Possible Causes of this DTC:
Vehicle operator not performing the parked regeneration
When DTC is Displayed: within the required time.
When the engine is running and the fault is active. The parked regeneration is interrupted before completing.
Related Information: Faulty parked regeneration needed indicator.
The ECU detects the parked regeneration has not been For details on operation and troubleshooting of
performed within the required time since requested. vehicle regeneration controls, refer to Section 235,
DTC 003719.16 becomes active when this fault becomes Group 55.
active.
Alarm Level:
OUMX258,000026B -19-16FEB16-1/1

TM130419 (24FEB16) 235-55-36 030916

PN=1130
 Diagnose—DTCs, ECU 004000—529999

ECU 522578.12 — ECU EEPROM Write Error

The ECU detects an internal fault.
OUMX258,000026C -19-16FEB16-1/3

Diagnostic Procedure
Troubleshooting Sequence:
522578.12
When DTC is Displayed:
The ECU detects an internal fault.
Related Information:
This DTC will be present if the ECU has not been programmed or may be present if there is an internal fault.
Alarm Level:
Warning
Control Unit Response:
The ECU derates the engine.
OUMX258,000026C -19-16FEB16-2/3

•1 Read DTCs 1. Ignition ON, engine OFF

2. Connect Service ADVISOR.

3. Refresh codes. YES: See engine CTM.
Is DTC 522578.12 active? NO: Perform Verification
Procedure.
OUMX258,000026C -19-16FEB16-3/3

TM130419 (24FEB16) 235-55-37 030916

PN=1131
 Diagnose—DTCs, ECU 004000—529999

ECU 522579.12 — EGR Valve Actuator Low

Resistance Error The EGR valve actuator has detected low
resistance on the motor coils.
OUMX258,000026D -19-16FEB16-1/3

Diagnostic Procedure
Trouble Shooting Sequence:
522579.12
When DTC is Displayed:
When the ignition is on, or engine is running, and the EGR actuator reports the fault is active.
Related Information:
This code is set when the EGR actuator detects an internal error. The EGR actuator sends a message via the CAN
communication system to the ECU stating that it has detected an internal error and the ECU sets the fault.
Alarm Level:
Warning
Control Unit Response:
The ECU derates the engine.
The ECU commands the EGR Valve fully closed.
Additional References:
For EGR actuator location, and more information on the Control Unit Information and Overview Test, see engine CTM.
For complete wiring information:
- see Main Schematic, T4
- see Engine Connector X5058 Schematic
located in Section 06, Group 190.
OUMX258,000026D -19-16FEB16-2/3

•1 Read DTCs 1. Connect Service ADVISOR.

2. Ignition ON, Engine OFF.

3. Ignition ON, engine running.
4. Refresh codes. YES: Replace EGR
valve actuator. Perform
Verification Procedure.
Is DTC 522579.12 active? NO: See Problem Not
Found Procedure.
OUMX258,000026D -19-16FEB16-3/3

TM130419 (24FEB16) 235-55-38 030916

PN=1132
 Diagnose—DTCs, ECU 004000—529999

ECU 522580.12 — EGR Valve Position

Internal Error The EGR valve actuator has detected an
internal position error.
OUMX258,000029A -19-16FEB16-1/3

Diagnostic Procedure
Trouble Shooting Sequence:
522580.12
When DTC is Displayed:
When the ignition is on, or engine is running, and the EGR actuator reports the fault is active.
Related Information:
This code is set when the EGR actuator detects an internal error. The EGR actuator sends a message via the CAN
communication system to the ECU stating that it has detected an internal error and the ECU sets the fault.
Alarm Level:
Warning
Control Unit Response:
The ECU derates the engine.
The ECU commands the EGR Valve fully closed.
Additional References:
See engine CTM.
For complete wiring information:
- see Main Schematic, T4
- see Engine Connector X5058 Schematic
located in Section 06, Group 190.
OUMX258,000029A -19-16FEB16-2/3

•1 Read DTCs and Store

Snapshot Information
1. Connect Service ADVISOR.

NOTE: When DTCs are cleared, Snapshot information for ALL DTCs is cleared.

2. Ignition ON, Engine OFF.

3. If any DTCs have snapshot capture or snapshot recording information, save the
information.
4. Ignition ON, engine running.
5. Refresh codes. YES: Replace EGR
valve actuator. Perform
Verification Procedure.
Is DTC 522580.12 active? NO: See Problem Not
Found Procedure.
OUMX258,000029A -19-16FEB16-3/3

TM130419 (24FEB16) 235-55-39 030916

PN=1133
 Diagnose—DTCs, ECU 004000—529999

ECU 522582.07 — EGR Valve Initialization

Warning
Error
Control Unit Response:
The ECU is indicating the EGR did not initialize
The ECU derates the engine.
within a specified amount of time.
The ECU commands the EGR Valve fully closed.
Troubleshooting Sequence:
Additional References:
522582.07
For more EGR valve information, seeCTM120419.
When DTC is Displayed:
For complete wiring information:
When the ignition is on, engine is running, and the fault
is active. - see Main Schematic, T4
Related Information: - see Engine Connector X5058 Schematic
This fault indicates that the initialization of the EGR valve located in Section 06, Group 190.
has exceeded a specified time.
Alarm Level:
A5502
K2
28 50 72 94
27 49 71 93 V13
26 48 70 92 Blu 671
X5058
25 47 69 91 68 Blu 670
24 46 68 90
23 45 67 89 01 Red 213 Red 212
22 44 66 88 03 Red 214
21 43 65 87
20 42 64 86 05 Red 215 Red 211 (B+) Org 420 1 6 5 4 3 2 1
19 41 63 85 54 Yel F250 Yel F250 2
18 40 62 84
17 39 61 83 76 Grn F150 Grn F150 3
16 38 60 82 4
02 Blk 128 Blk 122 12 11 10 9 8 7
15 37 59 81
14 36 58 80 04 Blk 124
13 35 57 79 06 Blk 125
12 34 56 78
11 33 55 77
Blk 121

10 32 54 76

TCT009803 —UN—13JAN14
9 31 53 75 A
8 30 52 74 B 4
7 29 51 73 A B C D 12 11 10 9 8 7
C 3
2 4 6 D 2 6 5 4 3 2 1
1
1 3 5 Y5400
R5606

EGR Valve Wiring Diagram

A5502 – 1—Supply A5502 – 76—CAN Low A5502 – 54—CAN High
A5502 – 2—Return
OUMX258,000029D -19-16FEB16-1/6

Diagnostic Procedure
OUMX258,000029D -19-16FEB16-2/6

•1 Read DTCs 1. Connect Service ADVISOR.

NOTE: When DTCs are cleared, Snapshot information for ALL DTCs is cleared.

2. Ignition ON, Engine OFF.

3. Refresh codes. YES: Go to next step.
Is DTC 522582.07 active? NO: See engine CTM.
Continued on next page OUMX258,000029D -19-16FEB16-3/6

TM130419 (24FEB16) 235-55-40 030916

PN=1134
 Diagnose—DTCs, ECU 004000—529999

•2 Terminal Check 1. Ignition OFF, Engine OFF.

2. Disconnect EGR valve connector Y5400.

3. Perform Terminal Test on valve and Y5400 connector. YES: Repair problem.
Perform Verification
Procedure.
Were any problems found? NO: Go to next step.
OUMX258,000029D -19-16FEB16-4/6

•3 Supply Voltage Check 1. Ignition ON, Engine OFF.

2. In Service ADVISOR monitor Unswitched Battery Voltage.

3. Monitor battery voltage on multimeter.
Data Point Normal Range YES: Go to “CAN Circuit
Check” step.
Unswitched Battery Voltage 12.0—14.0 V

Is reading within 0.5 V of unswitched battery voltage? NO: See engine CTM.
OUMX258,000029D -19-16FEB16-5/6

•4 CAN Circuit Check 1. Ignition OFF, Engine OFF

2. Disconnect Diagnostic Test Box.

3. Ignition ON, Engine OFF.
4. On Y5400 connector, measure voltage between female socket C(+) and B(-).
5. On Y5400 connector, measure voltage between female socket D(+) and B(-). YES: Replace EGR
valve. Perform Verification
Procedure.
Is voltage for both measurements between 1.5 and 3.5 V? NO: See engine CTM.
OUMX258,000029D -19-16FEB16-6/6

TM130419 (24FEB16) 235-55-41 PN=1135

030916
 Diagnose—DTCs, ECU 004000—529999

ECU 522583.01 — EGR Valve Actuator High

Temperature Sensor Fault The EGR valve actuator has detected a high
temperature sensor fault.
OUMX258,00002A9 -19-04JUN14-1/3

Diagnostic Procedure
Trouble Shooting Sequence:
522583.01
When DTC is Displayed:
When the ignition is on and the EGR actuator reports the fault is active.
Related Information:
This code is set when the EGR actuator detects a high temperature sensor fault. The EGR actuator sends a message
via the CAN communication system to the ECU stating that it has detected a high temperature sensor fault and the
ECU sets the fault.
Alarm Level:
Warning
Control Unit Response:
The ECU derates the engine.
The ECU commands the EGR Valve fully closed.
Additional References:
For more EGR valve information, seeCTM120419.
For complete wiring information:
- see Main Schematic, T4
- see Engine Connector X5058 Schematic
located in Section 06, Group 190.
OUMX258,00002A9 -19-04JUN14-2/3

•1 Read DTCs 1. Connect Service ADVISOR.

NOTE: When DTCs are cleared, Snapshot information for ALL DTCs is cleared.

2. Ignition ON, Engine OFF.

3. Refresh codes. YES: Replace EGR
valve actuator. Perform
Verification Procedure.
Is DTC 522583.01 active? NO: See Problem Not
Found Procedure.
OUMX258,00002A9 -19-04JUN14-3/3

TM130419 (24FEB16) 235-55-42 030916

PN=1136
 Diagnose—DTCs, ECU 004000—529999

ECU 522584.01 — EGR Valve Actuator Low

Temperature Sensor Fault The EGR valve actuator has detected a low
temperature sensor fault.
OUMX258,00002AA -19-04JUN14-1/3

Diagnostic Procedure
Trouble Shooting Sequence:
522584.01
When DTC is Displayed:
When the ignition is on and the EGR actuator reports the fault is active.
Related Information:
This code is set when the EGR actuator detects a low temperature sensor fault. The EGR actuator sends a message
via the CAN communication system to the ECU stating that it has detected a low temperature sensor fault and the
ECU sets the fault.
Alarm Level:
Warning
Control Unit Response:
The ECU derates the engine.
The ECU commands the EGR Valve fully closed.
Additional References:
For more EGR valve information, seeCTM120419.
For complete wiring information:
- see Main Schematic, T4
- see Engine Connector X5058 Schematic
located in Section 06, Group 190.
OUMX258,00002AA -19-04JUN14-2/3

•1 Read DTCs 1. Connect Service ADVISOR.

2. Ignition ON, Engine OFF.

3. Refresh codes. YES: Replace EGR
valve actuator. Perform
Verification Procedure.
Is DTC 522584.01 active? NO: See Problem Not
Found Procedure.
OUMX258,00002AA -19-04JUN14-3/3

TM130419 (24FEB16) 235-55-43 030916

PN=1137
 Diagnose—DTCs, ECU 004000—529999

ECU 522585.12 — ECU Internal Fault 17

The ECU detects an internal fault.
OUMX258,00002AB -19-16FEB16-1/3

Diagnostic Procedure
Troubleshooting Sequence:
522585.12
When DTC is Displayed:
The ECU detects an internal fault.
Related Information:
This DTC will be present if the ECU has not been programmed or may be present if there is an internal fault.
Alarm Level:
Warning
Control Unit Response:
The ECU derates the engine.
OUMX258,00002AB -19-16FEB16-2/3

•1 Read DTCs 1. Ignition ON, engine OFF

2. Connect Service ADVISOR.

3. Refresh codes. YES: See engine CTM.
Is DTC 522585.12 active? NO: Perform Verification
Procedure.
OUMX258,00002AB -19-16FEB16-3/3

TM130419 (24FEB16) 235-55-44 030916

PN=1138
 Diagnose—DTCs, ECU 004000—529999

ECU 522588.12 — ECU Internal Voltage High

Error The ECU detects an internal fault.
OUMX258,00002AC -19-16FEB16-1/3

Diagnostic Procedure
Troubleshooting Sequence:
522588.12
When DTC is Displayed:
The ECU detects an internal fault.
Related Information:
This DTC will be present if the ECU has not been programmed or may be present if there is an internal fault.
Alarm Level:
Warning
Control Unit Response:
The ECU derates the engine.
OUMX258,00002AC -19-16FEB16-2/3

•1 Read DTCs 1. Ignition ON, engine OFF

2. Connect Service ADVISOR.

3. Refresh codes. YES: See engine CTM.
Is DTC 522588.12 active? NO: Perform Verification
Procedure.
OUMX258,00002AC -19-16FEB16-3/3

TM130419 (24FEB16) 235-55-45 030916

PN=1139
 Diagnose—DTCs, ECU 004000—529999

ECU 523489.12 — ECU Internal Voltage Low

Error The ECU detects an internal fault.
OUMX258,00002AD -19-16FEB16-1/3

Diagnostic Procedure
Troubleshooting Sequence:
522589.12
When DTC is Displayed:
The ECU detects an internal fault.
Related Information:
This DTC will be present if the ECU has not been programmed or may be present if there is an internal fault.
Alarm Level:
Warning
Control Unit Response:
The ECU derates the engine.
OUMX258,00002AD -19-16FEB16-2/3

•1 Read DTCs 1. Ignition ON, engine OFF

2. Connect Service ADVISOR.

3. Refresh codes. YES: See engine CTM.
Is DTC 522589.12 active? NO: Perform Verification
Procedure.
OUMX258,00002AD -19-16FEB16-3/3

TM130419 (24FEB16) 235-55-46 030916

PN=1140
 Diagnose—DTCs, ECU 004000—529999

ECU 522591.12 — Sensor Supply #2 Voltage

Control Unit Response:
Error The ECU tries to maintain proper operating conditions.
The ECU detects a supply voltage above specification Additional References:
on the ECU 5 V supply #2 circuit. For more sensor supply #2 information, see engine CTM,
Section 03, Group 140.
Troubleshooting Sequence:
522591.12 For more fuel rail pressure sensor information, see engine
CTM, Section 03, Group 140.
When DTC is Displayed: For more aftertreatment pressure sensor information, see
When the ignition is on, and the error is active. engine CTM, Section 03, Group 140.
Related Information: For more air throttle actuator information, see engine
The ECU detects a supply voltage greater than 5.3 V on CTM, Section 03, Group 140.
the Sensor Supply #2 circuit. For connector repair or complete wiring information:
Alarm Level: - see Electrical Components, T4
Warning - see Engine Connector X5057 Schematic
- see Engine Connector X5058 Schematic
Components Using Sensor Supply #2 Voltage: - see Engine Connector X5059 Schematic
Camshaft Position Sensor, Air Throttle Actuator, Manifold located in Section 230, Group 20.
Air and Exhaust Pressure Sensor.

A5501
X5059
15 30 45 60
14 29 44 59
13 28 43 58
12 27 42 57
11 26 41 56 6 5 4 3 2 1
10 25 40 55 52 Wht 445 6
9 24 39 54 37 Blu 444 5
8 23 38 53 08 Pnk 443 4
7 22 37 52 12 11 10 9 8 7
6 21 36 51
5 20 35 50
B5302

TCT009790 —UN—08JAN14
4 19 34 49
3 18 33 48
2 17 32 47
1 16 31 46
12 11 10 9 8 7 6 1
5 2 1 2 3
6 5 4 3 2 1 4 3

Camshaft Position Sensor Wiring Diagram

A5501—08—Supply A5501—52—Return A5501—37—Signal

Continued on next page OUMX258,00002B6 -19-16FEB16-1/7

TM130419 (24FEB16) 235-55-47 030916

PN=1141
 Diagnose—DTCs, ECU 004000—529999

A5502

28 50 72 94
27 49 71 93
26 48 70 92
25 47 69 91
24 46 68 90 X5057
23 45 67 89
22 44 66 88
21 43 65 87
20 42 64 86
19 41 63 85
18 40 62 84 74 Brn 404 4 4 3 2 1
17 39 61 83
16 38 60 82 39 Wht 403 3
15 37 59 81 85 Pur 402 2 B5114
14 36 58 80 45 Pnk 401 1 8 7 6 5
13 35 57 79
12 34 56 78
11 33 55 77
10 32 54 76

TCT009799 —UN—09JAN14
9 31 53 75 2
8 30 52 74 3
7 29 51 73 4 4
8 7 6 5 3 5 6 5 4 3 2 1
2 4 6
4 3 2 1 2
1
1 3 5

Manifold Air and Exhaust Pressure Sensor Wiring Diagram

A5502—39—Manifold Aire A5502—45—Supply A5502—85—Exhaust Pressure
Pressure Sensor Signal A5502—74—Return Sensor Signal

A5502

28 50 72 94
27 49 71 93
26 48 70 92
25 47 69 91
24
23
46
45
68
67
90
89
X5058
22 44 66 88
21 43 65 87
20 42 64 86
19 41 63 85
18 40 62 84 23 Pnk 421 5
17 39 61 83 6 6 5 4 3 2 1
20 Grn 422
16 38 60 82 52 Brn 423 7
15 37 59 81 8
14 36 58 80
13 35 57 79 9 12 11 10 9 8 7
12 34 56 78
11 33 55 77
10 32 54 76
9 31 53 75
8 30 52 74
7 29 51 73 Y5401
9
2 4 6 12 11 10 9 8 7 8 A
7 B
6 5 4 3 2 1 A B C D E F
1 3 5 6 C
5 E
F
A5501

15 30 45 60
14 29 44 59
13 28 43 58
12 27 42 57
11 26 41 56
10 25 40 55
9 24 39 54 19 Org 424
8 23 38 53 20 Wht 425
7 22 37 52
TCT009802 —UN—13JAN14

6 21 36 51
5 20 35 50
4 19 34 49
3 18 33 48
2 17 32 47
1 16 31 46

Air Throttle Actuator Position Sensor Wiring Diagram

Continued on next page OUMX258,00002B6 -19-16FEB16-2/7

TM130419 (24FEB16) 235-55-48 030916

PN=1142
 Diagnose—DTCs, ECU 004000—529999

A5502—23—Supply A5502—52—Return A5501—20—Drive (-)

A5502—20—Signal A5501—19—Drive (+)
OUMX258,00002B6 -19-16FEB16-3/7

Diagnostic Procedure
OUMX258,00002B6 -19-16FEB16-4/7

•1 Read DTCs and Store

Snapshot Information
1. Connect Service ADVISOR.

NOTE: When DTCs are cleared, Snapshot Information for ALL DTCs is cleared.

2. Ignition ON, Engine OFF.

3. Refresh codes. YES: Go to next step.
Is DTC 522591.12 active? NO: See engine CTM.
OUMX258,00002B6 -19-16FEB16-5/7

•2 Terminal Check 1. Ignition OFF, Engine OFF.

2. Disconnect B5302 Camshaft Position Sensor.

3. Perform Terminal Test on camshaft position sensor and B5302 connector. YES: Repair problem.
Perform Verification
Procedure.
Were any problems found? NO: Go to next step.
OUMX258,00002B6 -19-16FEB16-6/7

•3 Terminal Check 1. Disconnect B5114 Manifold Air and Exhaust Pressure Sensor.

2. Perform Terminal Test on aftertreatment pressure sensor and B5114 connector. YES: Repair problem.
Perform Verification
Procedure.
Were any problems found? NO: Go to next step.
OUMX258,00002B6 -19-16FEB16-7/7

•4 Terminal Check 1. Disconnect Y5401 Air Throttle Actuator.

2. Perform Terminal Test on air throttle actuator and Y5401 connector. YES: Repair problem.
Perform Verification
Procedure.
Were any problems found? NO: See engine CTM.
OUMX258,00002B6 -19-16FEB16-8/7

TM130419 (24FEB16) 235-55-49 030916

PN=1143
 Diagnose—DTCs, ECU 004000—529999

ECU 522592.12 — Sensor Supply #3 Voltage Alarm Level:

Error Warning

The ECU detects a supply voltage above specification Components Using Sensor Supply #3 Voltage:
on the ECU 5 V supply #3 circuit. Fuel Rail Pressure Sensor, Aftertreatment Pressure
Sensor.
Troubleshooting Sequence:
003242.03 Control Unit Response:
003242.04 The ECU tries to maintain proper operating conditions.
003250.03 Additional References:
003250.04 For more sensor supply #2 information, see engine CTM,
000157.03 Section 03, Group 140.
000157.04
003251.03 For more fuel rail pressure sensor information, see engine
003251.04 CTM, Section 03, Group 140.
003609.03 For more aftertreatment pressure sensor information, see
003609.04 engine CTM, Section 03, Group 140.
522592.12
For connector repair or complete wiring information:
When DTC is Displayed: - see Electrical Components, T4,
When the ignition is on, and the error is active. - see Engine Connector X5059 Schematic,
- see Engine Controls and Sensors Schematic,
Related Information: located in Section 230, Group 20.
The ECU detects a supply voltage greater than 5.3 V on
the Sensor Supply #3 circuit.

A5501
X5059
15 30 45 60
14 29 44 59
13 28 43 58
12 27 42 57
11 26 41 56 6 5 4 3 2 1
10 25 40 55 25 Wht 442 3
9 24 39 54 26 Grn 441 2
8 23 38 53 07 Pnk 440 1
7 22 37 52 12 11 10 9 8 7
6 21 36 51
5 20 35 50
B5100

TCT009789 —UN—07JAN14
4 19 34 49
3 18 33 48
2 17 32 47
1 16 31 46
12 11 10 9 8 7 3 1
2 2 1 2 3
6 5 4 3 2 1 1 3

Fuel Rail Pressure Sensor Wiring Diagram

A5501—07—Supply A5501—25— Signal A5501—26—Return

Continued on next page OUMX258,00002B4 -19-16FEB16-1/5

TM130419 (24FEB16) 235-55-50 030916

PN=1144
 Diagnose—DTCs, ECU 004000—529999

A5502

28 50 72 94
27 49 71 93
26 48 70 92
25 47 69 91
24 46 68 90
23 45 67 89 B5109
22 44 66 88
21 43 65 87
20 42 64 86
19 41 63 85
18 40 62 84 77 Brn 360 Brn 361
17 39 61 83 2
16 38 60 82 24 Pnk 631 3
15 37 59 81 4
14 36 58 80 63 Blu 415 5 6 5 4 3 2 1
13 35 57 79
12 34 56 78
11 33 55 77
10 32 54 76
9 31 53 75
8 30 52 74
7 29 51 73
2 4 6

1 3 5

A5501

15 30 45 60
14 29 44 59
13 28 43 58
12 27 42 57
11 26 41 56
10 25 40 55
9 24 39 54
12 Grn 661
8 23 38 53
7 22 37 52

TCT010218 —UN—20JAN14
6 21 36 51
5 20 35 50
4 19 34 49
3 18 33 48
2 17 32 47
1 16 31 46

Aftertreatment Pressure Sensor

A5501—12—DPF Inlet Pressure A5502—24—Supply A5502—77—Return
Sensor Signal A5502—63—DPR Differential
Pressure Signal
OUMX258,00002B4 -19-16FEB16-2/5

Diagnostic Procedure
OUMX258,00002B4 -19-16FEB16-3/5

•1 Read DTCs and Store

Snapshot Information
1. Connect Service ADVISOR.

NOTE: When DTCs are cleared, Snapshot Information for ALL DTCs is cleared.

2. Ignition ON, Engine OFF.

3. Ignition OFF, Engine OFF.
4. Disconnect B5100 Fuel Rail Pressure Sensor.
5. Perform Terminal Test on fuel rail pressure sensor and B5100 connector. YES: Repair problem.
Perform Verification
Procedure.
Were any problems found? NO: Go to next step.
Continued on next page OUMX258,00002B4 -19-16FEB16-4/5

TM130419 (24FEB16) 235-55-51 030916

PN=1145
 Diagnose—DTCs, ECU 004000—529999

•2 Terminal Check 1. Disconnect B5109 Aftertreatment Pressure Sensor.

2. Perform Terminal Test on aftertreatment pressure sensor and B5109 connector. YES: Repair problem.
Perform Verification
Procedure.
Were any problems found? NO: See engine CTM.
OUMX258,00002B4 -19-16FEB16-5/5

ECU 522596.09 — No CAN Message Received None

From Source Address 1
Preliminary Checks:
Code Caused By: None
Communication error between controllers Diagnosis:
Alarm Level:
• Recall, record (Snapshot test under Interactive Tests)
Service Alert-continuous audible and clear codes.
Service ADVISOR™ : This procedure can be performed
SAE Lamp: by making a connection to the machine and using
the ”Diagnostics” tab to view and clear codes. Use
Amber Snapshot Test under Interactive Test tab for specific
To Clear Display: controller to record fault.
• Clear codes using Diagnostic tab
Alarm Frequency: • Recall codes again and check for return of this code.
Continuous • Recreate operating conditions that caused code.
• End of tests if code does not return.
Control Unit Response:
NOTE: Common conditions to cause code.
Limited functionality
• Faulty CAN bus wiring. CAN Message
Snapshot Recorded: Not Received
• Faulty CAN terminator(s). (See CAN
No Communication Fault Checks. CAN Bus
Required Tools: Terminator Test )

Service ADVISOR is a trademark of Deere & Company

OUMX258,00002B2 -19-25FEB14-1/1

TM130419 (24FEB16) 235-55-52 030916

PN=1146
 Diagnose—DTCs, ECU 004000—529999

ECU 522597.09 — No CAN Message Received None

From Source Address 2
Preliminary Checks:
Code Caused By: None
Communication error between controllers Diagnosis:
Alarm Level:
• Recall, record (Snapshot test under Interactive Tests)
Service Alert-continuous audible and clear codes.
Service ADVISOR™ : This procedure can be performed
SAE Lamp: by making a connection to the machine and using
the ”Diagnostics” tab to view and clear codes. Use
Amber
Snapshot Test under Interactive Test tab for specific
To Clear Display: controller to record fault.
• Clear codes using Diagnostic tab
Alarm Frequency: • Recall codes again and check for return of this code.
Continuous • Recreate operating conditions that caused code.
• End of tests if code does not return.
Control Unit Response:
NOTE: Common conditions to cause code.
Limited functionality
• Faulty CAN bus wiring. CAN Message
Snapshot Recorded: Not Received
• Faulty CAN terminator(s). (See CAN
No Communication Fault Checks. CAN Bus
Required Tools: Terminator Test )

Service ADVISOR is a trademark of Deere & Company

OUMX258,00002B3 -19-25FEB14-1/1

ECU 522599.09 — Vehicle Controller CAN • Recall, record (Snapshot test under Interactive Tests)
Communication Error #1 and clear codes.
Service ADVISOR™ : This procedure can be performed
Code Caused By: by making a connection to the machine and using
the ”Diagnostics” tab to view and clear codes. Use
CAN bus communication abnormal update rate. Snapshot Test under Interactive Test tab for specific
Alarm Level: controller to record fault.
• Clear codes using Diagnostic tab
Service alert - amber warning lamp • Recall codes again and check for return of this code.
To Clear Display: • Recreate operating conditions that caused code.
• End of tests if code does not return.
Alarm Frequency:
Key switch is in on position and ECU did not receive any
Control Unit Response: messages from other on board controllers.
Snapshot Recorded: Common tests:
Yes • CAN Bus physical wiring, connections and splices.
• CAN Bus terminator(s). (See CAN Bus Terminator Test).
Required Tools: • Electromagnetic interference. (See Erroneous
Multimeter Diagnostic Trouble Codes).
• Communication faults. (See CAN Communication Fault
Preliminary Checks: Checks).
Diagnosis:
Service ADVISOR is a trademark of Deere & Company
OUMX258,00002B5 -19-25FEB14-1/1

TM130419 (24FEB16) 235-55-53 030916

PN=1147
 Diagnose—DTCs, ECU 004000—529999

ECU 522600.09 — Vehicle Controller CAN • Recall, record (Snapshot test under Interactive Tests)
Communication Error #2 and clear codes.
Service ADVISOR™ : This procedure can be performed
Code Caused By: by making a connection to the machine and using
the ”Diagnostics” tab to view and clear codes. Use
CAN bus communication abnormal update rate. Snapshot Test under Interactive Test tab for specific
Alarm Level: controller to record fault.
• Clear codes using Diagnostic tab
Service alert - amber warning lamp • Recall codes again and check for return of this code.
To Clear Display: • Recreate operating conditions that caused code.
• End of tests if code does not return.
Alarm Frequency:
Key switch is in on position and ECU did not receive any
Control Unit Response: messages from other on board controllers.
Snapshot Recorded: Common tests:
Yes • CAN Bus physical wiring, connections and splices.
• CAN Bus terminator(s). (See CAN Bus Terminator Test).
Required Tools: • Electromagnetic interference. (See Erroneous
Multimeter Diagnostic Trouble Codes).
• Communication faults. (See CAN Communication Fault
Preliminary Checks: Checks).
Diagnosis:
Service ADVISOR is a trademark of Deere & Company
CB12260,000008C -19-25FEB14-1/1

ECU 522601.09 — Vehicle Controller CAN • Recall, record (Snapshot test under Interactive Tests)
Communication Error #3 and clear codes.
Service ADVISOR™ : This procedure can be performed
Code Caused By: by making a connection to the machine and using
the ”Diagnostics” tab to view and clear codes. Use
CAN bus communication abnormal update rate. Snapshot Test under Interactive Test tab for specific
Alarm Level: controller to record fault.
• Clear codes using Diagnostic tab
Service alert - amber warning lamp • Recall codes again and check for return of this code.
To Clear Display: • Recreate operating conditions that caused code.
• End of tests if code does not return.
Alarm Frequency:
Key switch is in on position and ECU did not receive any
Control Unit Response: messages from other on board controllers.
Snapshot Recorded: Common tests:
Yes • CAN Bus physical wiring, connections and splices.
• CAN Bus terminator(s). (See CAN Bus Terminator Test).
Required Tools: • Electromagnetic interference. (See Erroneous
Multimeter Diagnostic Trouble Codes).
• Communication faults. (See CAN Communication Fault
Preliminary Checks: Checks).
Diagnosis:
Service ADVISOR is a trademark of Deere & Company
CB12260,000008D -19-25FEB14-1/1

TM130419 (24FEB16) 235-55-54 030916

PN=1148
 Diagnose—DTCs, ECU 004000—529999

ECU 522609.09 — Vehicle Controller CAN • Recall, record (Snapshot test under Interactive Tests)
Communication Error #4 and clear codes.
Service ADVISOR™ : This procedure can be performed
Code Caused By: by making a connection to the machine and using
the ”Diagnostics” tab to view and clear codes. Use
CAN bus communication abnormal update rate. Snapshot Test under Interactive Test tab for specific
Alarm Level: controller to record fault.
• Clear codes using Diagnostic tab
Service alert - amber warning lamp • Recall codes again and check for return of this code.
To Clear Display: • Recreate operating conditions that caused code.
• End of tests if code does not return.
Alarm Frequency:
Key switch is in on position and ECU did not receive any
Control Unit Response: messages from other on board controllers.
Snapshot Recorded: Common tests:
Yes • CAN Bus physical wiring, connections and splices.
• CAN Bus terminator(s). (See CAN Bus Terminator Test).
Required Tools: • Electromagnetic interference. (See Erroneous
Multimeter Diagnostic Trouble Codes).
• Communication faults. (See CAN Communication Fault
Preliminary Checks: Checks).
Diagnosis:
Service ADVISOR is a trademark of Deere & Company
CB12260,000008E -19-25FEB14-1/1

TM130419 (24FEB16) 235-55-55 030916

PN=1149
 Diagnose—DTCs, ECU 004000—529999

ECU 522610.09 — EGR Valve CAN Alarm Level:

Communication Error Warning

The ECU is indicating that it did not receive a CAN Control Unit Response:
message from the EGR valve. The ECU derates the engine.
The ECU commands the EGR Valve fully closed.
Troubleshooting Sequence:
522610.09 Additional references:
003719.00 For component location, and more EGR valve information,
see engine CTM
When DTC is Displayed:
When the ignition is ON, engine is OFF For connector repair or complete wiring information:
- see Electrical Components, T4,
Related Information: - see Engine Connector X5058 Schematic
This fault indicates that the ECU did not receive a CAN located in Section 230, Group 20.
message from the EGR valve.
A5502
K2
28 50 72 94
27 49 71 93 V13
26 48 70 92 Blu 671
X5058
25 47 69 91 68 Blu 670
24 46 68 90
23 45 67 89 01 Red 213 Red 212
22 44 66 88 03 Red 214
21 43 65 87
20 42 64 86 05 Red 215 Red 211 (B+) Org 420 1 6 5 4 3 2 1
19 41 63 85 54 Yel F250 Yel F250 2
18 40 62 84
17 39 61 83 76 Grn F150 Grn F150 3
16 38 60 82 4
02 Blk 128 Blk 122 12 11 10 9 8 7
15 37 59 81
14 36 58 80 04 Blk 124
13 35 57 79 06 Blk 125
12 34 56 78
11 33 55 77
Blk 121

10 32 54 76

TCT009803 —UN—13JAN14
9 31 53 75 A
8 30 52 74 B 4
7 29 51 73 A B C D 12 11 10 9 8 7
C 3
2 4 6 D 2 6 5 4 3 2 1
1
1 3 5 Y5400
R5606

EGR Valve Wiring Diagram

A5502 – 01—Supply A5502 – 04—Return A5502 – 54—CAN High
A5502 – 02—Return A5502 – 05—Supply A5502 – 76—CAN Low
A5502 – 03—Supply A5502 – 06—Return
OUMX258,00002B8 -19-16FEB16-1/3

Diagnostic Procedure
OUMX258,00002B8 -19-16FEB16-2/3

•1 Read DTCs and Store

Snapshot Information
1. Connect Service ADVISOR.

NOTE: When DTCs are cleared, Snapshot information for ALL DTCs is cleared.

2. Ignition ON, Engine OFF.

3. If any DTCs have snapshot capture or snapshot recording information, save the
information.
4. Refresh codes. YES: Perform Verification
Procedure.
Is DTC 522610.09 active? NO: See engine CTM.
OUMX258,00002B8 -19-16FEB16-3/3

TM130419 (24FEB16) 235-55-56 030916

PN=1150
 Diagnose—DTCs, ECU 004000—529999

ECU 522617.12 — EGR Valve Position sends a message via the CAN communication system to
Mismatch the ECU stating that it has detected the position mismatch
error and the ECU sets the fault.
The EGR valve actuator has detected a position Alarm Level:
mismatch between the commanded position from the Warning
ECU and the actual valve position.
Control Unit Response:
Trouble Shooting Sequence: The ECU derates the engine.
522617.12 The ECU commands the EGR Valve fully closed.
When DTC is Displayed: Additional references:
When the ignition is on and the EGR actuator reports the For component location, and more EGR valve information,
fault is active. see engine CTM
Related Information: For connector repair or complete wiring information:
This code is set when the EGR actuator detects a position - see Electrical Components, T4,
mismatch between the commanded position from the - see Engine Connector X5058 Schematic
ECU and the actual valve position. The EGR actuator located in Section 230, Group 20.

A5502
K2
28 50 72 94
27 49 71 93 V13
26 48 70 92 Blu 671
X5058
25 47 69 91 68 Blu 670
24 46 68 90
23 45 67 89 01 Red 213 Red 212
22 44 66 88 03 Red 214
21 43 65 87
20 42 64 86 05 Red 215 Red 211 (B+) Org 420 1 6 5 4 3 2 1
19 41 63 85 54 Yel F250 Yel F250 2
18 40 62 84
17 39 61 83 76 Grn F150 Grn F150 3
16 38 60 82 4
02 Blk 128 Blk 122 12 11 10 9 8 7
15 37 59 81
14 36 58 80 04 Blk 124
13 35 57 79 06 Blk 125
12 34 56 78
11 33 55 77
Blk 121

10 32 54 76

TCT009803 —UN—13JAN14
9 31 53 75 A
8 30 52 74 B 4
7 29 51 73 A B C D 12 11 10 9 8 7
C 3
2 4 6 D 2 6 5 4 3 2 1
1
1 3 5 Y5400
R5606

EGR Valve Wiring Diagram

A5502 – 01—Supply A5502 – 04—Return A5502 – 54—CAN High
A5502 – 02—Return A5502 – 05—Supply A5502 – 76—CAN Low
A5502 – 03—Supply A5502 – 06—Return
OUMX258,00002B9 -19-16FEB16-1/3

Diagnostic Procedure
Continued on next page OUMX258,00002B9 -19-16FEB16-2/3

TM130419 (24FEB16) 235-55-57 030916

PN=1151
 Diagnose—DTCs, ECU 004000—529999

•1 Read DTCs and Store

Snapshot Information
1. Connect Service ADVISOR.
NOTE: When DTCs are cleared, Snapshot information for ALL DTCs is cleared.

2. Ignition ON, Engine OFF.

3. If any DTCs have snapshot capture or snapshot recording information, save the
information..
4. Ignition ON, Engine OFF.
5. Refresh codes. YES: See engine CTM.
Is DTC 5222617.12 active? NO: See Problem Not
Found Procedure.
OUMX258,00002B9 -19-16FEB16-3/3

ECU 522618.09 — Vehicle Controller CAN • Recall, record (Snapshot test under Interactive Tests)
communication Error #5 and clear codes.
Service ADVISOR™ : This procedure can be performed
Code Caused By: by making a connection to the machine and using
the ”Diagnostics” tab to view and clear codes. Use
CAN bus communication abnormal update rate. Snapshot Test under Interactive Test tab for specific
Alarm Level: controller to record fault.
• Clear codes using Diagnostic tab
Service alert - amber warning lamp • Recall codes again and check for return of this code.
To Clear Display: • Recreate operating conditions that caused code.
• End of tests if code does not return.
Alarm Frequency:
Key switch is in on position and ECU did not receive any
Control Unit Response: messages from other on board controllers.
Snapshot Recorded: Common tests:
Yes • CAN Bus physical wiring, connections and splices.
• CAN Bus terminator(s). (See CAN Bus Terminator Test).
Required Tools: • Electromagnetic interference. (See Erroneous
Multimeter Diagnostic Trouble Codes).
• Communication faults. (See CAN Communication Fault
Preliminary Checks: Checks).
Diagnosis:
Service ADVISOR is a trademark of Deere & Company
CB12260,0000090 -19-25FEB14-1/1

TM130419 (24FEB16) 235-55-58 030916

PN=1152
 Diagnose—DTCs, ECU 004000—529999

ECU 522619.09 — Vehicle Controller • Recall, record (Snapshot test under Interactive Tests)
Communication Error and clear codes.
Service ADVISOR™ : This procedure can be performed
Code Caused By: by making a connection to the machine and using
the ”Diagnostics” tab to view and clear codes. Use
CAN bus communication abnormal update rate. Snapshot Test under Interactive Test tab for specific
Alarm Level: controller to record fault.
• Clear codes using Diagnostic tab
Service alert - amber warning lamp • Recall codes again and check for return of this code.
To Clear Display: • Recreate operating conditions that caused code.
• End of tests if code does not return.
Alarm Frequency:
Key switch is in on position and ECU did not receive any
Control Unit Response: messages from other on board controllers.
Snapshot Recorded: Common tests:
Yes • CAN Bus physical wiring, connections and splices.
• CAN Bus terminator(s). (See CAN Bus Terminator Test).
Required Tools: • Electromagnetic interference. (See Erroneous
Multimeter Diagnostic Trouble Codes).
• Communication faults. (See CAN Communication Fault
Preliminary Checks: Checks).
Diagnosis:
Service ADVISOR is a trademark of Deere & Company
CB12260,0000091 -19-25FEB14-1/1

ECU 522744.04 — ECU Power Supply Output Alarm Level:

#1 Circuit Has Low Resistance Warning

The ECU power supply output #1 has low resistance. Components Using Power Supply Output #1:
EGR Valve Relay.
Troubleshooting Sequence:
522744.04 Control Unit Response:
The ECU tries to maintain proper operating conditions.
When DTC is Displayed:
When the ignition is on, and the error is active. Additional References:
For more sensor power supply output #1 information, see
Related Information: engine CTM.
The ECU detect excessive current draw on power supply
output #1. Engine Controls and Sensors Schematic
OUMX258,00002BA -19-16FEB16-1/5

Diagnostic Procedure
OUMX258,00002BA -19-16FEB16-2/5

•1 Read DTCs and Store

Snapshot Information
1. Connect Service ADVISOR.

NOTE: When DTCs are cleared, Snapshot Information for ALL DTCs is cleared.

