Complete Diagnosis & Tests Technical Manual with electrical wiring diagrams for John Deere 5075GV, 5090GV, 5075GN, 5090GN, 5100GN, and 5075GL Tractors, with workshop information to maintain, diagnose, and rebuild like professional mechanics.
John Deere 5075GV, 5090GV, 5075GN, 5090GN, 5100GN, and 5075GL Tractors workshop Diagnosis & Tests technical manual includes:
* Numbered table of contents easy to use so that you can find the information you need fast.
* Detailed sub-steps expand on repair procedure information
* Numbered instructions guide you through every repair procedure step by step.
* Troubleshooting and electrical service procedures are combined with detailed wiring diagrams for ease of use.
* Notes, cautions and warnings throughout each chapter pinpoint critical information.
* Bold figure number help you quickly match illustrations with instructions.
* Detailed illustrations, drawings and photos guide you through every procedure.
* Enlarged inset helps you identify and examine parts in detail.
tm409119 – 5075GV, 5090GV, 5075GN, 5090GN, 5100GN, and 5075GL Tractors Diagnostic (North-American Edition) Technical Manual.pdf
tm409128 – Diagnostic des tracteurs 5075GV, 5090GV, 5075GN, 5090GN, 5100GN et 5075GL -: (Édition pour lAmérique du Nord) French.pdf
PRODUCT DETAILS:
Total Pages: 3,821 pages
File Format: PDF/EPUB/MOBI/AZW (PC/Mac/Android/Kindle/iPhone/iPad; bookmarked, ToC, Searchable, Printable)
Language: English French
TABLE OF CONTENTS…1
Section 210: General Information…3761
Group 05: Safety Measures…68
General Information – Safety – Summary of References…73
Recognize Safety Information…75
Understand Signal Words…76
Follow Safety Instructions…77
Prepare for Emergencies…78
Wear Protective Clothing…79
Protect Against Noise…80
Handle Fuel Safely—Avoid Fires…81
Handle Starting Fluid Safely…82
Fire Prevention…83
In Case of Fire…84
Avoid Static Electricity Risk When Refueling…85
Keep ROPS Installed Properly…87
Use Foldable ROPS and Seat Belt Properly…88
Stay Clear of Rotating Drivelines…89
Use Steps and Handholds Correctly…91
Read Operator’s Manuals for ISOBUS Controllers…92
Use Seat Belt Properly…93
Operating the Tractor Safely…94
Avoid Backover Accidents…96
Limited Use in Forestry Operation…97
Operating the Loader Tractor Safely…98
Keep Riders Off Machine…99
Instructional Seat…100
Use Safety Lights and Devices…101
Use a Safety Chain…102
Transport Towed Equipment at Safe Speeds…103
Use Caution on Slopes, Uneven Terrain, and Rough Ground…105
Freeing a Mired Machine…106
Avoid Contact with Agricultural Chemicals…107
Handle Agricultural Chemicals Safely…108
Handling Batteries Safely…110
Avoid Heating Near Pressurized Fluid Lines…112
Remove Paint Before Welding or Heating…113
Handle Electronic Components and Brackets Safely…114
Practice Safe Maintenance…115
Avoid Hot Exhaust…117
Clean Exhaust Filter Safely…118
Work In Ventilated Area…121
Support Machine Properly…122
Prevent Machine Runaway…123
Park Machine Safely…124
Transport Tractor Safely…125
Service Cooling System Safely…126
Service Accumulator Systems Safely…127
Service Tires Safely…128
Service Front-Wheel Drive Tractor Safely…129
Tightening Wheel Retaining Bolts/Nuts…130
Avoid High-Pressure Fluids…131
Do Not Open High-Pressure Fuel System…132
Store Attachments Safely…133
