Introduction
Foreword
This manual is written for an experienced technician. Essential tools required in performing certain service work are identified in this manual and are recommended for use.
Live with safety: Read the safety messages in the introduction of this manual and the cautions presented throughout the text of the manual.
This is the safety-alert symbol. When you see this symbol on the machine or in this manual, be alert to the potential for personal injury.
Technical manuals are divided in two parts: repair and operation and tests. Repair sections tell how to repair the components. Operation and tests sections help you identify the majority of routine failures quickly.
Information is organized in groups for the various components requiring service instruction. At the beginning of each group are summary listings of all applicable essential tools, service equipment and tools, other materials needed to do the job, service parts kits, specifications, wear tolerances, and torque values.
Technical Manuals are concise guides for specific machines. They are on-the-job guides containing only the vital information needed for diagnosis, analysis, testing, and repair.
Fundamental service information is available from other sources covering basic theory of operation, fundamentals of troubleshooting, general maintenance, and basic type of failures and their causes.
770G, 770GP, 772G and 772GP Motor Grader Operation and Test
SECTION 9000 General Information
Group 01 Safety
SECTION 9001 Diagnostics
Group 10 Transmission Control Unit (TCU)
Diagnostic Trouble Codes
Group 20 Engine Control Unit (ECU) Diagnostic
Trouble Codes
Group 30 Advance Display Unit (ADU) Diagnostic
Trouble Codes
Group 40 Flex Load Controller (FLC) Diagnostic
Trouble Codes
Group 50 Hydraulic Valve Controller (HVC)
Diagnostic Trouble Codes
Group 60 Auxiliary Valve Controller (AVC)
Diagnostic Trouble Codes
Group 70 Sealed Switch Module (SSM) Diagnostic
Trouble Codes
Group 80 Six Wheel Drive (6WD) Diagnostic
Trouble Codes
Group 90 LJ1 Diagnostic Trouble Codes
Group 100 LJ2 Diagnostic Trouble Codes
Group 110 LJ3 Diagnostic Trouble Codes
Group 120 LJ4 Diagnostic Trouble Codes
Group 130 RJ1 Diagnostic Trouble Codes
Group 140 RJ2 Diagnostic Trouble Codes
Group 150 RJ3 Diagnostic Trouble Codes
Group 160 RJ4 Diagnostic Trouble Codes
SECTION 9005 Operational Checkout Procedure
Group 10 Operational Checkout Procedure
SECTION 9010 Engine
Group 05 Theory of Operation
Group 15 Diagnostic Information
Group 25 Tests
SECTION 9015 Electrical System
Group 05 System Information
Group 10 System Diagrams
Group 15 Sub-System Diagnostics
Group 16 Monitor Operation
Group 20 References
SECTION 9016—Six Wheel Drive (6WD)
Group 05 Theory of Operation
Group 15 Diagnostic Information
Group 20 Adjustments
Group 25 Tests
SECTION 9020 Power Train
Group 05 Theory of Operation
Group 15 Diagnostic Information
Group 25 Tests
SECTION 9025—Hydraulic System
Group 05 Theory of Operation
Group 15 Diagnostic Information
Group 25 Tests
SECTION 9031—Heating and Air Conditioning
Group 05 Theory of Operation
Group 15 Diagnostic Information
Group 20 Adjustments
Group 25 Tests
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.
770G,i7i70GP, 772G and 772GP Motor Grader Operation and Test
Group 01 Safety9000-01-1
Recognize Safety Information
This is the safety alert symbol. When this symbol is noticed on the machine or in this manual, be alert for the potential of personal injury.
Follow the precautions and safe operating practices highlighted by this symbol.
A signal word DANGER, WARNING, or CAUTION is used with the safety alert symbol. DANGER identifies the most serious hazards.
On the machine, DANGER signs are red in color, WARNING signs are orange, and CAUTION signs are yellow. DANGER and WARNING signs are located near specific hazards. General precautions are on CAUTION labels.
Follow Safety Instructions
Read the safety messages in this manual and on the machine. Follow these warnings and instructions carefully. Review them frequently. Keep safety signs in good condition. Replace missing or damaged safety signs. Be sure new equipment components and repair parts include the current safety signs. Replacement safety signs are available from your John Deere dealer.
Be sure all operators of this machine understand every safety message. Replace operator’s manual and safety labels immediately if missing or damaged.
Operate Only If Qualified
Do not operate this machine unless the operator’s manual has been read carefully, and you have been qualified by supervised training and instruction.
machine functions with the machine in an open area before starting to work.
Know and observe all safety rules that may apply to Operator should be familiar with the job site and every work situation and work site. surroundings before operating. Try all controls and
Wear Protective Equipment
Guard against injury from flying pieces of metal or debris; wear goggles or safety glasses.
Wear close fitting clothing and safety equipment appropriate to the job.
Prolonged exposure to loud noise can cause impairment or loss of hearing. Wear suitable hearing protection such as earmuffs or earplugs to protect against objectionable or uncomfortable loud noises.
Avoid Unauthorized Machine Modifications
John Deere recommends using only genuine John Deere replacement parts to ensure machine performance. Never substitute genuine John Deere parts with alternate parts not intended for the application as these can create hazardous situations or hazardous performance. Non-John Deere parts, or any damage or failures resulting from their use are not covered by any John Deere warranty.