2. Ignition ON, Engine OFF.

3. Refresh codes. YES: Go to next step.
Is DTC 522744.04 active? NO: See engine CTM.

Continued on next page OUMX258,00002BA -19-16FEB16-3/5

TM130419 (24FEB16) 235-55-59 030916

PN=1153
 Diagnose—DTCs, ECU 004000—529999

•2 Check for Short to

Ground
Disconnect ECU connector and remove EGR Valve Relay. Ohm out wire. does is
has continuity to ground?
YES: Repair wiring

NO: Go To Next Step

OUMX258,00002BA -19-16FEB16-4/5

•3 Check Relay Is the relay internally shorted? YES: Replace relay

and perform Verification
Procedure.
SeeRelay Test NO: Recheck wiring for
EGR valve relay if all tests
good suspect faulty ECU.
OUMX258,00002BA -19-16FEB16-5/5

ECU 522994.04 — ECU Power Supply Output Alarm Level:

#2 Circuit Has Low Resistance Warning

The ECU power supply output #2 has low resistance. Components Using Power Supply Output #1:
EGR Valve Relay.
Troubleshooting Sequence:
522744.04 Control Unit Response:
The ECU tries to maintain proper operating conditions.
When DTC is Displayed:
When the ignition is on, and the error is active. Additional References:
For more sensor power supply output #1 information, see
Related Information: engine CTM.
The ECU detect excessive current draw on power supply
output #1. Engine Controls and Sensors Schematic
OUMX258,00002BB -19-16FEB16-1/5

Diagnostic Procedure
OUMX258,00002BB -19-16FEB16-2/5

•1 Read DTCs and Store

Snapshot Information
1. Connect Service ADVISOR.

NOTE: When DTCs are cleared, Snapshot Information for ALL DTCs is cleared.

2. Ignition ON, Engine OFF.

3. Refresh codes. YES: Go to next step.
Is DTC 522744.04 active? NO: See engine CTM.

OUMX258,00002BB -19-16FEB16-3/5

•2 Check for Short to

Ground
Disconnect ECU connector and remove EGR Valve Relay. Ohm out wire. does is
has continuity to ground?
YES: Repair wiring

NO: Go To Next Step

OUMX258,00002BB -19-16FEB16-4/5

•3 Check Relay Is the relay internally shorted? YES: Replace relay

and perform Verification
Procedure.
SeeRelay Test NO: Recheck wiring for
EGR valve relay if all tests
good suspect faulty ECU.

OUMX258,00002BB -19-16FEB16-5/5

TM130419 (24FEB16) 235-55-60 PN=1154

030916
 Diagnose—DTCs, ECU 004000—529999

ECU 523249.05 — Crankshaft Position and Alarm Level:

Camshaft Position Signals Invalid Stop

The ECU has not detected the crankshaft position Control Unit Response:
signal and camshaft position signal. The ECU will not permit engine to run.

Troubleshooting Sequence: Additional References:

522400.05 For more crankshaft position sensor information, and more
522401.05 camshaft position sensor information, see engine CTM.
523249.05 For connector repair or complete wiring information:
When DTC is Displayed: - see Electrical Components, T4,
When the engine cranks and will not start. - see Engine Connector X5059 Schematic
located in Section 230, Group 20.
Related Information:
The ECU has not detected the crankshaft position signal
and camshaft position signal.

A5501
X5059
15 30 45 60
14 29 44 59
13 28 43 58
12 27 42 57
11 26 41 56 6 5 4 3 2 1
10 25 40 55 8 Blk 448 9
9 24 39 54
8 23 38 53 4 Org 447 8
7 22 37 52 9 Pnk 446 7 12 11 10 9 8 7
6 21 36 51
5 20 35 50 B5301

TCT009791 —UN—07JAN14
4 19 34 49
3 18 33 48
2 17 32 47
1 16 31 46
12 11 10 9 8 7 8 1
1 2
6 5 4 3 2 1 7 2

Crankshaft Position Sensor Wiring Diagram

A5501—54—Return A5501—39—Signal A5501—38—Shield

A5501
X5059
15 30 45 60
14 29 44 59
13 28 43 58
12 27 42 57
11 26 41 56 6 5 4 3 2 1
10 25 40 55 52 Wht 445 6
9 24 39 54 37 Blu 444 5
8 23 38 53 08 Pnk 443 4
7 22 37 52 12 11 10 9 8 7
6 21 36 51
5 20 35 50
B5302
TCT009790 —UN—08JAN14

4 19 34 49
3 18 33 48
2 17 32 47
1 16 31 46
12 11 10 9 8 7 6 1
5 2 1 2 3
6 5 4 3 2 1 4 3

Camshaft Position Sensor Wiring Diagram

A5501—08—Supply A5501—52—Return A5501—37—Signal
Continued on next page OUMX258,00002BC -19-16FEB16-1/4

TM130419 (24FEB16) 235-55-61 030916

PN=1155
 Diagnose—DTCs, ECU 004000—529999

Diagnostic Procedure
OUMX258,00002BC -19-16FEB16-2/4

•1 Read DTCs and Store

Snapshot Information
1. Connect Service ADVISOR.
NOTE: When DTCs are cleared, Snapshot Information for ALL DTCs is cleared.

2. Ignition ON, Engine OFF.

3. If any DTCs have snapshot capture or snapshot recording information, save the
information.
4. See DTC 522400.05 procedure. YES: Repair problem.
Perform Verification
Procedure.
Were any problems found? NO: Go to next step.
OUMX258,00002BC -19-16FEB16-3/4

•2 Sensor Test Perform DTC 522401.05 procedure. YES: Repair problem.

Perform Verification
Procedure.
Were any problems found? NO: See Problem Not
Found Procedure.
OUMX258,00002BC -19-16FEB16-4/4

TM130419 (24FEB16) 235-55-62 030916

PN=1156
 Diagnose—DTCs, ECU 004000—529999

ECU 523460.07 — Fuel Rail Pressure Error The root cause of the rail pressure error must be
For a Duration determined and repaired prior to replacing the rail
pressure limiter.
The ECU has detected a fuel rail pressure error for a The rail pressure limiter has a finite number of opening
duration greater than a threshold value defined in the ECU. cycles and must be replaced once the threshold is
exceeded.
Troubleshooting Sequence:
Any SPN 157 DTC Alarm Level:
Any SPN 174 DTC Stop
Any SPN 633 DTC Control Unit Response:
522571.03 The ECU derates the engine.
522571.06
522572.06 Additional references:
522572.11 For component location, more suction control valve
523489.00 information, high-pressure fuel system information, and
information on the Fuel Rail Pressure Relief Valve Counter
When DTC is Displayed: Reset test, see engine CTM.
When the ignition is on, engine running, and the fault is
active. For connector repair or complete wiring information:
- see Electrical Components, T4,
Related Information: - see Engine Connector X5059 Schematic,
The ECU has detected a fuel rail pressure error for a - see Engine Connector X5060 Schematic,
duration greater than a threshold value defined in the ECU. located in Section 230, Group 20.
This fault can be caused by a rail pressure sensor system
fault, a suction control valve system fault, or a fuel
temperature sensor fault.

A5501
X5059
15 30 45 60
14 29 44 59
13 28 43 58
12 27 42 57
11 26 41 56 6 5 4 3 2 1
10 25 40 55 25 Wht 442 3
9 24 39 54 26 Grn 441 2
8 23 38 53 07 Pnk 440 1
7 22 37 52 12 11 10 9 8 7
6 21 36 51
5 20 35 50
B5100

TCT009789 —UN—07JAN14
4 19 34 49
3 18 33 48
2 17 32 47
1 16 31 46
12 11 10 9 8 7 3 1
2 2 1 2 3
6 5 4 3 2 1 1 3

Fuel Rail Pressure Sensor Wiring Diagram

A5501—07—Supply A5501—25— Signal A5501—26—Return

Continued on next page OUMX258,00002BD -19-16FEB16-1/5

TM130419 (24FEB16) 235-55-63 030916

PN=1157
 Diagnose—DTCs, ECU 004000—529999

A5501
X5060
15 30 45 60
14 29 44 59
13 28 43 58
12 27 42 57
11 26 41 56 6 5 4 3 2 1
10 25 40 55 Grn 466 9
9 24 39 54 04 Grn 468 Grn 467 10
8 23 38 53 05 Wht 471 Wht 469 11
7 22 37 52 Wht 470 12 12 11 10 9 8 7
6 21 36 51
5 20 35 50 Y5002

TCT009796 —UN—08JAN14
4 19 34 49
3 18 33 48
2 17 32 47
1 16 31 46 9
12 11 10 9 8 7 10 1
11 1 2
6 5 4 3 2 1 2
12

Suction Control Valve Wiring Diagram

A5501—5—Drive - A5501—4—Drive +
OUMX258,00002BD -19-16FEB16-2/5

Diagnostic Procedure
OUMX258,00002BD -19-16FEB16-3/5

•1 Read DTCs 1. Connect Service ADVISOR.

NOTE: When DTCs are cleared, Snapshot information for ALL DTCs is cleared.

2. Ignition ON, Engine OFF.

3. Ignition ON, engine running.
4. Refresh codes. YES: Perform diagnostics
for those DTCs. Once root
problem is resolved, replace
rail pressure limiter and
perform Fuel Rail Pressure
Relief Valve Counter Reset
test. See engine CTM for
replacement procedure.
Are any of the DTCs in the Trouble Shooting Sequence active or stored? NO: Go to next step.
OUMX258,00002BD -19-16FEB16-4/5

•2 Fuel System Check Perform High-Pressure Fuel System Check procedure. See engine CTM for check
procedure.
YES: See Problem Not
Found Procedure.

Did the high-pressure fuel system check pass? NO: Repair problem.
Replace rail pressure
limiter and perform Fuel
Rail Pressure Relief Valve
Counter Reset test.
OUMX258,00002BD -19-16FEB16-5/5

TM130419 (24FEB16) 235-55-64 030916

PN=1158
 Diagnose—DTCs, ECU 004000—529999

ECU 523462.13 — Injector #1 Calibration

Error The ECU detects an injector calibration data error.
OUMX258,00002BE -19-16FEB16-1/3

Diagnostic Procedure
Troubleshooting Sequence:
523462.13
When DTC is Displayed:
When the ignition is on and the error is active.
Related Information:
The ECU detects an injector calibration data error. Engine performance may be dramatically affected. The engine
may also be out of emissions compliance.
Alarm Level:
Stop
Control Unit Response:
The ECU commands an engine stop.
Additional References:
For more fuel injector information, see engine CTM, Section 03, Group 130.
For more fuel system information, see engine CTM, Section 03, Group 130.
For more electronic injector calibration information, see engine CTM, Section 04, Group 160.
OUMX258,00002BE -19-16FEB16-2/3

•1 Read DTCs 1. Connect Service ADVISOR.

2. Ignition ON, Engine OFF.

3. In Service ADVISOR, perform Electronic Injector—Calibration Information.
4. Refresh codes. YES: Contact DTAC.
Is DTC 523462.13 active? NO: Perform Verification
Procedure.
OUMX258,00002BE -19-16FEB16-3/3

TM130419 (24FEB16) 235-55-65 030916

PN=1159
 Diagnose—DTCs, ECU 004000—529999

ECU 523463.13 — Injector #2 Calibration

Error The ECU detects an injector calibration data error.
OUMX258,00002BF -19-16FEB16-1/3

Diagnostic Procedure
Troubleshooting Sequence:
523463.13
When DTC is Displayed:
When the ignition is on and the error is active.
Related Information:
The ECU detects an injector calibration data error. Engine performance may be dramatically affected. The engine
may also be out of emissions compliance.
Alarm Level:
Stop
Control Unit Response:
The ECU commands an engine stop.
Additional References:
For more fuel injector information, see engine CTM, Section 03, Group 130.
For more fuel system information, see engine CTM, Section 03, Group 130.
For more electronic injector calibration information, see engine CTM, Section 04, Group 160.
OUMX258,00002BF -19-16FEB16-2/3

•1 Read DTCs 1. Connect Service ADVISOR.

2. Ignition ON, Engine OFF.

3. In Service ADVISOR, perform Electronic Injector—Calibration Information
4. Refresh codes. YES: Contact DTAC.
Is DTC 523463.13 active? NO: Perform Verification
Procedure.
OUMX258,00002BF -19-16FEB16-3/3

TM130419 (24FEB16) 235-55-66 030916

PN=1160
 Diagnose—DTCs, ECU 004000—529999

ECU 523464.13 — Injector #3 Calibration

Error The ECU detects an injector calibration data error.
OUMX258,00002C0 -19-16FEB16-1/3

Diagnostic Procedure
Troubleshooting Sequence:
523464.13
When DTC is Displayed:
When the ignition is on and the error is active.
Related Information:
The ECU detects an injector calibration data error. Engine performance may be dramatically affected. The engine
may also be out of emissions compliance.
Alarm Level:
Stop
Control Unit Response:
The ECU commands an engine stop.
Additional References:
For more fuel injector information, see engine CTM, Section 03, Group 130.
For more fuel system information, see engine CTM, Section 03, Group 130.
For more electronic injector calibration information, see engine CTM, Section 04, Group 160.
OUMX258,00002C0 -19-16FEB16-2/3

•1 Read DTCs and Store

Snapshot Information
1. Connect Service ADVISOR.

2. Ignition ON, Engine OFF.

3. In Service ADVISOR, perform Electronic Injector—Calibration Information
4. Refresh codes. YES: Contact DTAC.
Is DTC 523464.13 active? NO: Perform Verification
Procedure.
OUMX258,00002C0 -19-16FEB16-3/3

TM130419 (24FEB16) 235-55-67 030916

PN=1161
 Diagnose—DTCs, ECU 004000—529999

ECU 523468.09 — Rail Pressure Limiter Open The rail pressure limiter has a finite number of opening
cycles and must be replaced once the threshold is
The ECU has detected the rail pressure limiter has exceeded.
opened and is not able to control fuel rail pressure. Alarm Level:
Troubleshooting Sequence: Stop
Any SPN 157 DTC Control Unit Response:
Any SPN 633 DTC The ECU derates the engine.
522571.03 The ECU commands the EGR Valve fully closed.
522571.06
522572.06 Additional references:
522572.11 For component location, more suction control valve
523470.00 information, high-pressure fuel system information, and
information on the Fuel Rail Pressure Relief Valve Counter
When DTC is Displayed:
Reset test, see engine CTM.
When the ignition is on, engine running, and the fault is
active. For connector repair or complete wiring information:
- see Electrical Components, T4,
Related Information:
- see Engine Connector X5059 Schematic,
The ECU has detected the rail pressure limiter has
- see Engine Connector X5060 Schematic,
opened and is not able to control fuel rail pressure.
located in Section 230, Group 20.
This fault can be caused by a problem with the rail
pressure sensor or the suction control valve.
The root cause of the rail pressure limiter opening must
be determined and repaired prior to replacing the rail
pressure limiter.

A5501
X5059
15 30 45 60
14 29 44 59
13 28 43 58
12 27 42 57
11 26 41 56 6 5 4 3 2 1
10 25 40 55 25 Wht 442 3
9 24 39 54 26 Grn 441 2
8 23 38 53 07 Pnk 440 1
7 22 37 52 12 11 10 9 8 7
6 21 36 51
5 20 35 50
B5100

TCT009789 —UN—07JAN14
4 19 34 49
3 18 33 48
2 17 32 47
1 16 31 46
12 11 10 9 8 7 3 1
2 2 1 2 3
6 5 4 3 2 1 1 3

Fuel Rail Pressure Sensor Wiring Diagram

A5501—07—Supply A5501—25— Signal A5501—26—Return
OUMX258,00002C1 -19-16FEB16-1/4

Diagnostic Procedure
Continued on next page OUMX258,00002C1 -19-16FEB16-2/4

TM130419 (24FEB16) 235-55-68 030916

PN=1162
 Diagnose—DTCs, ECU 004000—529999

•1 Read DTCs 1. Connect Service ADVISOR.

NOTE: When DTCs are cleared, Snapshot information for ALL DTCs is cleared.

2. Ignition ON, Engine OFF.

3. Ignition ON, engine running.
4. Refresh codes. YES: Perform diagnostics
for those DTCs. Once root
problem is resolved, replace
rail pressure limiter and
perform Fuel Rail Pressure
Relief Valve Counter Reset
test. See engine CTM for
test procedure.
Are any of the DTCs in the Trouble Shooting Sequence active or stored? NO: Go to next step.
OUMX258,00002C1 -19-16FEB16-3/4

•2 Fuel System Check Perform High-Pressure Fuel System Check procedure. See engine CTM for check
procedure.
YES: See Problem Not
Found Procedure.

Did the high-pressure fuel system check pass? NO: Repair problem.
Replace rail pressure
limiter and perform Fuel
Rail Pressure Relief Valve
Counter Reset test.
OUMX258,00002C1 -19-16FEB16-4/4

TM130419 (24FEB16) 235-55-69 PN=1163

030916
 Diagnose—DTCs, ECU 004000—529999

ECU 523469.00 — Rail Pressure Limiter The rail pressure limiter has a finite number of opening
Occurrence Count Extremely High cycles and must be replaced once the threshold is
exceeded.
The ECU has detected the rail pressure limiter has Alarm Level:
opened a greater number of occurrences than a Stop
threshold value defined in the ECU.
Control Unit Response:
Troubleshooting Sequence: The ECU derates the engine.
Any SPN 157 DTC The ECU commands the EGR Valve fully closed.
Any SPN 633 DTC
522571.03 Additional references:
522571.06 For component location, more suction control valve
522572.06 information, high-pressure fuel system information, and
522572.11 information on the Fuel Rail Pressure Relief Valve Counter
523469.00 Reset test, see engine CTM.
When DTC is Displayed: For connector repair or complete wiring information:
When the ignition is on, and the fault is active. - see Electrical Components, T4,
- see Engine Connector X5059 Schematic,
Related Information: - see Engine Connector X5060 Schematic,
The ECU has detected the rail pressure limiter has located in Section 230, Group 20.
opened a greater number of occurrences than a threshold
value defined in the ECU.
The root cause of the rail pressure limiter must be
determined and repaired prior to replacing the rail
pressure limiter.

A5501
X5059
15 30 45 60
14 29 44 59
13 28 43 58
12 27 42 57
11 26 41 56 6 5 4 3 2 1
10 25 40 55 25 Wht 442 3
9 24 39 54 26 Grn 441 2
8 23 38 53 07 Pnk 440 1
7 22 37 52 12 11 10 9 8 7
6 21 36 51
5 20 35 50
B5100

TCT009789 —UN—07JAN14
4 19 34 49
3 18 33 48
2 17 32 47
1 16 31 46
12 11 10 9 8 7 3 1
2 2 1 2 3
6 5 4 3 2 1 1 3

Fuel Rail Pressure Sensor Wiring Diagram

A5501—07—Supply A5501—25— Signal A5501—26—Return
OUMX258,00002C2 -19-16FEB16-1/4

Diagnostic Procedure
Continued on next page OUMX258,00002C2 -19-16FEB16-2/4

TM130419 (24FEB16) 235-55-70 030916

PN=1164
 Diagnose—DTCs, ECU 004000—529999

•1 Read DTCs 1. Connect Service ADVISOR.

NOTE: When DTCs are cleared, Snapshot information for ALL DTCs is cleared.

2. Ignition ON, Engine OFF.

3. Refresh codes. YES: Perform diagnostics
for those DTCs. Once root
problem is resolved, replace
rail pressure limiter and
perform Fuel Rail Pressure
Relief Valve Counter Reset
test.
Are any of the DTCs in the Trouble Shooting Sequence active or stored? NO: Go to next step.
OUMX258,00002C2 -19-16FEB16-3/4

•2 Fuel System Check Perform High-Pressure Fuel System Check procedure. See engine CTM for check
procedure.
YES: See Problem Not
Found Procedure.

Did the high-pressure fuel system check pass? NO: Repair problem.
Replace rail pressure
limiter and perform Fuel
Rail Pressure Relief Valve
Counter Reset test.
OUMX258,00002C2 -19-16FEB16-4/4

TM130419 (24FEB16) 235-55-71 PN=1165

030916
 Diagnose—DTCs, ECU 004000—529999

ECU 523470.00 — Rail Pressure Limiter The rail pressure limiter has a finite number of opening
Cumulative Time Extremely High cycles and must be replaced once the threshold is
exceeded.
The ECU has detected the amount of cumulative time Alarm Level:
the rail pressure limiter has opened is greater than Stop
a threshold value defined in the ECU.
Control Unit Response:
Troubleshooting Sequence: The ECU derates the engine.
Any SPN 157 DTC The ECU commands the EGR Valve fully closed.
Any SPN 633 DTC
522571.03 Additional references:
522571.06 For component location, more suction control valve
522572.06 information, high-pressure fuel system information, and
522572.11 information on the Fuel Rail Pressure Relief Valve Counter
523470.00 Reset test, see engine CTM.
When DTC is Displayed: For connector repair or complete wiring information:
When the ignition is on, and the fault is active. - see Electrical Components, T4,
- see Engine Connector X5059 Schematic,
Related Information: - see Engine Connector X5060 Schematic,
The ECU has detected the amount of cumulative time the located in Section 230, Group 20.
rail pressure limiter has opened is greater than a threshold
value defined in the ECU.
The root cause of the rail pressure limiter must be
determined and repaired prior to replacing the rail
pressure limiter.

A5501
X5059
15 30 45 60
14 29 44 59
13 28 43 58
12 27 42 57
11 26 41 56 6 5 4 3 2 1
10 25 40 55 25 Wht 442 3
9 24 39 54 26 Grn 441 2
8 23 38 53 07 Pnk 440 1
7 22 37 52 12 11 10 9 8 7
6 21 36 51
5 20 35 50
B5100

TCT009789 —UN—07JAN14
4 19 34 49
3 18 33 48
2 17 32 47
1 16 31 46
12 11 10 9 8 7 3 1
2 2 1 2 3
6 5 4 3 2 1 1 3

Fuel Rail Pressure Sensor Wiring Diagram

A5501—07—Supply A5501—25— Signal A5501—26—Return
OUMX258,00002C3 -19-16FEB16-1/4

Diagnostic Procedure
Continued on next page OUMX258,00002C3 -19-16FEB16-2/4

TM130419 (24FEB16) 235-55-72 030916

PN=1166
 Diagnose—DTCs, ECU 004000—529999

•1 Read DTCs 1. Connect Service ADVISOR.

NOTE: When DTCs are cleared, Snapshot information for ALL DTCs is cleared.

2. Ignition ON, Engine OFF.

3. Refresh codes. YES: Perform diagnostics
for those DTCs. Once root
problem is resolved, replace
rail pressure limiter and
perform Fuel Rail Pressure
Relief Valve Counter Reset
test. See engine CTM
for replacement and test
procedures.
Are any of the DTCs in the Trouble Shooting Sequence active or stored? NO: Go to next step.
OUMX258,00002C3 -19-16FEB16-3/4

•2 Fuel System Check Perform High-Pressure Fuel System Check procedure. See engine CTM for check
procedure.
YES: See Problem Not
Found Procedure.

Did the high-pressure fuel system check pass? NO: Repair problem.
Replace rail pressure
limiter and perform Fuel
Rail Pressure Relief
Valve Counter Reset test.
See engine CTM for test
procedure.
OUMX258,00002C3 -19-16FEB16-4/4

TM130419 (24FEB16) 235-55-73 PN=1167

030916
 Diagnose—DTCs, ECU 004000—529999

ECU 523489.00 — Fuel Rail Pressure The root cause of the extremely high rail pressure must
Extremely High For a Duration be determined and repaired prior to replacing the rail
pressure limiter.
The ECU has detected fuel rail pressure greater than a The rail pressure limiter has a finite number of opening
threshold value defined in the ECU for a duration greater cycles and must be replaced once the threshold is
than a threshold value defined in the ECU. exceeded.

Troubleshooting Sequence: Alarm Level:

Any SPN 157 DTC Stop
Any SPN 633 DTC Control Unit Response:
522571.03 The ECU derates the engine.
522571.06 The ECU commands the EGR Valve fully closed.
522572.06
522572.11 Additional references:
523489.00 For component location, more suction control valve
information, high-pressure fuel system information, and
When DTC is Displayed: information on the Fuel Rail Pressure Relief Valve Counter
When the ignition is on, engine running, and the fault is Reset test, see engine CTM.
active.
For connector repair or complete wiring information:
Related Information: - see Electrical Components, T4,
The ECU has detected fuel rail pressure greater than a - see Engine Connector X5059 Schematic,
threshold value defined in the ECU for a duration greater - see Engine Connector X5060 Schematic,
than a threshold value defined in the ECU. located in Section 230, Group 20.
This fault can be caused by a rail pressure sensor
system fault, a suction control valve system fault, or a
rail pressure limiter failure.

A5501
X5059
15 30 45 60
14 29 44 59
13 28 43 58
12 27 42 57
11 26 41 56 6 5 4 3 2 1
10 25 40 55 25 Wht 442 3
9 24 39 54 26 Grn 441 2
8 23 38 53 07 Pnk 440 1
7 22 37 52 12 11 10 9 8 7
6 21 36 51
5 20 35 50
B5100

TCT009789 —UN—07JAN14
4 19 34 49
3 18 33 48
2 17 32 47
1 16 31 46
12 11 10 9 8 7 3 1
2 2 1 2 3
6 5 4 3 2 1 1 3

Fuel Rail Pressure Sensor Wiring Diagram

A5501—07—Supply A5501—25— Signal A5501—26—Return
OUMX258,00002C4 -19-16FEB16-1/4

Diagnostic Procedure
Continued on next page OUMX258,00002C4 -19-16FEB16-2/4

TM130419 (24FEB16) 235-55-74 030916

PN=1168
 Diagnose—DTCs, ECU 004000—529999

•1 Read DTCs 1. Connect Service ADVISOR.

NOTE: When DTCs are cleared, Snapshot information for ALL DTCs is cleared.

2. Ignition ON, Engine OFF.

3. Ignition ON, engine running.
4. Refresh codes. YES: Perform diagnostics
for those DTCs. Once root
problem is resolved, replace
rail pressure limiter and
perform Fuel Rail Pressure
Relief Valve Counter Reset
test. See engine CTM
for replacement and test
procedures.
Are any of the DTCs in the Trouble Shooting Sequence active or stored? NO: Go to next step.
OUMX258,00002C4 -19-16FEB16-3/4

•2 Fuel System Check Perform High-Pressure Fuel System Check procedure. See engine CTM for check
procedure.
YES: See Problem Not
Found Procedure.

Did the high-pressure fuel system check pass? NO: Repair problem.
Replace rail pressure
limiter and perform Fuel
Rail Pressure Relief
Valve Counter Reset test.
See engine CTM for test
procedure.
OUMX258,00002C4 -19-16FEB16-4/4

TM130419 (24FEB16) 235-55-75 PN=1169

030916
 Diagnose—DTCs, ECU 004000—529999

ECU 523491.00 — Fuel Temperature The root cause of the extremely high fuel temperature
Extremely High For a Duration must be determined and repaired prior to replacing the
rail pressure limiter.
The ECU has detected fuel temperature is greater than a The rail pressure limiter has a finite number of opening
threshold value defined in the ECU for a duration greater cycles and must be replaced once the threshold is
than a threshold value defined in the ECU. exceeded.

Troubleshooting Sequence: Alarm Level:

Any SPN 157 DTC Stop
Any SPN 633 DTC Control Unit Response:
522571.03 The ECU derates the engine.
522571.06 The ECU commands the EGR Valve fully closed.
522572.06 DPF regeneration will be aborted and inhibited while the
522572.11 fault is active.
523491.00
Additional references:
When DTC is Displayed: For component location, high-pressure fuel system
When the ignition is on, engine running, and the fault is information, and information on the Fuel Rail Pressure
active. Relief Valve Counter Reset test, see engine CTM.
Related Information: For connector repair or complete wiring information:
The ECU has detected fuel temperature is greater than a - see Electrical Components, T4,
threshold value defined in the ECU for a duration greater - see Engine Connector X5059 Schematic,
than a threshold value defined in the ECU. - see Engine Connector X5060 Schematic,
This fault can be caused by a rail pressure sensor located in Section 230, Group 20.
system fault, a suction control valve system fault, or a rail
pressure limiter failure. A fault in any of these systems
can result in excessive rail pressure causing extremely
high fuel temperature.

A5501
X5059
15 30 45 60
14 29 44 59
13 28 43 58
12 27 42 57
11 26 41 56 6 5 4 3 2 1
10 25 40 55
9 24 39 54
8 23 38 53 51 Brn 450 12
7 22 37 52 11 Blu 449 11 12 11 10 9 8 7
6 21 36 51
5 20 35 50 B5209

TCT009792 —UN—07JAN14
4 19 34 49
3 18 33 48
2 17 32 47
1 16 31 46
12 11 10 9 8 7 11 1
1 2
6 5 4 3 2 1 12 2

Fuel Temperature Sensor Wiring Diagram

A5501—11—Signal A5501—51—Return
OUMX258,00002C5 -19-16FEB16-1/4

Diagnostic Procedure
Continued on next page OUMX258,00002C5 -19-16FEB16-2/4

TM130419 (24FEB16) 235-55-76 030916

PN=1170
 Diagnose—DTCs, ECU 004000—529999

•1 Read DTCs 1. Connect Service ADVISOR.

NOTE: When DTCs are cleared, Snapshot information for ALL DTCs is cleared.

2. Ignition ON, Engine OFF.

3. Refresh codes. YES: Perform diagnostics
for those DTCs. Once root
problem is resolved, replace
rail pressure limiter and
perform Fuel Rail Pressure
Relief Valve Counter Reset
test.
Are any of the DTCs in the Trouble Shooting Sequence active or stored? NO: Go to next step.
OUMX258,00002C5 -19-16FEB16-3/4

•2 Fuel System Check Perform High-Pressure Fuel System Check procedure. See engine CTM for check
procedure.
YES: See Problem Not
Found Procedure.

Did the high-pressure fuel system check pass? NO: Repair problem.
Replace rail pressure
limiter and perform Fuel
Rail Pressure Relief Valve
Counter Reset test.
OUMX258,00002C5 -19-16FEB16-4/4

TM130419 (24FEB16) 235-55-77 PN=1171

030916
 Diagnose—DTCs, ECU 004000—529999

TM130419 (24FEB16) 235-55-78 030916

PN=1172
 Section 240
Power Train Operation, Tests, and Adjustments
Contents

Page
Page
Group 10—Diagnosis—Single Speed
Differential Will Not Lock when Rear Wheels Do Not Drive—2
Lock Pedal Is Pressed—Single Speed......................................................240-20-4
Speed......................................................240-10-1 Rear Wheels Do Not Drive ..........................240-20-4
Differential Will Not Lock when Lock
Pedal Is Pressed .....................................240-10-1 Group 30—Tests and Adjustments—Single Speed
Machine Moves with Travel Pedals in Summary of References.............................. 240-30-1
Neutral—Single Speed............................240-10-1 Test and Adjust Transaxle Neutral
Machine Moves with Travel Pedals in Creep....................................................... 240-30-1
Neutral.....................................................240-10-1 Adjust F-N-R Linkage .................................. 240-30-2
Machine Will Not Move when Travel Adjust Differential Lock................................ 240-30-3
Pedals Are Pressed—Single Adjust 4WD Axle Pivot Pin
Speed......................................................240-10-2 Clearance ................................................ 240-30-4
Machine Will Not Move when Travel
Pedals Are Pressed ................................240-10-2 Group 40—Tests and Adjustments—2 Speed
Machine Will Not Reach Full Summary of References.............................. 240-40-1
Speed—Single Speed.............................240-10-2 Test and Adjust Transaxle Neutral
Machine Will Not Reach Full Creep—2 Speed...................................... 240-40-1
Speed......................................................240-10-2 Adjust F-N-R Linkage—2 Speed ................. 240-40-2
PTO Turns with PTO Switch Adjust Differential Lock—2 Speed................ 240-40-3
Off—Single Speed ..................................240-10-3 Adjust 4WD Axle Pivot Pin
PTO Turns with PTO Switch Off ..................240-10-3 Clearance—2 Speed ............................... 240-40-4
PTO Shaft Will Not Turn—Single
Speed......................................................240-10-3
PTO Shaft Will Not Turn ..............................240-10-3
Rear Wheels Do Not Drive—Single
Speed......................................................240-10-4
Rear Wheels Do Not Drive ..........................240-10-4

Group 20—Diagnosis—2 Speed

Differential Will Not Lock when Lock
Pedal Is Pressed—2 Speed ....................240-20-1
Differential Will Not Lock when Lock
Pedal Is Pressed .....................................240-20-1
Machine Moves with Travel Pedals in
Neutral—2 Speed....................................240-20-1
Machine Moves with Travel Pedals in
Neutral.....................................................240-20-1
Machine Will Not Move when
Travel Pedals Are Pressed—2
Speed......................................................240-20-2
Machine Will Not Move when Travel
Pedals Are Pressed ................................240-20-2
Machine Will Not Reach Full Speed—2
Speed......................................................240-20-2
Machine Will Not Reach Full
Speed......................................................240-20-2
PTO Shaft Turns with PTO Switch
Off—2 Speed ..........................................240-20-3
PTO Shaft Turns with PTO Switch
Off ...........................................................240-20-3
PTO Shaft Will Not Turn—2
Speed......................................................240-20-3
PTO Shaft Will Not Turn ..............................240-20-3

TM130419 (24FEB16) 240-1 030916

PN=1
 Contents

TM130419 (24FEB16) 240-2 030916

PN=2
 Group 10
Diagnosis—Single Speed
Differential Will Not Lock when Lock Pedal Is
Pressed—Single Speed Differential Will Not Lock when Lock Pedal Is
Pressed, Single Speed
OUMX258,0000AAB -19-16SEP14-1/5

Differential Will Not Lock when Lock Pedal Is Pressed

OUMX258,0000AAB -19-16SEP14-2/5

•1 Procedure Is differential linkage in good condition, not worn or damaged? YES: Go to next step.

NO: Replace worn or

damaged parts.

OUMX258,0000AAB -19-16SEP14-3/5

•2 continued Is differential lock linkage adjusted correctly? YES: Go to next step.

NO: Adjust linkage. (See

Adjust Differential Lock.)

OUMX258,0000AAB -19-16SEP14-4/5

•3 continued Is differential lock assembly in good condition, not worn or damaged? NO: Repair or replace as
necessary.

OUMX258,0000AAB -19-16SEP14-5/5

Machine Moves with Travel Pedals in

Neutral—Single Speed Machine Moves with Travel Pedals in Neu-
tral, Single Speed
OUMX258,0000AAC -19-25JUL14-1/5

Machine Moves with Travel Pedals in Neutral

OUMX258,0000AAC -19-25JUL14-2/5

•1 Procedure Are hydrostatic pedal linkage and cables in good condition, not worn or damaged?
(See Adjust F-N-R Linkage.)
YES: Go to next step.

NO: Replace parts as

necessary.

OUMX258,0000AAC -19-25JUL14-3/5

•2 continued Is neutral adjustment set properly? (See Test and Adjust Transaxle Neutral Creep.) YES: Go to next step.

NO: Adjust neutral creep.

OUMX258,0000AAC -19-25JUL14-4/5

•3 continued Are hydrostatic pedal linkage and cable adjusted properly? (See Adjust F-N-R Linkage.) NO: Adjust as necessary.

OUMX258,0000AAC -19-25JUL14-5/5

TM130419 (24FEB16) 240-10-1 030916

PN=1175
 Diagnosis—Single Speed

Machine Will Not Move when Travel Pedals NOTE: The following condition may be caused by systems
Are Pressed—Single Speed other than power train. Check the brake system if
the following procedures do not correct the problem.
Machine Will Not Move when Travel Pedals Are
Pressed, Single Speed
OUMX258,0000AAD -19-25JUL14-1/5

Machine Will Not Move when Travel Pedals Are Pressed

OUMX258,0000AAD -19-25JUL14-2/5

•1 Procedure Is transmission fluid level to correct level? YES: Go to next step.

NO: Adjust to proper level.

OUMX258,0000AAD -19-25JUL14-3/5

•2 continued Is transmission fluid clean, not contaminated or foamy? YES: Go to next step.

NO: Contaminated: Drain

system, replace oil filter,
and fill with specified oil.
Foamy: see “Hydraulic Oil
Foams” in the Steering
Diagnosis section.

OUMX258,0000AAD -19-25JUL14-4/5

•3 continued Is System charge pressure correct? (See Charge Pressure Relief Valve Test.) NO: Replace charge
pressure relief valve.

OUMX258,0000AAD -19-25JUL14-5/5

Machine Will Not Reach Full Speed—Single NOTE: This condition may be caused by systems other
Speed than power train. Check the brake system if the
following procedures do not correct the problem.
Machine Will Not Reach Full Speed, Single Speed
OUMX258,0000AAE -19-25JUL14-1/7

Machine Will Not Reach Full Speed

OUMX258,0000AAE -19-25JUL14-2/7

Procedure Is transmission fluid level to correct level? YES: Go to next step.

NO: Adjust to proper level.

OUMX258,0000AAE -19-25JUL14-3/7

continued Is transmission fluid clean, not contaminated or foamy? YES: Go to next step.
NO: Contaminated: Drain
system, replace oil filter,
and fill with specified oil.
Foamy: see “Hydraulic Oil
Foams” in the Steering
Diagnosis section.

Continued on next page OUMX258,0000AAE -19-25JUL14-4/7

TM130419 (24FEB16) 240-10-2 030916

PN=1176
 Diagnosis—Single Speed

continued Are hydrostatic pedal linkage and cables in good condition, not worn or damaged? YES: Go to next step.
(See Adjust F-N-R Linkage and Adjust Differential Lock.)
NO: Replace parts as
necessary.
OUMX258,0000AAE -19-25JUL14-5/7

continued Is System charge pressure correct? (See Charge Pressure Relief Valve Test.) YES: Go to next step.
NO: Replace charge
pressure relief valve.
OUMX258,0000AAE -19-25JUL14-6/7

continued Is hydrostatic motor in good condition, not leaking or damaged? NO: Repair or replace
hydrostatic motor.
OUMX258,0000AAE -19-25JUL14-7/7

PTO Turns with PTO Switch Off—Single

Speed PTO Turns with PTO Switch Off, Single Speed
OUMX258,0000AAF -19-25JUL14-1/5

PTO Turns with PTO Switch Off

OUMX258,0000AAF -19-25JUL14-2/5

Procedure Is PTO switch functioning properly? (See PTO Switch Test, Non-T4.) YES: Go to next step.
NO: Replace switch.

OUMX258,0000AAF -19-25JUL14-3/5

continued Is PTO solenoid functioning properly? (See PTO Solenoid Test.) YES: Go to next step.
NO: Replace solenoid.

OUMX258,0000AAF -19-25JUL14-4/5

continued Check PTO brake for wear or damage. (See Disassemble, Inspect, and Assemble NO: Replace brake parts
PTO.) Is brake in good condition, not worn or damaged? as necessary.

OUMX258,0000AAF -19-25JUL14-5/5

PTO Shaft Will Not Turn—Single Speed

PTO Shaft Will Not Turn, Single Speed
OUMX258,0000AB0 -19-25JUL14-1/7

PTO Shaft Will Not Turn

OUMX258,0000AB0 -19-25JUL14-2/7

•1 Procedure Is transmission fluid level to correct level? YES: Go to next step.

NO: Adjust to proper level.

Continued on next page OUMX258,0000AB0 -19-25JUL14-3/7

TM130419 (24FEB16) 240-10-3 030916

PN=1177
 Diagnosis—Single Speed

•2 continued Is transmission fluid clean, not contaminated or foamy? YES: Go to next step.

NO: Contaminated: Drain

system, replace oil filter,
and fill with specified oil.
Foamy: see “Hydraulic Oil
Foams” in the Steering
Diagnosis section.
OUMX258,0000AB0 -19-25JUL14-4/7

•3 continued Is PTO switch functioning properly? (See PTO Switch Test, Non-T4.) YES: Go to next step.

NO: Replace switch.

OUMX258,0000AB0 -19-25JUL14-5/7

•4 continued Is PTO solenoid functioning properly? (See PTO Solenoid Test.) YES: Go to next step.

NO: Replace solenoid.

OUMX258,0000AB0 -19-25JUL14-6/7

•5 continued Check PTO brake for wear or damage. (See Disassemble, Inspect, and Assemble
PTO.) Is brake in good condition, not worn or damaged?
NO: Replace brake parts
as necessary.

OUMX258,0000AB0 -19-25JUL14-7/7

Rear Wheels Do Not Drive—Single Speed

Rear Wheels Do Not Drive, Single Speed
OUMX258,0000AB1 -19-16SEP14-1/6

Rear Wheels Do Not Drive

OUMX258,0000AB1 -19-16SEP14-2/6

•1 Procedure Check MFWD lever linkage for wear or damage. Is lever in good condition, not worn
or damaged?
YES: Go to next step.

NO: Repair or replace as

necessary.