Decommissioning — Proper Recycling and Disposal of Fluids and Components…134
Live With Safety…995
Safety Measures on Electronic Control Units…136
Servicing Electronic Control Units…137
Welding Near Electronic Control Units…138
Keep Electronic Control Unit Connectors Clean…139
Safety Instructions for Replacing a Halogen Bulb…140
Safety Instructions for Replacing Xenon (HID) Bulbs and Ballast Units…142
Group 10: General References…69
General Information – General References, Summary of References…145
General Information – Electrical System, Approach to Tabular Diagnostic Procedures…146
General Information – Electrical System, Troubleshooting Unsolved Problems…148
General Information – Electrical System, Worksheet for Circuit/Harness Test…149
General Information – Electrical System, Visual Check…151
General Information – Electrical System, Electrical Circuit Malfunctions…152
Section 211: Diagnostic Trouble Codes…157
Group ECU_F5D: Engine Control Unit for Engine F5D (DOC/DPF)…157
ECU 004151.12 – Fuel Rail Pressure Relief Valve (PRV) Fault…157
ECU 065564.03 – Water-in-Fuel detected…157
ECU 065585.03 – Coolant Temperature Sensor, Voltage Too High…157
ECU 065585.04 – Coolant Temperature Sensor, Voltage Too Low…157
ECU 065587.03 – Manifold Air Temperature Sensor (High-Pressure Pump), Voltage Too High…157
ECU 065587.04 – Manifold Air Temperature Sensor (High-Pressure Pump), Voltage Too Low…157
ECU 065588.00 – Manifold Air Pressure Sensor (High-Pressure Pump) Fault…157
ECU 065588.01 – Manifold Air Pressure Sensor (High-Pressure Pump) Fault…157
ECU 065588.03 – Manifold Air Pressure Sensor (High-Pressure Pump), Voltage Too High…157
ECU 065588.04 – Manifold Air Pressure Sensor (High-Pressure Pump), Voltage Too Low…157
ECU 065589.03 – Fuel Temperature Sensor, Voltage Too High…157
ECU 065589.04 – Fuel Temperature Sensor, Voltage Too Low…157
ECU 065590.03 – Fuel Rail Pressure Sensor, Voltage Too High…157
ECU 065590.04 – Fuel Rail Pressure Sensor, Voltage Too Low…157
ECU 065591.02 – Fuel Rail Pressure Relief Valve (PRV), Opens Too Often…157
ECU 065591.03 – Fuel Rail Pressure Relief Valve (PRV) Fault…157
ECU 065591.04 – Fuel Rail Pressure Relief Valve (PRV) is forced to open by system test…157
ECU 065596.03 – Ambient Temperature Sensor, Voltage Too High…157
ECU 065596.04 – Ambient Temperature Sensor, Voltage Too Low…157
ECU 065601.02 – Crankshaft Position Sensor Fault…157
ECU 065601.04 – Camshaft Position Sensor Signal Invalid…157
ECU 065603.02 – Camshaft Position Sensor Fault…157
ECU 065603.04 – Camshaft Position Sensor Fault…157
ECU 065604.03 – Engine Speed Sensor Signal Mismatch…157
ECU 065609.02 – Fuel Filter Heater Fault…157
ECU 065609.03 – Fuel Filter Heater, Voltage Too High…157
ECU 065609.04 – Fuel Filter Heater, Voltage Too Low…157
ECU 065609.12 – Fuel Filter Heater, Temperature too High…157
ECU 065617.03 – High Pressure Fuel System Fault…157
ECU 065619.03 – High Pressure Fuel System Fault…157
ECU 065619.03 – High Pressure Fuel System Fault…157
ECU 065621.03 – High Pressure Fuel Control Valve Fault…158
ECU 065623.03 – High Pressure Fuel Control Valve Fault…158
ECU 065624.03 – Leakage in Fuel System…158
ECU 065625.02 – High Pressure Fuel Control Valve Fault…158
ECU 065629.03 – Diesel Particulate Filter Fault (Derate Level 1)…158
ECU 065630.03 – EGR Valve Fault (Derate Level 1)…158