Modifications of this machine, or addition of unapproved products or attachments, may affect
machine stability or reliability, and may create a hazard for the operator or others near the machine. The installer of any modification which may affect the electronic controls of this machine is responsible for establishing that the modification does not adversely affect the machine or its performance.
Always contact an authorized dealer before making machine modifications that change the intended use, weight or balance of the machine, or that alter machine controls, performance or reliability.
Inspect machine carefully each day by walking around it before starting.
Keep all guards and shields in good condition and properly installed. Fix damage and replace worn or broken parts immediately. Pay special attention to hydraulic hoses and electrical wiring.
Stay Clear of Moving Parts
Entanglements in moving parts can cause serious injury.
Stop engine before examining, adjusting or maintaining any part of machine with moving parts.
Keep guards and shields in place. Replace any guard or shield that has been removed for access as soon as service or repair is complete.
Avoid High-Pressure Fluids
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.
Avoid High-Pressure Oils
This machine uses a high-pressure hydraulic system. Escaping oil under pressure can penetrate the skin causing serious injury.
Never search for leaks with your hands. Protect hands. Use a piece of cardboard to find location of escaping oil. Stop engine and relieve pressure before disconnecting lines or working on hydraulic system.
If hydraulic oil penetrates your skin, see a doctor immediately. Injected oil must be removed surgically within hours or gangrene may result. Contact a knowledgeable medical source or the Deere & Company Medical Department in Moline, Illinois, U.S.A.
Beware of Exhaust Fumes
Prevent asphyxiation. Engine exhaust fumes can cause sickness or death.
If you must operate in an enclosed space, provide adequate ventilation. Use an exhaust pipe extension to remove the exhaust fumes or open doors and windows to bring outside air into the area.
Prevent Fires
Handle Fuel Safely: Store flammable fluids away from fire hazards. Never refuel machine while smoking or when near sparks or flame.
Clean Machine Regularly: Keep trash, debris, grease and oil from accumulating in engine compartment, around fuel lines, hydraulic lines, exhaust components, and electrical wiring. Never store oily rags or flammable materials inside a machine compartment.
Maintain Hoses and Wiring: Replace hydraulic hoses immediately if they begin to leak, and clean up any oil spills. Examine electrical wiring and connectors frequently for damage.
Keep A Fire Extinguisher Available: Always keep a multipurpose fire extinguisher on or near the machine. Know how to use extinguisher properly.
Prevent Battery Explosions
Battery gas can explode. Keep sparks, lighted matches, and open flame away from the top of battery.
Never check battery charge by placing a metal object across the posts. Use a voltmeter or hydrometer.
Do not charge a frozen battery; it may explode. Warm battery to 16C (60F).
Handle Chemical Products Safely
Exposure to hazardous chemicals can cause serious injury. Under certain conditions, lubricants, coolants, paints and adhesives used with this machine may be hazardous.
If uncertain about safe handling or use of these chemical products, contact your authorized dealer for a Material Safety Data Sheet (MSDS) or go to http://www.jdmsds.com. The MSDS describes physical and health hazards, safe use procedures, and emergency response techniques for chemical substances. Follow MSDS recommendations to handle chemical products safely. TX03679,00016D7 –
Dispose of Waste Properly
Improper disposal of waste can threaten the environment. Fuel, oils, coolants, filters and batteries used with this machine may be harmful if not disposed of properly.
Never pour waste onto the ground, down a drain, or into any water source.
Air conditioning refrigerants can damage the atmosphere. Government regulations may require using a certified service center to recover and recycle used refrigerants.
If uncertain about the safe disposal of waste, contact your local environmental or recycling center or your authorized dealer for more information.
Prepare for Emergencies
Be prepared if an emergency occurs or 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.
Use Steps and Handholds Correctly
Prevent falls by facing the machine when getting on and off. Maintain 3-point contact with steps and handrails. Never use machine controls as handholds.
Use extra care when mud, snow, or moisture present slippery conditions. Keep steps clean and free of grease or oil. Never jump when exiting machine. Never mount or dismount a moving machine.
Start Only From Operator’s Seat
Avoid unexpected machine movement. Start engine only while sitting in operator’s seat. Ensure all controls and working tools are in proper position for a parked machine.
Never attempt to start engine from the ground. Do not attempt to start engine by shorting across the starter solenoid terminals.
Use and Maintain Seat Belt
Use seat belt when operating machine. Remember to fasten seat belt when loading and unloading from trucks and during other uses.
Examine seat belt frequently. Be sure webbing is not cut or torn. Replace seat belt immediately if any part is damaged or does not function properly.
The complete seat belt assembly should be replaced every 3 years, regardless of appearance.
Prevent Unintended Machine Movement
Be careful not to accidentally actuate controls when coworkers are present.
Lower all equipment to the ground during work interruptions. Place transmission control and park brake lever in park position P before allowing anyone to approach the machine.
Follow these same precautions before standing up, leaving the operator’s seat, or exiting the machine.
Avoid Work Site Hazards
Avoid contact with gas lines, buried cables and water lines. Call utility line location services to identify all underground utilities before starting work.