OUMX258,0000AB1 -19-16SEP14-3/6

•2 continued Check MFWD driveshaft for wear or damage. Is drive shaft in place and not damaged? YES: Go to next step.

NO: Repair or replace as

necessary.

Continued on next page OUMX258,0000AB1 -19-16SEP14-4/6

TM130419 (24FEB16) 240-10-4 PN=1178

030916
 Diagnosis—Single Speed

•3 continued Check transaxle MFWD gear case assembly for wear or damage. Is case in good
condition, not damaged?
YES: Go to next step.

NO: Repair or replace as

necessary.
OUMX258,0000AB1 -19-16SEP14-5/6

•4 continued Check MFWD axle assembly for wear or damage. (See Disassemble, Inspect, and
Assemble 4WD Axle.) Is axle in good condition, not worn or damaged?
NO: Repair or replace as
necessary.

OUMX258,0000AB1 -19-16SEP14-6/6

TM130419 (24FEB16) 240-10-5 030916

PN=1179
 Diagnosis—Single Speed

TM130419 (24FEB16) 240-10-6 030916

PN=1180
 Group 20
Diagnosis—2 Speed
Differential Will Not Lock when Lock Pedal
Is Pressed—2 Speed Differential Will Not Lock when Lock Pedal Is
Pressed, 2 Speed
OUMX258,0000ACE -19-31DEC13-1/5

Differential Will Not Lock when Lock Pedal Is Pressed

OUMX258,0000ACE -19-31DEC13-2/5

•1 Procedure Is differential linkage in good condition, not worn or damaged? YES: Go to next step.

NO: Replace worn or

damaged parts.

OUMX258,0000ACE -19-31DEC13-3/5

•2 continued Is Differential lock linkage adjusted correctly? YES: Go to next step.

NO: Adjust linkage. (See

Adjust Differential Lock—2
Speed.)

OUMX258,0000ACE -19-31DEC13-4/5

•3 continued Is differential lock assembly in good condition, not worn or damaged? NO: Repair or replace
as necessary. (See
Disassemble, Inspect,
and Assemble Differential
Assembly.)

OUMX258,0000ACE -19-31DEC13-5/5

Machine Moves with Travel Pedals in

Neutral—2 Speed Machine Moves with Travel Pedals in Neutral, 2 Speed

OUMX258,0000ACF -19-31DEC13-1/5

Machine Moves with Travel Pedals in Neutral

OUMX258,0000ACF -19-31DEC13-2/5

Procedure Are hydrostatic pedal linkage and cables in good condition, not worn or damaged? YES: Go to next step.
(See Test and Adjust Transaxle Neutral Creep—2 Speed and Adjust F-N-R Linkage—2
Speed.)
NO: Replace parts as
necessary.

OUMX258,0000ACF -19-31DEC13-3/5

continued Is neutral adjustment set properly? (See Test and Adjust Transaxle Neutral Creep—2 YES: Go to next step.
Speed.)
NO: Adjust neutral creep.

OUMX258,0000ACF -19-31DEC13-4/5

continued Are hydrostatic pedal linkage and cable adjusted properly? (See Adjust F-N-R NO: Adjust as necessary.
Linkage—2 Speed and Adjust Differential Lock—2 Speed.)

OUMX258,0000ACF -19-31DEC13-5/5

TM130419 (24FEB16) 240-20-1 030916

PN=1181
 Diagnosis—2 Speed

Machine Will Not Move when Travel Pedals NOTE: The following condition may be caused by systems
Are Pressed—2 Speed other than power train. Check the brake system if
the following procedures do not correct the problem.
Machine Will Not Move when Travel Pedals
Are Pressed, 2 Speed
OUMX258,0000AD0 -19-31DEC13-1/6

Machine Will Not Move when Travel Pedals Are Pressed

OUMX258,0000AD0 -19-31DEC13-2/6

Procedure Is range transmission engaged? YES: Go to next step.

NO: Engage range
transmission.
OUMX258,0000AD0 -19-31DEC13-3/6

continued Is transmission fluid level to correct level? YES: Go to next step.

NO: Adjust to proper level.

OUMX258,0000AD0 -19-31DEC13-4/6

continued Is transmission fluid clean, not contaminated or foamy? YES: Go to next step.
NO: Contaminated: Drain
system, replace oil filter,
and fill with specified oil.
Foamy: see “Hydraulic Oil
Foams” in the Steering
Diagnosis section.

OUMX258,0000AD0 -19-31DEC13-5/6

continued Is System charge pressure correct? (See Charge Pressure Relief Valve Test.) NO: Replace charge
pressure relief valve.

OUMX258,0000AD0 -19-31DEC13-6/6

Machine Will Not Reach Full Speed—2 Speed NOTE: This condition may be caused by systems other
than power train. Check the brake system if the
Machine Will Not Reach Full Speed, 2 Speed following procedures do not correct the problem.
OUMX258,0000AD1 -19-31DEC13-1/7

Machine Will Not Reach Full Speed

OUMX258,0000AD1 -19-31DEC13-2/7

Procedure Is transmission fluid level to correct level? YES: Go to next step.

NO: Adjust to proper level.

OUMX258,0000AD1 -19-31DEC13-3/7

continued Is transmission fluid clean, not contaminated or foamy? YES: Go to next step.
NO: Contaminated: Drain
system, replace oil filter,
and fill with specified oil.
Foamy: see “Hydraulic Oil
Foams” in the Steering
Diagnosis section.

Continued on next page OUMX258,0000AD1 -19-31DEC13-4/7

TM130419 (24FEB16) 240-20-2 030916

PN=1182
 Diagnosis—2 Speed

continued Are hydrostatic pedal linkage and cables in good condition, not worn or damaged? YES: Go to next step.
(See Test and Adjust Transaxle Neutral Creep—2 Speed and Adjust F-N-R Linkage—2
Speed.)
NO: Replace parts as
necessary.
OUMX258,0000AD1 -19-31DEC13-5/7

continued Is System charge pressure correct? (See Charge Pressure Relief Valve Test.) YES: Go to next step.
NO: Replace charge
pressure relief valve.
OUMX258,0000AD1 -19-31DEC13-6/7

continued Is hydrostatic motor in good condition, not leaking or damaged? NO: Repair or replace
hydrostatic motor.
OUMX258,0000AD1 -19-31DEC13-7/7

PTO Shaft Turns with PTO Switch Off—2

Speed PTO Shaft Turns with PTO Switch Off, 2 Speed
OUMX258,0000AD2 -19-07JUL14-1/5

PTO Shaft Turns with PTO Switch Off

OUMX258,0000AD2 -19-07JUL14-2/5

Procedure Is PTO switch functioning properly? (See PTO Switch Test, T4.) YES: Go to next step.
NO: Replace switch.

OUMX258,0000AD2 -19-07JUL14-3/5

continued Is PTO solenoid functioning properly? (See PTO Solenoid Test.) YES: Go to next step.
NO: Replace solenoid.

OUMX258,0000AD2 -19-07JUL14-4/5

continued Check PTO brake for wear or damage. (See Disassemble, Inspect, and Assemble NO: Replace brake parts
PTO.) Is brake in good condition, not worn or damaged? as necessary.

OUMX258,0000AD2 -19-07JUL14-5/5

PTO Shaft Will Not Turn—2 Speed

PTO Shaft Will Not Turn, 2 Speed
OUMX258,0000AD3 -19-07JUL14-1/7

PTO Shaft Will Not Turn

OUMX258,0000AD3 -19-07JUL14-2/7

Procedure Is transmission fluid level to correct level? YES: Go to next step.

NO: Adjust to proper level.

Continued on next page OUMX258,0000AD3 -19-07JUL14-3/7

TM130419 (24FEB16) 240-20-3 030916

PN=1183
 Diagnosis—2 Speed

continued Is transmission fluid clean, not contaminated or foamy? YES: Go to next step.
NO: Contaminated: Drain
system, replace oil filter,
and fill with specified oil.
Foamy: see “Hydraulic Oil
Foams” in the Steering
Diagnosis section.
OUMX258,0000AD3 -19-07JUL14-4/7

continued Is PTO switch functioning properly? (See PTO Switch Test, T4.) YES: Go to next step.
NO: Replace switch.
OUMX258,0000AD3 -19-07JUL14-5/7

continued Is PTO solenoid functioning froperly? (See PTO Solenoid Test.) YES: Go to next step.
NO: Replace solenoid.
OUMX258,0000AD3 -19-07JUL14-6/7

continued Check PTO brake for wear or damage. (See Disassemble, Inspect, and Assemble NO: Replace brake parts
PTO.) Is brake in good condition, not worn or damaged? as necessary.

OUMX258,0000AD3 -19-07JUL14-7/7

Rear Wheels Do Not Drive—2 Speed

Rear Wheels Do Not Drive, 2 Speed
OUMX258,0000AD4 -19-31DEC13-1/6

Rear Wheels Do Not Drive

OUMX258,0000AD4 -19-31DEC13-2/6

Procedure Check MFWD lever linkage for wear or damage. Is lever in good condition, not worn YES: Go to next step.
or damaged?
NO: Repair or replace as
necessary.

OUMX258,0000AD4 -19-31DEC13-3/6

continued Check MFWD driveshaft for wear or damage. Is drive shaft in place and not damaged? YES: Go to next step.
NO: Repair or replace as
necessary.

OUMX258,0000AD4 -19-31DEC13-4/6

continued Check transaxle MFWD gear case assembly for wear or damage. Is case in good YES: Go to next step.
condition, not damaged?
NO: Repair or replace as
necessary.

OUMX258,0000AD4 -19-31DEC13-5/6

continued Check MFWD axle assembly for wear or damage. (See Disassemble, Inspect, and NO: Repair or replace as
Assemble 4WD Axle.) Is axle in good condition, not worn or damaged? necessary.

OUMX258,0000AD4 -19-31DEC13-6/6

TM130419 (24FEB16) 240-20-4 PN=1184

030916
 Group 30
Tests and Adjustments—Single Speed
Summary of References • Adjust Differential Lock
• Test and Adjust Transaxle Neutral Creep • Adjust 4WD Axle Pivot Pin Clearance
• Adjust F-N-R Linkage
OUMX258,0000AB6 -19-22MAR13-1/1

Test and Adjust Transaxle Neutral Creep

Reason
To ensure that the machine does not creep when pedals
are in neutral.
Special or Required Tools

• Hoist

TCAL29176 —UN—02JUL12
• Jack Stand (4 used)
NOTE: If creep is intermittent, inspect hydrostatic
pedal linkage for wear, damage, or binding
before adjusting transaxle neutral.

Procedure

CAUTION: When servicing a 4WD equipped

machine with front wheels supported off A—Locknut B—Eccentric Nut
ground and engine running, always support
rear wheels in a similar manner. The 4WD is
always engaged and will push machine off
supports if wheels are not raised. 7. Hold adjustment and tighten locknut. Make sure that
adjustment did not change.
1. Lift machine with a hoist and support both front and 8. Depress both forward and reverse speed pedals, then
rear wheels off the ground. release.
2. Put jack stands under frame. 9. Check neutral adjustment. Repeat adjustment as
3. Loosen locknut (A). necessary.

CAUTION: Use extreme caution when doing this CAUTION: Remove jumper wire from seat
adjustment. Drive wheels are free to spin. switch if installed.

4. Have someone push down center of seat cushion to 10. Lower machine to the ground. Remove seat switch
activate seat safety switch, or use a jumper wire to jumper wire if used.
bypass the seat switch. Results
5. Start engine and run at slow idle.
• If drive wheels continue to turn, check for worn or binding
6. With brakes unlocked, turn eccentric nut (B) left or hydrostatic pedal linkage or internal transaxle problems.
right until drive wheels stop turning.
OUMX258,0000AB2 -19-15SEP14-1/1

TM130419 (24FEB16) 240-30-1 030916

PN=1185
 Tests and Adjustments—Single Speed

Adjust F-N-R Linkage

TCAL29177 —UN—02JUL12
A—Neutral Safety Arm D—Hydrostatic Control Arm G—Forward Pedal K—Reverse Cable
B—F-N-R Bellcrank E—Hydrostatic Control Link H—Reverse Pedal
C—Linkage Support Bracket F— Brake Pedal I— Forward Cable
J— Neutral Safety Link

Install and Adjust Cable

11. Adjust hydrostatic control link (E) until the roller of the
1. Park machine safely on level surface. neutral safety arm (A) is centered in the forward cam
slot of F-N-R bellcrank (B) as the safety arm and roller
2. Disengage PTO. swing forward. Tighten control link jam nuts.
3. With machine running, release brake and check for 12. Adjust forward and reverse cables until pedal
creep. If machine creeps, adjust neutral creep before pad distance from floor is to specification and the
continuing with linkage adjustment. (See Test and hydrostatic control arm (D) hits the hard stops on the
Adjust Transaxle Neutral Creep.) transaxle.
4. Turn key switch off. Specification
Forward and
5. Open floor access panel. Reverse Pedal-to-
6. Loosen locknuts on ball joint ends of hydrostatic Floor—Clearance............................................................................ 3 mm
control link (E). Disconnect link from hydrostatic (0.1 in.)
control arm (D). 13. Tighten jam nuts on forward and reverse cables.
7. Adjust length of control link to 179 mm (7 in.), 14. Verify correct pedal travel and operation of park brake.
measuring from center-to-center of ball joint studs.
Ensure sufficient thread engagement in both ball joint 15. Operate machine and check for neutral creep. (See
ends. Test and Adjust Transaxle Neutral Creep.)
8. Install link and tighten ball joint nuts, but do not tighten Install and Adjust Link
jam nuts at this time.
NOTE: If installing neutral safety link, make sure
9. Loosen nuts on clevis of forward (I) and reverse (K) the thread engagement in both front and rear
cables. ball joints is to specification.
10. Adjust jam nut on forward cable until threaded end of Specification
cable extends approximately 20 mm (0.8 in.) beyond Neutral Safety Link Ball
nut. Adjust rear cable until end extends approximately Joint Thread—Minimum
12 mm (0.5 in.) beyond jam nut. Do not tighten nuts Engagement.................................................................................... 8 mm
at this time. (0.3 in.)
Continued on next page OUMX258,0000AB3 -19-16SEP14-1/2

TM130419 (24FEB16) 240-30-2 PN=1186

030916
 Tests and Adjustments—Single Speed

Tighten locknut attaching link to arm and jam nut on

1. Loosen locknut on rear ball joint of neutral safety link
rod.
(J). Disconnect link from neutral safety arm (A) and
adjust length of link to approximately 305 mm (12 in.), 3. With the brakes off, operate the forward (G) and
measuring from center-to-center of ball joint studs. reverse (H) pedals. Make sure that the neutral safety
arm does not impede forward and reverse pedal
2. Install link on safety arm (A) and adjust the length of
strokes.
the safety link (J), as necessary, until the roller of the
neutral safety arm (A) is about 2-4 mm (0.08-0.16 in.) 4. Check operation of park brake (F) and park brake
from the rear surface of F-N-R bellcrank cam slot. switch.
OUMX258,0000AB3 -19-16SEP14-2/2

Adjust Differential Lock

1. Park machine on level ground.
2. With at least one wheel off the ground, turn the tire
and depress the differential lock pedal until it locks
into position.
• If pedal hits floor and will not lock into position,
shorten the differential lock link until it locks.
3. Adjust the length of the differential lock link to
specification.
Specification
Differential Lock Pedal to

TCAL29178 —UN—02JUL12
Floor—Gap.................................................................................1—3 mm
(0.04—0.12 in.)

4. Tighten jam nuts.

A—Differential Lock Pedal C—Differential Lock Link

B—Differential Lock Pivot Assembly
D—Differential Lock Arm

OUMX258,0000AB4 -19-16SEP14-1/1

TM130419 (24FEB16) 240-30-3 030916

PN=1187
 Tests and Adjustments—Single Speed

Adjust 4WD Axle Pivot Pin Clearance

Procedure
1. Safely raise rear frame so axle is free to pivot.
2. With feeler gage, measure gap between rear edge of
axle housing and front edge of frame bushing.
3. Loosen flanged cap screws (B) and locknuts to add or

TCAL29179 —UN—02JUL12
remove shims (C) between pin flange (A) and machine
frame until a dimension within specification is achieved.
Specification
4WD Axle—End Play...................................................0.127—1.016 mm
(0.005—0.040 in.)

4. Tighten flanged cap screws and locknuts to

specification.
Specification
A—Pin Flange C—Shims
4WD Axle Flanged
B—Flanged Cap Screws
Cap Screw and
Locknut—Torque...........................................................................88 N·m
(65 lb.-ft.)

5. Measure gap again to ensure specified end play has

been achieved.
OUMX258,0000AB5 -19-16SEP14-1/1

TM130419 (24FEB16) 240-30-4 030916

PN=1188
 Group 40
Tests and Adjustments—2 Speed
Summary of References • Adjust Differential Lock—2 Speed
• Test and Adjust Transaxle Neutral Creep—2 Speed • Adjust 4WD Axle Pivot Pin Clearance—2 Speed
• Adjust F-N-R Linkage—2 Speed
OUMX258,0000ACD -19-22MAR13-1/1

Test and Adjust Transaxle Neutral Creep—2

Speed
Reason
To ensure that machine does not creep when pedals are
in neutral.
Special or Required Tools

TCAL29449 —UN—09JUL12
• Hoist
• Jackstand (4 used)
NOTE: If creep is intermittent, inspect hydrostatic
pedal linkage for wear, damage, or binding
before adjusting transaxle neutral.

Procedure

CAUTION: When servicing a 4WD equipped A—Locknut B—Eccentric Nut

machine with front wheels supported off
ground and engine running, always support
rear wheels in a similar manner. The 4WD is 7. Hold adjustment and tighten locknut. Make sure
always engaged and will push machine off adjustment did not change.
supports if wheels are not raised.
8. Depress forward and reverse pedals, then release.
1. Lift machine with a hoist and support both front and 9. Check neutral adjustment. Repeat adjustment as
rear wheels off the ground. necessary.
2. Put jackstands under frame.
CAUTION: Remove jumper wire from seat
3. Loosen locknut (A). switch if installed.

CAUTION: Use extreme caution when doing this 10. Lower machine to the ground. Remove seat switch
adjustment. Drive wheels are free to spin. jumper wire if used.

4. Have someone push down center of seat cushion to Results

activate seat safety switch, or use a jumper wire to
bypass the seat switch. • If drive wheels continue to turn, check for worn or binding
hydrostatic pedal linkage or internal transaxle problems.
5. Start engine and run at slow idle.
6. With brakes unlocked, turn eccentric nut (B) left or
right until drive wheels stop turning.
OUMX258,0000AC9 -19-15SEP14-1/1

TM130419 (24FEB16) 240-40-1 030916

PN=1189
 Tests and Adjustments—2 Speed

Adjust F-N-R Linkage—2 Speed

TCAL29450 —UN—09JUL12
A—Neutral Safety Arm D—Hydrostatic Control Arm G—Forward Pedal K—Reverse Cable
B—F-N-R Bellcrank E—Hydrostatic Control Link H—Reverse Pedal
C—Linkage Support Bracket F— Brake Pedal I— Forward Cable
J— Neutral Safety Link

Install and Adjust Cable 10. Adjust forward and reverse cables until pedal pad is
1. Park machine safely on level surface. the specified distance from floor and the hydrostatic
control arm (D) hits the hard stops on the transaxle.
2. Disengage PTO.
Specification
3. With machine running, release brake and check for Forward and Reverse
creep. If machine creeps, adjust neutral creep before Pedal-to-Floor
continuing with linkage adjustment. (See Test and Clearance—Distance...................................................................... 3 mm
Adjust Transaxle Neutral Creep—2 Speed.) (0.1 in.)

4. Turn key switch off. 11. Tighten jam nuts on forward and reverse cables.
5. Open floor access panel. 12. Recheck pedal travel and operation of park brake.
6. Loosen locknuts on ball joint ends of hydrostatic 13. Operate machine and check for neutral creep. (See
control link (E). Disconnect link from hydrostatic Test and Adjust Transaxle Neutral Creep—2 Speed.)
control arm (D). Adjust length of control link to 179 mm
(7 in.), measuring from center-to-center of ball joint Install and Adjust Link
studs. Ensure sufficient thread engagement in both NOTE: If installing neutral safety link, make sure
ball joint ends. Install link and tighten ball joint nuts, the thread engagement in both front and rear
but do not tighten jam nuts at this time. ball joints is to specification.
7. Loosen nuts on clevis of forward (I) and reverse (K) Specification
cables. Neutral Safety Link
Ball Joint—Thread
8. Adjust jam nut on forward cable until threaded end of
Engagement Distance
cable extends approximately 20 mm (0.8 in.) beyond
(Minimum)....................................................................................... 8 mm
nut. Adjust rear cable until end extends approximately
(0.3 in.)
12 mm (0.5 in.) beyond jam nut. Do not tighten nuts
at this time.
1. Loosen locknut on rear ball joint of neutral safety link
9. Adjust hydrostatic control link (E) until the roller of the (J). Disconnect link from neutral safety arm (A) and
neutral safety arm (A) is centered in the forward cam adjust length of link to approximately 305 mm (12 in.),
slot of F-N-R bellcrank (B) as the safety arm and roller measuring from center-to-center of ball joint studs.
swing forward. Tighten control link jam nuts.

Continued on next page OUMX258,0000ACA -19-16SEP14-1/2

TM130419 (24FEB16) 240-40-2 PN=1190

030916
 Tests and Adjustments—2 Speed

2. Install link on safety arm (A) and adjust the length of arm does not impede forward and reverse pedal
the safety link (J), as necessary, until the roller of the strokes.
neutral safety arm (A) is about 2—4 mm (0.08—0.16 4. Check operation of brake pedal (F) and park brake
in.) from the rear surface of F-N-R bellcrank cam slot. switch.
Tighten locknut attaching link to arm and jam nut on
rod.
3. With the brakes off, operate the forward (G) and
reverse (H) pedals. Make sure that the neutral safety
OUMX258,0000ACA -19-16SEP14-2/2

Adjust Differential Lock—2 Speed

Adjust
1. Park machine on level ground.
2. With at least one wheel off the ground, turn the tire
and depress the differential lock pedal until it locks
into position.
• If pedal hits floor and will not lock into position,
shorten the differential lock link until it locks.
3. Adjust the length of the differential lock link so that a
gap meeting specifications exists between the pedal

TCAL29451 —UN—09JUL12
and floor.
Specification
Differential Lock—Gap
Between the Pedal and
Floor...........................................................................................1—3 mm
(0.04—0.12 in.)

4. Tighten jam nuts.

A—Differential Lock Pedal C—Differential Lock Link

B—Differential Lock Pivot Assembly
D—Differential Lock Arm

OUMX258,0000ACB -19-16SEP14-1/1

TM130419 (24FEB16) 240-40-3 030916

PN=1191
 Tests and Adjustments—2 Speed

Adjust 4WD Axle Pivot Pin Clearance—2

Speed
Procedure
1. Safely raise rear frame so axle is free to pivot.
2. With feeler gage, measure gap between rear edge of
axle housing and front edge of frame bushing.

TCAL29452 —UN—09JUL12
3. Loosen flanged cap screws and locknuts (A) to add or
deduct shims (B) between pin flange (C) and machine
frame until you gain a dimension within specifications.
Specification
4WD Axle End Play—End
Play..............................................................................0.127—1.016 mm
(0.005—0.040 in.)

4. Tighten flanged cap screws and locknuts to

A—Flanged Cap Screws and C—Pin Flange
specification. Locknuts
Specification B—Shims
4WD Axle Flanged
Cap Screw and
Locknut—Torque...........................................................................88 N·m
(65 lb.-ft.)

5. Re-check gap to ensure proper specified end play has

been obtained.
OUMX258,0000ACC -19-16SEP14-1/1

TM130419 (24FEB16) 240-40-4 030916

PN=1192
 Section 250
Hydraulics Operation, Tests, and Adjustments
Contents

Page

Group 10—Theory of Operation

Summary of References.............................. 250-10-1
Hydraulic System Operation........................ 250-10-1
Lift Circuit Operation.................................... 250-10-1
Auxiliary Hydraulic Operation ...................... 250-10-1
GLC Circuit Operation ................................. 250-10-2

Group 20—Schematics
Summary of References.............................. 250-20-1
Main Hydraulic Schematic Without
Optional Auxiliary Valve ........................... 250-20-2
Main Hydraulic Schematic With
Optional Auxiliary Valve ........................... 250-20-5
Single Spool Auxiliary Hydraulic Kit
Schematic................................................ 250-20-7
Double Spool Auxiliary Hydraulic
Kit Schematic........................................... 250-20-8
GLC Hydraulic Schematic ........................... 250-20-9

Group 30—Diagnosis
System: Lift System ....................................250-30-1
Lift System Diagnostic Tests........................250-30-1
Test Procedure B: ........................................250-30-3
System: Auxiliary Hydraulic.........................250-30-4
Auxiliary Hydraulic System Tests.................250-30-4
Test Procedure B .........................................250-30-5
Test Procedure C.........................................250-30-5
System: Weight Transfer.............................250-30-6
Weight Transfer System Tests.....................250-30-6
Test Procedure B .........................................250-30-7

Group 40—Tests and Adjustments

Summary of References.............................. 250-40-1
Hydraulic Oil Warm-Up
Procedure ................................................ 250-40-1
Hydraulic System Bleeding
Procedure ................................................ 250-40-1
Charge Pressure Relief Valve
Test .......................................................... 250-40-2
Hydraulic Pump Flow and
Implement Relief Valve Test .................... 250-40-4
PTO Solenoid Valve Check ......................... 250-40-7
PTO Relief Valve Test.................................. 250-40-8
MCS600 Plus Test ..................................... 250-40-10

TM130419 (24FEB16) 250-1 030916

PN=1
 Contents

TM130419 (24FEB16) 250-2 030916

PN=2
 Group 10
Theory of Operation
Summary of References • Lift Circuit Operation
• Hydraulic System Operation • Auxiliary Hydraulic Operation
• GLC Circuit Operation
OUMX258,000019F -19-09JAN14-1/1

Hydraulic System Operation The priority valve and integral PTO orifice supply priority
Function oil to the PTO clutch circuit. The priority valve is controlled
by oil pressure on each side of the PTO orifice.
To provide hydraulic fluid to the hydraulic pump and motor,
PTO system, steering valve, lift control valve, auxiliary The remaining oil flow through the priority valve is used
control valves and lift cylinders. as make-up oil for the hydrostatic pump and motor.
The charge relief valve limits the maximum make-up oil
Theory of Operation pressure. Forward and reverse check balls prevent oil
back flow in the make-up oil circuit. The reverse ball check
The hydraulic system consists of hydrostatic charge includes an orifice which gives a wider neutral band and
pump, hydraulic pump, hydro pump and motor, priority less jerky feel in reverse. The forward and reverse relief
valve, charge pump relief valve, implement relief valve, valves limit the maximum oil pressure in the hydrostatic
forward and reverse check ball, forward and reverse relief loop circuit.
valves, steering valve, single-lift spool valve, oil cooler
and oil filter. The system can also include an optional The hydraulic pump sends oil to the steering valve and
auxiliary single- or double-spool valve. then to the auxiliary valves, if installed, and then to the
implement lift valve. Oil from these valves is used to
Oil flow starts at the reservoir and is drawn through the operate auxiliary and lift cylinders respectively. Return oil
oil filter to the charge pump and hydraulic pump. From from the cylinders and excess oil not used for cylinder
the charge pump, oil is routed to the priority valve in the operation, flows through the oil cooler and back to the
hydro center section. transaxle sump. Located in the steering valve is an
implement relief valve that limits the output pressure from
the hydraulic pump.
OUMX258,0000AFF -19-22MAR13-1/1

Lift Circuit Operation valve. The optional weight transfer valve operates when
the lift valve is in float and return oil passes through a
Function variable orifice. This causes a restriction in the return
circuit which increases lift pressure to the lift cylinders. The
To lift front-mounted equipment.
lift cylinders try to partially raise the implement transferring
Theory of Operation weight to the drive tires. When no optional equipment is
installed, oil is returned to the oil cooler and sump.
The lift circuit is a hydraulic circuit and consists of
hydrostatic charge pump (1400 Series), hydraulic pump When the optional auxiliary control valves are installed, oil
(1500 Series), steering valve, implement lift valve, optional is routed from the steering valve to the optional auxiliary
weight transfer valve, front lift cylinders, and optional control valves and implement lift valve. From the optional
auxiliary control valves. auxiliary control valves, oil is routed to the implement lift
cylinders and passed on to the oil cooler and sump.
From the steering valve, oil is routed to the implement
lift valve and passes through the optional weight transfer
OUMX258,0000B00 -19-22MAR13-1/1

Auxiliary Hydraulic Operation • An optional single-spool valve used for extra cylinder
Function control.
• An optional double-spool valve used with the MCS
To provide hydraulic fluid to optional equipment. system to control both the dump and the lift cylinders.
Theory of Operation Oil from the steering valve is routed to the optional
auxiliary valve and passed on to the implement lift valve.
There are two optional auxiliary valves added to the When the optional auxiliary control levers activate the
system in series before the implement lift valve (the last auxiliary valves, oil from the auxiliary valves is passed to
valve in the circuit). the auxiliary lift cylinders. From the auxiliary lift cylinders,
returned oil is sent back to the oil cooler and sump.
OUMX258,0000B01 -19-22MAR13-1/1

TM130419 (24FEB16) 250-10-1 030916

PN=1195
 Theory of Operation

GLC Circuit Operation line shows a sudden increased pressure that ramps down
until the blower motor stops.
Function
A pressure relief valve protects the drive system and
To drive the MCS hydraulic blower motor. opens at 210 bar (3045 psi).
Theory of Operation The blower is switched on via the button in the console.
The device can only be switched on when the engine
The grass and leaf collection (GLC) system hydraulic of the machine is running, the operator is sitting in the
circuit consists of a hydraulic pump, control unit operated operator’s seat, and the collection container is in the
hydraulic valve, hydraulic blower motor, oil cooler with lowest position. If the operator switches off the mower the
electric fan, and oil reservoir. (See GLC Hydraulic turbine comes to a stop. When the mower is switched on
Schematic.) again the turbine starts up again. The turbine cannot be
From the mower deck-mounted pump oil is sent to the switched off via the on-off button. In order to switch off the
valve block. While the blower motor valve is off oil is turbine the machine must be shut off.
routed through a low-pressure check valve, oil is returned For safety the turbine also switches off when the operator
to the oil cooler and reservoir. leaves the seat or lifts up the collection container. When
When the blower motor valve is actuated by the GLC the machine engine is switched back on, or if the container
control module, oil is routed from the valve to the hydraulic is lowered, the turbine does not automatically start. To
blower motor. From the blower motor, oil is routed to the switch on the turbine the on-off button must be activated
flow control valve and passed on to the oil cooler and again.
sump. A separate hydraulic system is connected to the machine’s
The flow control valve starts to open at approximately 80 rear auxiliary ports to raise and lower, and open and close
bar (1160 psi) and is fully open at 130 bar (1885 psi). the material collection container.

When the blower motor valve is shut off, the circuit slows
the blower motor down. As the motor slows, the return
OUMX258,0000B02 -19-06APR15-1/1

TM130419 (24FEB16) 250-10-2 030916

PN=1196
 Group 20
Schematics
Summary of References • Single Spool Auxiliary Hydraulic Kit Schematic
• Main Hydraulic Schematic Without Optional Auxiliary • Double Spool Auxiliary Hydraulic Kit Schematic
Valve
• GLC Hydraulic Schematic
• Main Hydraulic Schematic With Optional Auxiliary Valve
OUMX258,000019E -19-09JAN14-1/1

TM130419 (24FEB16) 250-20-1 030916

PN=1197
 Schematics

Main Hydraulic Schematic Without Optional Auxiliary Valve

TCAL29786 —UN—02JUL12

Continued on next page OUMX258,0000B03 -19-22MAR13-1/3

TM130419 (24FEB16) 250-20-2 030916

PN=1198
 Schematics

Main Hydraulic Schematic Without Optional

Auxiliary Valve (2 of 2)

TCAL29787 —UN—02JUL12

Continued on next page OUMX258,0000B03 -19-22MAR13-2/3

TM130419 (24FEB16) 250-20-3 030916

PN=1199
 Schematics

A—Left Lift Cylinder G—PTO Relief Valve Q—Check Valve (reverse) X—Hydraulic Pump (gear 5
B—Right Lift Cylinder H—PTO Solenoid Valve R—Check Valve (forward) cc/rev)
C—Orifice (use N220668 for 72-in. I— PTO Clutch S—Hydrostatic Motor Y—Hydrostatic Pump
decks; use T121143 for 60-in. J— PTO Brake T— Hydraulic Oil Reservoir (8.7 L Z— Input Shaft
and 62-in. decks) K—Accumulator [2.3 gal] 4WD) AA—Oil Cooler
D—Implement Lift Valve L— Priority Valve U—Vented Reservoir Cap AB—Steering Cylinder
E—Weight Transfer Valve M—Charge Pressure Relief Valve V—Hydraulic Oil Filter AC—Steering Control Valve
(optional) N—Relief Valve (forward) W—Charge Pump (trochoid 5 AD—Implement Pressure-Relief
F— Transaxle O—Relief Valve (reverse) cc/rev) Valve
P—Orifice
OUMX258,0000B03 -19-22MAR13-3/3

TM130419 (24FEB16) 250-20-4 030916

PN=1200
 Schematics

Main Hydraulic Schematic With Optional Auxiliary Valve

TCAL29790 —UN—02JUL12

Continued on next page OUMX258,0000B04 -19-22MAR13-1/3

TM130419 (24FEB16) 250-20-5 030916

PN=1201
 Schematics

Main Hydraulic Schematic With Optional

Auxiliary Valve (2 of 2)

TCAL29791 —UN—02JUL12

Continued on next page OUMX258,0000B04 -19-22MAR13-2/3

TM130419 (24FEB16) 250-20-6 030916

PN=1202
 Schematics

A—Left Lift Cylinder H—Auxiliary Cylinder S—Priority Valve AC—Hydraulic Oil Filter
B—Right Lift Cylinder I— Spool Valve Assembly T— Charge Relief Valve AD—Charge Pump (trochoid 5
C—Orifice (use N220668 for 72-in. J— Single Spool Auxiliary U—Relief Valve (forward) cc/rev)
decks; use T121143 for 60-in. Hydraulics Valve (optional) V—Relief Valve (reverse) AE—Hydraulic Pump (gear 5
and 62-in. decks) K—Auxiliary Cylinder W—Orifice cc/rev)
D—Implement Lift Valve L— Single-Spool Valve Assembly X—Check Valve (reverse) AF—Hydrostatic Pump
E—Weight Transfer Valve M—Transaxle Y—Check Valve (forward) AG—Input Shaft
(optional) N—PTO Relief Valve Z— Hydrostatic Motor AH—Oil Cooler
F— Double Spool Auxiliary O—PTO Solenoid Valve AA—Hydraulic Oil Reservoir (8.7 AI— Steering Cylinder
Hydraulics Valve (optional) P—PTO Clutch L [2.3 gal] 4WD) AJ—Steering Control Valve
G—Auxiliary Cylinder Q—PTO Brake AB—Vented Reservoir Cap AK—Implement Pressure-Relief
R—Accumulator Valve
OUMX258,0000B04 -19-22MAR13-3/3

Single Spool Auxiliary Hydraulic Kit Schematic

TCAL29792 —UN—02JUL12
A—Single Spool Hydraulics Valve B—Spool Valve Assembly D—Line to Lift Valve F— Line from Steering Valve
(optional) C—Auxiliary Lift Cylinder E—Line to Oil Cooler
OUMX258,0000B05 -19-22MAR13-1/1

TM130419 (24FEB16) 250-20-7 030916

PN=1203
 Schematics

Double Spool Auxiliary Hydraulic Kit Schematic

TCAL29793 —UN—02JUL12
A—Double Spool Hydraulics C—Auxiliary Lift Cylinder E—Line to Implement Lift Valve G—Line from Steering Valve
Valve (optional) D—Spool Valve Assembly F— Line to Oil Cooler
B—Auxiliary Lift Cylinder
OUMX258,0000B06 -19-22MAR13-1/1

TM130419 (24FEB16) 250-20-8 030916

PN=1204
 Schematics

GLC Hydraulic Schematic

8

7
T

1 3
2
P 6
9

10

TCT008667 —UN—28JAN14
5 11

1— Mower Gearbox 5— Tank 9— Turbine, Blower

2— Coupler 6— Filter 10— Belt Drive
3— Pump 7— Oil Cooler 11— Hydraulic Motor
4— Suction Line 8— Changeover Valve
OUMX258,0000B07 -19-09JAN14-1/1

TM130419 (24FEB16) 250-20-9 030916

PN=1205
 Schematics

TM130419 (24FEB16) 250-20-10 030916

PN=1206
 Group 30
Diagnosis
System: Lift System
OUMX258,0000B08 -19-31DEC13-1/9

Lift System Diagnostic Tests

Lift System Tests
NOTE: In order to properly diagnose the hydraulic system, it is important to verify that the hydraulic
components and control function inputs and outputs related to the hydraulic system are
working properly before diagnosing hydraulic components.
In many cases, the combination and sequence of activation of controls are critical to successful lift system
activation. Follow the sequence listed in the test conditions to ensure correct activation.
OUMX258,0000B08 -19-31DEC13-2/9

•1 Test Procedure A Test Conditions

• Machine parked safely.

• Key switch to OFF position.
• Park brake locked.
YES: Go to next step.

TCAL29795 —UN—02JUL12
Check hydraulic oil level in transaxle. Normal oil level? NO: Fill transaxle to normal
level with clean oil of correct
specification.

Continued on next page OUMX258,0000B08 -19-31DEC13-3/9

TM130419 (24FEB16) 250-30-1 PN=1207

030916
 Diagnosis

•2 continued YES: Go to next step.

TCAL29796 —UN—02JUL12
Check hydraulic oil and system for air or contamination. Oil not contaminated? NO: If air in hydraulic
system, bleed hydraulic
system. If contaminated,
drain system and fill
transaxle to proper
level with oil meeting
specifications. Replace oil
filter.
OUMX258,0000B08 -19-31DEC13-4/9

•3 continued YES: Go to next step.

TCAL29797 —UN—02JUL12
Check hydraulic hoses. Hoses have no sharp bends or restrictions? NO: If hoses have bends or
restrictions, replace hose(s)
with hoses of proper size.
If hoses are cracked or cut,
replace hoses as needed
with hoses of proper size. If
hoses are loose or leaking,
tighten connections and
replace O-rings as needed.
If hoses are chafed, pinched
or damaged, replace hoses
as needed. Route hoses
in a manner to keep them
from rubbing and away
from moving parts or heat
sources.
Continued on next page OUMX258,0000B08 -19-31DEC13-5/9

TM130419 (24FEB16) 250-30-2 PN=1208

030916
 Diagnosis

•4 continued YES: Go to Test Procedure

B.

TCAL29798 —UN—02JUL12
Check lift cylinder(s) condition. Lift cylinder(s) not damaged or leaking? NO: Lift cylinders damaged
or leaking. Replace lift
cylinder(s) as needed.
OUMX258,0000B08 -19-31DEC13-6/9

Test Procedure B:
OUMX258,0000B08 -19-31DEC13-7/9

•1 Lift Cylinder Test Conditions

• Operator on seat.
• Engine running.
• Park brake locked.
YES: Go to next step.

TCAL29799 —UN—02JUL12
Implement lift valve operates properly? NO: Implement lift valve
not operating properly.
Replace implement lift
valve.
Continued on next page OUMX258,0000B08 -19-31DEC13-8/9

TM130419 (24FEB16) 250-30-3 030916

PN=1209
 Diagnosis

•2 continued YES: Test complete.

TCAL29800 —UN—02JUL12
Lift cylinder(s) operate properly? NO: Lift cylinder(s) not
operating properly. Replace
lift cylinder(s).
OUMX258,0000B08 -19-31DEC13-9/9

System: Auxiliary Hydraulic

OUMX258,0000B09 -19-31DEC13-1/7

Auxiliary Hydraulic System Tests

OUMX258,0000B09 -19-31DEC13-2/7

•1 Test Procedure A Test Conditions

• Operator on seat.
• Engine running at high idle.
• Park brake unlocked.
• PTO switch in OFF position.
• Place control lever in raise position, then release lever.
YES: Go to Test Procedure
B.

TCAL29801 —UN—02JUL12
Control lever returns to neutral, and attachment raises and holds position without NO: Lever does not return
settling? to neutral, or attachment
does not raise and hold
position without settling.
Repair or replace auxiliary
control valve.

Continued on next page OUMX258,0000B09 -19-31DEC13-3/7

TM130419 (24FEB16) 250-30-4 PN=1210

030916
 Diagnosis

Test Procedure B
OUMX258,0000B09 -19-31DEC13-4/7

•1 Auxiliary Hydraulic Test Conditions

• Operator on seat.
• Engine running at fast idle.
• Park brake unlocked.
• PTO switch in OFF position.
• Lower attachment to ground.
• Place control lever in float position, then release lever.
YES: Go to Test Procedure
C.