ECU 065633.02 – Injector No. 1, Short Circuit…158
ECU 065634.02 – Injector No. 2, Short Circuit…158
ECU 065635.02 – Injector No. 3, Short Circuit…158
ECU 065636.02 – Injector No. 4, Short Circuit…158
ECU 065639.02 – Injector No. 1 Fault…158
ECU 065640.02 – Injector No. 2 Fault…158
ECU 065641.02 – Injector No. 3 Fault…158
ECU 065642.02 – Injector No. 4 Fault…158
ECU 065649.03 – Injector Wiring Bank 1, Short Circuit…158
ECU 065651.03 – Injector Wiring Bank 2, Short Circuit…158
ECU 065660.12 – Control Software Internal Fault…158
ECU 065662.02 – Control Software Internal Fault…158
ECU 065662.03 – Control Software Internal Fault…158
ECU 065662.04 – Control Software Internal Fault…158
ECU 065662.12 – Fuel Injection Limited…158
ECU 065663.12 – Injector No. 1, Incorrect Calibration Code…158
ECU 065679.02 – Oxygen Sensor Fault…158
ECU 065679.03 – Oxygen Sensor, Voltage Too High…158
ECU 065679.04 – Oxygen Sensor, Voltage Too Low…158
ECU 065689.02 – Turbocharger Wastegate Fault…158
ECU 065693.04 – Engine Power Derate Condition Exists…158
ECU 065694.04 – Engine Power Derate Condition Exists…158
ECU 065713.03 – CAN Bus Voltage Too High…158
ECU 065713.04 – CAN Bus Voltage Too Low…158
ECU 065719.02 – Incorrect CAN Bus Message…158
ECU 065736.03 – Incorrect CAN Bus Message…158
ECU 065745.03 – Control Software Internal Fault…158
ECU 065746.02 – Control Software Internal Fault…159
ECU 065746.03 – Control Software Internal Fault…159
ECU 065746.04 – Control Software Internal Fault…159
ECU 065746.12 – Control Software Internal Fault…159
ECU 065747.12 – Control Software Internal Fault…159
ECU 065748.12 – Control Software Internal Fault…159
ECU 065752.12 – Control Software Internal Fault…159
ECU 065753.02 – Control Software Internal Fault…159
ECU 065753.03 – Control Software Internal Fault…159
ECU 065753.12 – Control Software Internal Fault…159
ECU 065754.12 – Control Software Internal Fault…159
ECU 065763.03 – Control Software Internal Fault…159
ECU 065764.03 – Control Software Internal Fault…159
ECU 065766.12 – ECU Supply Voltage No. 1 Fault…159
ECU 065767.03 – ECU Supply Voltage No. 2 Fault…159
ECU 065768.03 – ECU Supply Voltage No. 2 Fault…159
ECU 065771.03 – Barometric Air Pressure, Voltage Too High…159
ECU 065771.04 – Barometric Air Pressure, Voltage Too Low…159
ECU 065777.03 – DPF Differential Pressure Sensor, Voltage Too High…159
ECU 065777.04 – DPF Differential Pressure Sensor, Voltage Too Low…159
ECU 065779.12 – DPF Differential Pressure Sensor Fault…159
ECU 065783.00 – DOC Outlet Temperature Sensor Fault…159
ECU 065783.03 – DOC Outlet Temperature Sensor, Voltage Too High…159
ECU 065783.04 – DOC Outlet Temperature Sensor, Voltage Too Low…159
ECU 065791.02 – Engine Oil Viscosity Too Low…159
ECU 065791.04 – Engine Oil Viscosity Low…159
ECU 131109.03 – Main Relay, Voltage Too High…159
ECU 131109.04 – Main Relay, Voltage Too Low…159
ECU 131110.03 – Unswitched Battery Voltage Too High…159
ECU 131110.04 – Unswitched Battery Voltage Too Low…159
ECU 131127.03 – Fuel Rail Pressure Relief Valve (PRV), Opens Too Often…159
ECU 131127.04 – Fuel Rail Pressure Relief Valve (PRV) is forced to open by system test…159
ECU 131127.12 – Fuel Rail Pressure Relief Valve (PRV) is forced to open by system test…159
ECU 131128.03 – Engine Oil Pressure Sensor Fault…160
ECU 131128.04 – Engine Oil Pressure Low…160