Prepare work site properly. Avoid operating near structures or objects that could fall onto the machine. Clear away debris that could move unexpectedly if run over.
Avoid boom or attachment contact with overhead obstacles or overhead electrical lines. Never move machine closer than 3 m (10 ft) plus twice the line insulator length to overhead wires.
Keep bystanders clear at all times. Keep bystanders away from raised booms, attachments, and unsupported loads. Avoid swinging or raising booms, attachments, or loads over or near personnel. Use barricades or a signal person to keep vehicles and pedestrians away. Use a signal person if moving machine in congested areas or where visibility is restricted. Always keep signal person in view. Coordinate hand signals before starting machine.
Operate only on solid footing with strength sufficient to support machine. Be especially alert working near embankments or excavations.
Avoid working under over-hanging embankments or stockpiles that could collapse under or on machine.
Reduce machine speed when operating with tool on or near ground when obstacles may be hidden (e.g., during snow removal or clearing mud, dirt, etc.). At high speeds hitting obstacles (rocks, uneven concrete or manholes) can cause a sudden stop. Always wear your seat belt.
Keep Riders Off Machine
Only allow operator on machine.
Riders are subject to injury. They may fall from machine, be caught between machine parts, or be struck by foreign objects.
Riders may obstruct operator’s view or impair his ability to operate machine safely.
Avoid Backover Accidents
Before moving machine, be sure all persons or vehicles are clear of machine path. Turn around and look directly for best visibility. Use mirrors to assist in checking all around machine. Keep windows and mirrors clean, adjusted, and in good repair.
Be certain reverse warning alarm is working properly.
Use a signal person when backing if view is obstructed or when in close quarters. Keep signal person in view at all times. Use prearranged hand signals to communicate.
Do not rely on the rear camera to determine if personnel are behind the machine.
Avoid Machine Tip-Over
Use seat belt at all times.
Do not jump if the machine tips. You will be unlikely to jump clear and the machine may crush you.
Load and unload from trucks or trailers carefully. Be sure truck is wide enough and on a firm level surface. Use loading ramps and attach them properly to truck bed.
Be careful on slopes. Drive directly up or down steep slopes whenever possible. Minimize articulation for best machine stability when driving and turning across slopes. Use extra care on wet, soft or frozen surfaces because machine may slide more easily with these conditions.
Ensure solid footing. Do not operate close to banks or open excavations that may cave in and cause machine to tip or fall.
Operating Or Traveling On Public Roads
Machines that work near vehicle traffic or travel slower than normal highway speeds must have proper lighting and markings to assure they are visible to other drivers.
Install additional lights, beacons, slow moving vehicle (SMV) emblems, or other devices and use as required to make the machine visible and identify it as a work machine. Check state and local regulations to assure compliance. Keep these devices clean and in working condition.
Inspect and Maintain ROPS
A damaged roll-over protective structure (ROPS) should be replaced, not reused.
To maintain the ROPS:
• Replace missing hardware using correct grade
The protection offered by ROPS will be impaired if hardware. ROPS is subjected to structural damage, is involved in
• Check hardware torque. an overturn incident, or is in any way altered by
• Check isolation mounts for damage, looseness or welding, bending, drilling, or cutting. wear; replace them if necessary.
If ROPS was loosened or removed for any reason, inspect it carefully before operating the machine again.
Add and Operate Attachments Safely
Always verify compatibility of attachments by contacting your authorized dealer. Adding unapproved attachments may affect machine stability or reliability, and may create a hazard for others near the machine.
Ensure that a qualified person is involved in attachment installation. Add guards to machine if operator protection is required or recommended. Verify
• Check ROPS for cracks or physical damage.
TX03679,000179F –19–20APR01–1/1
that all connections are secure and attachment responds properly to controls.
Carefully read attachment manual and follow all instructions and warnings. In an area free of bystanders and obstructions, carefully operate attachment to learn its characteristics and range of motion.
TX03679,00016F0 –19–24JAN07–1/1
Park And Prepare For Service Safely
Warn others of service work. Always park and prepare your machine for service or repair properly.
• Park machine on a level surface and lower equipment to the ground.
• Place transmission control and park brake lever in P park position. Stop engine.
• Attach a Do Not Operate tag in an obvious place in the operator’s station.
Securely support machine or attachment before working under it.
• Do not support machine with any hydraulically actuated equipment.
• Do not support machine with cinder blocks or wooden pieces that may crumble or crush.
• Do not support machine with a single jack or other devices that may slip out of place.
Understand service procedures before beginning repairs. Keep service area clean and dry. Use two people whenever the engine must be running for service work.
Service Cooling System Safely
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.
Remove Paint Before Welding or Heating
Hazardous fumes can be generated when paint is heated by welding or using a torch. Dust from sanding or grinding paint can also be hazardous.
Remove paint to at least 76 mm (3 in.) from area to be heated. Wear an approved respirator when sanding or grinding paint. If a solvent or paint stripper is used, wash area with soap and water. Remove solvent or paint stripper containers from work area, and allow fumes to disperse at least 15 minutes before welding or heating.