TCAL29802 —UN—02JUL12
Auxiliary lift cylinders retract and extend freely? NO: Auxiliary lift cylinders
do not retract and extend
freely. Repair or replace
auxiliary control valve.
Auxiliary lift lever does not
stay in float position. Repair
or replace auxiliary control
valve.
OUMX258,0000B09 -19-31DEC13-5/7

Test Procedure C
OUMX258,0000B09 -19-31DEC13-6/7

•1 Auxiliary Hydraulic Test Conditions

• Operator on seat.
• Engine running at fast idle.
• Park brake unlocked.
• PTO switch in OFF position.
• Lower attachment to ground.
• Pull and push auxiliary control lever (raise/lower) to cycle auxiliary lift cylinders.
YES: Test complete.

TCAL29803 —UN—02JUL12
Auxiliary lift cylinders retract and extend freely? NO: Auxiliary lift cylinders
do not operate properly.
Replace auxiliary lift
cylinders.

OUMX258,0000B09 -19-31DEC13-7/7

TM130419 (24FEB16) 250-30-5 PN=1211

030916
 Diagnosis

System: Weight Transfer

OUMX258,0000B0A -19-31DEC13-1/6

Weight Transfer System Tests

NOTE: Weight transfer valve is optional.
OUMX258,0000B0A -19-31DEC13-2/6

•1 Test Procedure A Test Conditions

• Operator on seat.
• Engine running.
• Park brake unlocked.
• PTO switch in OFF position.
YES: Go to next step.

TCAL29804 —UN—02JUL12
Check hydraulic tubes and connections from implement lift valve to weight transfer NO: Tubes or connections
valve. Tubes and connections not leaking or damaged? leak or are damaged.
Replace tubes and
connections as needed.
OUMX258,0000B0A -19-31DEC13-3/6

•2 continued YES: Go to Test Procedure

B.

TCAL29805 —UN—02JUL12
Check hydraulic hoses from lift cylinders to weight transfer valve for leaks or damage. NO: Hydraulic hoses
Hydraulic hoses not leaking or damaged? leaking or damaged.
Replace hoses as needed.

Continued on next page OUMX258,0000B0A -19-31DEC13-4/6

TM130419 (24FEB16) 250-30-6 030916

PN=1212
 Diagnosis

Test Procedure B
OUMX258,0000B0A -19-31DEC13-5/6

•1 Weight Transfer
System
Test Conditions

• Operator on seat.
• Engine running.
• Park brake unlocked.
• PTO switch in OFF position.
YES: Test complete.

TCAL29806 —UN—02JUL12
Operate machine and attachments a short distance with implement lift valve in float NO: Machine and
position. Machine and attachment operating properly with no jerking motion or feel? attachment has a jerking
motion or feel. Replace
weight transfer valve.
OUMX258,0000B0A -19-31DEC13-6/6

TM130419 (24FEB16) 250-30-7 030916

PN=1213
 Diagnosis

TM130419 (24FEB16) 250-30-8 030916

PN=1214
 Group 40
Tests and Adjustments
Summary of References • Hydraulic Pump Flow and Implement Relief Valve Test
• Hydraulic Oil Warm-Up Procedure • PTO Solenoid Valve Check
• PTO Relief Valve Test
• Hydraulic System Bleeding Procedure • MCS600 Plus Test
• Charge Pressure Relief Valve Test
OUMX258,0000B12 -19-22MAR13-1/1

Hydraulic Oil Warm-Up Procedure

Reason
CAUTION: Engine exhaust fumes can cause To verify that hydraulic oil is at normal operating
sickness or death. temperature.
If it is necessary to run an engine in an Equipment
enclosed area, use an exhaust pipe extension
to remove the fumes. • JDG282 Temperature Gauge
OUMX258,0000B0B -19-15SEP14-1/3

Temperature Gauge.............................................. JDG282 Used for checking hydraulic oil temperature.

OUMX258,0000B0B -19-15SEP14-2/3

Procedure NOTE: Periodically distribute heated oil by cycling

1. Park machine safely. all hydraulic functions.

2. Install JDG282 Temperature Gauge on hydraulic pump 4. Run engine until oil temperature reaches 49° C (120°
outlet. F).
3. Start and run engine at fast idle.
OUMX258,0000B0B -19-15SEP14-3/3

Hydraulic System Bleeding Procedure 3. Start engine and run at slow idle.

CAUTION: Engine exhaust fumes can cause 4. Turn steering wheel full left and hold for five seconds.
sickness or death. 5. Turn steering wheel full right and hold for five seconds.
If it is necessary to run an engine in an 6. Cycle implement lift cylinders up and down ten times.
enclosed area, use an exhaust pipe extension
to remove the fumes. 7. Return wheels to the straight forward position.

Reason 8. Drive machine forward approximately 5 m (20 ft.).

To ensure that air is purged from the hydraulic system 9. Drive machine in reverse approximately 3 m (10 ft.)
after the hydraulic hoses or lines have been disconnected. 10. Place key switch in off position.
Procedure 11. Check all hoses and connections for leaks. Tighten
connections and replace hoses as needed.
1. Park machine safely.
12. Check transaxle oil level. Add oil as needed.
2. Check level of hydraulic oil. Fill as needed.
OUMX258,0000B0C -19-15SEP14-1/1

TM130419 (24FEB16) 250-40-1 030916

PN=1215
 Tests and Adjustments

Charge Pressure Relief Valve Test

CAUTION: Engine exhaust fumes can cause

sickness or death.
If it is necessary to run an engine in an

TCAL29811 —UN—02JUL12
enclosed area, use an exhaust pipe extension
to remove the fumes.

CAUTION: Escaping fluid under pressure can

penetrate the skin causing serious injury.
Avoid the hazard by relieving pressure before
disconnecting hydraulic or other lines. Tighten
all connections before applying pressure. Search
for leaks with a piece of cardboard. Protect hands
and body from high-pressure fluids.
If an accident occurs, see a doctor immediately.
Any fluid injected into the skin must be surgically
removed within a few hours or gangrene may
result. Doctors unfamiliar with this type of
injury should reference a knowledgeable medical
source. Such information is available from Deere
& Company Medical Department in Moline, Illinois,
U.S.A. Information may be obtained in the United
States and Canada only by calling 1-800-822-8262.

Reason
To verify proper function of the charge pressure relief valve.
Special or Required Tools

• JT03017 Hydraulic Test Hose

• JT03349 Fitting
• JT05584 Gauge with Quick Coupler 0—2 800 kPa
(0—400 psi)
Test Conditions

• Hydraulic oil at operating temperature.

• Implements lowered to ground.
• Engine at slow idle.
• PTO switch in OFF position.
Procedure
1. Park machine safely.
2. Turn key switch to off position.
NOTE: Thoroughly clean area around all hydraulic
test connection points to eliminate possibility of
contaminating internal parts during disassembly.

3. Locate charge pressure test port plug on left side of

transaxle just below PTO shaft. Remove plug.
Continued on next page OUMX258,0000B0D -19-16SEP14-1/2

TM130419 (24FEB16) 250-40-2 030916

PN=1216
 Tests and Adjustments

4. Install JT03349 Fitting (A) into transmission test port.

Attach JT03017 Hydraulic Test Hose (B) and JT05584
Gauge (C).
5. Tighten all fittings.
6. Start engine and run at fast idle.
7. Bring hydraulic oil to operating temperature.
8. Check gauge reading and record results.

TCAL29812 —UN—02JUL12
Specification
Charge Pressure at Fast
Idle—Pressure................................................................ 1 850 ± 150 kPa
(268 ± 22 psi)

9. Reduce engine to slow idle.

Specification
Charge Pressure at Slow
Idle—Pressure................................................................ 1 500 ± 150 kPa
(218 ± 22 psi) A—JT03349 Fitting C—JT05584 Gauge
B— JT03017 Hydraulic Test
10. Check gauge reading and record results. Hose

Results

• If specifications are not met, replace charge pressure

relief valve.
OUMX258,0000B0D -19-16SEP14-2/2

TM130419 (24FEB16) 250-40-3 030916

PN=1217
 Tests and Adjustments

Hydraulic Pump Flow and Implement Relief Special or Required Tools

Valve Test
• D01169AA In-Line Hydraulic Tester
CAUTION: Escaping fluid under pressure can • JT03216 9/16-18 M 37° x 9/16-18 M ORB Fitting
penetrate the skin causing serious injury. • JT03341 9/16-18 M 37° x 9/16-18 F 37° SW 90° Elbow
Avoid the hazard by relieving pressure before • JT03342 9/16-18 F 37° x 3/4 F NPT Coupler
disconnecting hydraulic or other lines. Tighten • JT03056 7/8-14 M 37° x 9/16-18 F ORB Adapter
all connections before applying pressure. Search • JT03385 7/8-14 F 37° x 3/4 F NPT Coupler
for leaks with a piece of cardboard. Protect hands
and body from high-pressure fluids. Test Conditions

If an accident occurs, see a doctor immediately. • Hydraulic oil at operating temperature.

Any fluid injected into the skin must be surgically • High/low range selector in neutral position.
removed within a few hours or gangrene may • 4WD selector in 2WD position.
result. Doctors unfamiliar with this type of • Implements lowered to ground.
injury should reference a knowledgeable medical • Engine at fast idle.
source. Such information is available from Deere
Procedure
& Company Medical Department in Moline, Illinois,
U.S.A. Information may be obtained in the United 1. Park machine safely.
States and Canada only by calling 1-800-822-8262.
2. Lower mower decks to ground.
CAUTION: Engine exhaust fumes can cause 3. Turn key switch to stop position.
sickness or death.
4. Remove steering wheel.
If it is necessary to run an engine in an
5. Remove steering column cover.
enclosed area, use an exhaust pipe extension
to remove the fumes. NOTE: Thoroughly clean area around all hydraulic
test connection points to eliminate possibility of
CAUTION: Help prevent serious injury. Use contaminating internal parts during disassembly.
caution when performing this service procedure.
Keep hands, feet and clothing away from rotating 6. Disconnect pressure hose (A) from auxiliary (AUX)
blades, pulleys and other components. port of steering valve (B).

Reason
To verify proper flow from the hydraulic pump.

Continued on next page OUMX258,0000B0E -19-16SEP14-1/4

TM130419 (24FEB16) 250-40-4 030916

PN=1218
 Tests and Adjustments

A—Pressure Hose B—Auxiliary Port of Steering

Valve

TCAL29816 —UN—02JUL12
Auxiliary port is marked AUX on fitting end of valve. There are
two different positions in which the steering valve may have been
installed. The nuts holding the valve may have to be removed
and the valve rotated to access the AUX port.
OUMX258,0000B0E -19-16SEP14-2/4

7. Connect hydraulic test hose (I), JT03216 Fitting (C),

JT03341 90° Elbow (D), and JT03342 Coupler (E) to
AUX port of steering valve.
8. Connect hydraulic test hose (J), JT03056 Adapter
(G), and JT03385 Coupler (H) to hose disconnected
from AUX port (F).

C— JT03216 Fitting G—JT03056 Adapter

D—JT03341 90° Elbow H—JT03385 Coupler

TCAL29817 —UN—02JUL12
E— JT03342 Coupler I— Hydraulic Test Hose
F— Auxiliary Port J— Hydraulic Test Hose

Continued on next page OUMX258,0000B0E -19-16SEP14-3/4

TM130419 (24FEB16) 250-40-5 030916

PN=1219
 Tests and Adjustments

9. Connect hydraulic test hose (I) to inlet (K) of

D01169AA In-Line Hydraulic Tester.
10. Connect hydraulic test hose (J) to outlet (L) of in-line
hydraulic tester.
11. Tighten all fittings.
NOTE: Make sure there is no load set on in-line
hydraulic tester during warm-up procedure. Set
load knob (M) all the way to decrease.

TCAL29818 —UN—02JUL12
12. Start engine and bring hydraulic oil to operating
temperature.
13. Perform bleed procedures to remove air from hydraulic
system.
NOTE: Do not turn steering wheel during testing.

14. Run engine at fast idle.

15. Increase load by turning knob (M) on in-line hydraulic I— Hydraulic Test Hose L— Outlet of D01169AA In-Line
tester clockwise to 2950 kPa (428 psi) and record test J— Hydraulic Test Hose Hydraulic Tester
results. K—Inlet of D01169AA In-Line M—Knob on In-Line Hydraulic
Hydraulic Tester Tester
Specification
Hydraulic Pump—Flow
Rate at Slow Idle.................................................12.6 L/min@ 2 950 kPa —Pressure at Zero Flow
(3.3 gpm @ 428 psi) and Slow Idle................................................................... 9307 ± 689 kPa
Hydraulic Pump—Flow (1350 ± 100 psi)
Rate at Fast Idle..................................................14.5 L/min@ 2 950 kPa
(3.8 gpm @ 428 psi) 17. Decrease load completely on in-line hydraulic tester.

16. Continue to increase load by turning knob on in-line Results

hydraulic tester clockwise until flow stops. Record
pressure. • If hydraulic pump flow is not within specification, replace
hydraulic pump.
Specification • If pressure is not within specification, replace steering
Hydraulic valve.
Pump—Pressure at Zero
Flow and Fast Idle........................................................ 11 031 ± 689 kPa
(1600 ± 100 psi)
OUMX258,0000B0E -19-16SEP14-4/4

TM130419 (24FEB16) 250-40-6 PN=1220

030916
 Tests and Adjustments

PTO Solenoid Valve Check

Reason
To determine if the PTO solenoid valve is mechanically
functional.
Special or Required Tools

• 12 VDC Power Supply or 12 V Battery

• 17 mm Wrench
• 25 mm Wrench
Procedure

TCAL29819 —UN—02JUL12
1. Park machine safely.
2. Disconnect PTO solenoid connector (A) from wiring
harness.
3. Remove fastening nut (B) from solenoid stud.
4. Remove O-ring and magnet from solenoid stud.
NOTE: Rolled pin is inside solenoid stud.
A—PTO Solenoid B—Fastening Nut
5. Remove solenoid stud, inner spool, outer spool, and
spring from PTO housing.
6. Inspect parts for wear and damage. Replace as 9. Screw in solenoid stud and tighten to specifications.
needed. Do not over-tighten.
Specification
IMPORTANT: Do not over-tighten solenoid stud or
Solenoid Stud—Torque................................................... 20.5—22.5 N·m
fastening nut or damage to the assembly may
(185—202 lb.-in.)
result. Tighten to specified torque only.
10. Install magnet and new O-ring onto solenoid stud.
NOTE: Inner spool slides into slot of outer spool. Ensure
that there is tension between spring and inner spool 11. Screw on fastening nut and tighten to specifications.
after installing spool assembly into PTO housing. Specification
PTO Solenoid Valve
7. Install spring, inner spool, and outer spool in PTO Fastening Nut—Torque....................................................... 3.9—5.9 N·m
housing. (35—53 lb.-in.)
8. Install new O-ring on solenoid stud.
OUMX258,0000B0F -19-16SEP14-1/1

TM130419 (24FEB16) 250-40-7 PN=1221

030916
 Tests and Adjustments

PTO Relief Valve Test

CAUTION: Engine exhaust fumes can cause
sickness or death.
If it is necessary to run an engine in an
enclosed area, use an exhaust pipe extension
to remove the fumes.

TCAL29820 —UN—02JUL12
CAUTION: Escaping fluid under pressure can
penetrate the skin causing serious injury.
Avoid the hazard by relieving pressure before
disconnecting hydraulic or other lines. Tighten
all connections before applying pressure. Search
for leaks with a piece of cardboard. Protect hands
and body from high-pressure fluids.
If an accident occurs, see a doctor immediately. A—JT05471 Gauge C—Fitting
Any fluid injected into the skin must be surgically B—JT03017 Hydraulic Test D—Fitting
Hose
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. Information may be obtained in the United
States and Canada only by calling 1-800-822-8262.

Reason
To verify the proper function of PTO relief valve.
Special or Required Tools

• JT05487 Fitting 1/8 Male NPT x 7/16-20 M 37°

• JT05483 Fitting 90° 7/16-20 F 37° Sw x 7/16-20 M 37°
• JT03017 Hose with Male Quick Coupler
• JT05471 Gauge with Male Quick Coupler
Test Conditions

• Operator on seat.
• Park brake off.
• Implements lowered to ground.
• Engine at slow idle.
• PTO switch on.
Procedure
1. Park machine safely.
2. Turn key to off position.
NOTE: Thoroughly clean area around all hydraulic
test connection points to eliminate possibility of
contaminating internal parts during disassembly.

3. Assemble JT05483 and JT05487 Fittings (C and D),

JT03017 Hydraulic Test Hose (B) and JT05471 Gauge
(A).
Continued on next page OUMX258,0000B10 -19-16SEP14-1/2

TM130419 (24FEB16) 250-40-8 030916

PN=1222
 Tests and Adjustments

4. Connect test gauge assembly to test port (E), located

below PTO solenoid (F).
5. Tighten all fittings.
6. Start engine and run at fast idle.
7. Bring hydraulic oil to operating temperature.

TCAL29821 —UN—02JUL12
8. Turn on PTO.
9. Check gauge reading and record results.
Specification
PTO Relief—Pressure at
Fast Idle.......................................................................... 1 930 ± 206 kPa
(280 ± 30 psi)

10. Reduce engine to slow idle.

E—Test Port F— PTO Solenoid
11. Check gauge and record results.
Specification
PTO Relief—Pressure at • If specifications are not met, replace PTO relief valve.
Slow Idle......................................................................... 1 724 ± 206 kPa
(250 ± 30 psi)
OUMX258,0000B10 -19-16SEP14-2/2

TM130419 (24FEB16) 250-40-9 030916

PN=1223
 Tests and Adjustments

MCS600 Plus Test

CAUTION: Engine exhaust fumes can cause

TCAL29826 —UN—02JUL12
sickness or death.
If it is necessary to run an engine in an
enclosed area, use an exhaust pipe extension
to remove the fumes.

CAUTION: Escaping fluid under pressure can

penetrate the skin causing serious injury.
Avoid the hazard by relieving pressure before A—Test Port B—Test Port
disconnecting hydraulic or other lines. Tighten
all connections before applying pressure. Search
for leaks with a piece of cardboard. Protect hands
and body from high-pressure fluids. 6. Tighten all fittings.
If an accident occurs, see a doctor immediately. 7. Start engine and run at fast idle.
Any fluid injected into the skin must be surgically
8. Bring hydraulic oil to operating temperature.
removed within a few hours or gangrene may
result. Doctors unfamiliar with this type of 9. Turn MCS blower on.
injury should reference a knowledgeable medical
source. Such information is available from Deere NOTE: At full speed the turbine restriction should cause
& Company Medical Department in Moline, Illinois, the pressure relief valve to function and keep the oil
USA. Information may be obtained in the United pressure at relief pressure, even with no load.
States and Canada only by calling 1-800-822-8262.
10. Check gauge reading and record results.
Reason Specification
MCS Hydraulic
To verify proper function of the implement relief valve.
Valve Block—Port B
Special or Required Tools —Pressure................................................................................... 180 bar
(2610 psi)
• JT03017 Hydraulic Test Hose Relief Valve—Opening
• Fittings Pressure....................................................................................... 180 bar
• JT03345 Pressure Gauge 0—20684 kPa (0—3000 psi) (2610 psi)

Test Conditions 11. Stop engine.

• Operator on seat. 12. Remove gauge from test port (B). Install and tighten
• Park brake off. port plug.
• Implements lowered to ground. 13. Remove plug from test port (A) located on top of MCS
• Engine at slow idle. hydraulic valve block.
• PTO switch off.
14. Connect test gauge assembly to test port (A).
Procedure
15. Tighten all fittings.
1. Park machine safely.
16. Start engine and run at fast idle.
2. Turn key switch to OFF position.
NOTE: The flow control valve opens at 80 bar (1160 psi)
NOTE: Thoroughly clean area around all hydraulic and fully opens at 130 bar (1885 psi).
test connection points to eliminate possibility of
contaminating internal parts during disassembly. 17. Turn MCS on and allow it to come to operating speed.
3. Assemble fittings, hose and test gauge. 18. Check gauge reading and record results.
4. Remove plug from test port (B) located on bottom of Specification
MCS hydraulic valve block. MCS Hydraulic
Valve Block—Port
NOTE: Ports A and B may be connected at the same A—Pressure........................................................................... 2—130 bar
time if there are two gauge assemblies. (29—1885 psi)

5. Connect test gauge assembly to test port (B).

Continued on next page OUMX258,0000B11 -19-16SEP14-1/2

TM130419 (24FEB16) 250-40-10 PN=1224

030916
 Tests and Adjustments

NOTE: When shutting off the MCS blower, the hydraulic • If specifications are not met:
oil reverse flow will slow the blower motor down. a. Clean the valve and replace O-rings;
Therefore, when shutting off, test port A will b. Check valve for proper adjustment;
show sudden increased pressure then pressure c. Replace valve id specifications cannot be met.
ramping down until the blower stops. • Return line (test port A) will always show minimal
pressure.
19. Stop MCS blower, watch test gauge while stopping • The pressure relief valve will prevent an oil pressure
MCS blower. spike above relief pressure specification. Replace
pressure relief valve if specification is not met.
20. Stop engine.
21. Remove gauge from test port (B). Install and tighten
port plug.
OUMX258,0000B11 -19-16SEP14-2/2

TM130419 (24FEB16) 250-40-11 030916

PN=1225
 Tests and Adjustments

TM130419 (24FEB16) 250-40-12 030916

PN=1226
 Section 260
Steering and Brakes Operation, Tests, and Adjustments
Contents

Page

Group 10—Theory of Operation

Summary of References.............................. 260-10-1
Steering System Operation -
Neutral ..................................................... 260-10-1
Steering System Operation - Power
Turn ......................................................... 260-10-2
Steering System Operation -
Manual Turn............................................. 260-10-3
Brake System Operation ............................. 260-10-3

Group 20—Steering Diagnosis

High Steering Effort in Both
Directions ................................................260-20-1
High Steering Effort in Both
Directions ................................................260-20-1
Hydraulic Oil Foams ....................................260-20-2
Hydraulic Oil Foams ....................................260-20-2
Lost Motion in Steering Wheel.....................260-20-3
Lost Motion in Steering Wheel.....................260-20-3
Machine Continues to Turn after
Steering Wheel Has Returned to
Center Position........................................260-20-4
Machine Continues to Turn after
Steering Wheel Has Returned to
Center Position........................................260-20-4
Sluggish Steering Response .......................260-20-4
Sluggish Steering Response .......................260-20-4
Steering Not Driving Straight .......................260-20-5
Steering Not Driving Straight .......................260-20-5
Steering Operation Reversed ......................260-20-7
Steering Operation Reversed ......................260-20-7
Steering Wheel Vibration.............................260-20-7
Steering Wheel Vibration.............................260-20-7

Group 30—Brakes Diagnosis

Machine Will Not Move................................260-30-1
Machine Will Not Move................................260-30-1
Brake Will Not Engage or Hold
Machine...................................................260-30-1
Brake Will Not Engage or Hold
Machine...................................................260-30-1
Excessive Brake Wear ................................260-30-1
Excessive Brake Wear ................................260-30-1
Machine Pulls to One Side ..........................260-30-2
Machine Pulls to One Side ..........................260-30-2

Group 50—Tests and Adjustments

Summary of References.............................. 260-50-1
Check and Adjust Steering Toe-In................ 260-50-1
Test Steering System Leakage.................... 260-50-2
Test Steering Valve Leakage ....................... 260-50-3
Check and Adjust Turn Brake...................... 260-50-4
Adjust Brake Switch..................................... 260-50-6

TM130419 (24FEB16) 260-1 030916

PN=1
 Contents

TM130419 (24FEB16) 260-2 030916

PN=2
 Group 10
Theory of Operation
Summary of References • Steering System Operation - Manual Turn
• Steering System Operation - Neutral • Brake System Operation
• Steering System Operation - Power Turn
CB12260,00001EF -19-15SEP14-1/1

Steering System Operation - Neutral

Function
To block the flow of pressurized oil to the steering cylinder
when no turning action is desired.
Theory of Operation
The steering valve assembly (C) consists of a
self-centering fluid control valve section (D) and a
gerotor (E). These are hydraulically and mechanically
interconnected inside the unit.
Pressurized oil (A) is supplied to the steering valve P port
by the charge pump.
Whenever the steering wheel (F) is released, spring
pressure moves the control valve section to the neutral
position. In this position, pressurized oil from the charge
pump enters the steering valve at the P port. It is then
allowed to flow through the control valve section and flows
out through the EF port. In this position, the control valve
prevents pressurized oil from reaching the gerotor, and

TCAL29856 —UN—12JUN12
stops the flow of pressurized oil to the steering cylinder (G).
As the oil exits the EF port of the steering valve, the oil is
used as a charge flow for the implement lift valve.
While the steering valve is in the neutral position, trapped
oil (B) in the steering cylinder is allowed to flow into the
control valve section. This slight flow will give the operator
a feel of any change in the direction of the rear wheel,
through the steering system, because of the mechanical
link (H) between the gerotor and steering wheel. A—High-Pressure Oil F— Steering Wheel
B—Trapped Oil G—Steering Cylinder
C—Steering Valve Assembly H—Mechanical Link
D—Control Valve Section I— Relief Valve [10411 kPa
E—Gerotor (1510 psi)]
J— Check Valve

OUMX258,0000B1A -19-22MAR13-1/1

TM130419 (24FEB16) 260-10-1 030916

PN=1229
 Theory of Operation

Steering System Operation - Power Turn

Function
To supply pressurized oil to the proper side of the steering
cylinder to turn the rear wheels.
Theory of Operation
NOTE: Right turn shown.

When the steering wheel (D) is turned to the right, the

control valve section (E) is shifted by the mechanical
link (F). This allows pressurized oil to flow through the
control valve section to the inlet of the gerotor (G). As the
steering wheel continues to turn, system oil flows through
the gerotor and control valve section. Metered oil (B)
is directed to the right side of the steering cylinder (H),
forcing the piston to the left. Oil is forced out the other
side of the cylinder and flows back to the reservoir. In this
position, no oil is allowed to flow out of the EF port to the
implement lift valve.
If the steering wheel is held against the stop, the
implement relief valve 6895 kPa (1000 psi) would open
before the steering relief valve (I) at 10 411 kPa (1510 psi)
differential, allowing the high-pressure oil to bypass the

TCAL29857 —UN—12JUN12
control valve and exit the steering valve assembly.

A—High-Pressure Oil G—Gerotor

B—Metered Oil H—Steering Cylinder
C—Return (Charge Pressure) I— Relief Valve [10 411 kPa
Oil (1510 psi)]
D—Steering Wheel J— Check Valve
E—Control Valve Section K—Steering Valve Assembly
F— Mechanical Link

OUMX258,0000B1B -19-22MAR13-1/1

TM130419 (24FEB16) 260-10-2 030916

PN=1230
 Theory of Operation

Steering System Operation - Manual Turn

Function
To allow manual steering if hydraulic pressure is not
available.
Theory of Operation
NOTE: Right turn shown.

If hydraulic pressure is lost, the machine can still be

steered without hydraulic assistance. All components still
function the same, with the exception of the gerotor and
check valve.
The gerotor (D) now acts as a pump, moving oil from one
side of the gerotor to the other as the steering wheel (E)
is turned. The check valve (F) opens, allowing oil to be
drawn from the return side of the steering cylinder (G).
Hydraulic oil is forced by the gerotor to either end of the
steering cylinder, depending on which way the steering
wheel is turned.
When the steering wheel is released, the centering
springs move the control valve section (H) to the center
(neutral) position, and will remain there until the steering

TCAL29858 —UN—12JUN12
wheel is turned again.

A—Low-Pressure Oil G—Steering Cylinder

B—Metered Oil H—Control Valve Section
C—Return (Charge Pressure) I— Relief Valve [10 411 kPa
Oil (1510 psi)]
D—Gerotor J— Mechanical Link
E—Steering Wheel K—Steering Valve Assembly
F— Check Valve

OUMX258,0000B1C -19-22MAR13-1/1

Brake System Operation The brake friction disks are splined to the axle shafts.
Function The separator plates are keyed to the brake actuator
lever/cam shaft and cannot move.
To provide a means of stopping the machine and to
prevent the machine from moving when not in use. When the brake pedal is depressed, the brake actuator
lever/cams rotate, forcing the brake actuator plate to
Theory of Operation rotate.

The brake system consists of plates and disks located As the actuator plate rotates, the ramps on the plate will
inside the axle housing on each side of the transaxle allow the plate to ride up, forcing the plate against the
assembly. friction disks and separator plates, causing drag and
slowing the machine.
The brakes are activated by a common pedal hooked
to linkage connected to the individual brake assemblies When the pedal is released, the return springs return the
located in each of the axle shaft housings. The brakes brake actuator lever/cams to the rest position, allowing
may be activated individually by depressing either the left the actuator plates to release the pressure on the friction
turn brake pedal or the right turn brake pedal. disks and separator plates.

Inside each axle shaft housing, the brake components The machine is equipped with a park brake lock. When
consist of a brake actuator lever/cam, actuator plate, and the brake pedal is depressed and held, and the park brake
pairs of alternating friction disks and separator plates. lock lever is pulled up, a pawl engages with the teeth on
the pivot shaft, locking the brake linkage.
The brake actuator plate is mounted on six steel balls,
which ride inside pockets with ramps on the actuator plate.
OUMX258,0000B1D -19-22MAR13-1/1

TM130419 (24FEB16) 260-10-3 030916

PN=1231
 Theory of Operation

TM130419 (24FEB16) 260-10-4 030916

PN=1232
 Group 20
Steering Diagnosis
High Steering Effort in Both Directions
OUMX258,0000B1E -19-31DEC13-1/14

High Steering Effort in Both Directions

OUMX258,0000B1E -19-31DEC13-2/14

•1 Procedure Is tire pressure set to correct pressure at each tire? YES: Go to next step.

NO: Adjust tire pressure

as required. See Operator’s
manual for proper tire
pressure specifications.

OUMX258,0000B1E -19-31DEC13-3/14

•2 continued Is wheel mounting hardware secure? YES: Go to next step.

NO: Tighten wheel

hardware as required.

OUMX258,0000B1E -19-31DEC13-4/14

•3 continued Check rear wheel toe-in alignment. (See Check and Adjust Steering Toe-In.) Is toe-in
adjusted properly?
YES: Go to next step.

NO: Adjust steering toe-in.

OUMX258,0000B1E -19-31DEC13-5/14

•4 continued Is hydraulic oil in reservoir at correct level? YES: Go to next step.

NO: Adjust oil level as

necessary.

OUMX258,0000B1E -19-31DEC13-6/14

•5 continued Are spindle bearings in good condition, not worn or damaged? YES: Go to next step.

NO: Replace spindle

bearings.

OUMX258,0000B1E -19-31DEC13-7/14

•6 continued Are steering system hoses properly routed, not bent or restricted? YES: Go to next step.

NO: Route hoses properly

or replace as needed.

Continued on next page OUMX258,0000B1E -19-31DEC13-8/14

TM130419 (24FEB16) 260-20-1 030916

PN=1233
 Steering Diagnosis

•7 continued Are steering cylinder ends in good condition, not worn or damaged? YES: Go to next step.

NO: Replace steering

cylinder.
OUMX258,0000B1E -19-31DEC13-9/14

•8 continued Is steering cylinder mounting end hardware properly torqued, not loose or damaged? YES: Go to next step.

NO: Tighten hardware as

required. Replace damaged
hardware.
OUMX258,0000B1E -19-31DEC13-10/14

•9 continued Check charge pump pressure. (See Charge Pressure Relief Valve Test.) Is charge
pressure within specifications?
YES: Go to next step.

NO: Replace charge

pressure relief valve.
OUMX258,0000B1E -19-31DEC13-11/14

•10 continued Check charge pump flow. (See Hydraulic Pump Flow and Implement Relief Valve Test.) YES: Go to next step.
Is charge pump flow within specifications?

NO: Replace charge

pump.

OUMX258,0000B1E -19-31DEC13-12/14

•11 continued Test steering valve for leakage. (See Test Steering Valve Leakage.) Is steering valve
leakage within specifications?
YES: Go to next step.

NO: Replace steering

valve.

OUMX258,0000B1E -19-31DEC13-13/14

•12 continued Test steering cylinder for leakage. (See Test Steering System Leakage.) Is steering
system leakage within specifications?
NO: Replace steering
cylinder.

OUMX258,0000B1E -19-31DEC13-14/14

Hydraulic Oil Foams

OUMX258,0000B1F -19-31DEC13-1/5

Hydraulic Oil Foams

OUMX258,0000B1F -19-31DEC13-2/5

•1 Procedure Is hydraulic oil in good condition, not contaminated? YES: Go to next step.

NO: Drain system, replace

oil filter and fill with specified
oil.

Continued on next page OUMX258,0000B1F -19-31DEC13-3/5

TM130419 (24FEB16) 260-20-2 PN=1234

030916
 Steering Diagnosis

•2 continued Are steering system hoses properly routed, not bent or restricted? YES: Go to next step.

NO: Route hoses properly

or replace as needed.
OUMX258,0000B1F -19-31DEC13-4/5

•3 continued Are hydraulic hoses in good condition and connections tight? NO: Tighten loose
connections and replace
cracked or cut lines.
OUMX258,0000B1F -19-31DEC13-5/5

Lost Motion in Steering Wheel

OUMX258,0000B20 -19-31DEC13-1/7

Lost Motion in Steering Wheel

OUMX258,0000B20 -19-31DEC13-2/7

•1 Procedure Is hydraulic oil in good condition, not contaminated? YES: Go to next step.

NO: Drain system, replace

oil filter and fill with specified
oil.

OUMX258,0000B20 -19-31DEC13-3/7

•2 continued Is hydraulic oil in reservoir at correct level? YES: Go to next step.

NO: Adjust oil level as

necessary.

OUMX258,0000B20 -19-31DEC13-4/7

•3 continued Is steering valve mounting hardware properly torqued? YES: Go to next step.

NO: Tighten hardware as

required.

OUMX258,0000B20 -19-31DEC13-5/7

•4 continued Test steering valve for leakage. (See Test Steering Valve Leakage.) Is steering valve
leakage within specifications?
YES: Go to next step.

NO: Replace steering

valve.

OUMX258,0000B20 -19-31DEC13-6/7

•5 continued Test steering cylinder for leakage. (See Test Steering System Leakage.) Is steering
system leakage within specifications?
NO: Replace steering
cylinder.

OUMX258,0000B20 -19-31DEC13-7/7

TM130419 (24FEB16) 260-20-3 PN=1235

030916
 Steering Diagnosis

Machine Continues to Turn after Steering

Wheel Has Returned to Center Position
OUMX258,0000B21 -19-31DEC13-1/5

Machine Continues to Turn after Steering Wheel Has Returned to Center Position
OUMX258,0000B21 -19-31DEC13-2/5

•1 Procedure Is steering valve functioning properly, not sticking? YES: Go to next step.

NO: Replace steering

valve.
OUMX258,0000B21 -19-31DEC13-3/5

•2 continued Is hydraulic oil in good condition, not contaminated? YES: Go to next step.

NO: Drain system, replace

oil filter and fill with specified
oil.

OUMX258,0000B21 -19-31DEC13-4/5

•3 continued Is hydraulic oil in reservoir at correct level? NO: Adjust oil level as
necessary.

OUMX258,0000B21 -19-31DEC13-5/5

Sluggish Steering Response

OUMX258,0000B22 -19-31DEC13-1/11

Sluggish Steering Response

OUMX258,0000B22 -19-31DEC13-2/11

•1 Procedure Is reservoir filled with proper viscosity hydraulic oil? YES: Go to next step.

NO: Drain and fill with

proper viscosity oil.

OUMX258,0000B22 -19-31DEC13-3/11

•2 continued Is hydraulic oil in good condition, not contaminated? YES: Go to next step.

NO: Drain system, replace

oil filter and fill with specified
oil.

Continued on next page OUMX258,0000B22 -19-31DEC13-4/11

TM130419 (24FEB16) 260-20-4 PN=1236

030916
 Steering Diagnosis

•3 continued Is hydraulic oil in reservoir at correct level? YES: Go to next step.

NO: Adjust oil level as

necessary.
OUMX258,0000B22 -19-31DEC13-5/11

•4 continued Are steering system hoses properly routed, not bent or restricted? YES: Go to next step.

NO: Route hoses properly

or replace as needed.
OUMX258,0000B22 -19-31DEC13-6/11

•5 continued Is steering valve functioning properly, not sticking? YES: Go to next step.

NO: Replace steering

valve.
OUMX258,0000B22 -19-31DEC13-7/11

•6 continued Test steering valve for leakage. (See Test Steering Valve Leakage.) Is steering valve
leakage within specifications?
YES: Go to next step.

NO: Replace steering

valve.

OUMX258,0000B22 -19-31DEC13-8/11

•7 continued Test steering cylinder for leakage. (See Test Steering System Leakage.) Is steering
system leakage within specifications?
YES: Go to next step.

NO: Replace steering

cylinder.

OUMX258,0000B22 -19-31DEC13-9/11

•8 continued Check charge pump pressure. (See Charge Pressure Relief Valve Test.) Is charge
pressure within specifications?
YES: Go to next step.

NO: Replace charge

pressure relief valve.

OUMX258,0000B22 -19-31DEC13-10/11

•9 continued Check charge pump flow. (See Hydraulic Pump Flow and Implement Relief Valve Test.) NO: Replace charge
pump.

OUMX258,0000B22 -19-31DEC13-11/11

Steering Not Driving Straight

OUMX258,0000B23 -19-31DEC13-1/14

Steering Not Driving Straight

Continued on next page OUMX258,0000B23 -19-31DEC13-2/14

TM130419 (24FEB16) 260-20-5 030916

PN=1237
 Steering Diagnosis

•1 Procedure Is tire pressure set to correct pressure at each tire? YES: Go to next step.

NO: Adjust tire pressure

as required. See Operator’s
Manual for proper tire
pressure specifications.
OUMX258,0000B23 -19-31DEC13-3/14

•2 continued Is wheel mounting hardware secure? YES: Go to next step.

NO: Tighten wheel

hardware as required.
OUMX258,0000B23 -19-31DEC13-4/14

•3 continued Is hydraulic oil in reservoir at correct level? YES: Go to next step.

NO: Adjust oil level as

necessary.
OUMX258,0000B23 -19-31DEC13-5/14

•4 continued Is hydraulic oil in good condition, not contaminated? YES: Go to next step.

NO: Drain system, replace

oil filter and fill with specified
oil.

OUMX258,0000B23 -19-31DEC13-6/14

•5 continued Are rear wheel bearings in good condition, not worn or damaged? YES: Go to next step.

NO: Replace rear wheel

bearings.

OUMX258,0000B23 -19-31DEC13-7/14

•6 continued Are spindle bearings in good condition, not worn or damaged? YES: Go to next step.

NO: Replace spindle

bearings.

OUMX258,0000B23 -19-31DEC13-8/14

•7 continued Are steering cylinder ends in good condition, not worn or damaged? YES: Go to next step.

NO: Replace steering

cylinder.

Continued on next page OUMX258,0000B23 -19-31DEC13-9/14

TM130419 (24FEB16) 260-20-6 PN=1238

030916
 Steering Diagnosis

•8 continued Is steering cylinder mounting end hardware properly torqued, not loose or damaged? YES: Go to next step.

NO: Tighten hardware as

required. Replace damaged
hardware.
OUMX258,0000B23 -19-31DEC13-10/14

•9 continued Is steering valve functioning properly, not sticking? YES: Go to next step.

NO: Replace steering

valve.
OUMX258,0000B23 -19-31DEC13-11/14

•10 continued Test steering valve for leakage. (See Test Steering Valve Leakage.) Is steering valve
leakage within specifications?
YES: Go to next step.

NO: Replace steering

valve.
OUMX258,0000B23 -19-31DEC13-12/14

•11 continued Test steering cylinder for leakage. (See Test Steering System Leakage.) Is steering
system leakage within specifications?
YES: Go to next step.

NO: Replace steering

cylinder.

OUMX258,0000B23 -19-31DEC13-13/14

•12 continued Are steering system hoses or fittings sealed properly, not leaking? NO: Tighten connections
and replace damaged
hoses.

OUMX258,0000B23 -19-31DEC13-14/14

Steering Operation Reversed

OUMX258,0000B24 -19-31DEC13-1/3

Steering Operation Reversed

OUMX258,0000B24 -19-31DEC13-2/3

•1 Procedure Are steering hoses installed properly? NO: Disconnect hoses as

required and install properly.