ECU 131158.03 – Engine Power Derate Condition Exists…160
ECU 131161.03 – High Pressure Fuel Control Valve, Voltage Too High…160
ECU 131162.03 – Injector No. 1, Calibration Fault…160
ECU 131162.04 – Injector No. 1, Calibration Fault…160
ECU 131165.03 – Diesel Particulate Filter Fault (Derate Level 3)…160
ECU 131166.03 – EGR Valve Fault (Derate Level 3)…160
ECU 131183.04 – Fuel Rail Pressure Fault…160
ECU 131199.12 – Injector No. 2, Incorrect Calibration Code…160
ECU 131225.04 – Turbocharger Wastegate Fault…160
ECU 131227.03 – Turbocharger Inlet Temperature, Voltage Too High…160
ECU 131227.04 – Turbocharger Inlet Temperature, Voltage Too Low…160
ECU 131252.02 – Incorrect CAN Bus Message…160
ECU 131281.03 – Control Software Internal Fault…160
ECU 131283.12 – Control Software Internal Fault…160
ECU 131284.04 – Control Software Internal Fault…160
ECU 196651.02 – Indicator Light for Glow Plug Fault…160
ECU 196651.03 – Glow Plug, Voltage Too High…160
ECU 196651.04 – Glow Plug, Voltage Too Low…160
ECU 196651.12 – Glow Plug System, Temperature Too High…160
ECU 196697.04 – High Pressure Fuel Control Valve, Voltage Too Low…160
ECU 196698.03 – Injector No. 2, Calibration Fault…160
ECU 196698.04 – Injector No. 2, Calibration Fault…160
ECU 196735.12 – Injector No. 3, Incorrect Calibration Code…160
ECU 196755.02 – Turbocharger Wastegate Valve Fault…160
ECU 196755.03 – Turbocharger Wastegate Valve, Voltage Too High…160
ECU 196755.04 – Turbocharger Wastegate Valve, Voltage Too Low…160
ECU 196755.12 – Turbocharger Wastegate Valve, Temperature Too High…160
ECU 196765.04 – Engine Power Derate Condition Exists…160
ECU 196766.04 – Engine Power Derate Condition Exists…160
ECU 196808.02 – Incorrect CAN Bus Message…160
ECU 196817.12 – Control Software Internal Fault…160
ECU 196820.02 – Control Software Internal Fault…161
ECU 196820.03 – Control Software Internal Fault…161
ECU 196820.04 – Control Software Internal Fault…161
ECU 196820.12 – Control Software Internal Fault…161
ECU 196835.00 – Control Software Internal Fault…161
ECU 196835.01 – Control Software Internal Fault…161
ECU 196835.02 – Control Software Internal Fault…161
ECU 196835.03 – Control Software Internal Fault…161
ECU 196835.04 – Control Software Internal Fault…161
ECU 196835.12 – Control Software Internal Fault…161
ECU 196849.04 – Diesel Particulate Filter Fault…161
ECU 196851.12 – DPF Differential Pressure Sensor Fault…161
ECU 196854.03 – DOC Inlet Temperature Sensor, Voltage Too High…161
ECU 196854.04 – DOC Inlet Temperature Sensor, Voltage Too Low…161
ECU 196857.03 – Diesel Particulate Filter Fault…161
ECU 262182.03 – Engine Control Unit, Voltage Too High…161
ECU 262182.04 – Engine Control Unit, Voltage Too Low…161
ECU 262194.03 – Engine Temperature Too High…161
ECU 262197.12 – Fuel Rail Pressure Sensor Fault…161
ECU 262229.03 – High Pressure Fuel System Fault…161
ECU 262233.03 – High Pressure Fuel Control Valve Fault…161
ECU 262234.03 – Injector No. 3, Calibration Fault…161
ECU 262234.04 – Injector No. 3, Calibration Fault…161
ECU 262271.12 – Injector No. 4, Incorrect Calibration Code…161
ECU 262281.03 – EGR Valve Fault…161
ECU 262285.02 – Actuator for Throttle Fault…161
ECU 262285.12 – Actuator for Throttle, Temperature Too High…161
ECU 262299.03 – Turbocharger Pressure Sensor, Voltage Too High…161