Work outside or in a well-ventilated area. Dispose of waste, paint, and solvents properly. TX03679,0001732
Make Welding Repairs Safely
IMPORTANT: Disable electrical power before welding. Turn off main battery switch or disconnect positive battery cable. Separate harness connectors to engine and vehicle microprocessors.
Avoid welding or heating near pressurized fluid lines. Flammable spray may result and cause severe burns if pressurized lines fail as a result of heating. Do not let heat go beyond work area to nearby pressurized lines.
Remove paint properly. Do not inhale paint dust or fumes. Use a qualified welding technician for structural repairs. Make sure there is good ventilation. Wear eye protection and protective equipment when welding. TX03679,00016D5
Drive Metal Pins Safely
Always wear protective goggles or safety glasses and other protective equipment before striking hardened parts. Hammering hardened metal parts such as pins and bucket teeth may dislodge chips at high velocity.
Use a soft hammer or a brass bar between hammer and object to prevent chipping.
Service Tires Safely
Explosive separation of a tire and rim parts can cause serious injury or death.
Do not attempt to mount a tire unless you have the proper equipment and experience to perform the job.
Always maintain the correct tire pressure. Do not inflate the tires above the recommended pressure. Never weld or heat a wheel and tire assembly. The heat can cause an increase in air pressure resulting in a tire explosion. Welding can structurally weaken or deform the wheel.
When inflating tires, use a clip-on chuck and extension hose long enough to allow you to stand to one side and NOT in front of or over the tire assembly. Use a safety cage if available.
Check wheels for low pressure, cuts, bubbles, damaged rims or missing lug bolts and nuts.
Section 9001 Diagnostics
Clutch 1 Hold Pressure Too Low Diagnostic Group 10 Transmission Control Unit (TCU)
Has Taken On An Invalid Value.
525.12 Request For An Undefined Shift
Request For An Undefined Shift Being Made
Engine Speed Sensor Bias
522252.00 Clutch 1 Hold Pressure Too
Clutch 1 Hold Pressure Too High Diagnostic
522252.01 Clutch 1 Hold Pressure Too Low
Continued on next page
Clutch C Hold Pressure Too High Diagnostic
9001 Procedure.......................................................9001-10-25
522258.01 Clutch C Hold Pressure Too Low 9001-10-26
Clutch C Hold Pressure Too Low Diagnostic Procedure 9001-10-26
522259.00 Clutch D Hold Pressure Too High.................................................................9001-10-27
Clutch D Hold Pressure Too High Diagnostic Procedure 9001-10-27
522259.01 Clutch D Hold Pressure Too Low 9001-10-28
Clutch D Hold Pressure Too High Diagnostic Procedure.......................................................9001-10-28
522397.04 Not In Forward Or Reverse While In Gear.................................................9001-10-29
Not In Forward Or Reverse While In Gear Diagnostic Procedure 9001-10-29
522398.12 Park And Not Park Both Active 9001-10-31
Park And Not Park Both Active 9001-10-31
522405.05 Park Brake Pressure Low At Power-up 9001-10-33
Park Brake Pressure Low At Power-up
Diagnostic Procedure...................................9001-10-34
522413.12 Gear Bits Active In Park 9001-10-35 Park Brake Pressure Low At Power-up Diagnostic Procedure...................................9001-10-36
522414.03 Transmission Clutch D Short To Power 9001-10-38
Transmission Clutch D Short To Power Diagnostic Procedure 9001-10-38
522414.05 Transmission Clutch D Open/Short To Ground ................................9001-10-39
Transmission Clutch D Open/Short To Ground Diagnostic Procedure.....................9001-10-39
522507.14 Inching Pedal During Trans
523700.16 Trans Clutch Protect Active
Reduce Inching
9001-10-46
Transmission Clutch Protect Active Reduce Inching Diagnostic Procedure.......9001-10-47
523700.31 Transmission Direction Clutch Slipping............................................................9001-10-48
Transmission Direction Clutch Slipping Diagnostic Procedure 9001-10-48
523708.02 Inching Switch Signal Bad 9001-10-50
Inching Switch Signal Bad Diagnostic Procedure 9001-10-50
523712.31 Transmission CAL Without Park Brake Set 9001-10-51
Transmission CAL Without Park Brake Set Diagnostic Procedure....................................9001-10-51
523717.31 Helper Clutch Pressure High 9001-10-53
Helper Clutch Pressure High Diagnostic Procedure 9001-10-53
523718.31 Clutch Drum Speed Decel Excessive 9001-10-54
Clutch Drum Speed Decel Excessive Diagnostic Procedure....................................9001-10-54
523720.00 Clutch D Fill Time Too Long.................................................................9001-10-55
Clutch D Fill Time Too Long Diagnostic Procedure .......................................................9001-10-55
523720.01 Clutch D Fill Time Too Short 9001-10-56
Clutch D Fill Time Too Long Diagnostic Procedure 9001-10-56
523721.00 Clutch C Fill Time Too Long 9001-10-57
Clutch C Fill Time Too Long Diagnostic
Procedure .......................................................9001-10-57
523721.01 Clutch C Fill Time Too Short
Clutch C Fill Time Too Long Diagnostic Calibration .9001-10-40 Procedure
Inching Pedal During Trans Calibration
9001-10-58
9001-10-58
523722.00 Clutch B Fill Time Too Diagnostic Procedure. 9001-10-40 Long 9001-10-59
523655.03 Forward And Reverse Both
Clutch B Fill Time Too Long Diagnostic Active 9001-10-41 Procedure .......................................................9001-10-59 Forward and Reverse Both Active Diagnostic