OUMX258,0000B24 -19-31DEC13-3/3

Steering Wheel Vibration

OUMX258,0000B25 -19-31DEC13-1/10

Steering Wheel Vibration

Continued on next page OUMX258,0000B25 -19-31DEC13-2/10

TM130419 (24FEB16) 260-20-7 PN=1239

030916
 Steering Diagnosis

•1 Procedure Is tire pressure set to correct pressure at each tire? YES: Go to next step.

NO: Adjust tire pressure

as required. See Operator’s
Manual for proper tire
pressure specifications.
OUMX258,0000B25 -19-31DEC13-3/10

•2 continued Is wheel mounting hardware secure? YES: Go to next step.

NO: Tighten wheel

hardware as required.
OUMX258,0000B25 -19-31DEC13-4/10

•3 continued Is hydraulic oil in reservoir at correct level? YES: Go to next step.

NO: Adjust oil level as

necessary.
OUMX258,0000B25 -19-31DEC13-5/10

•4 continued Is hydraulic oil in good condition not contaminated? YES: Go to next step.

NO: Drain system, replace

oil filter and fill with specified
oil.

OUMX258,0000B25 -19-31DEC13-6/10

•5 continued Are rear wheel bearings in good condition, not worn or damaged? YES: Go to next step.

NO: Replace rear wheel

bearings.

OUMX258,0000B25 -19-31DEC13-7/10

•6 continued Are spindle bearings in good condition, not worn or damaged? YES: Go to next step.

NO: Replace spindle

bearings.

OUMX258,0000B25 -19-31DEC13-8/10

•7 continued Are steering cylinder ends in good condition, not worn or damaged? YES: Go to next step.

NO: Replace steering

cylinder.

Continued on next page OUMX258,0000B25 -19-31DEC13-9/10

TM130419 (24FEB16) 260-20-8 PN=1240

030916
 Steering Diagnosis

•8 continued Is steering cylinder mounting end hardware properly torqued, not loose or damaged? NO: Tighten hardware as
required. Replace damaged
hardware.
OUMX258,0000B25 -19-31DEC13-10/10

TM130419 (24FEB16) 260-20-9 030916

PN=1241
 Steering Diagnosis

TM130419 (24FEB16) 260-20-10 030916

PN=1242
 Group 30
Brakes Diagnosis
Machine Will Not Move
Machine Will Not Move, Brakes
OUMX258,0000B26 -19-31DEC13-1/5

Machine Will Not Move

OUMX258,0000B26 -19-31DEC13-2/5

•1 Procedure Does park brake lock lever assembly move freely? YES: Go to next step.

NO: Repair worn or

damaged parts as
necessary.

OUMX258,0000B26 -19-31DEC13-3/5

•2 continued Is turn brake adjusted properly? (See Check and Adjust Turn Brake.) YES: Go to next step.

NO: Adjust turn brake.

OUMX258,0000B26 -19-31DEC13-4/5

•3 continued Are brake return springs installed properly and in good condition? NO: Replace springs.

OUMX258,0000B26 -19-31DEC13-5/5

Brake Will Not Engage or Hold Machine

Brake Will Not Engage or Hold Machine
OUMX258,0000B27 -19-31DEC13-1/4

Brake Will Not Engage or Hold Machine

OUMX258,0000B27 -19-31DEC13-2/4

•1 Procedure Is brake linkage properly adjusted? (See Check and Adjust Turn Brake.) YES: Go to next step.

NO: Adjust turn brake.

OUMX258,0000B27 -19-31DEC13-3/4

•2 continued Are the brake friction discs and separator plates in good condition, not worn or damaged? NO: Replace worn or
damaged friction discs and
separator plates.

OUMX258,0000B27 -19-31DEC13-4/4

Excessive Brake Wear

Brake Will Not Engage or Hold Machine
OUMX258,0000B28 -19-31DEC13-1/6

Excessive Brake Wear

Continued on next page OUMX258,0000B28 -19-31DEC13-2/6

TM130419 (24FEB16) 260-30-1 PN=1243

030916
 Brakes Diagnosis

•1 Procedure Are brake pedal shaft and bushings in good condition, not worn or damaged? YES: Go to next step.

NO: Repair or replace

damaged parts as
necessary.
OUMX258,0000B28 -19-31DEC13-3/6

•2 continued Is the park brake lock lever assembly in good condition, not worn or damaged? YES: Go to next step.

NO: Repair or replace

damaged parts as
necessary.
OUMX258,0000B28 -19-31DEC13-4/6

•3 continued Are the brake return springs in good condition? YES: Go to next step.

NO: Replace brake return

springs.
OUMX258,0000B28 -19-31DEC13-5/6

•4 continued Are the brake separator plates in good condition, not worn or damaged? NO: Replace separator
plates.

OUMX258,0000B28 -19-31DEC13-6/6

Machine Pulls to One Side

Machine Pulls to One Side
OUMX258,0000B29 -19-31DEC13-1/6

Machine Pulls to One Side

OUMX258,0000B29 -19-31DEC13-2/6

•1 Procedure Is brake linkage properly adjusted? (See Check and Adjust Turn Brake.) YES: Go to next step.

NO: Adjust brake linkage.

OUMX258,0000B29 -19-31DEC13-3/6

•2 continued Is park brake lock lever assembly in good condition, not worn or damaged? YES: Go to next step.

NO: Repair or replace

damaged parts as
necessary.

Continued on next page OUMX258,0000B29 -19-31DEC13-4/6

TM130419 (24FEB16) 260-30-2 030916

PN=1244
 Brakes Diagnosis

•3 continued Are brake return springs in good condition? YES: Go to next step.

NO: Replace brake return

springs.
OUMX258,0000B29 -19-31DEC13-5/6

•4 continued Are the brake friction discs and separator plates in good condition, not worn or damaged? NO: Replace worn or
damaged friction discs and
separator plates.
OUMX258,0000B29 -19-31DEC13-6/6

TM130419 (24FEB16) 260-30-3 PN=1245

030916
 Brakes Diagnosis

TM130419 (24FEB16) 260-30-4 030916

PN=1246
 Group 50
Tests and Adjustments
Summary of References • Test Steering Valve Leakage
• Check and Adjust Steering Toe-In • Check and Adjust Turn Brake
• Adjust Brake Switch
• Test Steering System Leakage
OUMX258,0000B31 -19-25MAR13-1/1

Check and Adjust Steering Toe-In

Reason
Correct toe-in prevents excessive tire wear and steering
wander.

TCAL29859 —UN—12JUN12
Check Procedure
1. Park machine safely.
2. Measure the distance between the rear tires at the
rear of the tires (A).
3. Measure the distance between the rear tires at the
front of the tires (B). The distance between tires
(toe-in) should be within specification. If adjustment is
required, perform adjustment procedure. A—Distance Between the Rear B—Distance Between the Rear
Tires at the Rear of the Tires Tires at the Front of the
Specification Tires
Between Tires
(Toe-In)—Distance.................................................3—9 mm (0.12—0.35
in.) less in the front than the rear

OUMX258,0000B2A -19-25MAR13-1/2

Adjustment Procedure
1. Remove cotter pin (E) and castle nut (F) from tie rod
end (H).
2. Remove tie rod end from steering arm (G).

TCAL29860 —UN—12JUN12
3. Loosen jam nuts (D) on both sides of tie rod (C).
4. With one tie rod end free, turn tie rod one or more full
turns to adjust toe-in.
NOTE: Tie rod must be turned complete full turns so bend
in tie rod is always toward the rear of machine.
If tie rod is turned, the tie rod end that is
free must also be turned the same amount C—Tie Rod F— Castle Nut
and in the same direction. D—Jam Nut G—Steering Arm
E—Cotter Pin H—Tie Rod End
5. Turn the free tie rod end into or out of the tie rod the
same direction as the tie rod was turned.
6. Install tie rod end in steering arm. Tighten castle nut. Specification
Between Tires
7. Measure toe-in. If within specification, install cotter (Toe-In)—Distance.................................................3—9 mm (0.12—0.35
pin and tighten jam nuts. in.) less in the front than the rear

OUMX258,0000B2A -19-25MAR13-2/2

TM130419 (24FEB16) 260-50-1 PN=1247

030916
 Tests and Adjustments

Test Steering System Leakage 5. Set throttle to slow idle.

Reason 6. With steering wheel at the maximum right turn position,
To check the steering system for internal leakage. apply a constant specified torque.
Specification
Procedure Turn Steering at Constant
1. Park machine on level surface. Specified—Torque........................................................................6.8 N·m
(72 lb.-in.)
2. Lower all implements to the ground. Steering Wheel Turns per
Minute—Rotation................................................................. 6 (maximum)
3. Lock park brake.
Count the number of rotations occurring in one minute.
CAUTION: Engine exhaust fumes can cause 7. Repeat the previous step with the steering wheel at
sickness or death. the maximum left turn position.
If it is necessary to run an engine in an Results
enclosed area, use an exhaust pipe extension
to remove the fumes. If the number of rotations exceeds the specification, see
Test Steering Valve Leakage.
Always try to work in a well-ventilated area.

4. Start engine and bring hydraulic system oil to operating

temperature.
OUMX258,0000B2B -19-16SEP14-1/1

TM130419 (24FEB16) 260-50-2 PN=1248

030916
 Tests and Adjustments

Test Steering Valve Leakage

Reason
To determine if leakage is in steering valve or in steering
cylinder.
Procedure

TCAL29861 —UN—12JUN12
CAUTION: Escaping fluid under pressure can
penetrate the skin causing serious injury.
Avoid the hazard by relieving pressure before
disconnecting hydraulic or other lines. Tighten
all connections before applying pressure. Search
for leaks with a piece of cardboard. Protect hands
and body from high-pressure fluids.
If an accident occurs, see a doctor immediately.
Any fluid injected into the skin must be surgically
removed within a few hours or gangrene may A—Steering Hose Connection B—Steering Hose Connection
result. Doctors unfamiliar with this type of
injury should reference a knowledgeable medical
source. Such information is available from Deere
Always try to work in a well-ventilated area.
& Company Medical Department in Moline, Illinois,
U.S.A. Information may be obtained in the United
6. Start engine and bring hydraulic system oil to operating
States and Canada only by calling 1-800-822-8262.
temperature.
1. Park machine on level surface. 7. Set throttle to slow idle.
2. Lower all implements to the ground. 8. With steering wheel at the maximum right turn position,
apply a constant specified torque. Count the number
3. Lock park brake.
of rotations occurring in one minute.
4. Move key switch to stop position. Specification
Constant Specified
CAUTION: To avoid injury from escaping hydraulic —Torque.......................................................................................6.8 N·m
oil under pressure, relieve the pressure in the (72 lb.-in.)
system by operating all the hydraulic controls. Steering Wheel Turns per
Minute—Rotation................................................................. 6 (maximum)
NOTE: Mark all hydraulic hoses before removing to
ensure correct installation. 9. Repeat the previous step with the steering wheel at
the maximum left turn position.
5. Disconnect and cap steering cylinder hoses (A and B). Results

CAUTION: Engine exhaust fumes can cause • If the number of rotations exceeds the specification,
sickness or death. replace steering valve.
• If the number of rotations is less than the specification,
If it is necessary to run an engine in an replace steering cylinder.
enclosed area, use an exhaust pipe extension
to remove the fumes.
OUMX258,0000B2C -19-16SEP14-1/1

TM130419 (24FEB16) 260-50-3 PN=1249

030916
 Tests and Adjustments

Check and Adjust Turn Brake

Check Turn Brake Pedal Free Play
1. Park machine on level ground.
2. Unlock park brake.
3. Place a piece of tape (A) on the front surface of each
turn brake pedal and extending below the floor (C).
4. Make a mark (B) at the same height of the floor on
the tape.

TCAL29875 —UN—11JUN12
A—Tape C—Floor
B—Mark

OUMX258,0000B2D -19-16SEP14-1/4

5. Press turn brake pedal until brake engages. Mark

position of floor (D) on tape.
6. Release brake pedal and measure the distance (E)
between the front edge of the marks on the tape to
determine pedal travel.
7. Repeat steps 3—6 for the other turn brake pedal.
8. If brake pedal free play is not within specification, the
brakes require adjustment.
Specification
Brake Pedal Free

TCAL29876 —UN—11JUN12
Play—Distance.......................................................................25—30 mm
(0.98—1.18 in.)

D—Position of Floor E—Brake Travel Distance

Continued on next page OUMX258,0000B2D -19-16SEP14-2/4

TM130419 (24FEB16) 260-50-4 030916

PN=1250
 Tests and Adjustments

Adjust Turn Brake

1. Using tape installed earlier, make two marks (A) at 25
mm and 30 mm (0.98 and 1.18 in.) above the floor.

A—Marks

TCAL29877 —UN—11JUN12
OUMX258,0000B2D -19-16SEP14-3/4

2. Loosen locknuts (B), and adjust turnbuckle (C) until

brake begins to engage when the pedal is between
the specified marks on the tape.
Specification
Brake Pedal Free

TCAL29878 —UN—11JUN12
Play—Distance.......................................................................25—30 mm
(0.98—1.18 in.)

3. Repeat for other pedal, keeping left and right side

pedals adjusted evenly.
4. Tighten turnbuckle locknuts.
5. If brakes cannot be adjusted within the range of the
turnbuckles, check the transaxle brake plates and
disks. B—Locknuts C—Turnbuckle

OUMX258,0000B2D -19-16SEP14-4/4

TM130419 (24FEB16) 260-50-5 030916

PN=1251
 Tests and Adjustments

Adjust Brake Switch

Check
1. Park machine on level surface.

TCAL29879 —UN—11JUN12
2. Unlock park brake.
3. Disconnect battery negative (—) cable.
4. Open service hatch.
5. Inspect brake switch. If boot, plunger, or brake switch
are worn or damaged, replace brake switch.
6. Depress master brake pedal. Plunger on brake switch
(A) should extend when mixer (B) and neutral safety
arm (C) are activated. A—Brake Switch D—Neutral Safety link
B—Mixer E—Ball Joint
7. Release master brake pedal. Plunger on brake switch C—Neutral Safety Arm
should retract completely when neutral safety arm is
activated by neutral safety link (D) and ball joint (E).
OUMX258,0000B2E -19-25MAR13-1/4

Adjust
IMPORTANT: Improper adjustment may cause damage
to plunger and brake switch. Adjust brake
switch with park brake lock lever in unlocked
position and brakes disengaged.

TCAL29880 —UN—11JUN12
1. Loosen locknut (A) and washer (B) on inside of frame
rail.

A—Locknut B—Washer

OUMX258,0000B2E -19-25MAR13-2/4

2. Move brake switch (C) toward front of machine until

plunger is fully retracted when contacting neutral
safety arm.
3. Tighten screw (D) and locknut.

TCAL29881 —UN—11JUN12
4. Depress master brake pedal and release. Ensure that
neutral safety arm properly contacts plunger. Adjust if
necessary.
5. Check brake switch for proper operation:
a. Operate machine with PTO switch in ON position.
b. While depressing master brake pedal, ensure PTO
disengages.
c. Adjust or replace brake switch if necessary. C—Brake Switch D—Screw

Continued on next page OUMX258,0000B2E -19-25MAR13-3/4

TM130419 (24FEB16) 260-50-6 030916

PN=1252
 Tests and Adjustments

Remove
1. Disconnect connector (A) on back of brake switch.
2. Remove screw, locknut and brake switch from
machine.

TCAL29882 —UN—11JUN12
3. Replace brake switch.
Install
Installation is done in the reverse order of removal.
• Perform steps 2—5 in Adjust section.
• Check brake switch for proper operation.
A—Connector

OUMX258,0000B2E -19-25MAR13-4/4

TM130419 (24FEB16) 260-50-7 030916

PN=1253
 Tests and Adjustments

TM130419 (24FEB16) 260-50-8 030916

PN=1254
 Section 270
Attachments Operation, Tests, and Adjustments
Contents

Page
Page
Group 10—Diagnosis
System: 60, 62 and 72-Inch Mower Check and Adjust 60, 62 and
Decks ......................................................270-10-1 72-Inch (Side Discharge) Mower
Test Procedure A: Mower Deck Drive Belt Tension.................................... 270-20-7
Linkage....................................................270-10-1 Check and Adjust 72-Inch (Rear
Mower Deck Level .......................................270-10-1 Discharge) Mower Deck Belt
Mower Deck Drive Belt ................................270-10-2 Tension .................................................... 270-20-7
Mower Drive Belt Tension Spring ................270-10-3 Check and Adjust V-Flex Deck
Drive Belt Adjustment Arm ..........................270-10-3 Drive Belt Tension.................................... 270-20-8
Spindle Sheave ...........................................270-10-3 Checking and Adjusting Blower
Spindle and Housing ...................................270-10-4 Fan Drive Belt.......................................... 270-20-8
Mower Blades..............................................270-10-5 Adjusting the Hopper Hinges....................... 270-20-9
Caster Wheels .............................................270-10-6 Adjusting Cover Closing Force .................. 270-20-10
Caster Wheel Yoke Assemblies ..................270-10-7 Adjusting the Seal Between Blow-In
Test Procedure B: Engine............................270-10-8 Port and Container ................................ 270-20-10
Mower Deck PTO Shaft...............................270-10-9 Adjusting Cover Seal
System: 7-Iron V-Flex Deck ......................270-10-10 Compression ......................................... 270-20-11
Test Procedure A: Mower Deck Balancing the Blower Blade....................... 270-20-12
Linkage..................................................270-10-10
Mower Deck Level .....................................270-10-10
Mower Deck Drive Belt ..............................270-10-11
Vertical Drive Belts ....................................270-10-13
Mower Drive Belt Tension Spring ..............270-10-14
Vertical Drive Belt Tension
Springs ..................................................270-10-14
Spindle Sheave .........................................270-10-15
Spindle and Housing .................................270-10-15
Mower Blades............................................270-10-16
Caster Wheels ...........................................270-10-17
Caster Wheel Yoke Assemblies ................270-10-18
System: 60-Inch Heavy-Duty
Snowblower...........................................270-10-19
Test Procedure A: Auger Drive
System ..................................................270-10-19
Spout Control System................................270-10-19
System: Grass and Leaf Collection
System (GLC) .......................................270-10-20
Suction System..........................................270-10-20
Suction Capacity........................................270-10-20
Turbine Vibration .......................................270-10-21
Turbine Noise ............................................270-10-21
Turbine Does Not Run...............................270-10-22
Material Escapes Between Front and
Rear Shell .............................................270-10-22
Material Escapes Between Blow-In
Port and Front Shell ..............................270-10-23

Group 20—Tests and Adjustments

Summary of References.............................. 270-20-1
Check and Adjust Mower Deck
Level ........................................................ 270-20-2
Check V-Flex Deck Level ............................ 270-20-6

TM130419 (24FEB16) 270-1 030916

PN=1
 Contents

TM130419 (24FEB16) 270-2 030916

PN=2
 Group 10
Diagnosis
System: 60, 62 and 72-Inch Mower Decks
Special or Required Tools
60, 62 and 72-Inch Mower Decks • Leveling Gage
OUMX258,0000B59 -19-31DEC13-1/36

Test Procedure A: Mower Deck Linkage

OUMX258,0000B59 -19-31DEC13-2/36

Step 1 Test Conditions

• Machine parked safely.
• PTO disengaged.

NO: Tighten or replace

hardware.

TCT006681 —UN—10APR13
Is the mounting hardware in place and secure?

OUMX258,0000B59 -19-31DEC13-3/36

Mower Deck Level

OUMX258,0000B59 -19-31DEC13-4/36

Step 1 YES: Go to next step.

TCT006682 —UN—10APR13
Is mower deck level side-to-side?
NO: Adjust as needed.
(See Check and Adjust
Mower Deck Level.)

Continued on next page OUMX258,0000B59 -19-31DEC13-5/36

TM130419 (24FEB16) 270-10-1 030916

PN=1257
 Diagnosis

Step 2 NO: Adjust as needed.

(See Check and Adjust
Mower Deck Level.)

TCT006683 —UN—10APR13
Is mower deck level front-to-back?
OUMX258,0000B59 -19-31DEC13-6/36

Mower Deck Drive Belt

OUMX258,0000B59 -19-31DEC13-7/36

Step 1 YES: Go to next step.

TCAL29893 —UN—03JUL12
Are the drive belt and sheaves free of debris?
NO: Remove belt shields
and remove debris.
OUMX258,0000B59 -19-31DEC13-8/36

Step 2 YES: Go to next step.

TCAL29894 —UN—03JUL12
Is the correct belt installed?
NO: Replace belt.

OUMX258,0000B59 -19-31DEC13-9/36

Step 3 YES: Replace belt if

necessary.

TCAL29895 —UN—03JUL12
Is the drive belt damaged, worn, stretched or broken?

Continued on next page OUMX258,0000B59 -19-31DEC13-10/36

TM130419 (24FEB16) 270-10-2 030916

PN=1258
 Diagnosis

Mower Drive Belt Tension Spring

OUMX258,0000B59 -19-31DEC13-11/36

Step 1 YES: Replace spring.

TCT006684 —UN—10APR13
Is the tension spring damaged, worn or weak?
OUMX258,0000B59 -19-31DEC13-12/36

Drive Belt Adjustment Arm

OUMX258,0000B59 -19-31DEC13-13/36

Step 1 YES: Repair as needed.

TCT006685 —UN—10APR13
Is the adjustment arm binding or damaged?

OUMX258,0000B59 -19-31DEC13-14/36

Spindle Sheave
Continued on next page OUMX258,0000B59 -19-31DEC13-15/36

TM130419 (24FEB16) 270-10-3 030916

PN=1259
 Diagnosis

Step 1 YES: Go to next step.

TCT006686 —UN—10APR13
Is the spindle sheave running straight and true, not damaged or bent?
NO: Repair or replace as
needed.
OUMX258,0000B59 -19-31DEC13-16/36

Step 2 YES: Install or replace belt.

TCAL29899 —UN—03JUL12
Is the belt off sheave?
OUMX258,0000B59 -19-31DEC13-17/36

Spindle and Housing

OUMX258,0000B59 -19-31DEC13-18/36

Step 1 YES: Remove material.

TCAL29900 —UN—03JUL12
Is there material wrapped around spindle or blade?
NO: Go to next step.

Continued on next page OUMX258,0000B59 -19-31DEC13-19/36

TM130419 (24FEB16) 270-10-4 PN=1260

030916
 Diagnosis

Step 2 YES: Go to next step.

TCT006687 —UN—10APR13
Are the spindle and housing properly lubricated?
NO: Apply specified
grease to lube fittings at top
of spindle.
OUMX258,0000B59 -19-31DEC13-20/36

Step 3 YES: Repair or replace

spindles as needed.

TCAL29902 —UN—03JUL12
Do bearings not rotate freely or are they worn or damaged?
OUMX258,0000B59 -19-31DEC13-21/36

Mower Blades
Continued on next page OUMX258,0000B59 -19-31DEC13-22/36

TM130419 (24FEB16) 270-10-5 PN=1261

030916
 Diagnosis

Step 1 YES: Go to next step.

TCAL29903 —UN—03JUL12
Are blades tight on spindle?
NO: Tighten blade cap
screw.
OUMX258,0000B59 -19-31DEC13-23/36

Step 2 YES: Replace blades.

TCAL29904 —UN—03JUL12
Are the blades bent, worn or damaged?
NO: Go to next step.
OUMX258,0000B59 -19-31DEC13-24/36

Step 3 NO: Sharpen and balance

blades.

TCAL29905 —UN—03JUL12
Are the blades properly sharpened and balanced?
OUMX258,0000B59 -19-31DEC13-25/36

Caster Wheels
Continued on next page OUMX258,0000B59 -19-31DEC13-26/36

TM130419 (24FEB16) 270-10-6 030916

PN=1262
 Diagnosis

Step 1 YES: Go to next step.

TCT007156 —UN—10APR13
Are the tires properly inflated?
NO: Inflate tires to
specifications.
OUMX258,0000B59 -19-31DEC13-27/36

Step 2 NO: Apply specified

grease to wheel lubrication
fitting.

TCT007157 —UN—10APR13
Are the wheels properly lubricated?
OUMX258,0000B59 -19-31DEC13-28/36

Caster Wheel Yoke Assemblies

Continued on next page OUMX258,0000B59 -19-31DEC13-29/36

TM130419 (24FEB16) 270-10-7 PN=1263

030916
 Diagnosis

Step 1 YES: Go to next step.

TCT007158 —UN—10APR13
Are the caster wheel yoke assemblies properly lubricated?
NO: Apply specified
grease to pivot lubrication
fittings.
OUMX258,0000B59 -19-31DEC13-30/36

Step 2 NO: Replace bearings as

needed.

TCT007158 —UN—10APR13
Do the assemblies rotate freely and are the bearings not worn or damaged?
OUMX258,0000B59 -19-31DEC13-31/36

Test Procedure B: Engine

Continued on next page OUMX258,0000B59 -19-31DEC13-32/36

TM130419 (24FEB16) 270-10-8 PN=1264

030916
 Diagnosis

Step 1 Test Conditions

• Machine parked on a clean, level surface, away from people and objects.
• Engine running at fast idle.
• Engine at operating temperature.
• Mower deck lowered to the ground.
• PTO engaged.

NO: Check engine

operation.

TCAL29910 —UN—03JUL12
Is the engine running at the correct rpm?
OUMX258,0000B59 -19-31DEC13-33/36

Mower Deck PTO Shaft

OUMX258,0000B59 -19-31DEC13-34/36

Step 1 YES: Go to next step.

TCT007159 —UN—10APR13
Is the PTO shaft operating smoothly, without any unusual noises or vibrations?
NO: Slowly reduce engine
rpm and listen for problem
area. Disengage PTO and
stop engine. Repair or
replace faulty or damaged
components.
Continued on next page OUMX258,0000B59 -19-31DEC13-35/36

TM130419 (24FEB16) 270-10-9 030916

PN=1265
 Diagnosis

Step 2 NO: Inspect and repair

PTO brake. (See
Disassemble, Inspect,
and Assemble PTO or
Disassemble, Inspect, and
Assemble PTO—2 Speed.)

TCT007159 —UN—10APR13
Does PTO stop quickly?
OUMX258,0000B59 -19-31DEC13-36/36

System: 7-Iron V-Flex Deck

OUMX258,0000B5A -19-31DEC13-1/36

Test Procedure A: Mower Deck Linkage

7-Iron V-Flex Deck

OUMX258,0000B5A -19-31DEC13-2/36

Step 1 Test Conditions

• Machine parked safely.
• PTO disengaged.

NO: Tighten or replace

hardware.

TCAL29913 —UN—03JUL12
Is the mounting hardware in place and secure?

OUMX258,0000B5A -19-31DEC13-3/36

Mower Deck Level

Continued on next page OUMX258,0000B5A -19-31DEC13-4/36

TM130419 (24FEB16) 270-10-10 030916

PN=1266
 Diagnosis

Step 1 YES: Go to next step.

TCT007160 —UN—10APR13
Is there uneven cut?
NO: Adjust level or height
of cut as needed. (See
Check V-Flex Deck Level.)
OUMX258,0000B5A -19-31DEC13-5/36

Step 2 YES: Cutting height set too

low; adjust as needed.

TCT007161 —UN—10APR13
Does mower deck load down machine?
OUMX258,0000B5A -19-31DEC13-6/36

Mower Deck Drive Belt

Continued on next page OUMX258,0000B5A -19-31DEC13-7/36

TM130419 (24FEB16) 270-10-11 PN=1267

030916
 Diagnosis

Step 1 YES: Go to next step.

TCT007162 —UN—10APR13
Are the drive belt and sheaves free of debris?
NO: Remove belt shields
and remove debris.
OUMX258,0000B5A -19-31DEC13-8/36

Step 2 YES: Go to next step.

TCT007163 —UN—10APR13
Is the correct belt installed?
NO: Replace belt.
OUMX258,0000B5A -19-31DEC13-9/36

Step 3 YES: Replace belt if

necessary.

TCAL29918 —UN—03JUL12
Is the drive belt damaged, worn, stretched or broken?
NO: Go to next step.
Continued on next page OUMX258,0000B5A -19-31DEC13-10/36

TM130419 (24FEB16) 270-10-12 030916

PN=1268
 Diagnosis

Step 4 YES: Check belt tension,

debris in sheaves or worn
belt.

TCAL29919 —UN—03JUL12
Does the belt slip?
OUMX258,0000B5A -19-31DEC13-11/36

Vertical Drive Belts

OUMX258,0000B5A -19-31DEC13-12/36

Step 1 YES: Go to next step.

TCAL29920 —UN—03JUL12
Are the sheaves and belts free of debris?
NO: Remove belt shields
and remove debris.
OUMX258,0000B5A -19-31DEC13-13/36

Step 2 YES: Go to next step.

TCAL29921 —UN—03JUL12
Are the belts installed correctly?
NO: Install belts according
to procedures.

Continued on next page OUMX258,0000B5A -19-31DEC13-14/36

TM130419 (24FEB16) 270-10-13 PN=1269

030916
 Diagnosis

Step 3 YES: Replace belts.

TCT007164 —UN—10APR13
Are the vertical drive belts damaged, worn, stretched or broken?
OUMX258,0000B5A -19-31DEC13-15/36

Mower Drive Belt Tension Spring

OUMX258,0000B5A -19-31DEC13-16/36

Step 1 YES: Replace spring.

TCT007165 —UN—10APR13
Is the tension spring damaged, worn or weak?
OUMX258,0000B5A -19-31DEC13-17/36

Vertical Drive Belt Tension Springs

OUMX258,0000B5A -19-31DEC13-18/36

Step 1 YES: Replace spring.

TCT007166 —UN—10APR13
Is the tension spring damaged, worn or weak?

Continued on next page OUMX258,0000B5A -19-31DEC13-19/36

TM130419 (24FEB16) 270-10-14 030916

PN=1270
 Diagnosis

Spindle Sheave
OUMX258,0000B5A -19-31DEC13-20/36

Step 1 YES: Go to next step.

TCAL29925 —UN—03JUL12
Is the spindle sheave running straight and true, not damaged or bent?
NO: Repair or replace as
needed.
OUMX258,0000B5A -19-31DEC13-21/36

Step 2 YES: Install or replace belt.

TCAL29926 —UN—03JUL12
Is a belt off sheave?
OUMX258,0000B5A -19-31DEC13-22/36

Spindle and Housing

OUMX258,0000B5A -19-31DEC13-23/36

Step 1 YES: Remove material.

TCAL29927 —UN—03JUL12
Is there material wrapped around spindle or blade?
NO: Go to next step.

Continued on next page OUMX258,0000B5A -19-31DEC13-24/36

TM130419 (24FEB16) 270-10-15 PN=1271

030916
 Diagnosis

Step 2 YES: Go to next step.

TCAL29928 —UN—03JUL12
Are the spindle and housing properly lubricated?
NO: Apply specified
grease to lube fittings at top
of spindle.
OUMX258,0000B5A -19-31DEC13-25/36

Step 3 YES: Repair or replace

spindles as needed.

TCAL29929 —UN—03JUL12
Do bearings not rotate freely or are they worn or damaged?
OUMX258,0000B5A -19-31DEC13-26/36

Mower Blades
OUMX258,0000B5A -19-31DEC13-27/36

Step 1 YES: Go to next step.

TCAL29930 —UN—03JUL12
Are blades tight on spindle?
NO: Tighten blade cap
screw.

Continued on next page OUMX258,0000B5A -19-31DEC13-28/36

TM130419 (24FEB16) 270-10-16 PN=1272

030916
 Diagnosis

Step 2 YES: Replace blades.

TCAL29931 —UN—03JUL12
Are the blades bent, worn or damaged?
NO: Go to next step.
OUMX258,0000B5A -19-31DEC13-29/36

Step 3 NO: Sharpen and balance

blades.

TCAL29932 —UN—03JUL12
Are the blades properly sharpened and balanced?
OUMX258,0000B5A -19-31DEC13-30/36

Caster Wheels
OUMX258,0000B5A -19-31DEC13-31/36

Step 1 YES: Go to next step.

TCT007156 —UN—10APR13
Are the tires properly inflated?
NO: Inflate tires to
specifications.

Continued on next page OUMX258,0000B5A -19-31DEC13-32/36

TM130419 (24FEB16) 270-10-17 030916

PN=1273
 Diagnosis

Step 2 NO: Apply specified

grease to wheel lubrication
fitting.

TCT007157 —UN—10APR13

TCAL29934 —UN—03JUL12
Are the wheels properly lubricated?
OUMX258,0000B5A -19-31DEC13-33/36

Caster Wheel Yoke Assemblies

OUMX258,0000B5A -19-31DEC13-34/36

Step 1 YES: Go to next step.

TCAL29935 —UN—03JUL12
Are the caster wheel yoke assemblies properly lubricated?
NO: Apply specified
grease to pivot lubrication
fittings.
Continued on next page OUMX258,0000B5A -19-31DEC13-35/36

TM130419 (24FEB16) 270-10-18 PN=1274

030916
 Diagnosis

Step 2 NO: Replace bearings as

needed.

TCAL29936 —UN—03JUL12
Do the assemblies rotate freely and are the bearings not worn or damaged?
OUMX258,0000B5A -19-31DEC13-36/36

System: 60-Inch Heavy-Duty Snowblower

OUMX258,0000B5B -19-25MAR13-1/7

Test Procedure A: Auger Drive System

60-Inch Heavy-Duty Snowblower
OUMX258,0000B5B -19-25MAR13-2/7

Step 1 Test Conditions YES: Go to next step.

• Machine parked safely.

NO: Check or replace

shear bolts.

TCAL29937 —UN—03JUL12
Does the auger engage and disengage?

OUMX258,0000B5B -19-25MAR13-3/7

Step 2 NO: Check if auger bolt

is missing or sheared and
replace.

TCAL29938 —UN—03JUL12
Does the auger engage and disengage?

OUMX258,0000B5B -19-25MAR13-4/7

Spout Control System

Continued on next page OUMX258,0000B5B -19-25MAR13-5/7

TM130419 (24FEB16) 270-10-19 030916

PN=1275
 Diagnosis

Step 1 YES: Go to next step.

TCAL29939 —UN—03JUL12
Does the spout rotate freely?
NO: Check if hydraulic
hoses are connected.
OUMX258,0000B5B -19-25MAR13-6/7

Step 2 NO: Check if cables are

installed and operating.

TCAL29940 —UN—03JUL12
Does the spout rotate freely?
OUMX258,0000B5B -19-25MAR13-7/7

System: Grass and Leaf Collection System

(GLC) Grass and Leaf Collection System (GLC)
BS62576,000178F -19-16APR14-1/28

•
1 Suction System

BS62576,000178F -19-16APR14-2/28

Test Procedure Is suction port blocked? YES: Turn engine

off, manually remove
obstructed material.
NO: Go to next step.

BS62576,000178F -19-16APR14-3/28

Continued Is suction hose or turbine channel blocked? YES: Turn engine off,
remove suction hose and
clean out obstruction.
NO: Go to next step.

BS62576,000178F -19-16APR14-4/28

•
2 Suction Capacity

Continued on next page BS62576,000178F -19-16APR14-5/28

TM130419 (24FEB16) 270-10-20 030916

PN=1276
 Diagnosis

Test Procedure Is the exhaust grill or filter blocked? YES: Clean exhaust grill
and filter.
NO: Go to next step.
BS62576,000178F -19-16APR14-6/28

Continued Is mower deck adjusted to low? YES: Adjust mower to a

higher position.
NO: Go to next step.
BS62576,000178F -19-16APR14-7/28

Continued Is there low hydraulic oil pressure supplied at blower fan motor? YES: Adjust oil pressure to
correct level.
NO: Go to next step.
BS62576,000178F -19-16APR14-8/28

•
3 Turbine Vibration

BS62576,000178F -19-16APR14-9/28

Test Procedure Is there strong vibration when turbine is in operation? YES: Turn engine off,
remove suction hose and
turbine cover. Remove and
clean any fouling built up on
fan or housing. Reassemble
turbine cover and suction
hose. Test machine.

BS62576,000178F -19-16APR14-10/28

Continued Is turbine still vibrating after cleaning and test trial run. YES: Turbine is
unbalanced. (See
Balancing the Blower
Blade.)

BS62576,000178F -19-16APR14-11/28

•
4 Turbine Noise

BS62576,000178F -19-16APR14-12/28

Test Procedure Is there a loud noise coming from the turbine when switching off? YES: Valve on hydraulic
motor is out of adjustment.
Adjust valve. Turbine
should stop turning
approximately 7 seconds
after switch-off.
YES: Check for turbine
bearing damage.

Continued on next page BS62576,000178F -19-16APR14-13/28

TM130419 (24FEB16) 270-10-21 PN=1277

030916
 Diagnosis

•
5 Turbine Does Not Run

BS62576,000178F -19-16APR14-14/28

Test Procedure Is the mower deck engaged? YES: Go to next step.

NO: Engage mower deck.
BS62576,000178F -19-16APR14-15/28

Continued Is the container lifted? YES: Lower container to

operating position.
NO: Go to next step.
BS62576,000178F -19-16APR14-16/28

Continued Is the limit switch defective? YES: Replace limit switch.

NO: Go to next step.

BS62576,000178F -19-16APR14-17/28

Continued Is the GLC hydraulic oil above 80° C (176° F)? YES: Clean out GLC
hydraulic cooler. Wait until
oil temperature drops to
normal operating condition.

BS62576,000178F -19-16APR14-18/28

•
6 Material Escapes Between Front and Rear Shell

BS62576,000178F -19-16APR14-19/28

Test Procedure Is the closing force adjusted correctly? YES: Go to next step.
NO: Adjust closing force.
(See Adjusting Cover
Closing Force.)

BS62576,000178F -19-16APR14-20/28

Continued Is the rubber seal between the shells worn? YES: Replace rubber seal.
NO: Go to next step.

BS62576,000178F -19-16APR14-21/28

Continued Is the stop valve defective? YES: Replace stop valve.

NO: Go to next step.

BS62576,000178F -19-16APR14-22/28

Continued Are there leaks in the hydraulic system? YES: Repair components
or leaks as necessary.
NO: Go to next step.

BS62576,000178F -19-16APR14-23/28

Continued Are one of the lift cylinders defective? YES: Replace defective lift
cylinder as necessary.

Continued on next page BS62576,000178F -19-16APR14-24/28

TM130419 (24FEB16) 270-10-22 PN=1278

030916
 Diagnosis

•
7 Material Escapes Between Blow-In Port and Front Shell

BS62576,000178F -19-16APR14-25/28

Test Procedure Is blow-in port seal worn? YES: Replace seal.

NO: Go to next step.
BS62576,000178F -19-16APR14-26/28

Continued Is the seal adjusted correctly? YES: Adjust blow-in port

seal. (See Adjusting the
Seal Between Blow-In Port
and Container.)
NO: Go to next step.
BS62576,000178F -19-16APR14-27/28

Continued If the lift cylinder leaking or defective? YES: Repair leaks or

replace defective lift
cylinder.

BS62576,000178F -19-16APR14-28/28

TM130419 (24FEB16) 270-10-23 030916

PN=1279
 Diagnosis

TM130419 (24FEB16) 270-10-24 030916

PN=1280
 Group 20
Tests and Adjustments
Summary of References • Check and Adjust V-Flex Deck Drive Belt Tension
• Check and Adjust Mower Deck Level • Checking and Adjusting Blower Fan Drive Belt
• Adjusting the Hopper Hinges
• Check V-Flex Deck Level • Adjusting Cover Closing Force
• Check and Adjust 60, 62 and 72-Inch (Side Discharge) • Adjusting the Seal Between Blow-In Port and Container
Mower Drive Belt Tension
• Adjusting Cover Seal Compression
• Check and Adjust 72-Inch (Rear Discharge) Mower • Balancing the Blower Blade
Deck Belt Tension
OUMX258,0000B5C -19-15APR14-1/1

TM130419 (24FEB16) 270-20-1 030916

PN=1281
 Tests and Adjustments

Check and Adjust Mower Deck Level

Special or Required Tools

• Leveling Gauge
Checking Mower Deck Level

TCAL29941 —UN—03JUL12
CAUTION: Mower blades may be sharp. Wear
heavy gloves or wrap the blade edges with a
rag to prevent injury during handling.

1. Park machine on level surface.

2. Lower mower deck to the ground.
3. Check tire pressures on all machine tires and deck A—Distance
caster wheels. Adjust pressure to specifications.
Specification
Machine Front Results
Tires—Pressure........................................................................... 140 kPa
(20 psi) • The blade cutting heights should be equal side-to-side.
Machine Front Tires • The blade height front-to-rear should be to the specified
(72-Inch Rear Discharge difference.
Deck)—Pressure......................................................................... 144 kPa
Specification
(21 psi)
Blade—Height..........................................6 mm (0.25 in.) Higher in Rear
Machine Rear
Tires—Pressure........................................................................... 140 kPa
(20 psi)
Machine Rear Tires
(72-Inch Rear Discharge
Deck)—Pressure........................................................................... 90 kPa
(13 psi)
Mower Deck Caster
Tires—Pressure........................................................................... 152 kPa
(22 psi)

4. Set mower deck to desired cutting height.

5. Make sure that mower deck caster wheels and rear
hangers are set to the same height.
6. Adjust anti-scalp wheel to proper height specification
on left and right sides of mower deck.
Specification
Anti-Scalp
Wheel—Height................................................................................ 6 mm
(0.25 in.)