ECU 262299.04 – Turbocharger Pressure Sensor, Voltage Too Low…161
ECU 262301.04 – Engine Power Derate Condition Exists…161
ECU 262302.04 – Engine Power Derate Condition Exists…161
ECU 262356.03 – Control Software Internal Fault…161
ECU 262356.04 – Control Software Internal Fault…161
ECU 262371.03 – Control Software Internal Fault…162
ECU 262371.04 – Control Software Internal Fault…162
ECU 262371.12 – Control Software Internal Fault…162
ECU 262393.03 – Diesel Particulate Filter Fault…162
ECU 327724.01 – Glow Plug Control Unit Fault…162
ECU 327730.03 – Engine Temperature Too High…162
ECU 327733.03 – Fuel Rail Pressure Sensor, Pressure Too High…162
ECU 327756.03 – Engine Speed Extremely High…162
ECU 327769.12 – High Pressure Fuel Control Valve, Temperature Too High…162
ECU 327770.03 – Injector No. 4, Calibration Fault…162
ECU 327770.04 – Injector No. 4, Calibration Fault…162
ECU 327817.03 – EGR Valve Fault…162
ECU 327817.04 – EGR Valve Fault…162
ECU 327819.02 – EGR Valve Fault…162
ECU 327819.12 – EGR Valve, Temperature Too High…162
ECU 327820.03 – Actuator for Throttle Fault…162
ECU 327820.04 – Actuator for Throttle Fault…162
ECU 327821.03 – Actuator for Throttle, Voltage Too High…162
ECU 327821.04 – Actuator for Throttle, Voltage Too Low…162
ECU 327890.03 – Control Software Internal Fault…162
ECU 327892.02 – Control Software Internal Fault…162
ECU 327892.03 – Control Software Internal Fault…162
ECU 327892.04 – Control Software Internal Fault…162
ECU 327892.12 – Control Software Internal Fault…162
ECU 327907.03 – Control Software Internal Fault…162
ECU 327907.04 – Control Software Internal Fault…162
ECU 327907.12 – Control Software Internal Fault…162
ECU 327925.12 – Diesel Particulate Filter Fault…162
ECU 393217.02 – Oxygen Sensor Fault…162
ECU 393218.02 – Oxygen Sensor Fault…162
ECU 393221.03 – Oxygen Sensor Wiring, Short Circuit…162
ECU 393222.02 – Oxygen Sensor Fault…162
ECU 393223.03 – Oxygen Sensor Fault…162
ECU 393223.04 – Oxygen Sensor Fault…163
ECU 393225.02 – Control Software Internal Fault…163
ECU 393226.04 – Oxygen Sensor, Voltage Too High…163
ECU 393227.03 – Oxygen Sensor, Voltage Too High…163
ECU 393227.04 – Oxygen Sensor, Voltage Too Low…163
ECU 393228.03 – Oxygen Sensor, Temperature Too High…163
ECU 393228.04 – Oxygen Sensor, Temperature Too Low…163
ECU 393355.00 – EGR Valve, Voltage Too High…163
ECU 393355.01 – EGR Valve, Voltage Too Low…163
ECU 393355.02 – EGR Valve Fault…163
ECU 393355.03 – EGR Valve, Voltage Too High…163
ECU 393355.04 – EGR Valve, Voltage Too Low…163
ECU 393355.07 – EGR Valve Fault…163
ECU 393357.03 – Actuator for Throttle, Voltage Too High…163
ECU 393357.04 – Actuator for Throttle, Voltage Too Low…163
ECU 393374.04 – Engine Power Derate Condition Exists…163
ECU 393428.02 – Control Software Internal Fault…163
ECU 393428.03 – Control Software Internal Fault…163
ECU 393428.04 – Control Software Internal Fault…163
ECU 393428.12 – Control Software Internal Fault…163
ECU 393460.12 – Regeneration Fault…163
ECU 458796.00 – Glow Plug No.1, Current Too Low…163
ECU 458796.01 – Glow Plug No.3, Current Too Low…163
ECU 458796.02 – Glow Plug No.4, Current Too Low…163
ECU 458796.03 – Glow Plug No.2, Current Too Low…163
ECU 458889.00 – EGR Valve (Position Sensor), Voltage Too High…163
ECU 458889.01 – EGR Valve (Position Sensor), Voltage Too Low…163