523722.01 Clutch B Fill Time Too Procedure .
. . .9001-10-41 Short 9001-10-60
523699.31 Transmission Speed Clutch
Clutch B Fill Time Too Long Diagnostic Slipping .9001-10-42 Procedure 9001-10-60
Transmission Speed Clutch Slipping
523723.00 Clutch A Fill Time Too Diagnostic Procedure. 9001-10-42 Long 9001-10-61
523700.00 Clutch Protection Excessive
Clutch A Fill Time Too Long Diagnostic Inching. .
. .9001-10-44 Procedure 9001-10-61
Clutch Protection Excessive Inching Diagnostic Procedure................................... 9001-10-44
Continued on next page
523723.01 Clutch A Fill Time Too
523731.31 Transmission Output Speed Short .9001-10-62
Clutch A Fill Time Too Long Diagnostic
Detected At Calibration 9001-10-76
Transmission Output Speed Detected At Procedure .9001-10-62
523724.00 Clutch 4 Fill Time Too
Calibration Diagnostic Procedure ...............9001-10-76 9001
523732.31 Engine Speed Too Low To Long
.9001-10-63
Calibrate The Transmission.........................
9001-10-78
Clutch 4 Fill Time Too Long Diagnostic Engine Speed Too Low To Calibrate The Procedure .9001-10-63 Transmission Diagnostic Procedure 9001-10-78
523724.01 Clutch 4 Fill Time Too
523733.31 Engine Speed Too High To Short .9001-10-64
Calibrate The Transmission 9001-10-80
Clutch 4 Fill Time Too Long Diagnostic Engine Speed Too Low To Calibrate The Procedure .9001-10-64 Transmission Diagnostic Procedure 9001-10-80
523725.00 Clutch 3 Fill Time Too
523734.31 Transmission Too Cold To Long .9001-10-65 Calibrate ..........................................................9001-10-82
Clutch 3 Fill Time Too Long Diagnostic Transmission Too Cold To Calibrate Procedure
Procedure ...................................9001-10-82
523725.01 Clutch 3 Fill Time Too 523735.04 Valve Driver Supply Voltage Short
Clutch 3 Fill Time Too Long Diagnostic Valve Driver Supply Voltage Low Diagnostic
523726.00 Clutch 2 Fill Time Too 523736.14 Bad Gear Position Switch Long .9001-10-67
Clutch 2 Fill Time Too Long Diagnostic Bad Gear Position Switch State Diagnostic Procedure .9001-10-67
523726.01 Clutch 2 Fill Time Too 523738.02 Shifter Handle Problem...........9001-10-86 Short
.9001-10-68 Shifter Handle Problem Diagnostic
Clutch 2 Fill Time Too Long Diagnostic Procedure.......................................................9001-10-86 Procedure .9001-10-68
523738.31 Shifter Handle Problem 9001-10-87
523727.00 Clutch 1 Fill Time Too Shifter Handle Problem Diagnostic Long .9001-10-69 Procedure 9001-10-88
Clutch 1 Fill Time Too Long Diagnostic
523739.31 Not Park And Forward/Reverse Procedure .9001-10-69 Mismatch 9001-10-89
523727.01 Clutch 1 Fill Time Too Not Park And Forward/Reverse Mismatch Short .9001-10-70 Diagnostic Procedure ...................................
Clutch 1 Fill Time Too Long Diagnostic
523728.31 Transmission Reverse Forward/Reverse Switch And Gear Mismatch Cylinder Speed Incorrect At Diagnostic Procedure 9001-10-91 Calibration .9001-10-70 523741.31 Started In
Incorrect At Calibration Diagnostic
Vsense Low Diagnostic 523729.31 Transmission Forward
.......................................................
Cylinder Speed Incorrect At
Park and Not Park Both Calibration
Transmission Reverse Cylinder Speed Park and Not Park Both Passive Diagnostic Incorrect At Calibration Diagnostic
523730.31 No Transmission Cylinder Or Neutral 9001-10-96 Speed During Calibration. .9001-10-74 Not Park Passive In Gear Or Neutral
Transmission Reverse Cylinder Speed Incorrect At Calibration Diagnostic Procedure 9001-10-74
Continued on next page
9001
523754.03
Not Park Active At Startup .9001-10-98 524194.07
Not Park Active At Startup Diagnostic Procedure 9001-10-99
523755.05 Park Start Input Passive At Power Up .....................................................9001-10-101
Park Start Input Passive At Power Up Diagnostic Procedure 9001-10-101
523761.03 Transmission Clutch 4 Short To Power 9001-10-102
Transmission Clutch 4 Short To Power Diagnostic Procedure.................................9001-10-103
523761.05 Transmission Clutch 4 Open/Short To Ground 9001-10-103
Transmission Clutch 4 Open/Short To Ground Diagnostic Procedure 9001-10-103
523762.03 Transmission Clutch 3 Short To Power......................................................9001-10-105
Transmission Clutch 3 Short To Power Diagnostic Procedure.................................9001-10-105
523762.05 Transmission Clutch 3 Open/Short To Ground 9001-10-105
Transmission Clutch 3 Open/Short To Ground Diagnostic Procedure 9001-10-105
523763.03 Transmission Clutch 2 Short To Power......................................................9001-10-107
Transmission Clutch 2 Short To Power Diagnostic Procedure 9001-10-107
523763.05 Transmission Clutch 2 Open/Short To Ground 9001-10-107
Transmission Clutch 2 Open/Short To Ground Diagnostic Procedure 9001-10-107
523764.03 Transmission Clutch 1 Short
To Power.