7. Turn the blade until parallel to front axle.

8. Measure distance (A) from tip of outside blade to the
ground using AM130907 Leveling Gage. Repeat steps
7 and 8 for outer blade tip on opposite side of deck.
9. Turn outer mower blades to face front-to-rear,
perpendicular to front axle.
10. Measure distance from front left and right blade tips to
ground. Repeat step for left and right blade tips.
Continued on next page OUMX258,0000B5D -19-06APR15-1/8

TM130419 (24FEB16) 270-20-2 PN=1282

030916
 Tests and Adjustments

Adjust Deck Level Side-to-Side: 60-Inch, 72-Inch Side

Discharge and 72-Inch Rear Discharge Mower Decks
1. Raise mower deck and lock lift arm service latches (A).

A—Lift Arm Service latches

TCAL29942 —UN—03JUL12
OUMX258,0000B5D -19-06APR15-2/8

2. Support bottom of caster wheel with one hand while

removing quick pull pin (B).
3. Lower caster wheel and yoke from support arm.
4. Adjust height of caster wheel.
• To raise deck, move one spacer (C) from top of
support arm to bottom position (D).
• To lower deck, move one spacer from bottom of
support arm to top position. (Leave one flat washer

TCT007167 —UN—10APR13
at bottom position at all times.)
5. Install caster wheel and yoke into support arm. Install
quick pull pin (B).
6. Lower mower deck and check side-to-side level. The
blades should be at the same height.
NOTE: If the blades are still not at equal height, the
air pressure in the caster wheel on the side
that is high can be reduced. B—Quick Pull Pin D—Bottom Position
C—Spacers
7. Adjust deck level front-to-rear.
OUMX258,0000B5D -19-06APR15-3/8

Adjust Deck Level Side-to-Side: 62-Inch Rear

Discharge Mower Decks
1. Raise mower deck and lock lift arm service latches (A).

A—Lift Arm Service Latches

TCAL29944 —UN—03JUL12

Continued on next page OUMX258,0000B5D -19-06APR15-4/8

TM130419 (24FEB16) 270-20-3 030916

PN=1283
 Tests and Adjustments

2. Support bottom of caster wheel with one hand while

removing quick-lock pin (B) and guard (C).
3. Lower caster wheel and yoke from pivot (E).
4. Adjust height of caster wheel.

TCAL29945 —UN—03JUL12
• To raise deck, move one or more of the spacers (D)
from top of pivot to bottom position (F).
• To lower deck, move one or more spacers from
the bottom of pivot to top position. (Leave the flat
washer at bottom position of yoke on at all times.)
5. Install caster wheel and yoke into pivot. Install guard
and quick-lock pin.
6. Lower mower deck and check side-to-side level. The
B—Quick-Lock Pin E—Pivot
blades should be at the same height. C—Guard F— Bottom Position
D—Spacers
NOTE: If the blades are still not at the same height,
air pressure in the caster wheel on the side
that is high can be reduced.

7. Adjust deck level front-to-rear.

OUMX258,0000B5D -19-06APR15-5/8

Adjust Deck Level Front-to-Rear - All Decks

1. Raise mower deck and lock lift arm service latches (A).

A—Lift Arm Service Latches

TCAL29946 —UN—03JUL12
Continued on next page OUMX258,0000B5D -19-06APR15-6/8

TM130419 (24FEB16) 270-20-4 030916

PN=1284
 Tests and Adjustments

2. Loosen nut (B) on rear hanger.

3. Remove retainer ring (C) on hanger pin (D).
4. Remove hanger pin from adjustment plate (E).
5. While counting the number of turns, adjust the rear
hanger up or down to adjust deck height.
6. Insert hanger pin back into proper hole in adjustment
plate, and secure with retainer ring.

TCT007169 —UN—10APR13
7. Tighten locknut.
8. Repeat steps 2—7 for rear hanger on opposite side of
mower deck with equal number of turns of hanger.
9. Lower mower deck and check front-to-rear blade
height. The blade height should be to specifications.
Specification
Blade—Height..........................................6 mm (0.25 in.) Higher in Rear

Repeat adjustment if necessary. B—Nut D—Hanger Pin

C—Retainer Ring E—Adjustment Plate

Continued on next page OUMX258,0000B5D -19-06APR15-7/8

TM130419 (24FEB16) 270-20-5 030916

PN=1285
 Tests and Adjustments

Check V-Flex Deck Level

Special or Required Tools

• Leveling Gauge
1. Park machine on level surface.

TCAL29948 —UN—03JUL12
2. Check tire pressures on all machine tires and deck
caster wheels. Adjust to specifications.
Specification
Machine Front
Tires—Pressure........................................................................... 140 kPa
(20 psi)
Mower Deck Caster A convenient leveling gage (A), AM130907, is available from
Tires—Pressure........................................................................... 152 kPa your John Deere™ dealer.
(22 psi)
A—Leveling Gauge B—Outside Blade Height
3. Set the mower decks at the desired cutting height.
4. Check that the front mower deck caster wheels and
rear wheels or rollers are all set to the same height.
NOTE: The V-Flex Deck is designed for both the front and
rear wheels to run on the ground. The rake of 1/4
CAUTION: Mower blades may be sharp. Wear inch is designed into the deck. If more or less rake
heavy gloves or wrap the blade edges with a is required, adjust the rear wheel height of cut.
rag to prevent injury during handling.
• The blade cutting heights should be level
5. Turn the blades until parallel to the front axle. side-to-side.
6. Measure distance (B) from tip of outside blade to the • The blade height should be higher in the rear
ground. Repeat for outer blade on other side of deck. according to specifications.
Specification
7. Turn outer mower blades to face front-to-rear. Anti-Scalp
8. Measure height of front and rear of blades to ground. Wheel—Height................................................................................ 6 mm
Repeat for outer blade on other side of deck. (0.25 in.)
Blade—Height..........................................6 mm (0.25 in.) Higher in Rear
Results
John Deere is a trademark of Deere & Company
OUMX258,0000B5E -19-16SEP14-1/1

TM130419 (24FEB16) 270-20-6 PN=1286

030916
 Tests and Adjustments

Check and Adjust 60, 62 and 72-Inch (Side

Discharge) Mower Drive Belt Tension
Procedure
1. Park machine on level surface.
2. Lower mower deck to the ground.
3. Remove mower deck belt shield. (See Remove and

TCAL29949 —UN—03JUL12
Install 60, 62 and 72-Inch (Side Discharge) Mower
Deck Belt Shields.)
4. Loosen nuts (A).
5. Measure length of drive belt tension spring (C) from
hook to hook. Spring length should be to specifications.
Specification
60-Inch (Side Discharge)
Mower Drive Belt Tension
A—Nuts C—Drive Belt Tension Spring
Spring—Length........................................................................... 13.8 cm
B—Nut
(5.44 in.)
62-Inch (Side Discharge)
Mower Drive Belt Tension
Spring—Length........................................................................... 13.8 cm 6. Adjust nut (B) until length of spring is correct.
(5.44 in.)
72-Inch (Side Discharge)
7. Tighten nuts.
Mower Drive Belt Tension 8. Install mower deck belt shield.
Spring—Length........................................................................... 13.8 cm
(5.44 in.)
OUMX258,0000B5F -19-16SEP14-1/1

Check and Adjust 72-Inch (Rear Discharge)

Mower Deck Belt Tension
Check Procedure
1. Park machine on level surface.
2. Rotate or remove mower deck for service.
3. Remove belt shield. (See Remove and Install 72-Inch
Rear Discharge Mower Deck Belt Shield .)

TCAL29950 —UN—03JUL12
4. Rotate the mower down.
5. Measure length (A) of belt tension spring from hook to
hook and compare to specifications.
Specification
72-Inch (Rear Discharge)
Mower Drive Belt Tension
Spring—Length........................................................................... 13.8 cm Mower Deck
(5.44 in.)

Results A—Spring Length C—Nut

B—Nuts D—Bracket
If length of spring is not within specification, perform the
adjustment procedure.
Continued on next page OUMX258,0000B60 -19-16SEP14-1/2

TM130419 (24FEB16) 270-20-7 030916

PN=1287
 Tests and Adjustments

Adjustment Procedure
1. Loosen nuts (A).
2. Adjust nut (B) until length inside hooks (C) of
tensioning spring is within specification.
Specification
Drive Belt Tension
Spring—Length........................................................................... 12.5 cm

TCAL29951 —UN—03JUL12
(4.92 in.)

3. Install belt shield.

A—Nuts C—Hooks
B—Nut

Mower Deck S.N. (215001- ) shown.

OUMX258,0000B60 -19-16SEP14-2/2

Check and Adjust V-Flex Deck Drive Belt

Tension
1. Park machine on level surface.
2. Remove the mower deck belt shield.
3. Loosen nuts (A).

TCAL29952 —UN—03JUL12
4. Measure length of belt tension spring (B) from hook to
hook. Spring length should be to specification.
Specification
V-Flex Deck Drive Belt
Tension Spring—Length................................................................. 12 cm
(4.75 in.)

5. Adjust nut (C) until length of belt tension spring is Some parts removed for picture clarity.
correct.
6. Tighten nuts (A). A—Nuts C—Nut
B—Belt Tension Spring
7. Install belt shields.
OUMX258,0000B61 -19-16SEP14-1/1

Checking and Adjusting Blower Fan Drive

Belt
CAUTION: Avoid injury! Prevent injury from
crushing by locking the hydraulic cylinder if the
GLC is raised for service or cleaning.

1. Park machine safely. (See Parking Safely in the

TCT009206 —UN—05NOV13

SAFETY section.)
2. Raise the hopper to its highest position and install lift
cylinder safety channel. (See Using the Lift Cylinder
Safety Channel in the Safety section.)
3. Remove the hardware in two places securing the belt
guard (A) to the frame.
Components removed for clarity.

Continued on next page OUMX068,000039E -19-03JAN14-1/3

TM130419 (24FEB16) 270-20-8 030916

PN=1288
 Tests and Adjustments

4. Loosen the nuts (B) on the hydraulic motor.

5. Loosen the locknut (C) of the belt tension adjustment
screw.
6. Adjust the tension of the V belt by turning the screw.

TCT009247 —UN—05NOV13
OUMX068,000039E -19-03JAN14-2/3

7. Use diagram to adjust the correct belt tension:

a. The belt deflection (D) must be 11 mm (7/16 in.) at
50 N (11 lb.) Force (E).
b. Tighten the locknut.
c. Tighten the nuts on the hydraulic motor.
8. Install belt guard.

TCT009246 —UN—05NOV13
9. Unhook the lowering safeguard.
10. Lower the collection container.

OUMX068,000039E -19-03JAN14-3/3

Adjusting the Hopper Hinges

1. Ensure that the collection container is empty.
2. Open the rear shell so that there is a small gap.
3. Loosen the mounting bolts of the hinges: TCT009248 —UN—05NOV13

a. Loosen the rear (cover) bolts (A) to adjust the

alignment of the cover forward and backward.
b. Loosen the front (hopper) bolts (B) to adjust the
alignment of the cover side-to-side.
4. Align the cover accordingly.
5. Tighten the hinge bolts.
7. Repeat steps 1—5 if necessary.
6. Check whether the cover seals tightly. (See Adjusting
Cover Seal Compression in this section.)
OUMX068,00003E3 -19-03JAN14-1/1

TM130419 (24FEB16) 270-20-9 030916

PN=1289
 Tests and Adjustments

Adjusting Cover Closing Force

To adjust the closing force of the rear cover, the length of
the cylinder rods must be adjusted.
1. Lift the collection system to 1/4 height and open the

TCT009249 —UN—12FEB14
cover. Use suitable supports to safeguard it from
closing unintentionally.
2. Remove both cylinders on the rod-side end.
3. Loosen the locknuts (A) on the cylinder rods.
4. Adjust the lengths of the rods as required.
5. Tighten the locknuts on the cylinder rods.
6. Mount the cylinders. 9. Repeat steps 1—7 if necessary.
7. Close the rear cover.
8. Check whether the rear cover seals tightly. (See
Adjusting Cover Seal Compression in this section.)
OUMX068,00003E4 -19-06NOV13-1/1

Adjusting the Seal Between Blow-In Port and

Container
Change three settings to adjust how tightly the container
rests on the turbine channel:
• The length of the top link.

TCT009757 —UN—03JAN14
• The length of the container support (rubber buffer).
• The position of the blow-in port.
With correct closure the container first sits on the front area
(A) of the blow-in port, with a slight time offset it then sets
on the rear area (B). The container must rest full-surface
on the blow-in port. With moderate manual counter
pressure, the container must not lift off of the blow-in port.
OUMX068,00003E5 -19-03JAN14-1/4

Adjust the Length of the Top Link

1. Lower the container half way and secure it with
suitable supports.
2. Remove the bolt (A) of the upper link (B).
3. Loosen the locknut (C) on the upper link and adjust
the length of the upper link.
TCT009250 —UN—06NOV13

4. Tighten the locknut and remount the bolt of the upper

link.
5. Lift and lower the container again to ensure that it
rests tightly on the turbine channel.
6. Repeat steps 2 and 3 if necessary.
Components hidden for clarity.

Continued on next page OUMX068,00003E5 -19-03JAN14-2/4

TM130419 (24FEB16) 270-20-10 030916

PN=1290
 Tests and Adjustments

Adjust the Length of the Container Support

1. Raise the collection container.

CAUTION: Avoid injury! Prevent injury from

crushing by locking the hydraulic cylinder if the
GLC is raised for service or cleaning.

TCT009251 —UN—06NOV13
2. Lock lift cylinder in the raised position. (See Using the
Lift Cylinder Safety Channel in the Safety section.)
3. Loosen the locknuts (A).
4. Adjust the rubber buffer (B).
5. Tighten the locknuts.
6. Remove lift cylinder safety channel and return to
stored position.
9. Repeat steps 1—7 if necessary.
7. Lower the collection container.
8. Check whether the container seals tightly on the
turbine channel.
OUMX068,00003E5 -19-03JAN14-3/4

Adjust the Position of the Blow-In Port

1. Lift out the container approximately 5 cm.
2. Loosen the four nuts (A) of the blow-in port (B).

TCT009252 —UN—06NOV13
3. Align the upper closing surface so that it is
approximately parallel to the container closing surface.
The air gap between the blow-in port and the support
frame in the container must be approximately the
same size left and right.
4. Tighten the four nuts of the blow-in port.
5. Check that the container is correctly seated on the
blow-in port.
OUMX068,00003E5 -19-03JAN14-4/4

Adjusting Cover Seal Compression

Adjust Top Cover Seal Compression
1. Close cover.
NOTE: Right and left hinges can be adjusted separately.

2. Loosen cover hinge bolts (A). Adjust the cover closer

to the hopper or away from the hopper to get good
TCT009162 —UN—21OCT13

seal compression.
3. Tighten the cover hinge bolts.
4. Close cover and verify seal compression. Adjust as
necessary.

Continued on next page OUMX068,000039F -19-07NOV13-1/3

TM130419 (24FEB16) 270-20-11 030916

PN=1291
 Tests and Adjustments

Adjust Lower Cover Seal Compression

NOTE: Adjust right and left cylinders separately.
Slightly more seal compression can be adjusted
into the lower portion of the door seal to allow
for door flex when loaded with grass.

1. Increase or decrease cover cylinder length to adjust

seal compression.

TCT009163 —UN—21OCT13
a. Loosen the rod end nut (A).
b. Remove cotter pin and washer securing rod end
(B) to pivot (C).
c. Slide the rod end off the cover pivot.
d. Turn the rod end clockwise (increases seal
compression) or counterclockwise (decreases seal
compression) in 1/2 turn increments. 2. Bend cotter pins securing rod ends to pivots once
e. Tighten nut and secure rod end to pivot. correct door seal compression is achieved.

f. Close cover and check adjustment. Repeat as

necessary.
OUMX068,000039F -19-07NOV13-2/3

Seal Compression

• A—Too loose, seal has gap.

• B—Too tight, seal has significant crease.
• C—Good seal compression.

TCT009164 —UN—21OCT13
OUMX068,000039F -19-07NOV13-3/3

Balancing the Blower Blade

CAUTION: Avoid injury! Never start the

turbine unless the turbine cover and suction
hose are mounted.
Wait until the turbine has come to a standstill
before reaching in. The after run time is
TCT009255 —UN—06NOV13

slightly less than 10 seconds.

1. Park the machine safely. (See Parking Safely in the

SAFETY section.)
2. Remove the suction hose from the blower housing
cover.
3. Remove seven star handles (A) and three nuts (B).
Remove the blower housing cover (C).
Continued on next page OUMX068,00003E6 -19-16SEP14-1/2

TM130419 (24FEB16) 270-20-12 030916

PN=1292
 Tests and Adjustments

4. Remove bolt (D) and washer (E) securing blade to

drive shaft.
5. Use an M16 x 80 mm bolt to press the blade off the
drive shaft. Keep the feather key in a safe place.
6. Take the blade to an authorized John Deere service
center to have it balanced.
7. Insert the feather key into the groove in the drive shaft.

TCT009256 —UN—06NOV13
Use an M12 x 100 mm bolt to press the blade onto the
drive shaft. Remove bolt.
8. Secure the blade to the drive shaft with the washer
and bolt removed earlier. Tighten to specification.
Specification
Fan Blade Bolt—Torque..............................................................125 N·m
(92 lb.-ft.)

9. Install the blower housing cover and the suction hose. John Deere service center if you detect
vibration or unusual noise.
IMPORTANT: Avoid damage! Pay attention to any
vibration and noise. Contact your authorized 10. Perform a trial run.
OUMX068,00003E6 -19-16SEP14-2/2

TM130419 (24FEB16) 270-20-13 030916

PN=1293
 Tests and Adjustments

TM130419 (24FEB16) 270-20-14 030916

PN=1294
 Section 280
Cab Operation, Tests, and Adjustments
Contents

Page

Group 20—Operation
Operator Station Controls—1575
and 1585 (Cab Models) ........................... 280-20-1

TM130419 (24FEB16) 280-1 030916

PN=1
 Contents

TM130419 (24FEB16) 280-2 030916

PN=2
 Group 20
Operation
Operator Station Controls—1575 and 1585 (Cab Models)

TCT010626 —UN—20MAR14
Picture Note: 1585 model is shown.
A—Throttle Lever H—Auxiliary Hydraulics Control M—Operator Display S—Left Turn Brake Pedal
B—Work Lamp Switch Lever N—Axle Speed Lever T— Steering Column Tilt Lever
C—Key Switch I— Light Switch O—PTO Switch Lock
D—Park Brake Pedal J— Windshield Wiper Switch P—Park Brake Lock Lever
E—Forward Pedal K—Turn Signal Switch Q—Traction Assist Pedal
F— Reverse Pedal L— 4WD Control Lever R—Right Turn Brake Pedal
G—Attachment Lift Lever

OUMX068,0000680 -19-18DEC14-1/1

TM130419 (24FEB16) 280-20-1 030916

PN=1297
 Operation

TM130419 (24FEB16) 280-20-2 030916

PN=1298
 Section 290
HVAC Operation, Tests, and Adjustments
Contents

Page

Group 10—Tools and Materials

Essential or Recommended Tools................ 290-10-1
Other Material.............................................. 290-10-2
Service Parts Kits ........................................ 290-10-2

Group 20—General Information

Summary of References.............................. 290-20-1
System Information...................................... 290-20-1
Refrigerant Oil Information .......................... 290-20-1
Determine Correct Refrigerant Oil
Charge..................................................... 290-20-2

Group 30—Tests and Adjustments

Summary of References.............................. 290-30-1
Air Conditioner Specifications...................... 290-30-1
Heater Temperature Control Cable,
Adjust....................................................... 290-30-1
A/C Temperature Control Switch
Cable, Adjust ........................................... 290-30-2
Compressor Shaft Seal Leakage
Test .......................................................... 290-30-4
Compressor Clutch Hub Clearance
Check ...................................................... 290-30-4
Evaporator/Heater Core Leak
Test .......................................................... 290-30-4
Compressor Oil Charge Check.................... 290-30-5
Add Refrigerant Oil to System ..................... 290-30-5
Recover/Recycle Refrigerant....................... 290-30-6
Air Conditioning Receiver/Dryer .................. 290-30-7
Adjust A/C Compressor Belt
Tension .................................................... 290-30-7

TM130419 (24FEB16) 290-1 030916

PN=1
 Contents

TM130419 (24FEB16) 290-2 030916

PN=2
 Group 10
Tools and Materials
Essential or Recommended Tools RECOMMENDED TOOLS, as noted, are suggested to
NOTE: Order tools from the ServiceGard™ Catalog. perform the job correctly. Some tools are available from
local suppliers or can be fabricated.
ESSENTIAL TOOLS listed are required to perform the job
correctly and are obtainable only from the ServiceGard™
Catalog.
ServiceGard is a trademark of Deere & Company
OUMX258,0000A7C -19-06JUN14-1/15

Unit, Cool-Tech R/R/R ...................................... JDG10555 Used to recover/recycle air conditioning refrigerant.
Used to recover/recycle air conditioning refrigerant. Unit, Cool-Tech R/R/R .......................................JDG11730
A/C 690 Pro Recovery Recycling ................ JDG10974EU Used to recover/recycle air conditioning refrigerant.
OUMX258,0000A7C -19-06JUN14-2/15

Electronic Leak Detector ......................................JT02180

Used to detect refrigerant leaks.
OUMX258,0000A7C -19-06JUN14-3/15

Kit, Deluxe A/C Flushing (R12 and R134a) ..........JT02098 Used to test evaporator and heater core for leaks.
OUMX258,0000A7C -19-06JUN14-4/15

NOTE: Kit JT02098 is no longer available, but all of the

fittings and parts listed are available separately.
OUMX258,0000A7C -19-06JUN14-5/15

Adaptor, 7/8-18 M O-ring Tube x 7/16-20 M45.....JT02099 Used to check for refrigerant oil leaks.
OUMX258,0000A7C -19-06JUN14-6/15

Adaptor, 3/4-18 M O-ring Tube x 7/16-20 M45.....JT02100 Used to check for refrigerant oil leaks.
OUMX258,0000A7C -19-06JUN14-7/15

Adapter Fitting, Tube ............................................JT02103 Used to test evaporator and heater core for leaks.
OUMX258,0000A7C -19-06JUN14-8/15

Adapter Fitting, Tube ............................................JT02105 Used to test evaporator and heater core for leaks.
OUMX258,0000A7C -19-06JUN14-9/15

Test Block, O-Ring Ports ......................................JT02106 Used to test evaporator and heater core for leaks.
OUMX258,0000A7C -19-06JUN14-10/15

Holding Plate ........................................................JT02123 Used to test evaporator and heater core for leaks.
Continued on next page OUMX258,0000A7C -19-06JUN14-11/15

TM130419 (24FEB16) 290-10-1 030916

PN=1301
 Tools and Materials

Holding Plate ........................................................JT02124 Used to test evaporator and heater core for leaks.
OUMX258,0000A7C -19-06JUN14-12/15

Socket Head Screw, Short....................................JT02125

Used to test evaporator and heater core for leaks.
OUMX258,0000A7C -19-06JUN14-13/15

Socket Head Screw, Long ....................................JT02126 Used to test evaporator and heater core for leaks.
OUMX258,0000A7C -19-06JUN14-14/15

Cap, 7/16-20 F 45.................................................JT03194

Used to restrict discharge of refrigerant oil.
OUMX258,0000A7C -19-06JUN14-15/15

Other Material
Number Name Use
GENESOLV 2004™ Solvent Used to flush air conditioning system.

JT02077 (U.S.) (U.S.) ART338 A/C Flushing Solvent Used to flush air conditioning system.

Naphtha 673 Parts Solvent Used to flush air conditioning system.

TY15949 (12 oz) (U.S.), TY15951 Refrigerant R-134a Used to charge the air conditioning.
(30 lb) (U.S.) (U.S.)

TY22025 (U.S.) Low Viscosity (ISO 40) R134A PAG Oil Used to lubricate O-rings, gaskets,
and lip seal during assembly
of compressor.

OUMX258,0000A7D -19-21MAR13-1/1

Service Parts Kits • Compressor Clutch Hub and Pulley Kit

The following kits are available through your parts catalog:
• Compressor Clutch Coil Kit
• Compressor Hardware Kit
• Compressor Shaft Seal Kit
OUMX258,0000A7E -19-21MAR13-1/1

TM130419 (24FEB16) 290-10-2 030916

PN=1302
 Group 20
General Information
Summary of References • Refrigerant Oil Information
• System Information • Determine Correct Refrigerant Oil Charge
OUMX258,0000A87 -19-21MAR13-1/1

System Information • System was left open to the atmosphere long enough
for dirt, moisture, or debris to enter the tubing or
Flushing components.
Flushing the system or a component is a cleaning process • System has an internal blockage.
using a liquid solvent to wash out oil and debris. Purging When to Purge an Air Conditioning System
is always necessary after flushing to remove solvent from
the system or component. • After flushing system with solvent, to prevent oil dilution.
Purging
• System was contaminated with nitrogen or two
refrigerants.
Purging the system or a component is a cleaning process • System was left open to the atmosphere and flushing
could not be performed.
using a gas to force liquid from the system. Purging alone
will not force refrigerant oil out of the system. • A repair required installation of new lines, condenser, or
evaporator.
Evacuating
Solvents
Evacuating the system is a process to draw air and
The following three solvents are recommended for
moisture from the system with a vacuum.
flushing air conditioning systems. Each adequately
When to Flush an Air Conditioning System dissolves oil and sludge but at a different rate. Use only
solvents with an equivalent MSDS.
• The compressor has an internal failure.
• No oil remains in used compressor. • GENESOLV 2004® Solvent
• Oil drained from compressor appears or smells • ART338 A/C Flushing Solvent
overheated. • Naphtha 673 Parts Solvent
• System was contaminated with a mixture of refrigerant
oils.
GENESOLV 2004 is a trademark of Honeywell, Inc.
OUMX258,0000A7F -19-21MAR13-1/1

Refrigerant Oil Information Typically, 21 mL (0.7 fl oz) of oil covers internal surfaces
of the compressor exposed to refrigerant gas and cannot
CAUTION: Avoid Injury! New compressors are be drained.
charged with a mixture of nitrogen, R-134a
Specification
Refrigerant, and TY22025 (R-134a) Refrigerant Oil.
Compressor
Wear safety goggles and discharge compressor
Oil—Capacity after A/C
slowly to avoid possible injury.
has been operated......................................... 30—45 mL (1.0—1.5 fl oz)
New compressors contain 100 mL (3.4 fl oz) of new oil.
OUMX258,0000A80 -19-19JAN15-1/1

TM130419 (24FEB16) 290-20-1 PN=1303

030916
 General Information

Determine Correct Refrigerant Oil Charge oz.) of oil to compressor, plus any amount of oil lost
when compressor was removed.
Procedure
b. Used compressor (drained)- Not flushed, add 40
IMPORTANT: Avoid Damage! Use care in checking mL (1.4 fl oz.) of new oil.- Flushed, add 60 mL (2.0
and adding oil. Too much oil reduces cooling fl oz.) of new oil.
capacity. Too little oil results in poor lubrication
of the compressor, leading to early failure. Remove compressor to determine correct oil charge if any
components have been removed, drained, and flushed.
NOTE: Determine amount of oil charge for system
NOTE: If the complete system was purged with
before installation of compressor.
all components in place, the amount of
oil lost is negligible.
1. Compressors are divided into three categories when
determining correct oil charge:
Use the following chart as a guide for adding oil:
a. New compressor.
NOTE: Hoses = 2 mL per 30 cm (0.06 fl oz. per ft.).
b. Used compressor, not flushed. Approximate total length equals 600 cm (20 ft.).

c. Used compressor, flushed. Component Oil Charge

Evaporator 30 mL (1.0 fl oz.)
2. If complete system, lines, and components were
flushed, add correct amount of oil: Condenser 30 mL (1.0 fl oz.)
Receiver/Dryer 15 mL (0.5 fl oz.)
a. New compressor contains correct amount of new
oil, 100 mL (3.4 fl oz.). Add additional 50 mL (1.6 IMPORTANT: Avoid Damage! DO NOT leave the
oz.) of oil to compressor or discharge port. system or R-134a compressor oil containers
b. Used compressor (drained)- Not flushed, add open. Oil easily absorbs moisture. DO NOT
additional 120 mL (4.0 fl oz.) of new oil.- Flushed, spill R-134a compressor oil on acrylic or ABS
add 150 +15/-0 mL (5 fl oz.) of new oil. plastic. Oil deteriorates these materials rapidly.
Identify R-134a oil containers and measures to
3. If complete system was not flushed, add correct eliminate accidental mixing of different oils.
amount of oil for compressor, plus amount of oil for
each component serviced: If any section of hose is removed and flushed or replaced,
measure length of hose and use the formula to determine
a. New compressor contains 100 mL (3.4 fl oz.) of correct amount of oil to be added.
new oil. Connect battery to clutch coil and rotate
drive shaft to remove all oil. Return 25 mL (0.85 fl
OUMX258,0000A81 -19-19JAN15-1/1

TM130419 (24FEB16) 290-20-2 030916

PN=1304
 Group 30
Tests and Adjustments
Summary of References • Evaporator/Heater Core Leak Test
• Air Conditioner Specifications • Compressor Oil Charge Check
• Add Refrigerant Oil to System
• Heater Temperature Control Cable, Adjust • Recover/Recycle Refrigerant
• A/C Temperature Control Switch Cable, Adjust • Air Conditioning Receiver/Dryer
• Compressor Shaft Seal Leakage Test • Adjust A/C Compressor Belt Tension
• Compressor Clutch Hub Clearance Check
OUMX258,0000A82 -19-09JUN14-1/1

Air Conditioner Specifications

Item Measurement Specification
Refrigerant:
Type R-134a
Capacity of System (approximate) 1.13 kg (2.5 lb.) (2 lb. 8 oz.)
Torque:
Hub-to-Pulley Clearance Clearance 0.35—0.65 mm
(0.014—0.026 in.)
Clutch Hub Retaining Cap Screw Torque 14 N·m
(124 lb.-in.)
Condenser Outlet Line Torque 14—20 N·m
(124—177 lb.-in.)
Condenser Inlet Line Torque 33—39 N·m
(24—29 lb.-ft.)
Compressor Discharge Line Torque 33—39 N·m
(24—29 lb.-ft.)
Compressor Suction Line Torque 35—42 N·m
(25—31 lb.-ft.)
Compressor Relief Valve Torque 12—16 N·m
(106—142 lb.-in.)
Manifold Cap Screw Torque 26 N·m
(19 lb.-ft.)
Air Conditioning Receiver/Dryer Torque 14—20 N·m
Cap Screw (124—177 lb.-in.)
Receiver/Dryer Lines Torque 14—20 N·m
(124—177 lb.-in.)
OUMX258,0000A83 -19-19JAN15-1/1

Heater Temperature Control Cable, Adjust

Procedure
LVAL13672 —UN—08NOV10

1. Turn the heater temperature control knob (A) (CW)

to full heat position.

A—Heater Temperature Control

Knob

Continued on next page OUMX258,0000A84 -19-05JUN14-1/2

TM130419 (24FEB16) 290-30-1 030916

PN=1305
 Tests and Adjustments

NOTE: Heater cable adjuster is located under the

cab outer roof on the right side of machine.
Remove outer roof for adjustment.

2. Adjust cable adjuster (B) until the heater valve arm is

in the full open position (C).
3. Turn the heater temperature control knob to OFF
(CCW). Heater valve arm should be in the full closed
position. If cable cannot be adjusted properly using
cable adjuster (B) , move cable position in retainer clip

TCT010068 —UN—06JUN14
(D), as required, and readjust cable with adjuster (B).

B—Cable Adjuster D—Retainer Clip

C—Full Open Position

TCT010067 —UN—06JUN14
OUMX258,0000A84 -19-05JUN14-2/2

A/C Temperature Control Switch Cable,

Adjust
Procedure

LVAL13675 —UN—08NOV10
1. Turn the A/C temperature control knob (A) (CCW) to
full cool position.

A—A/C Temperature Control

Knob

Continued on next page OUMX258,0000A85 -19-09JUN14-1/3

TM130419 (24FEB16) 290-30-2 030916

PN=1306
 Tests and Adjustments

2. Adjust cable adjuster (B) until the temperature switch

is in the full cool position.

B—Cable Adjuster

TCT011274 —UN—09JUN14
OUMX258,0000A85 -19-09JUN14-2/3

NOTE: The A/C temperature control switch cable adjuster

is located under the cab outer roof on the right side
of machine. Remove outer roof for adjustment.

3. If there is not enough travel in the cable adjuster,

loosen set screw (C) and move the A/C temperature
control switch arm to the full cool position (shown).
Tighten set screw.
4. Make final adjustment with cable adjuster (B).

TCT010070 —UN—06JUN14
C—Set Screw

OUMX258,0000A85 -19-09JUN14-3/3

TM130419 (24FEB16) 290-30-3 030916

PN=1307
 Tests and Adjustments

Compressor Shaft Seal Leakage Test 6. Check the following for leaks using JT02180 Electronic
Leak Detector or 50-50 mix of soap and water:
Procedure
a. Shaft seal
1. Remove front plate from compressor pulley.
b. Manifold seal
IMPORTANT: Avoid Damage! Do not lose inner
clutch hub shims. c. Housing seals at front, rear, and midsection of
compressor body
2. Remove clutch hub and screw.
d. Relief valve
3. Install JT02099 Adapter in suction port and JT02100
e. Suction coupler Schrader® valve
Adapter in discharge port. Cap discharge port adapter
using JT03194. 7. Leakage should not exist. Repair compressor, if
necessary, and repeat test.
4. Connect gauge set and/or container of R-134a
Refrigerant to suction port of compressor. 8. Assemble compressor and add required oil. (See
Determine Correct Refrigerant Oil Charge.)
5. Open valves to pressurize compressor.
IMPORTANT: Avoid Damage! Do not exceed
range of low pressure gauge.
Schrader is a trademark of Schrader-Bridgeport Interna-
tional, Inc. Corporation
OUMX258,0000A86 -19-31DEC13-1/1

Compressor Clutch Hub Clearance Check 3. Check measurement with specifications below. If
Procedure gap is not correct, remove bolt and slide clutch off of
compressor shaft. There are shims between the clutch
1. Check clearance between pulley and clutch hub using hub and the compressor shaft. Add shims to increase
a feeler gauge. gap, remove shims to decrease gap.
2. Rotate the clutch and check for proper clearance 4. When gap is correct install clutch hub retaining bolt
specification in three equally spaced locations around and tighten to specification.
the clutch hub.
Specification
Specification Clutch Hub Retaining
Hub-to-Pulley Cap Screw—Torque......................................................................14 N·m
Clearance—Clearance.....................................................0.35—0.65 mm (124 lb.-in.)
(0.014—0.026 in.)
OUMX258,0000A88 -19-21MAR13-1/1

Evaporator/Heater Core Leak Test JT02123 Plates, JT02126 and JT02125 Screws, and
JT02105 and JT02103 Adapters. Cap one adapter
Equipment with JT03194. Connect shop air to other adapter.
• JT02098 Air Conditioning R12/R134a Fitting Kit 2. Apply shop air pressure and spray surface using 50-50
• JT02106 Test Block mixture of liquid soap and water to check for leaks.
• JT02124 Plate
• JT02123 Plate NOTE: Minor leaks may be repaired, but evaporator
• JT02126 Screws heater core should be replaced if there is a
• JT02125 Screws major leak or restriction.
• JT02105 Adapter
• JT02103 Adapter 3. Repair or replace evaporator/heater core as required.
• JT03194 Cap
Procedure
1. Using JT02098 Air Conditioning R12/R134a Fitting
Kit, install JT02106 Test Block using JT02124 and
OUMX258,0000A89 -19-21MAR13-1/1

TM130419 (24FEB16) 290-30-4 PN=1308

030916
 Tests and Adjustments

Compressor Oil Charge Check f. Install required oil. (See Determine Correct
Procedure Refrigerant Oil Charge.)

1. Remove compressor. g. Connect all components.

Specification
2. Remove manifold caps and drain oil. Record amount. Condenser Outlet
NOTE: Save oil if compressor is new. Line—Torque......................................................................... 14—20 N·m
(124—177 lb.-in.)
3. If MORE than 6 mL (0.2 fl oz) of oil was drained Condenser Inlet
and appears normal, or any other components Line—Torque......................................................................... 33—39 N·m
were replaced or flushed, (See Determine Correct (24—29 lb.-ft.)
Refrigerant Oil Charge.) Compressor Discharge
Line—Torque......................................................................... 33—39 N·m
4. If LESS than 6 mL (0.2 fl oz) of oil was drained or (24—29 lb.-ft.)
appears black: Compressor Suction
Line—Torque......................................................................... 35—42 N·m
a. Perform a volumetric efficiency test on compressor
(25—31 lb.-ft.)
to determine serviceable condition. Flush with
Compressor Relief
solvent to internally wash out oil if compressor is
Valve—Torque....................................................................... 12—16 N·m
serviceable.
(106—142 lb.-in.)
b. Remove, clean, and bench test expansion valve, Manifold Cap
but do not disassemble valve. Screw—Torque..............................................................................26 N·m
(19 lb.-ft.)
c. Remove and discard receiver/dryer.
h. Purge, evacuate, and charge system.
d. Install a new receiver/dryer.
e. Flush complete system.
OUMX258,0000A8B -19-21MAR13-1/1

Add Refrigerant Oil to System 50 mL (1.6 fl oz.) into discharge port when system
has been flushed. (See Determine Correct Refrigerant
Procedure Oil Charge.)
IMPORTANT: Avoid Damage! Use only TY22025 2. Install manifold to compressor, if removed. Tighten
(R-134a) Refrigerant Oil. cap screws to specification.

NOTE: Some oil may have to be added through Specification

compressor line and fitting. Manifold Cap
Screw—Torque..............................................................................26 N·m
1. Add approximately 100 mL (3.4 fl oz.) of R-134a (19 lb.-ft.)
Refrigerant Oil through compressor suction port and
OUMX258,0000A8A -19-19JAN15-1/1

TM130419 (24FEB16) 290-30-5 PN=1309

030916
 Tests and Adjustments

Recover/Recycle Refrigerant
Operate the air conditioning system for 10 min. with
engine at high idle if the compressor is operable. Set
temperature control for maximum cooling and blower
switch at high. This allows the refrigerant oil to be
circulated throughout the system and indicates the
quantity of oil in the compressor.
Stop the engine and use the following procedure to
recover and recycle the refrigerant.

TCT011475 —UN—19JUN14
IMPORTANT: Avoid Damage! Use only R314a
Refrigerant, Recycling, and Charging machines.
Do not mix R-134a equipment, refrigerant,
and refrigerant oils with R-12 systems to
prevent compressor damage.

NOTE: Use JDG10555 (NA), JDG10974EU (EU), or

JDG11730 (LAM) for R-134a Refrigerant Recovery,
Recycling, and Charging Stations. A—Suction Fitting

1. Connect R-134a refrigerant recovery and recycling

equipment to machine.
2. Connect low-side hose (blue) from the charging station
to suction line fitting (A).
OUMX258,0000A8C -19-06APR15-1/2

3. Connect high-side hose (red) to the discharge line

fitting (B).
4. Follow the manufacturer’s instructions and discharge
the system. Cap the fittings to prevent contamination
from entering the system.

B—Discharge Fitting

TCT011476 —UN—19JUN14

OUMX258,0000A8C -19-06APR15-2/2

TM130419 (24FEB16) 290-30-6 030916

PN=1310
 Tests and Adjustments

Air Conditioning Receiver/Dryer

The receiver/dryer is not serviceable. If the air conditioning
system is discharged for servicing and the receiver/dryer
is two years old or older, it should be replaced. If the
receiver/dryer is less than two years old it should be
replaced if the system was contaminated.
1. Recover/recycle air conditioning refrigerant. (See
Recover/Recycle Refrigerant.)

TCT010658 —UN—21FEB14
2. Disconnect lines (A and B) from receiver/dryer.
3. Remove cap screws (C) and receiver/dryer.
IMPORTANT: Avoid Damage! Receiver/dryer flow
direction must be correct for installation.
Note flow direction arrow.