ECU 458891.03 – Actuator for Throttle, Voltage Too High…163
ECU 458891.04 – Actuator for Throttle, Voltage Too Low…163
ECU 458893.03 – Actuator for Throttle, Voltage Too High…163
ECU 458893.04 – Actuator for Throttle, Voltage Too Low…163
ECU 458938.02 – Incorrect CAN Bus Message…163
ECU 458995.12 – Diesel Particulate Filter Fault…163
Group ECU_F5G: Engine Control Unit for Engine F5G (DOC/SCR)…164
ECU 004371.31 – Coolant Temperature Sensor, Voltage Too High…164
ECU 004421.31 – Fuel Rail Pressure Relief Valve (PRV), Opens Too Often…164
ECU 004449.31 – Unswitched Battery Voltage Too High…164
ECU 004477.31 – Unswitched Battery Voltage Too High…164
ECU 004506.31 – DEF Tank Level Sensor, Voltage Too High…164
ECU 004566.31 – DEF Dosing Unit Temperature Maximum Range Error…164
ECU 004826.31 – Catalyst Efficiency Fault…164
ECU 004961.31 – Unswitched Battery Voltage Too High…164
ECU 004980.31 – Manifold Air Temperature Sensor (High-Pressure Pump), Voltage Too High…164
ECU 005060.31 – Barometric Air Pressure, Voltage Too High…164
ECU 005157.31 – Fuel Rail Pressure Sensor, Voltage Too High…164
ECU 005176.31 – Turbocharger Wastegate Fault…164
ECU 005302.31 – DEF Dosing Unit Pressure Sensor Error, Voltage Too High…164
ECU 005477.31 – High Pressure Fuel System Fault…164
ECU 005479.31 – EGR Valve Fault…164
ECU 005604.31 – Actuator for Throttle, Voltage Too High…164
ECU 005658.31 – SCR Outlet Temperature, Voltage Too High…164
ECU 005859.31 – Catalyst Efficiency Fault…164
ECU 005957.31 – Fuel Rail Pressure Relief Valve (PRV), Opens Too Often…164
ECU 005961.31 – Catalyst Efficiency Fault…164
ECU 005976.31 – Turbocharger Pressure Sensor, Voltage Too High…164
ECU 006052.31 – Actuator for Throttle, Voltage Too High…164
ECU 006218.31 – DEF Dosing Unit Pump, Pressure Too High (Level 2)…164
ECU 006245.31 – High Pressure Fuel Control Valve Fault…164
ECU 006297.31 – DOC Inlet Temperature Sensor, Voltage Too High…164
ECU 006366.31 – NH3 Sensor Error…164
ECU 006596.31 – Ambient Temperature Sensor, Voltage Too High…164
ECU 006682.31 – DOC Outlet Temperature, Voltage Too High…164
ECU 006730.31 – DEF Dosing Unit Pump, Pressure Too High…164
ECU 006854.31 – DEF Dosing Unit Pump Maximum Range Error…164
ECU 007063.31 – EGR Valve (Position Sensor), Voltage Too Low…164
ECU 007094.31 – DEF Dosing Unit Pressure Sensor, Voltage Too High…164
ECU 007189.31 – Fuel Temperature Sensor, Voltage Too High…165
ECU 007366.31 – DEF Dosing Unit Heater Maximum Range Error…165
ECU 007524.31 – Manifold Air Pressure Sensor (High-Pressure Pump), Voltage Too High…165
ECU 007557.31 – Fuel Rail Pressure Sensor, Pressure Too High…165
ECU 007754.31 – DEF Filter Restricted Warning…165
ECU 007783.31 – EGR Valve Fault…165
ECU 007844.31 – Actuator for Throttle Fault…165
ECU 007860.31 – Actuator for Throttle Fault…165
ECU 007878.31 – DEF Dosing Unit Pump Maximum Range Error…165
ECU 007991.31 – EGR Valve Fault…165
ECU 008599.31 – EGR Valve Fault…165
ECU 008678.31 – DEF Tank CAN Sensor Error…165
ECU 008723.31 – Coolant Temperature Sensor, Voltage Too Low…165
ECU 008778.31 – DEF Dosing Unit Pump, Pressurization Not Possible…165
ECU 008801.31 – Unswitched Battery Voltage Too Low…165
ECU 008805.31 – High Pressure Fuel System Fault…165
ECU 008829.31 – Unswitched Battery Voltage Too Low…165
ECU 008858.31 – DEF Tank Level Sensor, Voltage Too Low…165