9001-10-109
Mismatch
Direction Sensor
9001-10-115
Direction Sensor Mismatch Diagnostic Procedure .....................................................9001-10-115
524271.03 Transmission Clutch C Short To Power ......................................................9001-10-116
Transmission Clutch C Short To Power Diagnostic Procedure 9001-10-116
524271.05 Transmission Clutch C Open/Short To Ground 9001-10-117
Transmission Clutch C Open/Short To Ground Diagnostic Procedure 9001-10-117
524272.03 Transmission Clutch B Short To Power ......................................................9001-10-118
Transmission Clutch B Short To Power Diagnostic Procedure..................................9001-10-118
524272.05 Transmission Clutch B Open/Short To Ground 9001-10-118
Transmission Clutch B Open/Short To Ground Diagnostic Procedure 9001-10-119
524273.03 Transmission Clutch A Short To Power 9001-10-120
Transmission Clutch A Short To Power Diagnostic Procedure..................................9001-10-120
524273.05 Transmission Clutch A Open/Short To Ground...............................9001-10-120
Transmission Clutch A Open/Short To Ground Diagnostic Procedure 9001-10-121
524275.31 Forward/Reverse Without Valid Gear 9001-10-122
Forward/Reverse Without Valid Gear Diagnostic Procedure 9001-10-122
Group 20 Engine Control Unit (ECU) Diagnostic
Transmission Clutch 1 Short To Power Trouble Codes Diagnostic Procedure. 9001-10-109 29.03 Decel Pedal Short to Power 9001-20-1 523764.05 Transmission Clutch 1
Decel Pedal Short to Power Diagnostic Open/Short To Ground 9001-10-109 Procedure .........................................................9001-20-1
Transmission Clutch 1 Open/Short To 91.03 Accel Pedal Short to Power 9001-20-2
Ground Diagnostic Procedure 9001-10-109
Accel Pedal Short to Power Diagnostic
524029.00 Inching Pedal Out Of Range Procedure 9001-20-2 High. 9001-10-111
Inching Pedal Out Of Range High Diagnostic
Accel Pedal Open or Short 9001-20-2
Accel Pedal Open or Short Diagnostic Procedure 9001-10-111 Procedure 9001-20-3
524029.01 Inching Pedal Out Of Range
Engine Air Filter Restricted
Low 9001-10-112 Engine Air Filter Restricted Diagnostic Inching Pedal Out Of Range Low Diagnostic Procedure 9001-20-4 Procedure 9001-10-112 596.31 Engine Speed Control Enable
524029.12 Inching Pedal Minimum Switch Fault......................................................9001-20-5
Voltage Exceeds Maximum Voltage. 9001-10-113 Engine Speed Control Enable Switch Fault
Inching Pedal Minimum Voltage Exceeds Diagnostic Procedure......................................9001-20-5
Maximum Voltage Diagnostic Procedure..................................................... 9001-10-113 Continued on next page
600.31 Engine Speed Accel/ Decel 2033.09
Communication Lost For Switch Fault 9001-20-7
Engine Speed Accel/ Decel Switch Fault
1196.31 ECU Anti Theft Locked..................
ECU Anti Theft Locked Diagnostic
1321.05 Starter Relay Open Circuit
Starter Relay Open Circuit Diagnostic Procedure 9001-20-8
1321.06 Starter Relay High Current 9001-20-10
Starter Relay High Current Diagnostic Procedure 9001-20-10
1321.30 Starter Engaged for 30 Seconds..........................................................9001-20-11
Starter Engaged for 30 Seconds Diagnostic Procedure 9001-20-11
1321.31 Starter Solenoid Open Circuit 9001-20-11
Starter Solenoid Open Circuit Diagnostic
CAN Communication Lost For FLC
Group 30 Advance Display Unit (ADU) Diagnostic Trouble Codes
158.03 Switched Power Voltage High 9001-30-1
Switched Power Voltage High Diagnostic Procedure 9001-30-1
158.04 Switched Power Voltage Low 9001-30-1
Switched Power Voltage Low Diagnostic Procedure .........................................................