NOTE: When a new receiver/dryer is installed and

there were no leaks found in the system, add 15 A—Line C—Cap Screw (2 used)
ml (0.5 oz.) of R-134a Refrigerant Oil. If leaks B—Line
are found in the system, follow procedure for
checking and adding refrigerant oil. (See Determine
Correct Refrigerant Oil Charge.)
5. Connect lines to receiver/dryer and tighten to
4. Install new receiver dryer and tighten cap screws to specification.
specification. Specification
Specification Receiver/Dryer
Air Conditioning Lines—Torque....................................................................... 14—20 N·m
Receiver/Dryer Cap (124—177 lb.-in.)
Screw—Torque...................................................................... 14—20 N·m
(124—177 lb.-in.)
OUMX258,0000A8D -19-21FEB14-1/1

Adjust A/C Compressor Belt Tension

1. Park machine safely.
2. Raise and safely support machine.
NOTE: Bolts have nuts on other side of mounting plate.

3. Loosen bolt (A) slightly to allow a pivot point for the

bracket.
4. Loosen bolts (B) and (C)
5. Insert a ratchet wrench into the square hole (D) in the
bracket and turn bracket CCW until belt tension is at
specification. Hold at proper tension and tighten bolt
(C), then bolts (B) and (A).
TCT010069 —UN—10JUN14

Specification
AC belt—Tension............................................................................. 85 lb.
Compressor Bracket
Bolt—Torque................................................................................140 N·m
105 lb.-ft.

A—Top Bolt C—Third Bolt

B—Second Bolt D—Square Hole

OUO2003,000007E -19-11JUN14-1/1

TM130419 (24FEB16) 290-30-7 PN=1311

030916
 Tests and Adjustments

TM130419 (24FEB16) 290-30-8 030916

PN=1312
 Section 299
Tools and Kits
Contents

Page

Group 10—Tools
Service Equipment and Tools ...................... 299-10-1
Tier 4 Engine Essential or
Recommended Tools............................... 299-10-5

TM130419 (24FEB16) 299-1 030916

PN=1
 Contents

TM130419 (24FEB16) 299-2 030916

PN=2
 Group 10
Tools
Service Equipment and Tools
NOTE: Order tools from the SERVICEGARD™ Catalog.

SERVICEGARD is a trademark of Deere & Company

OUMX258,0000C29 -19-04MAR15-1/52

Valve Spring Compressor......................................JDE138 Used to remove valves.

OUMX258,0000C29 -19-04MAR15-2/52

Valve Guide Driver................................................ JDG504

Used to install valve guides in cylinder head.
OUMX258,0000C29 -19-04MAR15-3/52

Nozzle Cleaning Kit ................................................. JDF13 Used to clean fuel injection nozzles.
OUMX258,0000C29 -19-04MAR15-4/52

Magnetic Follower Holder Kit............................D15001NU Used to hold cam followers away from camshaft.
OUMX258,0000C29 -19-04MAR15-5/52

Valve Guide Driver................................................. JDE118

Used to replace valve guides.
OUMX258,0000C29 -19-04MAR15-6/52

Valve Guide Reamer .........................................D20021WI

Used to properly size valve guide bore.
OUMX258,0000C29 -19-04MAR15-7/52

Magnetic Follower Holder Kit............................D15001NU Used to hold cam followers away from camshaft.
OUMX258,0000C29 -19-04MAR15-8/52

Nozzle Cleaning Kit ................................................. JDF13 Used to clean fuel injector nozzles.
OUMX258,0000C29 -19-04MAR15-9/52

Lifting Bracket.......................................................JT01748 Used with hoist to remove and install transaxle.

OUMX258,0000C29 -19-04MAR15-10/52

Retaining Ring Pliers ........................................ D05327ST Used to install snowblower gear assembly worm
gear retaining ring.
OUMX258,0000C29 -19-04MAR15-11/52

Retaining Ring Pliers ................................................JDT-1 Used to install snowblower gear assembly output
shaft retaining ring
Continued on next page OUMX258,0000C29 -19-04MAR15-12/52

TM130419 (24FEB16) 299-10-1 030916

PN=1315
 Tools

Belt Tension Gage .............................. JDG529 or JDST28 Used to measure drive belt deflection.
OUMX258,0000C29 -19-04MAR15-13/52

Gauge, Pressure ..................................................JT07043 Used to measure cylinder compression.

OUMX258,0000C29 -19-04MAR15-14/52

Adapter ............................................... JDG472 or JDG560

Used to install Compression Gage assembly.
OUMX258,0000C29 -19-04MAR15-15/52

Connector .............................................................JT03349
Used to connect gage to oil pressure switch port.
OUMX258,0000C29 -19-04MAR15-16/52

Hose Assembly.....................................................JT03017 Used to connect gage to oil pressure switch port.

OUMX258,0000C29 -19-04MAR15-17/52

0—700 kPa (0—100 psi) Gage ............................JT07034 Used to measure engine oil pressure.
OUMX258,0000C29 -19-04MAR15-18/52

Diesel Fuel Injection Nozzle Tester .................. D01109AA Used to test fuel injection nozzle.
OUMX258,0000C29 -19-04MAR15-19/52

Adapter Set........................................................D01110AA Used to install diesel fuel injection nozzle tester.

OUMX258,0000C29 -19-04MAR15-20/52

Straight Adapter........................................................23622 Used to install diesel fuel injection nozzle tester.

OUMX258,0000C29 -19-04MAR15-21/52

Cooling System Pressure Pump....................... D05104ST Used to pressurize cooling system to check for leaks.
OUMX258,0000C29 -19-04MAR15-22/52

Radiator Pressure Test Kit (Adapters) .................. JDG692 Used to connect pressure pump to radiator.
OUMX258,0000C29 -19-04MAR15-23/52

Cylinder Leakdown Tester ....................................JT03502 Used to test cylinder for compression pressure leakage.
OUMX258,0000C29 -19-04MAR15-24/52

Adapter ................................................................. JDG472

Used to install gage assembly.
Continued on next page OUMX258,0000C29 -19-04MAR15-25/52

TM130419 (24FEB16) 299-10-2 030916

PN=1316
 Tools

Fuel Pump Pressure Test Kit ................................ JDG356

Used to measure pump operating pressure.
OUMX258,0000C29 -19-04MAR15-26/52

Adapter ................................................................. JDG560

Used to install gage assembly.
OUMX258,0000C29 -19-04MAR15-27/52

Compression Gage Assembly ..............................JT01682 Used to measure cylinder compression.

OUMX258,0000C29 -19-04MAR15-28/52

Yanmar TNV Diesel Engine Timing Tool Kit ..... JDG10436 Adjust Fuel Injection Timing
OUMX258,0000C29 -19-04MAR15-29/52

Adapter ................................................................. JDG560 Used to pressurize cylinder with compressed air.

OUMX258,0000C29 -19-04MAR15-30/52

Cooling System Pressure Pump....................... D05104ST Used to pressure test cooling system.
OUMX258,0000C29 -19-04MAR15-31/52

Radiator Pressure Test Kit (Adapters) .................. JDG692 Used to pressure test cooling system.
OUMX258,0000C29 -19-04MAR15-32/52

Temperature Gage................................................ JDG282 Used for checking hydraulic oil temperature.

OUMX258,0000C29 -19-04MAR15-33/52

Hydraulic Test Hose..............................................JT03017 To connect to charge pump outlet.

OUMX258,0000C29 -19-04MAR15-34/52

Fitting....................................................................JT03349 To connect test hose to transaxle test port.

OUMX258,0000C29 -19-04MAR15-35/52

Gage with Quick Coupler 0—2800 kPa (0—400 To obtain charge pump relief pressure readings.
psi)........................................................................JT05584
OUMX258,0000C29 -19-04MAR15-36/52

In-Line Hydraulic Tester.................................... D01169AA Used to measure flow and pressure.

OUMX258,0000C29 -19-04MAR15-37/52

9/16-18 M 37° x 9/16-18 M ORB Fitting ...............JT03216 Used to connect hydraulic tester to machine.
Continued on next page OUMX258,0000C29 -19-04MAR15-38/52

TM130419 (24FEB16) 299-10-3 030916

PN=1317
 Tools

9/16-18 M 37° x 9/16-18 F 37° SW 90° Elbow .....JT03341

Used to connect hydraulic tester to machine.
OUMX258,0000C29 -19-04MAR15-39/52

9/16-18 F 37° x 3/4 F NPT Coupler ......................JT03342

Used to connect hydraulic tester to machine.
OUMX258,0000C29 -19-04MAR15-40/52

7/8-14 M 37° x 9/16-18 F ORB Adapter ...............JT03056

Used to connect hydraulic tester to machine.
OUMX258,0000C29 -19-04MAR15-41/52

7/8-14 F 37° x 3/4 F NPT Coupler ........................JT03385

Used to connect hydraulic tester to machine.
OUMX258,0000C29 -19-04MAR15-42/52

Fitting 1/8 Male NPT x 7/16-20 M 37° ..................JT05487 Used to connect test hose and gage to test port.
OUMX258,0000C29 -19-04MAR15-43/52

Fitting 90° 7/16-20 F 37° Sw x 7/16-20 M 37° ......JT05483 Used to connect JT05487 to test hose.
OUMX258,0000C29 -19-04MAR15-44/52

Hose with Male Quick Coupler .............................JT03017

Used to connect gage to test port.
OUMX258,0000C29 -19-04MAR15-45/52

Gage with Male Quick Coupler.............................JT05471 Used to obtain PTO relief valve pressure.
OUMX258,0000C29 -19-04MAR15-46/52

Hydraulic Test Hose..............................................JT03017 To connect to test ports.

OUMX258,0000C29 -19-04MAR15-47/52

Pressure Gauge 0—20 684 kPa (0—3000 psi) ....JT03345 To obtain implement relief valve pressure readings.
OUMX258,0000C29 -19-04MAR15-48/52

Leveling Gage .................................................. AM130907 To check blade level.

OUMX258,0000C29 -19-04MAR15-49/52

Electronic Leak Detector ......................................JT02180

Used to detect refrigerant oil leaks.
OUMX258,0000C29 -19-04MAR15-50/52

Kit, Deluxe A/C Flushing (R12 and R134a) ..........JT02098 Used to test evaporator/heater core for leaks.
Continued on next page OUMX258,0000C29 -19-04MAR15-51/52

TM130419 (24FEB16) 299-10-4 030916

PN=1318
 Tools

The JT02098 Kit contains the following fittings and other Holding Plate ........................................................JT02124
fittings that may be necessary.
Used to test evaporator/heater core for leaks.
Adaptor, 7/8-18 M O-ring Tube x 7/16-20 M45.....JT02099 Socket Head Screw, Short....................................JT02125
Used to check for refrigerant oil leaks. Used to test evaporator/heater core for leaks.
Adaptor, 3/4-18 M O-ring Tube x 7/16-20 M45.....JT02100 Socket Head Screw, Long ....................................JT02126
Used to check for refrigerant oil leaks. Used to test evaporator/heater core for leaks.
Adapter Fitting, Tube ............................................JT02103 Cap, 7/16-20 F 45.................................................JT03194
Used to test evaporator/heater core for leaks. Used to restrict discharge of refrigerant oil.
Adapter Fitting, Tube ............................................JT02105
Unit, Cool-Tech R/R/R ...................................... JDG10555
Used to test evaporator/heater core for leaks.
Test Block, O-Ring Ports ......................................JT02106 Used to recover/recycle air conditioning refrigerant.
A/C 690 Pro Recovery Recycling ................ JDG10974EU
Used to test evaporator/heater core for leaks.
Holding Plate ........................................................JT02123 Used to recover/recycle air conditioning refrigerant.
Unit, Cool-Tech R/R/R .......................................JDG11730
Used to test evaporator/heater core for leaks.
Used to recover/recycle air conditioning refrigerant.
OUMX258,0000C29 -19-04MAR15-52/52

Tier 4 Engine Essential or Recommended ESSENTIAL TOOLS listed are required to perform
Tools the job correctly and are obtainable only from the
NOTE: Order tools from the SERVICEGARD™ Catalog. SERVICEGARD™ Catalog.

SERVICEGARD is a trademark of Deere & Company

OUMX258,0000461 -19-16SEP14-1/23

Cord, Patch...................................................... J-35616-20

Engine Tests and Adjustments
OUMX258,0000461 -19-16SEP14-2/23

Test Box, Diagnostic ......................................... JDG10273 Engine Tests and Adjustments

OUMX258,0000461 -19-16SEP14-3/23

Kit, Flex Probe .................................................. JDG10466

Engine Tests and Adjustments
OUMX258,0000461 -19-16SEP14-4/23

Probe, Flex Male Blue/Gray (3PK) ....................JDG11233 Engine Tests and Adjustments
OUMX258,0000461 -19-16SEP14-5/23

Probe, Flex (Female) (3PK)...............................JDG11348 Engine Tests and Adjustments

OUMX258,0000461 -19-16SEP14-6/23

Probe, Flex(Male) (3 PK)...................................JDG11349 Engine Tests and Adjustments

Continued on next page OUMX258,0000461 -19-16SEP14-7/23

TM130419 (24FEB16) 299-10-5 030916

PN=1319
 Tools

Probe, Flex (3PK) ..............................................JDG11524 Engine Tests and Adjustments

OUMX258,0000461 -19-16SEP14-8/23

Probe, Flex (3PK) ..............................................JDG11525 Engine Tests and Adjustments

OUMX258,0000461 -19-16SEP14-9/23

Probe, Flex (3PK) ..............................................JDG11536 Engine Tests and Adjustments

OUMX258,0000461 -19-16SEP14-10/23

Probe, Flex (3PK) ..............................................JDG11537 Engine Tests and Adjustments

OUMX258,0000461 -19-16SEP14-11/23

Probe, Flex (3PK) ..............................................JDG11548 Engine Tests and Adjustments

OUMX258,0000461 -19-16SEP14-12/23

Probe, Flex (3PK) ..............................................JDG11549 Engine Tests and Adjustments

OUMX258,0000461 -19-16SEP14-13/23

Tool, Valve Guide Removal ...............................JDG11461

Engine Repair
OUMX258,0000461 -19-16SEP14-14/23

Installer, Valve Guide.........................................JDG11462

Engine Repair
OUMX258,0000461 -19-16SEP14-15/23

Tool, Connecting Rod Bushing ..........................JDG11463 Engine Repair

OUMX258,0000461 -19-16SEP14-16/23

Installer, Valve Stem Seal............................... JDG11465A

Engine Repair
OUMX258,0000461 -19-16SEP14-17/23

Tool, Camshaft Remove/Replace ......................JDG11466

Engine Repair
OUMX258,0000461 -19-16SEP14-18/23

Installer, Crankshaft Pulley ................................JDG11467 Engine Repair

OUMX258,0000461 -19-16SEP14-19/23

Adaptor, Compression Test ...............................JDG11508

Engine Repair
Continued on next page OUMX258,0000461 -19-16SEP14-20/23

TM130419 (24FEB16) 299-10-6 030916

PN=1320
 Tools

Tool, Rear Crankshaft Oil Seal ..........................JDG11647

Engine Repair
OUMX258,0000461 -19-16SEP14-21/23

Tool, Front Crankshaft Oil Seal..........................JDG11650

Engine Repair
OUMX258,0000461 -19-16SEP14-22/23

RECOMMENDED TOOLS, as noted, are suggested to Expander, Ring ......................................................JDE135

perform the job correctly. Some tools may be available
from local suppliers or may be fabricated. Engine Repair
Meter, Fluke 88-5/A ..............................................JT07306 Kit, Video Scope ..............................................JDG11100A
Engine Repair Engine Repair
Set, Bearing and Seal Driver ............................ D01045AA Engine Adaptor..................................................JDG11602
Engine Repair Engine Repair
Tester, Compression......................................... D01168AA Engine Adaptor..................................................JDG11648
Engine Tests and Adjustments Engine Repair
Straight Edge, Bevelled Edge........................D05012ST-A Fixture, Mounting................................................ JDG1676
Engine Repair Engine Repair
Brush, Wire....................................................... D17024BR Ring Compressor, Band ..................................... JDG1322
Engine Repair Engine Repair
Micrometer, Depth ..............................................D17511CI Kit, Universal Pressure Test .................................JT05470
Engine Repair Engine Repair
Indicator Dial...................................................... D17526CI Gun, Non-Contact Temperature Meter .................JT07253
Engine Repair Engine Repair
OUMX258,0000461 -19-16SEP14-23/23

TM130419 (24FEB16) 299-10-7 030916

PN=1321
 Tools

TM130419 (24FEB16) 299-10-8 030916

PN=1322
 Index
Page
Page
A
A/C Compressor belt tension B
Adjust ............................................................... 290-30-7
Adjustments Backup alarm
Controllers Wiring harness
Approved software for control Color codes .................................................. 30-20-42
units ............................................................ 235-10-1 Battery
Display setup screen .................................... 235-10-4 Load test .......................................................... 230-40-3
Service ADVISOR based Remove and install ............................................ 30-30-1
calibrations ................................................. 235-10-5 Test .................................................................. 230-40-2
Service timer menu ...................................... 235-10-2 Belt installation, drive
Aftertreatment Verification Procedure................ 235-15-17 60, 72-inch side discharge ............................... 70-10-10
Air preheater test ................................................. 230-40-8 72-inch rear discharge ..................................... 70-10-12
Alternator V-flex................................................................ 70-10-14
Drive belt tension check and adjustment Belt removal, drive
3TNV80F ...................................................... 220-40-1 60, 72-inch side discharge ................................. 70-10-9
3TNV82A, 3TNV88....................................... 220-45-1 72-inch rear discharge ..................................... 70-10-11
Remove and install ............................................ 30-30-2 V-flex................................................................ 70-10-14
Repair ................................................................ 30-30-3 Belt shield removal/installation
AMT386 diode pack test...................................... 230-40-8 60, 62, 72-inch side discharge ........................... 70-10-6
AMT477 diode pack test.................................... 230-40-10 72-inch rear discharge ....................................... 70-10-6
Attachments Belt, blower fan drive
60, 62-inch mower deck spindle Checking and adjusting.................................... 270-20-8
Disassembly/inspection................................ 70-10-26 Replacing ......................................................... 70-30-11
Removal/installation ..................................... 70-10-21 BioDiesel fuel......................................................... 10-20-3
72-inch mower deck spindle Bleeding procedure
Disassembly/inspection................................ 70-10-26 Hydraulic system.............................................. 250-40-1
Removal/installation ..................................... 70-10-21 Blow-in port seal, adjusting................................ 270-20-10
Mower blade, sharpen and balance................. 70-10-20 Blower blade, balancing .................................... 270-20-12
Mower deck blade removal/installa- Blower hose, install.............................................. 70-30-13
tion ................................................................. 70-10-19 Bolt and screw torque values
Mower deck drive shaft removal/installa- Metric ................................................................. 10-10-1
tion ................................................................. 70-10-33 Unified inch ........................................................ 10-10-2
Mower deck drive shaft repair.......................... 70-10-34 Brake system
Mower deck gearbox removal/installa- Adjustments
tion ................................................................. 70-10-35 Brake switch, adjust ..................................... 260-50-6
Mower deck gearbox repair ............................. 70-10-38 Operation ......................................................... 260-10-3
Mower deck level, check and adjust ................ 270-20-2 Repair
V-flex ............................................................ 270-20-6 Brake linkage, remove and install .................. 60-30-2
Mower drive belt tension check and Master brake pedal, remove and
adjustment install ............................................................ 60-30-6
V-flex ............................................................ 270-20-8 Park brake lock lever, remove and
Mower drive belt tension, check and install ............................................................ 60-30-8
adjust.............................................................. 270-20-7 Turn brake pedals, remove and
V-flex mower deck belt shield removal/ install ............................................................ 60-30-4
installation ...................................................... 70-10-13
Auxiliary hydraulic operation................................ 250-10-1 C
Auxiliary hydraulic valve
Disassemble and assemble ............................... 50-20-7 Cab
Remove and install ............................................ 50-20-6 Door, remove and install .................................... 80-10-5
Axle Removal and installation.................................... 80-10-6
Shaft housing disassembly/ Cab air filter, cleaning ............................................ 80-10-4
assembly ........................................................ 40-30-28 Cab door
Axle, 2 speed Remove and install ............................................ 80-10-5
Shaft housing Cab headliner
Disassemble, inspect, assemble .................. 40-40-59 Remove and install ............................................ 80-10-1

Continued on next page

TM130419 (24FEB16) Index-1 030916

PN=1
 Index

Page Page

Cab outer roof Disassemble and assemble ......................... 20-10-25

Remove and install ............................................ 80-10-2 Inspect.......................................................... 20-10-28
Camshaft Remove and install....................................... 20-10-23
3TNV80F Side play, check ........................................... 20-10-31
End play, check ............................................ 20-10-48 3TNV82A, 3TNV88
Inspect.......................................................... 20-10-45 Inspect.......................................................... 20-20-22
Remove and install....................................... 20-10-44 Remove and install....................................... 20-20-17
3TNV82A, 3TNV88 Side play, check ........................................... 20-20-33
End play check ............................................. 20-20-35 Connectors
Inspect.......................................................... 20-20-37 Accelerator sensor ........................................... 230-50-1
Remove and install....................................... 20-20-36 Beacon switch connector ............................... 230-50-14
Camshaft followers Fan speed switch connector .......................... 230-50-14
3TNV80F PTO switch connector, T4.............................. 230-50-10
Inspect.......................................................... 20-10-50 Wiper switch connector.................................. 230-50-14
Remove and install....................................... 20-10-50 Controllers
3TNV82A, 3TNV88 Adjustments
Remove and install....................................... 20-20-40 Approved software for control
Camshaft gear units ............................................................ 235-10-1
3TNV80F Display setup screen .................................... 235-10-4
Remove and install....................................... 20-10-49 Service ADVISOR based
3TNV82A, 3TNV88 calibrations ................................................. 235-10-5
Remove and install....................................... 20-20-40 Service timer menu ...................................... 235-10-2
Caster wheels, yoke and bearings CAN bus terminator test................................. 235-35-13
repair.................................................................. 70-10-39 CAN communication fault checks .................. 235-35-12
Charge pump CAN message not received ............................. 235-35-2
Disassembly/ inspection/ assembly ................... 40-30-7 CAN message received error........................... 235-35-3
Charge pump, 2 speed CAN message received is incorrect................. 235-35-4
Disassemble, inspect, assemble...................... 40-40-17 CAN network voltage checks ......................... 235-35-14
Collection system (GLC) Control unit messaging errors........................ 235-35-13
Install.................................................................. 70-30-6 Control unit readings
Remove.............................................................. 70-30-1 VCU............................................................ 235-35-18
Component location Diagnostic information ................................... 235-35-17
2 speed 4WD ..................................................... 40-20-3 DPF functions
4WD ................................................................... 40-10-3 Recovery .................................................... 235-15-12
Electrical DPF functions and DTCs
Cab relays ...................................................... 30-10-4 Diesel particulate filter operator
Cab, lower ...................................................... 30-10-5 display ........................................................ 235-15-6
Cab, upper...................................................... 30-10-4 ECU
Instrument cluster - A100 ............................... 30-10-1 Data points used in Service
Non-T4 ........................................................... 30-10-2 ADVISOR ................................................. 235-35-22
T4 ................................................................... 30-10-3 Electronic injector
Hydraulic Calibration information............................ 235-35-24
Auxiliary hydraulic kit components ................. 50-10-2 Erroneous diagnostic trouble codes............... 235-35-16
Lift system hydraulic hose routing .................. 50-10-5 PDU
Steering system hydraulic hose DOC calibration
routing........................................................... 50-10-3 Instructions ............................................. 235-15-18
System components....................................... 50-10-1 DPF calibration
Weight transfer system Instructions ............................................. 235-15-18
components .................................................. 50-10-4 DPF status screens .................................... 235-15-14
Hydrostatic pedal and neutral safety I-O status readings ..................................... 235-35-18
linkage Reprogramming.......................................... 235-20-11
2 speed........................................................... 40-20-2 Tier 4 warning popups................................ 235-15-17
Steering system ................................................. 60-10-1 Readings overview......................................... 235-35-17
Transaxle, 2 speed ............................................ 40-20-1 Service ADVISOR based tests ...................... 235-35-24
Transaxle, single speed ..................................... 40-10-1 Setup
Connecting rod PDU
3TNV80F Active DTC flow description...................... 235-20-5
Bearing clearance, check ............................. 20-10-32 Display setup screen detailed................... 235-20-8

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Language select ....................................... 235-20-4 3TNV82A, 3TNV88

Machine start pass code entry.................. 235-20-8 Disassemble and assemble ........................... 20-20-8
Machine status screens ............................ 235-20-4 Remove and install......................................... 20-20-6
Main screens navigation ........................... 235-20-1 Cylinder leakdown test
Pass codes ............................................... 235-20-7 3TNV80F........................................................ 220-40-17
Stored DTC flow description ..................... 235-20-6
Version information ................................. 235-20-11 D
Theory of operation
CAN trace..................................................... 235-30-2 Determine Correct Refrigerant Oil
Hour meter ................................................... 235-30-3 HVAC ............................................................... 290-20-2
Primary display unit (PDU) ........................... 235-30-3 Diagnose DTCs
Troubleshooting electronic control VCU
units.............................................................. 235-35-16 000070.14 .................................................... 235-45-3
Coolant 000158.00 .................................................... 235-45-4
Diesel engine 000158.01 .................................................... 235-45-4
Light duty........................................................ 10-20-9 000168.00 .................................................... 235-45-5
Engine................................................................ 10-10-8 000168.01 .................................................... 235-45-6
John deere COOL-GARD II coolant 000168.16 .................................................... 235-45-7
extender ......................................................... 10-20-10 000168.18 .................................................... 235-45-8
Testing.............................................................. 10-20-10 000595.03 .................................................... 235-45-9
Warm temperature climates ............................... 10-20-8 000595.04 .................................................. 235-45-10
Coolant temperature switch 000629.12 .................................................. 235-45-11
3TNV80F 000639.12 .................................................. 235-45-12
Remove and install....................................... 20-10-58 000639.14 .................................................. 235-45-12
Cooling system, pressure test 000677.04 .................................................. 235-45-13
3TNV80F........................................................ 220-40-15 000677.14 .................................................. 235-45-13
3TNV82A, 3TNV88 ........................................ 220-45-15 000677.31 .................................................. 235-45-14
Cover closing force, adjusting ........................... 270-20-10 000920.03 .................................................. 235-45-14
Cover seal compresion, adjusting ..................... 270-20-11 000920.04 .................................................. 235-45-15
Cover, rocker arm 000931.03 .................................................. 235-45-15
3TNV80F 000931.04 .................................................. 235-45-16
Remove and install......................................... 20-10-2 001504.31 .................................................. 235-45-17
3TNV82A, 3TNV88 001638.00 .................................................. 235-45-18
Remove and install......................................... 20-20-2 003509.03 .................................................. 235-45-19
Crankshaft 003509.04 .................................................. 235-45-20
3TNV80F 003941.14 .................................................. 235-45-21
End play, check ............................................ 20-10-42 003941.31 .................................................. 235-45-21
Inspect.......................................................... 20-10-39 516124.03 .................................................. 235-45-22
Remove and install....................................... 20-10-38 516124.04 .................................................. 235-45-23
3TNV82A, 3TNV88 516200.03 .................................................. 235-45-24
Remove and install....................................... 20-20-30 516200.04 .................................................. 235-45-25
Crankshaft end play check 516206.03 .................................................. 235-45-26
3TNV82A, 3TNV88 .......................................... 20-20-29 516206.04 .................................................. 235-45-26
Cruise control magnet test................................. 230-40-22 516206.05 .................................................. 235-45-27
Cylinder bore 516399.03 .................................................. 235-45-28
3TNV80F 516399.04 .................................................. 235-45-29
Inspect.......................................................... 20-10-33 520870.31 .................................................. 235-45-30
Taper and out-of-round, inspect ................... 20-10-35 520871.31 .................................................. 235-45-30
3TNV82A, 3TNV88 520872.31 .................................................. 235-45-31
Inspect.......................................................... 20-20-26 520873.31 .................................................. 235-45-32
Cylinder compression test 522011.08................................................... 235-45-32
3TNV80F.......................................................... 220-40-5 524265.31 .................................................. 235-45-33
3TNV82A, 3TNV88 ........................220-45-2, 220-45-15 Diagnosis
Cylinder head and valves Brakes
3TNV80F Brake will not engage or hold
Disassemble and assemble ........................... 20-10-7 machine ...................................................... 260-30-1
Inspect............................................................ 20-10-8 Exccessive brake wear................................. 260-30-1
Remove and install......................................... 20-10-5 Machine pulls to one side............................. 260-30-2

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Machine will not move .................................. 260-30-1 Machine will not move when travel
Engine pedals are pressed ..................................... 240-20-2
Diesel Machine will not reach full speed ................. 240-20-2
Diagnose coolant in crankcase............... 220-20-23 PTO shaft turns with PTO switch
Diagnose engine overheating ................. 220-20-25 off................................................................ 240-20-3
Diagnose engine runs rough - PTO shaft will not turn .................................. 240-20-3
excessive vibration................................ 220-20-19 Rear wheels do not drive.............................. 240-20-4
Diagnose engine runs rough - Power train, single speed
misfiring................................................. 220-20-15 Differential will not lock when pedal is
Diagnose engine runs rough - surges pressed....................................................... 240-10-1
during idle ............................................. 220-20-18 Machine moves with travel pedals in
Diagnose engine runs rough - surges neutral......................................................... 240-10-1
under load ............................................. 220-20-19 Machine will not move when travel
Diagnose engine runs rough - uneven pedals are pressed ..................................... 240-10-2
combustion sound................................. 220-20-16 Machine will not reach full speed ................. 240-10-2
Diagnose engine starts but does PTO shaft will not turn .................................. 240-10-3
not continue running - excessive PTO turns with PTO switch off ..................... 240-10-3
exhaust smoke........................................ 220-20-4 Rear wheels do not drive.............................. 240-10-4
Diagnose engine starts but does Steering
not continue running - no exhaust High steering effort in both
smoke ..................................................... 220-20-3 directions .................................................... 260-20-1
Diagnose engine will not start................... 220-20-1 Hydraulic oil foams ....................................... 260-20-2
Diagnose excessive fuel Lost motion in steering wheel....................... 260-20-3
consumption.......................................... 220-20-20 Machine continues to turn after steering
Diagnose excessive oil wheel is centered........................................ 260-20-4
consumption.......................................... 220-20-21 Sluggish steering response .......................... 260-20-4
Diagnose exhaust color black under Steering not driving straight.......................... 260-20-5
load ....................................................... 220-20-12 Steering operation reversed ......................... 260-20-7
Diagnose exhaust color white under Steering wheel vibration ............................... 260-20-7
load ....................................................... 220-20-10 Diagnostic trouble codes (DTCs)
Diagnose fuel oil in crankcase ................ 220-20-22 VCU
Diagnose high exhaust Quick reference table ................................... 235-45-1
temperature........................................... 220-20-13 Diagnostic Trouble Codes (DTCs)
Diagnose low compression..................... 220-20-26 SPN/FMI
Diagnose low engine coolant 000028.00 .................................................... 235-50-1
temperature........................................... 220-20-26 000028.01 .................................................... 235-50-2
Diagnose low engine output - black 000028.03 .................................................... 235-50-3
exhaust color........................................... 220-20-8 000028.04 .................................................... 235-50-4
Diagnose low engine output - normal 000051.03 .................................................... 235-50-5
exhaust color........................................... 220-20-6 000051.04 .................................................... 235-50-7
Diagnose low engine output - white 000100.01 .................................................. 235-50-10
exhaust color........................................... 220-20-7 000100.04 .................................................. 235-50-12
Diagnose low oil pressure....................... 220-20-24 000102.03 .................................................. 235-50-14
Diagnose starter motor does not 000102.04 .................................................. 235-50-17
rotate..................................................... 220-20-27 000102.13 .................................................. 235-50-20
Diagnose starter rotates slowly............... 220-20-28 000105.03 .................................................. 235-50-23
Diagnose starter starter rotates but 000105.04 .................................................. 235-50-25
does not crank ...................................... 220-20-29 000108.03 .................................................. 235-50-27
Engine will not start ...................................... 220-30-1 000108.04 .................................................. 235-50-28
Hydraulics 000108.10 .................................................. 235-50-29
Auxiliary system checks ............................... 250-30-4 000110.00................................................... 235-50-30
Lift system checks ........................................ 250-30-1 000110.03................................................... 235-50-32
Weight transfer system checks .................... 250-30-6 000110.04................................................... 235-50-34
Power train, 2 speed 000157.00 .................................................. 235-50-36
Differential will not lock when lock pedal 000157.03 .................................................. 235-50-39
is pressed ................................................... 240-20-1 000157.04 .................................................. 235-50-41
Machine moves with travel pedlas in 000157.15 .................................................. 235-50-43
neutral......................................................... 240-20-1 000157.16 .................................................. 235-50-46

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000157.18 .................................................. 235-50-49 003720.00 .................................................. 235-54-36

000167.01 .................................................. 235-50-52 003720.16 .................................................. 235-54-37
000167.05 .................................................. 235-50-53 004257.12 .................................................... 235-55-1
000173.03 .................................................. 235-50-54 422571.03 .................................................. 235-55-20
000173.04 .................................................. 235-50-56 422571.06 .................................................. 235-55-23
000174.00 .................................................. 235-50-58 422572.06 .................................................. 235-55-26
000174.03 .................................................. 235-50-60 422572.11................................................... 235-55-29
000174.04 .................................................. 235-50-62 423469.00 .................................................. 235-55-70
000190.00 .................................................. 235-50-64 423470.00 .................................................. 235-55-72
000412.03 .................................................... 235-51-1 522243.05 .................................................... 235-55-2
000412.04 .................................................... 235-51-3 522243.06 .................................................... 235-55-3
000630.12 .................................................... 235-51-5 522329.00 .................................................... 235-55-4
000633.03 .................................................... 235-51-6 522400.02 .................................................... 235-55-7
000633.05 .................................................... 235-51-9 522400.05 .................................................... 235-55-9
000633.06 .................................................. 235-51-12 522401.02 .................................................. 235-55-11
000651.03 .................................................. 235-51-32 522401.05 .................................................. 235-55-14
000652.03 .................................................. 235-51-15 522401.07 .................................................. 235-55-17
000652.05 .................................................. 235-51-18 522573.00 .................................................. 235-55-32
000652.06 .................................................. 235-51-20 522574.00 .................................................. 235-55-33
000653.03 .................................................. 235-51-23 522575.07 .................................................. 235-55-34
000653.05 .................................................. 235-51-26 522576.12 .................................................. 235-55-35
000653.06 .................................................. 235-51-29 522577.11................................................... 235-55-36
000654.05 .................................................. 235-51-34 522579.12 .................................................. 235-55-38
000654.06 .................................................. 235-51-37 522580.12 .................................................. 235-55-39
001209.03 .................................................... 235-52-1 522582.07 .................................................. 235-55-40
001209.04 .................................................... 235-52-3 522583.01 .................................................. 235-55-42
001209.13 .................................................... 235-52-6 522584.01 .................................................. 235-55-43
002791.00 .................................................... 235-53-1 522585.12 .................................................. 235-55-44
002791.01 .................................................... 235-53-3 522588.12 .................................................. 235-55-45
002791.07 .................................................... 235-53-6 522591.12 .................................................. 235-55-47
002791.09 .................................................... 235-53-7 522592.12 .................................................. 235-55-50
002791.12 .................................................... 235-53-8 522596.09 .................................................. 235-55-52
002797.06 .................................................... 235-53-9 522597.09 .................................................. 235-55-53
002798.06 .................................................. 235-53-10 522599.09 .................................................. 235-55-53
002950.03 .................................................. 235-53-11 522610.09 .................................................. 235-55-56
002950.04 .................................................. 235-53-13 522617.12 .................................................. 235-55-57
002950.05 .................................................. 235-53-15 522744.04 .................................................. 235-55-59
002950.06 .................................................. 235-53-18 522994.04 .................................................. 235-55-60
002951.03 .................................................. 235-53-21 523249.05 .................................................. 235-55-61
002951.04 .................................................. 235-53-24 523460.00 .................................................. 235-55-63
003242.00 .................................................... 235-54-1 523462.13 .................................................. 235-55-65
003242.03 .................................................... 235-54-3 523463.13 .................................................. 235-55-66
003242.04 .................................................... 235-54-5 523464.13 .................................................. 235-55-67
003250.00 .................................................... 235-54-7 523468.09 .................................................. 235-55-68
003250.01 .................................................... 235-54-9 523473.12 .................................................. 235-55-37
003250.03 .................................................. 235-54-11 523489.00 .................................................. 235-55-74
003250.04 .................................................. 235-54-13 523489.12 .................................................. 235-55-46
003251.00 .................................................. 235-54-15 523491.00 .................................................. 235-55-76
003251.03 .................................................. 235-54-17 Diagnostic trouble codes overview ...................... 235-30-3
003251.04 .................................................. 235-54-19 Diesel fuel, testing
003251.13 .................................................. 235-54-21 Testing Diesel Fuel............................................. 10-20-2
003609.03 .................................................. 235-54-23 Diesel Fuel, Using ................................................. 10-20-1
003609.04 .................................................. 235-54-25 Differential
003695.14 .................................................. 235-54-27 Disassembly/ inspection/ assembly ................. 40-30-28
003719.00 .................................................. 235-54-28 Lock lever disassembly/ assembly................... 40-30-28
003719.07 .................................................. 235-54-30 Differential assembly
003719.09 .................................................. 235-54-32 Hydrostatic assembly separation/
003719.16 .................................................. 235-54-34 installation ........................................................ 40-30-4

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differential assembly, 2 speed Alarm buzzer, T4 .......................................... 230-50-2

Hydrostatic assembly Alternator, non-T4......................................... 230-50-2
Separate, install.............................................. 40-40-7 Alternator, T4................................................ 230-50-2
Differential, 2 speed Auxiliary cab power ...................................... 230-50-3
Disassemble, inspect, assemble...................... 40-40-59 Brake switch ................................................. 230-50-9
Lock lever Cab power .................................................. 230-50-13
Disassemble, inspect, assemble .................. 40-40-59 Cab power relay ......................................... 230-50-11
Diode Control module module, 6 pin ...................... 230-50-3
Test ................................................................ 230-40-14 Control module module, 8 pin ...................... 230-50-3
Disassembly/inspection/assembly Cruise control brake switch ........................ 230-50-12
4WD axle ......................................................... 40-30-79 Cruise control relay .................................... 230-50-11
Disassembly/inspection/assemby Cruise control switch .................................. 230-50-12
4WD gear case ................................................ 40-30-67 Diode pack ................................................. 230-50-13
PTO.................................................................. 40-30-47 Display unit
DPF T4.............................................................. 230-50-8
Diesel particulate filter operator Engine control module (ecu), 60
display ............................................................ 235-15-6 pin............................................................... 230-50-6
DPF functions Engine control module (ecu), 94
DPF recovery ................................................. 235-15-12 pin............................................................... 230-50-5
Drive belt installation Engine preheat timer module ....................... 230-50-4
60, 72-inch side discharge ............................... 70-10-10 Flasher relay............................................... 230-50-13
72-inch rear discharge ..................................... 70-10-12 Fuel pull-in relay ......................................... 230-50-11
V-flex................................................................ 70-10-14 Fuel shutoff solenoid .................................... 230-50-7
Drive belt removal Fuel transfer pump, non-T4.......................... 230-50-7
60, 72-inch side discharge ................................. 70-10-9 Fuel transfer pump, T4 ................................. 230-50-7
72-inch rear discharge ..................................... 70-10-11 Headlights .................................................. 230-50-10
V-flex................................................................ 70-10-14 Homologation harness ............................... 230-50-15
Driveshaft Hydraulic oil temperature switch,
Remove and install ............................................ 40-30-1 non-T4 ........................................................ 230-50-8
Driveshaft, 2 speed Hydraulic oil temperature switch,
Remove and install ............................................ 40-40-1 T4 ............................................................... 230-50-8
Driveshaft, remove and install Instrument cluster, non-T4............................ 230-50-8
2 speed ............................................................ 40-40-98 Key switch connector ................................... 230-50-9
Light switch.................................230-50-9, 230-50-12
E Power outlet ................................................. 230-50-2
PTO shutdown relay................................... 230-50-12
Electrical PTO solenoid.............................................. 230-50-10
Air ride seat PTO switch, non-T4.................................... 230-50-10
Splice table................................................... 30-20-43 Seat switch ................................................... 230-50-9
Air ride seat wiring harness Terminal Test ................................................ 235-35-5
Color codes .................................................. 30-20-43 Diagnostic trouble codes overview .................. 235-30-3
Alternator, remove and install ............................ 30-30-2 Electronic Controllers
Alternator, repair ................................................ 30-30-3 Accessing the Address and Diagnostic
Backup alarm Trouble Codes .......................................... 235-35-11
Splice table................................................... 30-20-42 Homologation schematic
Wiring harness color codes .......................... 30-20-42 Components ............................................... 230-20-29
Battery load test ............................................... 230-40-3 Homologation wiring harness
Battery test....................................................... 230-40-2 Splice table................................................... 30-20-32
Component location Main schematic, T4
Cab relays ...................................................... 30-10-4 Components ................................................. 230-20-6
Cab, lower ...................................................... 30-10-5 Main shematic, non T4
Cab, upper...................................................... 30-10-4 Components ................................................. 230-20-1
Instrument cluster - A100 ............................... 30-10-1 Relay test, cab power ...................................... 230-40-7
Non-T4 ........................................................... 30-10-2 Schematics
T4 ................................................................... 30-10-3 Backup alarm ............................................. 230-20-34
Connectors Beacon light................................................ 230-20-35
Air heater relay ........................................... 230-50-11 Cab schematic
Alarm buzzer, non-T4 ................................... 230-50-1 Lower ...................................................... 230-20-21