168.03
Battery Voltage High Diagnostic
168.04 Battery Voltage Low 9001-30-4
Switched Power Voltage Low Diagnostic
442.00
Display Temperature High Diagnostic
CAN Low Voltage Low Diagnostic
524076.10 Information Button Stuck.........9001-30-15 Information Button Stuck Diagnostic
9001-30-16
524077.10 Back Key Button Stuck ...........9001-30-16
Back Key Button Stuck Diagnostic
.......................................................9001-30-16
524078.10 Menu Select Button Stuck 9001-30-17
Menu Select Button Stuck Diagnostic
.......................................................9001-30-17
524080.10 Down Arrow Button Stuck 9001-30-18
Down Arrow Button Stuck Diagnostic
524082.10 Up Arrow Button Stuck............9001-30-19
Up Arrow Button Stuck Diagnostic
442.01 Display Temperature Low .9001-30-6 Group 40 Flex Load Controller (FLC) Diagnostic
Display Temperature Low Diagnostic Trouble Codes Procedure .9001-30-6 96.03 Fuel Level Sender Open or 1491.11 LCD Backlight Failure 9001-30-7
LCD Backlight Failure Diagnostic Procedure 9001-30-7
9001-40-1
Continued on next page
Fuel Level Sender Open or Short Diagnostic 977.07 Fan Pressure Too High to Procedure .9001-40-1 Reverse........................................................... 9001-40-19
96.04 Fuel Level Sender Short To Reversing Fan Pressure Too High to Reverse Ground .9001-40-2 Diagnostic Procedure................................... 9001-40-19
Fuel Level Sender Short To Ground 1045.04 Brake Light Switch Short to Diagnostic Procedure. .9001-40-2 Ground 9001-40-20
117.01 Service Brake Pressure Low. . . . .9001-40-3 Brake Light Switch Short to Ground Service Brake Pressure Low Diagnostic Diagnostic Procedure 9001-40-20 Procedure .
.9001-40-3 1071.03 Fan Speed Solenoid Open or
117.04 Service Brake Accumulator Short 9001-40-21 Switch Short to Ground .9001-40-4 Fan Speed Solenoid Open or Short Service Brake Accumulator Switch Short Diagnostic Procedure................................... 9001-40-21 to Ground Diagnostic Procedure .9001-40-4 1071.04 Fan Speed Solenoid High
167.03 System Voltage Above Normal . .9001-40-5
System Voltage Above Normal Diagnostic Fan Speed Solenoid High Current Diagnostic Procedure .9001-40-5
167.04 System Voltage Below Normal . . .9001-40-6 1550.05 AC Clutch Open Circuit 9001-40-24
System Voltage Below Normal Diagnostic Air Conditioning Clutch Open Circuit Procedure .9001-40-6 Diagnostic Procedure 9001-40-24
168.03 High Battery Voltage .9001-40-7 1550.06 AC Clutch Short to Ground
High Battery Voltage Diagnostic Air Conditioning Clutch Short to Ground ......
Procedure .9001-40-7 1638.00 Hydraulic Oil High 168.04 Low Battery Voltage .9001-40-8
Low Battery Voltage Diagnostic Hydraulic Oil High Temperature Diagnostic Procedure
628.12 Updating Software .9001-40-9
Hydraulic Oil Temp Short To Controller in Boot Diagnostic Procedure .
746.05 Differential Lock Solenoid Open Hydraulic Oil Temperature Sensor Short or Short
Differential Lock Solenoid Open or Short 1713.01
Oil Filter Diagnostic Procedure. 9001-40-10
746.06 Differential Lock Solenoid High
Oil Filter Restricted 9001-40-28 Current .9001-40-11
Oil Filter Switch Short
Differential Lock Solenoid High Current to Power......................................................... 9001-40-29 Diagnostic Procedure. 9001-40-11 Hydraulic Oil Filter Restricted 9001-40-29
880.05 Brake Lights Open or Short 9001-40-12
Brake Lights Open or Short Diagnostic Procedure 9001-40-12
880.06 Brake Lights High Current 9001-40-14 Brake Lights High Current Diagnostic Procedure.......................................................9001-40-14
977.05 Reverse Fan Solenoid Open or Short 9001-40-15
Reversing Fan Solenoid Open or Short Diagnostic Procedure 9001-40-16
977.06 Reverse Fan Solenoid Short to Ground 9001-40-17
Reversing Fan Solenoid Short to Ground Diagnostic Procedure 9001-40-17
977.07 Reversing Fan Pressure Too High
1762.01 Hydraulic Pressure Low.............. 9001-40-30 Hydraulic Pressure Low Diagnostic Procedure 9001-40-30
1762.03 Hydraulic Pressure Short to Power 9001-40-31
Hydraulic Pressure Short to Power Diagnostic Procedure 9001-40-31
1762.04 Hydraulic Pressure Short to Ground ........................................................... 9001-40-32 Hydraulic Pressure Short to Power Diagnostic Procedure ...................................................... 9001-40-32
2000.09 CAN Communication Lost For ECU 9001-40-33 CAN Communication Lost For ECU to Reverse .9001-40-18 Diagnostic Procedure....................................9001-40-34
Reversing Fan Pressure Too High to Reverse Diagnostic Procedure. 9001-40-18 Continued on next page
2003.09 CAN Communication Lost For
2225.09 CAN Communication Lost For TCU..................................................................9001-40-36
CAN Communication Lost For TCU Diagnostic Procedure 9001-40-36
2034.09 CAN Communication Lost For AVC 9001-40-38
CAN Communication Lost For AVC Diagnostic Procedure....................................9001-40-38
2040.09 CAN Communication Lost For ADU 9001-40-40
CAN Communication Lost For ADU Diagnostic Procedure 9001-40-40
2141.09 CAN Communication Lost For SSM.................................................................9001-40-42
CAN Communication Lost For Sealed Switch Module.............................................................9001-40-42
2160.09 CAN Communication Lost For RJ1 9001-40-44
CAN Communication Lost For RJ1 Diagnostic Procedure 9001-40-44
2161.09 CAN Communication Lost For RJ2...................................................................9001-40-46
CAN Communication Lost For RJ2 Diagnostic Procedure 9001-40-46
2162.09 CAN Communication Lost For RJ3 9001-40-48
CAN Communication Lost For RJ3 Diagnostic Procedure .......................................................9001-40-48
2163.09 CAN Communication Lost For RJ4 9001-40-50
CAN Communication Lost For RJ4 Diagnostic Procedure 9001-40-50
2165.09 CAN Communication Lost For LJ1...................................................................9001-40-52
CAN Communication Lost For LJ1 Diagnostic Procedure .......................................................9001-40-52
2166.09 CAN Communication Lost For 6WD
9001-40-62
CAN Communication Lost For Six Wheel Drive Diagnostic Procedure.........................9001-40-62
2348.05 Hi Beam Lamps Open Circuit...............................................................9001-40-64
High Beam Lamps Open Circuit Diagnostic
2348.06 High Beam Lamps High
High Beam Lamps High Current Diagnostic
2350.05 Low Beam Lamps Open
...............................................................