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Upper ...................................................... 230-20-23 Cold start circuit ...................................... 230-15-23

Engine connector Cranking circuit ....................................... 230-15-10
Controls and sensors.............................. 230-20-20 Cruise control circuit ............................... 230-15-24
X5057 ..................................................... 230-20-16 Engine coolant temperature
X5058 ..................................................... 230-20-17 circuit..................................................... 230-15-19
X5059 ..................................................... 230-20-18 Engine oil pressure circuit....................... 230-15-18
X5060 ..................................................... 230-20-19 Hydraukic oil temperature
Front work lights ......................................... 230-20-33 circuit..................................................... 230-15-21
GLC ............................................................ 230-20-27 Operator presence and PTO interlock
Homologation ............................................. 230-20-30 Circuit.................................................... 230-15-16
Main schematic Switched power circuit .............................. 230-15-6
Non-T4...................................................... 230-20-2 Unswitched power circuit
T4.............................................................. 230-20-7 operation ................................................. 230-15-2
Starting motor Turn signal switch, test .................................. 230-40-11
Inspect and repair........................................... 30-30-7 Wiring harness
Remove and install......................................... 30-30-7 Beacon lamp harness................................... 30-20-29
Tests and adjustments Beacon lamp harness, wire table ................. 30-20-30
Battery charge .............................................. 230-40-4 Beacon lamp splice table ............................. 30-20-29
Beacon light swtich test................................ 230-40-6 Cab harness ................................................. 30-20-21
Dome light switch test ................................ 230-40-16 Cab harness, splice table ............................. 30-20-28
DPF differentiaal pressure sensor test, Cab harness, wire table................................ 30-20-26
T4 ............................................................. 230-40-23 Front work light............................................. 30-20-41
DPF inlet temperature sensor, T4 .............. 230-40-23 Homologation ............................................... 30-20-34
DPF mid temperature sensor, T4 ............... 230-40-24 Homologation wiring table ............................ 30-20-31
Fuel pump test............................................ 230-40-20 Keyswitch harness ....................................... 30-20-20
Fuel shutoff solenoid test, non T4 .............. 230-40-21 Main harness
Fuse test..................................................... 230-40-14 Non-T4........................................................ 30-20-2
Glow plug test............................................... 230-40-8 T4.............................................................. 30-20-10
Headlight switch test (single)...................... 230-40-10 Main harness, connectors ............................ 30-20-25
PTO solenoid test....................................... 230-40-18 Non-T4........................................................ 30-20-6
PTO switch, non-T4.................................... 230-40-17 T4.............................................................. 30-20-15
PTO switch, T4........................................... 230-40-17 Main harness, splice table
Regulated voltage output test....................... 230-40-4 Non-T4........................................................ 30-20-9
Sensors test, accelerator............................ 230-40-24 T4.............................................................. 30-20-18
Test coolant temperature switch................. 230-40-20 Main harness, terminal table
Test hydraulic temperature switch .............. 230-40-18 T4.............................................................. 30-20-19
Warning alarm test ..................................... 230-40-23 Main harness, wire table
Theory of operation Non-T4........................................................ 30-20-7
CAN bus message structure ........................ 235-30-1 T4.............................................................. 30-20-16
Data bus systems......................................... 235-30-2 Splice table................................................... 30-20-42
Non-T4 Work light wiring harness
Charging circuit......................................... 230-10-8 Color codes .................................................. 30-20-42
Cold start circuit ...................................... 230-10-20 Electrical.
Cranking circuit ......................................... 230-10-6 Theory of operation
Cruise control circuit ............................... 230-10-24 CAN bus ....................................................... 235-30-2
Engine coolant temperature light and Electronic Injector
buzzer circuit......................................... 230-10-16 Calibration Information................................... 235-35-24
Engine oil pressure light and buzzer Engine
circuit..................................................... 230-10-14 3TNV80F
Fuel shutoff solenoid circuit .................... 230-10-22 Alternator drive belt tension check and
Hydraulic oil temperature light and adjustment .................................................. 220-40-1
buzzer circuit......................................... 230-10-18 Camshaft
Operator presence and pto interlock End play, check......................................... 20-10-48
circuit....................................................... 230-10-9 Inspect ...................................................... 20-10-45
Power circuit, switched ............................. 230-10-3 Remove and install ................................... 20-10-44
Power circuit, unswitched ......................... 230-10-2 Camshaft followers
T4 Inspect ...................................................... 20-10-50
Charging circuit....................................... 230-15-13 Remove and install ................................... 20-10-50

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Camshaft gear, remove and install............... 20-10-49 Remove and install ................................... 20-10-23
Connecting rod Push rod
Bearing clearance, check ......................... 20-10-32 Inspect ........................................................ 20-10-4
Disassemble and assemble...................... 20-10-25 Radiator cap, pressure test ........................ 220-40-16
Inspect ...................................................... 20-10-28 Rocker arm
Remove and install ................................... 20-10-23 Inspect ........................................................ 20-10-4
Side play, check........................................ 20-10-31 Remove and install ..................................... 20-10-3
Coolant temperature switch, remove Rocker arm cover, remove and
and install ................................................... 20-10-58 install ............................................................ 20-10-2
Cooling system, pressure test .................... 220-40-15 Slow idle, adjust ........................................... 220-40-8
Crankshaft Thermostat test .......................................... 220-40-16
End play, check......................................... 20-10-42 Thermostat, remove and install .................... 20-10-57
Inspect ...................................................... 20-10-39 Throttle cable, adjust .................................... 220-40-9
Remove and install ................................... 20-10-38 Timing gear
Cylinder bore Backlash, check........................................ 20-10-49
Inspect ...................................................... 20-10-33 Timing gear cover
Taper and out-of-round, inspect................ 20-10-35 Remove and install ................................... 20-10-51
Cylinder compression test ............................ 220-40-5 Timing gear housing
Cylinder head and valves Remove and install ................................... 20-10-54
Disassemble and assemble........................ 20-10-7 Valve clearance adjustment ......................... 220-40-2
Inspect ........................................................ 20-10-8 Valve lift check.............................................. 220-40-4
Remove and install ..................................... 20-10-5 Valve seats, grind ......................................... 20-10-13
Cylinder leakdown test ............................... 220-40-17 Valves, lap .................................................... 20-10-15
Exhaust manifold, remove and Water pump
install .......................................................... 20-10-12 Inspect ...................................................... 20-10-59
Flywheel, remove and install ........................ 20-10-43 Remove and install ................................... 20-10-59
Fuel injection nozzle 3TNV82A, 3TNV88
Remove, inspect, and install..................... 20-10-18 Air preheater, test ......................................... 230-40-8
Test ......................................................... 220-40-11 Alternator drive belt tension check and
Fuel injection pump adjustment .................................................. 220-45-1
Remove and install ................................... 20-10-15 Camshaft
Fuel injection system test ........................... 220-40-10 End play check ......................................... 20-20-35
Fuel system leak test.................................... 220-40-7 Inspect ...................................................... 20-20-37
Fuel system priming ..................................... 220-40-7 Remove and install ................................... 20-20-36
Fuel transfer pump Camshaft followers
Flow test ................................................. 220-40-18 Remove and install ................................... 20-20-40
Pressure test........................................... 220-40-17 Camshaft gear, remove and install............... 20-20-40
Idler gear Connecting rod
Inspect ...................................................... 20-10-52 Inspect ...................................................... 20-20-22
Remove and install ................................... 20-10-52 Remove and install ................................... 20-20-17
Injection pump static timing ........................ 220-40-13 Side play, check........................................ 20-20-33
Intake manifold, remove and install.............. 20-10-13 Cooling system, pressure test .................... 220-45-15
Main bearings Crankshaft
Clearance, check ...................................... 20-10-41 Remove and install ................................... 20-20-30
Inspect ...................................................... 20-10-39 Crankshaft end play check
Remove and install ................................... 20-10-38 Front, replace............................................ 20-20-29
Oil pan and strainer Cylinder bore
Remove and install ................................... 20-10-54 Inspect ...................................................... 20-20-26
Oil pressure, test .......................................... 220-40-6 Cylinder compression test ......220-45-2,
Oil pump 220-45-15
Inspect ...................................................... 20-10-55 Cylinder head and valves
Remove and install ................................... 20-10-55 Disassemble and assemble........................ 20-20-8
Oil seal, crankshaft Remove and install ..................................... 20-20-6
Front, replace............................................ 20-10-36 Exhaust manifold, remove and
Rear, replace ............................................ 20-10-35 install .......................................................... 20-20-14
Piston Flywheel, remove and install ........................ 20-20-34
Disassemble and assemble...................... 20-10-25 Fuel injection nozzle
Inspect ...................................................... 20-10-28 Remove, inspect, and install..................... 20-20-57

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Test ......................................................... 220-45-12 Water separator

Fuel injection pump Disassemble and assemble...................... 20-20-51
Install ........................................................ 20-20-56 Coolant............................................................... 10-10-8
Remove .................................................... 20-20-52 Diagnosis
Fuel system leakage test............................ 220-45-19 Diesel
Fuel system priming ................................... 220-45-19 Diagnose coolant in crankcase............... 220-20-23
Fuel transfer pump Diagnose engine overheating ................. 220-20-25
Flow test ................................................. 220-45-18 Diagnose engine runs rough -
Pressure test........................................... 220-45-18 excessive vibration................................ 220-20-19
Idler gear Diagnose engine runs rough -
Remove and install ................................... 20-20-43 misfiring................................................. 220-20-15
Injection pump static timing .......................... 220-45-5 Diagnose engine runs rough - surges
Intake manifold, remove and install.............. 20-20-14 during idle ............................................. 220-20-18
Main bearings Diagnose engine runs rough - surges
Clearance, check ...................................... 20-20-33 under load ............................................. 220-20-19
Remove and install ................................... 20-20-30 Diagnose engine runs rough - uneven
Oil pan and strainer combustion sound................................. 220-20-16
Remove and install ................................... 20-20-44 Diagnose engine starts but does
Oil pressure, test ........................................ 220-45-17 not continue running - excessive
Oil pump exhaust smoke........................................ 220-20-4
Inspect ...................................................... 20-20-45 Diagnose engine starts but does
Remove and install ................................... 20-20-45 not continue running - no exhaust
Oil seal, crankshaft smoke ..................................................... 220-20-3
Front, replace............................................ 20-20-28 Diagnose engine will not start................... 220-20-1
Rear, replace ............................................ 20-20-28 Diagnose excessive fuel
Piston consumption.......................................... 220-20-20
Inspect ...................................................... 20-20-22 Diagnose excessive oil
Remove and install ................................... 20-20-17 consumption.......................................... 220-20-21
Piston to ylinder head clearance .................. 20-20-16 Diagnose exhaust color black under
Radiator load ....................................................... 220-20-12
Remove and install ................................... 20-20-49 Diagnose exhaust color white under
Radiator cap, pressure test ........................ 220-45-16 load ....................................................... 220-20-10
Rocker arm Diagnose fuel oil in crankcase ................ 220-20-22
Remove and install ..................................... 20-20-4 Diagnose high exhaust
Rocker arm cover, remove and temperature........................................... 220-20-13
install ............................................................ 20-20-2 Diagnose low compression..................... 220-20-26
Slow idle, adjust ........................................... 220-45-3 Diagnose low engine coolant
Thermostat test .......................................... 220-45-14 temperature........................................... 220-20-26
Thermostat, remove and install .................... 20-20-47 Diagnose low engine output - black
Throttle cable, adjust .................................... 220-45-4 exhaust color........................................... 220-20-8
Timing gear backlash check......................... 20-20-42 Diagnose low engine output - normal
Timing gear cover exhaust color........................................... 220-20-6
Remove and install ................................... 20-20-41 Diagnose low engine output - white
Timing gear mounting plate exhaust color........................................... 220-20-7
Remove and install ................................... 20-20-44 Diagnose low oil pressure....................... 220-20-24
Valve clearance adjustment ....................... 220-45-10 Diagnose starter motor does not
Valve guides ................................................. 20-20-12 rotate..................................................... 220-20-27
Valve lift check................................................ 20-20-3 Diagnose starter rotates slowly............... 220-20-28
Valve recession ............................................ 20-20-11 Diagnose starter starter rotates but
Valve seats ..................................................... 20-20-9 does not crank ...................................... 220-20-29
Valve seats, grind ......................................... 20-20-14 Engine will not start ...................................... 220-30-1
Valve springs ................................................ 20-20-13 Information ....................................................... 220-10-1
Valves, intake and exhaust........................... 20-20-10 Theory of operation
Valves, lap .................................................... 20-20-15 Diesel
Water pump Cooling system operation ......................... 220-10-1
Inspect ...................................................... 20-20-48 Fuel and air system operation .................. 220-10-2
Remove and install ................................... 20-20-48 Lubrication system operation.................... 220-10-2
Engine Oil .............................................................. 10-10-6

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Engine Serial Number ........................................... 10-30-2 3TNV82A, 3TNV88 ........................................ 220-45-18

Exhaust manifold Fuel transfer pump pressure test
3TNV80F 3TNV80F........................................................ 220-40-17
Remove and install....................................... 20-10-12 3TNV82A, 3TNV88 ........................................ 220-45-18
3TNV82A, 3TNV88
Remove and install....................................... 20-20-14 G
F GLC hydraulic circuit operation ........................... 250-10-2
Grease.....................................................10-10-7, 10-20-7
Filter, Exhaust Specific application ............................................ 10-20-7
Exhaust Filter System ...................................... 235-15-1
Final drive, 2 speed H
Disassemble, assemble ................................. 40-40-101
Flywheel Hardware torque values
3TNV80F Metric ................................................................. 10-10-1
Remove and install....................................... 20-10-43 Unified inch ........................................................ 10-10-2
3TNV82A, 3TNV88 Homologation schematic
Remove and install....................................... 20-20-34 Components................................................... 230-20-29
FNR linkage adjustment ...................................... 240-30-2 Hopper hinges, adjust.......................................... 270-20-9
FNR linkage adjustment, 2 speed ....................... 240-40-2 HVAC
Fuel A/C Compressor belt tension, adjust ............... 290-30-7
BioDiesel............................................................ 10-20-3 Air conditioning
Handling and storing .......................................... 10-20-2 Specifications ............................................... 290-30-1
Lubricity.............................................................. 10-20-2 Determine Correct Refrigerant Oil ................... 290-20-2
Proper Use......................................................... 10-10-6 Heater
Fuel injection nozzle Temperature control cable
3TNV80F Adjustment................................................ 290-30-1
Remove, inspect, and install ........................ 20-10-18 Receiver/ dryer................................................. 290-30-7
3TNV82A, 3TNV88 Recover/ recycle refrigerant............................. 290-30-6
Remove, inspect, and install ........................ 20-20-57 Refrigerant Oil Information............................... 290-20-1
Fuel injection nozzle test System Information .......................................... 290-20-1
3TNV80F Tests and adjustments
Test............................................................. 220-40-11 A/ C temperature control cable,
3TNV82A, 3TNV88 adjust .......................................................... 290-30-2
Test............................................................. 220-45-12 Compressor clutch clearance
Fuel injection pump Check........................................................ 290-30-4
3TNV80F Compressor oil charge
Remove and install....................................... 20-10-15 Check........................................................ 290-30-5
3TNV82A, 3TNV88 Compressor shaft seal
Install ............................................................ 20-20-56 Leakage test ............................................. 290-30-4
Remove ........................................................ 20-20-52 Evaporator/ heater core
Fuel injection system test Leak test ................................................... 290-30-4
3TNV80F........................................................ 220-40-10 Refrigerant oil to system
Fuel pump, electric Add ........................................................... 290-30-5
3TNV80F Hydraulic pump
Remove and install....................................... 20-10-22 Disassemble and assemble ............................. 50-20-10
Fuel shutoff solenoid Flow test........................................................... 250-40-4
3TNV80F Remove and install ............................................ 50-20-7
Remove and install....................................... 20-10-22 Hydraulic pump, 2 speed
Fuel system leak test Disassemble, inspect, assemble...................... 40-40-11
Diesel engine, 3TNV80F.................................. 220-40-7 Hydraulic pump, deck
Fuel system priming Install.................................................................. 70-30-9
Diesel engine, 3TNV80F.................................. 220-40-7 Hydraulic system operation ................................. 250-10-1
Diesel engine, 3TNV82A, 3TNV88 ................ 220-45-19 Hydraulics
Fuel tank Auxiliary hydraulic kit component
Remove and install ............................................ 90-10-4 location............................................................. 50-10-2
Fuel transfer pump flow test
3TNV80F........................................................ 220-40-18

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Double spool auxiliary hydraulic kit Lift system hydraulic hose routing ......................... 50-10-5
schematic ....................................................... 250-20-8 Linkage
GLC hydraulic schematic ................................. 250-20-9 FNR, adjustment .............................................. 240-30-2
Hydraulic oil warm-up procedure ..................... 250-40-1 Linkage, F-N-R, adjust
Hydraulic pump flow test.................................. 250-40-4 2- Speed .......................................................... 240-40-2
Hydraulic system bleeding proce- Lubricant
dure ................................................................ 250-40-1 Mixing................................................................. 10-20-7
Hydraulic system component location ............... 50-10-1 Lubricant Storage
Main hydraulic schematic Storage, Lubricant.............................................. 10-20-8
With auxiliary valve....................................... 250-20-5 Lubricants, Safety
Without auxiliary valve.................................. 250-20-2 Safety, Lubricants .............................................. 10-20-7
MCS600 plus test........................................... 250-40-10 Lubricity of diesel fuel ............................................ 10-20-2
Single spool auxiliary hydraulic kit
schematic ....................................................... 250-20-7 M
Weight transfer system component
location............................................................. 50-10-4 Machine Product Identification Number................. 10-30-1
Hydrostatic assembly Machine specifications .......................................... 10-30-1
Differential assembly separation/ Main bearings
installation ........................................................ 40-30-4 3TNV80F
Disassembly/ inspection/ assembly ................. 40-30-11 Clearance, check.......................................... 20-10-41
Hydrostatic assembly, 2 speed Inspect.......................................................... 20-10-39
Differential assembly Remove and install....................................... 20-10-38
Separate, install.............................................. 40-40-7 3TNV82A, 3TNV88
Disassemble, inspect, assemble...................... 40-40-43 Clearance, check.......................................... 20-20-33
Hydrostatic pedal and neutral safety linkage Remove and install....................................... 20-20-30
component location.............................................. 40-10-2 Main electrical schematic, T4
2 speed .............................................................. 40-20-2 Components..................................................... 230-20-6
Main electrical shemantic, non T4
I Components..................................................... 230-20-1
Metric bolt and screw torque values ...................... 10-10-1
Idler gear Metric torque values (grade 7)............................... 10-10-1
3TNV80F Miscellaneous
Inspect.......................................................... 20-10-52 Fuel tank
Remove and install....................................... 20-10-52 Remove and install......................................... 90-10-4
3TNV82A, 3TNV88 Right side panel
Remove and install....................................... 20-20-43 Remove and install......................................... 90-10-1
Implement lift valve Mixing lubricants.................................................... 10-20-7
Disassemble and assemble ............................... 50-20-4 Mower belt shield removal/installation
Remove and install ............................................ 50-20-3 60, 62, 72-inch side discharge ........................... 70-10-6
Injection pump static timing 72-inch rear discharge ....................................... 70-10-6
3TNV80F........................................................ 220-40-13 Mower blade, sharpen and balance .................... 70-10-20
3TNV82A, 3TNV88 .......................................... 220-45-5 Mower deck
Intake manifold Belt shield
3TNV80F Removal/ installation V-flex .......................... 70-10-13
Remove and install....................................... 20-10-13 Blade removal/installation ................................ 70-10-19
3TNV82A, 3TNV88 Drive shaft removal/installation ........................ 70-10-33
Remove and install....................................... 20-20-14 Drive shaft repair.............................................. 70-10-34
Gearbox removal/installation ........................... 70-10-35
K Gearbox repair ................................................. 70-10-38
Level check and adjust .................................... 270-20-2
Key switch test..................................................... 230-40-5 V-flex ............................................................ 270-20-6
Rotating for service
L 60, 62, and 72- inch (side
discharge)..................................................... 70-10-1
Lift circuit operation ............................................. 250-10-1 72-inch (rear discharge) ................................. 70-10-4
Lift cylinder, remove and install ............................. 50-20-4 Mower drive belt installation
Lift lever, remove and install .................................. 50-20-2 60, 72-inch side discharge ............................... 70-10-10
72-inch rear discharge ..................................... 70-10-12

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V-flex................................................................ 70-10-14
Mower drive belt removal P
60, 72-inch side discharge ................................. 70-10-9
72-inch rear discharge ..................................... 70-10-11 Park brake switch test ....................................... 230-40-23
V-flex................................................................ 70-10-14 Park brake, lock lever
Mower drive belt tension check and Remove and install ............................................ 60-30-8
adjustment PDU
V-flex................................................................ 270-20-8 DOC calibration
Mower drive belt tension, check and adjust Instructions ................................................. 235-15-18
60, 62, 72- inch (side discharge)...................... 270-20-7 DPF calibration
72- inch rear discharge) ................................... 270-20-7 Instructions ................................................. 235-15-18
DPF status screens........................................ 235-15-14
N setup
Display setup screen detailed ...................... 235-20-8
Neutral creep test and adjustment....................... 240-30-1 Setup
Neutral creep, test and adjust Active DTC flow description ......................... 235-20-5
2 Speed............................................................ 240-40-1 Language select ........................................... 235-20-4
Machine start pass code entry ..................... 235-20-8
Machine status screens................................ 235-20-4
O Main screen navigation ................................ 235-20-1
Pass Codes .................................................. 235-20-7
O-ring boss fittings................................................. 10-10-2
Stored DTC flow description......................... 235-20-6
Oil
Version information..................................... 235-20-11
4WD Rear Axle .................................................. 10-10-7
Tier 4 warning popups ................................... 235-15-17
Engine................................................................ 10-10-6
Pedal
MFWD axle housing and wheel hub .................. 10-20-6
Master brake, remove and install....................... 60-30-6
Transaxle ........................................................... 10-10-7
Piston
Oil cooler, inspect .................................................. 50-20-1
3TNV80F
Oil cooler, removand install ................................... 50-20-1
Disassemble and assemble ......................... 20-10-25
Oil filters................................................................. 10-20-5
Inspect.......................................................... 20-10-28
Oil pan and strainer
Remove and install....................................... 20-10-23
3TNV80F
3TNV82A, 3TNV88
Remove and install....................................... 20-10-54
Inspect.......................................................... 20-20-22
3TNV82A, 3TNV88
Remove and install....................................... 20-20-17
Remove and install....................................... 20-20-44
Piston to ylinder head clearance
Oil pressure, test
3TNV82A, 3TNV88 .......................................... 20-20-16
Diesel engine, 3TNV80F.................................. 220-40-6
Pivot pin clearance, 4WD axle, adjust
Diesel engine, 3TNV82A, 3TNV88 ................ 220-45-17
2 Speed............................................................ 240-40-4
Oil pump
Pivot pin clearance, 4wd axle,
3TNV80F
adjustment ......................................................... 240-30-4
Inspect.......................................................... 20-10-55
Problem not found procedure ............................ 235-35-10
Remove and install....................................... 20-10-55
PTO
3TNV82A, 3TNV88
Disassemble, inspect, assemble
Inspect.......................................................... 20-20-45
2 speed......................................................... 40-40-79
Remove and install....................................... 20-20-45
Disassembly/inspeciont/assembly ................... 40-30-47
Oil seal, crankshaft
Pump, charge
3TNV80F
Disassembly/ inspection/ assembly ................... 40-30-7
Front, replace ............................................... 20-10-36
Push rod
Rear, replace ................................................ 20-10-35
3TNV80F
3TNV82A, 3TNV88
Inspect............................................................ 20-10-4
Front, replace ............................................... 20-20-28
Rear, replace ................................................ 20-20-28
Oil, Engine ............................................................. 10-20-4 R
Operator controls
1575 and 1585 (Cab Models) .......................... 280-20-1 Radiator
3TNV82A, 3TNV88
Remove and install....................................... 20-20-49
Radiator cap, pressure test
3TNV80F........................................................ 220-40-16

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3TNV82A, 3TNV88 ........................................ 220-45-16

Receiver/ dryer - HVAC ....................................... 290-30-7 S
Recover/ recycle refrigerant ................................ 290-30-6
Refrigerant Oil Information Safety, Avoid High-Pressure Fluids
HVAC ............................................................... 290-20-1 Avoid High-Pressure Fluids ............................... 05-05-4
Regeneration Schematic
Active ............................................................... 235-15-9 Double spool auxiliary hydraulic kit
Inhibiting Active.............................................. 235-15-10 schematic ....................................................... 250-20-8
Parked............................................................ 235-15-10 GLC electrical schematic ............................... 230-20-27
Relay GLC hydraulic schematic ................................. 250-20-9
Test .................................................................. 230-40-7 Main hydraulic schematic
Relay test, cab power .......................................... 230-40-7 With auxiliary valve....................................... 250-20-5
Removal and installation Without auxiliary valve.................................. 250-20-2
4WD axle ......................................................... 40-30-77 Single spool auxiliary hydraulic kit
4WD drive shaft ............................................... 40-30-64 schematic ....................................................... 250-20-7
4WD gear case ................................................ 40-30-65 Schematics
Repair Electrical
Attachments Backup alarm ............................................. 230-20-34
60, 62-inch mower deck spindle Beacon light................................................ 230-20-35
Disassembly/inspection ............................ 70-10-26 Cab, Lower ................................................. 230-20-21
Removal/installation.................................. 70-10-21 Cab, Upper ................................................. 230-20-23
72-inch mower deck spindle Engine connector X5057 ............................ 230-20-16
Disassembly/inspection ............................ 70-10-26 Engine connector X5058 ............................ 230-20-17
Removal/installation.................................. 70-10-21 Engine connector X5059 ............................ 230-20-18
Mower deck blade Engine connector X5060 ............................ 230-20-19
Removal/installation.................................. 70-10-19 Engine controls and sensors ...................... 230-20-20
Mower deck drive shaft Front work lights ......................................... 230-20-33
Removal/installation.................................. 70-10-33 GLC ............................................................ 230-20-27
Repair ....................................................... 70-10-34 Homologation ............................................. 230-20-30
Mower deck gearbox Main, T4 ....................................................... 230-20-7
Removal/installation.................................. 70-10-35 Non-T4 ......................................................... 230-20-2
Repair ....................................................... 70-10-38 Seat switch test ................................................. 230-40-22
V-flex mower deck belt shield removal/ Service ADVISOR
installation................................................... 70-10-13 ECU data points used in ................................ 235-35-22
Brake system Short to voltage procedure .................................. 235-35-9
Brake linkage, remove and install .................. 60-30-2 Side panel, right
Master brake pedal, remove and Remove and install ............................................ 90-10-1
install ............................................................ 60-30-6 Slow idle, adjust
Turn brake pedals, remove and Diesel engine, 3TNV80F.................................. 220-40-8
install ............................................................ 60-30-4 Diesel engine, 3TNV82A, 3TNV88 .................. 220-45-3
Cab Specifications
Removal and installation ................................ 80-10-6 HVAC ............................................................... 290-30-1
Cab headliner Starting motor
Removal and installation ................................ 80-10-1 Remove and install ............................................ 30-30-7
Cab outer roof Repair ................................................................ 30-30-7
Remove and install......................................... 80-10-2 STC Fittings
Rocker arm Service Recommendations ................................ 10-10-5
3TNV80F Steering column repair kit
Inspect............................................................ 20-10-4 Remove and install ............................................ 60-20-1
Remove and install......................................... 20-10-3 Steering system
3TNV82A, 3TNV88 Component location ........................................... 60-10-1
Remove and install......................................... 20-20-4 Cylinder, remove and install............................... 60-20-2
Rocker arm cover Leakage test .................................................... 260-50-2
3TNV80F Operation
Remove and install......................................... 20-10-2 Manual turn .................................................. 260-10-3
3TNV82A, 3TNV88 Neutral.......................................................... 260-10-1
Remove and install......................................... 20-20-2 Power turn .................................................... 260-10-2

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Valve PTO switch, non-T4.................................... 230-40-17

Leakage test................................................. 260-50-3 PTO switch, T4........................................... 230-40-17
Steering system hose routing, Regulated voltage output test....................... 230-40-4
hydraulics............................................................. 50-10-3 Seat switch test .......................................... 230-40-22
Storing fuel ............................................................ 10-20-2 Sensor tests, accelerator............................ 230-40-24
Suction port, install .............................................. 70-30-12 Test coolant temperature switch................. 230-40-20
System Information Test hydraulic temperature switch .............. 230-40-18
HVAC ............................................................... 290-20-1 Warning alarm test ..................................... 230-40-23
Wiper switch
T Test ......................................................... 230-40-13
Engine, 3TNV80F
Terminal Test ....................................................... 235-35-5 Alternator drive belt tension check and
Tests and adjustments adjust .......................................................... 220-40-1
Attachments Cooling system, pressure test .................... 220-40-15
Mower deck level, check and Cylinder compression test ............................ 220-40-5
adjust .......................................................... 270-20-2 Cylinder leakdown test ............................... 220-40-17
Mower drive belt tension check and Fuel injection nozzle test ............................ 220-40-11
adjustment Fuel injection system test ........................... 220-40-10
V-flex deck ................................................ 270-20-8 Fuel system leak test.................................... 220-40-7
Mower drive belt tension, check and Fuel system priming ..................................... 220-40-7
adjust Fuel transfer pump
60, 62, 72- inch (side Flow test ................................................. 220-40-18
discharge) ............................................... 270-20-7 Pressure test........................................... 220-40-17
72- inch (rear discharge)........................... 270-20-7 Injection pump static timing ........................ 220-40-13
V-flex mower deck level, check and Oil pressure, test .......................................... 220-40-6
adjust .......................................................... 270-20-6 Radiator cap, pressure test ........................ 220-40-16
Brake switch, adjustment ................................. 260-50-6 Slow idle, adjust ........................................... 220-40-8
Electrical Thermostat test .......................................... 220-40-16
A/C (HVAC) switch Throttle cable, adjust .................................... 220-40-9
Test ......................................................... 230-40-15 Valve clearance adjustment ......................... 220-40-2
A/C temperature control switch Valve lift check.............................................. 220-40-4
Test ......................................................... 230-40-15 Engine, 3TNV82A, 3TNV88
Air preheater, test ......................................... 230-40-8 Alternator drive belt tension check and
Battery charge .............................................. 230-40-4 adjust .......................................................... 220-45-1
Battery load test ........................................... 230-40-3 Cooling system, pressure test .................... 220-45-15
Battery test ................................................... 230-40-2 Cylinder compression test ......220-45-2,
Beacon light swtich test................................ 230-40-6 220-45-15
Blower rotary switch test ............................ 230-40-12 Fuel injection nozzle test ............................ 220-45-12
Cruise brake switch test, Non-T4 ............... 230-40-13 Fuel system leakage test............................ 220-45-19
Cruise control switch test ........................... 230-40-12 Fuel system priming ................................... 220-45-19
Dome light switch test ................................ 230-40-16 Fuel transfer pump
Door switch Flow test ................................................. 220-45-18
Test ......................................................... 230-40-16 Pressure test........................................... 220-45-18
DPF differential pressure sensor test, Injection pump static timing .......................... 220-45-5
T4 ............................................................. 230-40-23 Oil pressure, test ........................................ 220-45-17
DPF inlet temperature sensor, T4 .............. 230-40-23 Radiator cap, pressure test ........................ 220-45-16
DPF mid temperature sensor, T4 ............... 230-40-24 Slow idle, adjust ........................................... 220-45-3
Engine Oil Pressure Switch Thermostat test .......................................... 220-45-14
Test ......................................................... 230-40-19 Throttle cable, adjust .................................... 220-45-4
Fuel pump test............................................ 230-40-20 Valve clearance adjustment ....................... 220-45-10
Fuel shutoff solenoid test, non-t4 ............... 230-40-21 HVAC
Fuse test..................................................... 230-40-14 A/ C temperature control cable,
Glow plug test............................................... 230-40-8 adjust .......................................................... 290-30-2
Headlight switch test (single)...................... 230-40-10 Compressor clutch clearance
Key switch test ............................................. 230-40-5 Check........................................................ 290-30-4
Lights rotary switch test.............................. 230-40-11 Compressor oil charge
Park brake switch test ................................ 230-40-23 Check........................................................ 290-30-5
PTO solenoid test....................................... 230-40-18

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Compressor shaft seal Unswitched power circuit .......................... 230-15-2

Leakage test ............................................. 290-30-4 Engine
Evaporator/ heater core Diesel
Leak test ................................................... 290-30-4 Cooling system operation ......................... 220-10-1
Heater Fuel and air system operation .................. 220-10-2
Temperature control cable Lubrication system operation.................... 220-10-2
adjust ...................................................... 290-30-1 Hydraulics
Refrigerant oil to system Auxiliary hydraulics....................................... 250-10-1
Add ........................................................... 290-30-5 GLC circuit.................................................... 250-10-2
Hydraulic Lift circuit ...................................................... 250-10-1
Hydraulic pump flow test .............................. 250-40-4 System operation ......................................... 250-10-1
Oil warm-up procedure................................. 250-40-1 Thermostat
System bleeding procedure.......................... 250-40-1 3TNV80F
MCS600 plus valve test ................................. 250-40-10 Remove and install....................................... 20-10-57
PTO relief valve test......................................... 250-40-8 Test............................................................. 220-40-16
PTO solenoid valve check ............................... 250-40-7 3TNV82A, 3TNV88
Steering system, leakage test.......................... 260-50-2 Remove and install....................................... 20-20-47
Steering valve, leakage test............................. 260-50-3 Test............................................................. 220-45-14
Toe-in, check and adjust .................................. 260-50-1 Throttle cable, adjust
Turn brake, adjust ............................................ 260-50-4 3TNV80F.......................................................... 220-40-9
Theory of operation 3TNV82A, 3TNV88 .......................................... 220-45-4
Brake system ................................................... 260-10-3 Timing gear
Controllers 3TNV80F
CAN trace..................................................... 235-30-2 Backlash, check ........................................... 20-10-49
Hour meter ................................................... 235-30-3 Timing gear backlash check
Primary display unit (PDU) ........................... 235-30-3 3TNV82A, 3TNV88 .......................................... 20-20-42
Electrical Timing gear cover
CAN bus message structure ........................ 235-30-1 3TNV80F
CAN bus operation ....................................... 235-30-2 Remove and install....................................... 20-10-51
Data bus systems......................................... 235-30-2 3TNV82A, 3TNV88
Non-T4 Remove and install....................................... 20-20-41
Charging circuit......................................... 230-10-8 Timing gear housing
Cold start circuit ...................................... 230-10-20 3TNV80F
Cranking circuit ......................................... 230-10-6 Remove and install....................................... 20-10-54
Cruise control circuit ............................... 230-10-24 Timing gear mounting plate
Engine coolant temperature light and 3TNV82A, 3TNV88
buzzer circuit......................................... 230-10-16 Remove and install....................................... 20-20-44
Engine oil pressure light and buzzer Toe-in, check and adjust...................................... 260-50-1
circuit..................................................... 230-10-14 Torque charts
Fuel shutoff solenoid circuit .................... 230-10-22 Metric ................................................................. 10-10-1
Hydraulic oil temperature light and Unified inch ........................................................ 10-10-2
buzzer circuit......................................... 230-10-18 Torque value
Operator presence and pto interlock Flat face O-ring seal fitting ................................. 10-10-4
circuit....................................................... 230-10-9 O-Ring boss fitting ............................................. 10-10-2
Power circuit, switched ............................. 230-10-3 Torque values
Power circuit, unswitched ......................... 230-10-2 Metric (grade 7).................................................. 10-10-1
T4 Transaxle
Charging circuit....................................... 230-15-13 Charge pump disassembly/ inspection/
Cold start circuit ...................................... 230-15-23 assembly .......................................................... 40-30-7
Cranking ................................................. 230-15-10 Component location
Cruise control circuit ............................... 230-15-24 Single speed................................................... 40-10-1
Engine coolant temperature Component location, 4WD ................................. 40-10-3
circuit..................................................... 230-15-19 Hydrostatic assembly disassembly/
Engine oil pressure circuit....................... 230-15-18 inspection/ assembly...................................... 40-30-11
Hydraulic oil temperature circuit ............. 230-15-21 Hydrostatic assembly- to- differential
Operator presence and PTO interlock assembly separation/ installation ..................... 40-30-4
circuit..................................................... 230-15-16 Removal and installation.................................... 40-30-2
Switched power circuit .............................. 230-15-6 Transaxle Oil ......................................................... 10-10-7

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Transaxle, 2 speed
Charge pump W
Disassemble, inspect, assemble .................. 40-40-11
Component location ........................................... 40-20-1 Warm-up procedure
Component location, 4wd .................................. 40-20-3 Hydraulic oil ..................................................... 250-40-1
Component location, hydrostatic pedal Water pump
and neutral safety linkage ................................ 40-20-2 3TNV80F
Hydrostatic assembly Inspect.......................................................... 20-10-59
Disassemble, inspect, assemble .................. 40-40-43 Remove and install....................................... 20-10-59
Hydrostatic assembly- to- differential 3TNV82A, 3TNV88
assembly Inspect.......................................................... 20-20-48
Separate, install.............................................. 40-40-7 Remove and install....................................... 20-20-48
Remove and install ............................................ 40-40-2 Water separator
Transmission/hydraulic filter element .................... 10-20-5 3TNV82A, 3TNV88 .......................................... 20-20-51
Turn brake, adjust................................................ 260-50-4 Wiggle Test
Turn signal switch, test ...................................... 230-40-11 Intermittent Diagnostics ................................... 235-35-8
Wiring harness
U Air ride seat
Color codes .................................................. 30-20-43
Unified inch bolt and screw torque Splice table................................................... 30-20-43
values .................................................................. 10-10-2 Backup alarm
Splice table................................................... 30-20-42
Beacon lamp
V Splice table................................................... 30-20-29
Beacon lamp harness ...................................... 30-20-29
Valve clearance adjustment
Beacon lamp harness, wire table..................... 30-20-30
3TNV80F.......................................................... 220-40-2
Cab harness..................................................... 30-20-21
3TNV82A, 3TNV88 ........................................ 220-45-10
Cab harness, connectors ................................. 30-20-25
Valve guides
Cab harness, splice table................................. 30-20-28
3TNV82A, 3TNV88 .......................................... 20-20-12
Cab harness, wire table ................................... 30-20-26
Valve lift check
Front work lights............................................... 30-20-41
3TNV80F.......................................................... 220-40-4
Homologation................................................... 30-20-34
3TNV82A, 3TNV88 ............................................ 20-20-3
Splice table................................................... 30-20-32
Valve recession
Wiring table .................................................. 30-20-31
3TNV82A, 3TNV88 .......................................... 20-20-11
Keyswitch harness ........................................... 30-20-20
Valve seats
Main harness
3TNV82A, 3TNV88 ............................................ 20-20-9
Non-T4 ........................................................... 30-20-2
Valve seats, grind
T4 ................................................................. 30-20-10
3TNV80F.......................................................... 20-10-13
Main harness, connectors
3TNV82A, 3TNV88 .......................................... 20-20-14
Non-T4 ........................................................... 30-20-6
Valve springs
T4 ................................................................. 30-20-15
3TNV82A, 3TNV88 .......................................... 20-20-13
Main harness, splice table
Valves, intake and exhaust
Non-T4 ........................................................... 30-20-9
3TNV82A, 3TNV88 .......................................... 20-20-10
T4 ................................................................. 30-20-18
Valves, lap
Main harness, terminal table
3TNV80F.......................................................... 20-10-15
T4 ................................................................. 30-20-19
3TNV82A, 3TNV88 .......................................... 20-20-15
Main harness, wire table
Verification
Non-T4 ........................................................... 30-20-7
Aftertreatment Verification Proce-
T4 ................................................................. 30-20-16
dure .............................................................. 235-15-17
Work lights
Verification procedure.......................................... 235-35-7
Splice table................................................... 30-20-42
Wiring table .................................................. 30-20-42

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