2362.05
Rear Cab Corner Lights Open
Steering Angle Sensor Short to Power Short Circuit 9001-40-78 to Power..........................................................9001-40-94
Rear Cab Corner Lights Open Circuit
2927.04 Steering Angle Sensor Short Diagnostic Procedure. 9001-40-78 to Ground........................................................9001-40-95
2362.06
Rear Cab Corner Lights High
Steering Angle Sensor Short to Ground Current .9001-40-79 Diagnostic Procedure 9001-40-95
Rear Cab Corner Lights High Current 3318.03 Blade Pitch Sensor Short to Diagnostic Procedure.
2366.05 Side Work Lights Open
Blade Pitch Sensor Short to Power Circuit 9001-40-80 Diagnostic Procedure 9001-40-96
Side Work Lights Open Circuit Diagnostic 3318.04 Blade Pitch Sensor Short to Procedure .9001-40-80 Ground 9001-40-98
2366.06 Side Work Lights High
Blade Pitch Sensor Short to Ground Current .9001-40-81 Diagnostic Procedure....................................9001-40-98
Side Work Lights High Current .9001-40-81 3319.03 Slope Sensor Short to 2368.05 Left Turn Lights Open Power 9001-40-99 Circuit 9001-40-82 Slope Sensor Short to Power Diagnostic
Left Turn Lights Open Circuit Diagnostic
Turn Lights High
to Power Diagnostic Left Turn Lights High Current Diagnostic
Rotate Sensor Short to 2370.05 Right Turn Lights Open
Right Turn Lights Open Circuit Diagnostic Diagnostic Procedure 9001-40-103 Procedure
.9001-40-85
Circle Rotate Sensor Short to
2370.06 Right Turn Lights High Ground 9001-40-104 Current .9001-40-86 Circle Rotate Sensor Short to Ground
Right Turn Lights High Current Diagnostic Diagnostic Procedure 9001-40-105 Procedure .9001-40-87 3509.04 Sensor Supply 1 Short to
2378.05 Marker/Tail Lights Open Ground ..........................................................9001-40-106 Circuit 9001-40-88 3510.03 Sensor Supply 2 Short to
Marker/Tail Lights Open Circuit Diagnostic Power
9001-40-106 Procedure
2378.06
.9001-40-88 Sensor Supply 2 Short to Power Diagnostic Current 9001-40-89
Marker/Tail Lights High
Marker/Tail Lights High Current Diagnostic Procedure 9001-40-89
2386.06 Rotary Beacon Short to Ground............................................................9001-40-90
Rotary Beacon Short to Ground Diagnostic Procedure.......................................................9001-40-91
2874.04 High Beam Switch Short to Ground............................................................9001-40-91
High Beam Switch Short to Ground Diagnostic Procedure 9001-40-91
2876.04 Turn Signal Switch Short to Ground 9001-40-92
3510.04 Sensor Supply Voltage 2 Short to Ground 9001-40-107
Sensor Supply Voltage 2 Short to Ground 9001-40-107
3511.03 Sensor Supply Voltage 3 Short to Power ............................................................9001-40-109
Sensor Supply Voltage 3 Short to Power Diagnostic Procedure..................................9001-40-109
3511.04 Sensor Supply Voltage 3 Short to Ground ..........................................................9001-40-110
Sensor Supply Voltage 3 Short to Ground Diagnostic Procedure..................................9001-40-110
Turn Signal Switch Short to Ground Procedure 9001-40-106
520450.03 Saddle Lock Pin Switch Short Diagnostic Procedure. 9001-40-92 to Power 9001-40-113
2927.03 Steering Angle Sensor Short to Power
.9001-40-93
Continued on next page