ECU 008918.31 – DEF Dosing Unit Temperature Minimum Range Error…165
ECU 009171.31 – Engine Oil Pressure Low…165
ECU 009313.31 – Unswitched Battery Voltage Too Low…165
ECU 009332.31 – Manifold Air Temperature Sensor (High-Pressure Pump), Voltage Too Low…165
ECU 009412.31 – Barometric Air Pressure, Voltage Too Low…165
ECU 009509.31 – Fuel Rail Pressure Sensor, Voltage Too Low…165
ECU 009582.31 – Inlet NOx Sensor Short Circuit…165
ECU 009614.31 – Inlet NOx Sensor Signal Short Circuit…165
ECU 009654.31 – DEF Dosing Unit Pressure Sensor Error, Voltage Too Low…165
ECU 009831.31 – EGR Valve Fault…165
ECU 010010.31 – SCR Outlet Temperature, Voltage Too Low…165
ECU 010034.31 – DOC Outlet Temperature, Voltage Too Low…165
ECU 010085.31 – High Pressure Fuel System Fault…165
ECU 010212.31 – Actuator for Throttle, Voltage Too Low…165
ECU 010296.31 – Turbocharger Wastegate Fault…165
ECU 010328.31 – Turbocharger Pressure Sensor, Voltage Too Low…166
ECU 010404.31 – Actuator for Throttle, Voltage Too Low…166
ECU 010570.31 – DEF Dosing Unit Pump, Pressure Too Low…166
ECU 010649.31 – DOC Inlet Temperature Sensor, Voltage Too Low…166
ECU 010948.31 – Ambient Temperature Sensor, Voltage Too Low…166
ECU 011062.31 – Fuel Rail Pressure Fault…166
ECU 011206.31 – DEF Dosing Unit Pump Minimum Range Error…166
ECU 011415.31 – EGR Valve (Position Sensor), Voltage Too Low…166
ECU 011446.31 – DEF Dosing Unit Pressure Sensor, Voltage Too Low…166
ECU 011541.31 – Fuel Temperature Sensor, Voltage Too Low…166
ECU 011718.31 – DEF Dosing Unit Heater Minimum Range Error…166
ECU 011738.31 – Catalyst Efficiency Fault…166
ECU 011876.31 – Manifold Air Pressure Sensor (High-Pressure Pump), Voltage Too Low…166
ECU 012090.31 – DEF Tank Temperature Fault…166
ECU 012196.31 – Actuator for Throttle Fault…166
ECU 012230.31 – DEF Dosing Unit Pump Minimum Range Error…166
ECU 012647.31 – EGR Valve Fault…166
ECU 012990.31 – Inlet NOx Sensor Error…166
ECU 013074.31 – Camshaft Position Sensor Fault…166
ECU 013130.31 – DEF Dosing Unit Pump Stabilization Error…166
ECU 013146.31 – DEF Dosing Unit Pump Speed Error…166
ECU 013386.31 – DEF Dosing Unit Purging Pump Error…166
ECU 013402.31 – DEF Dosing Unit Pump Speed Error…166
ECU 013523.31 – Engine Oil Pressure Sensor Fault…166
ECU 013612.31 – DOC Inlet Temperature Sensor, Voltage Too High…166
ECU 013642.31 – DEF Dosing Unit Pump Error…166
ECU 011034.31 – DOC Inlet Temperature Sensor, Voltage Too Low…166
ECU 013893.31 – Fuel Rail Pressure Relief Valve (PRV) Fault…166
ECU 014202.31 – DEF Dosing Valve Blocked Fault…166
ECU 014318.31 – NH3 Sensor Error…166
ECU 014539.31 – NH3 Sensor Error…166
ECU 014574.31 – NH3 Sensor Error…166
ECU 015162.31 – DOC Outlet Temperature Sensor Fault…166
ECU 015204.31 – Manifold Air Pressure Sensor (High-Pressure Pump) Fault…167
ECU 015205.31 – High Pressure Fuel Control Valve Fault…167
ECU 015418.31 – DOC Outlet Temperature Sensor Fault…167
ECU 015460.31 – Manifold Air Pressure Sensor (High-Pressure Pump) Fault…167
ECU 015461.31 – Leakage in Fuel System…167
ECU 015534.31 – Outlet NOx Sensor Error…167
ECU 015578.31 – Inlet NOx Sensor Error…167
ECU 015674.31 – DOC Outlet Temperature Sensor Fault…167
ECU 015796.31 – Actuator for Throttle Fault…167
ECU 015802.31 – DEF Pressure Line Blocked…167
ECU 015830.31 – DEF Tank Level Sensor CAN Message Fault…167
ECU 015911.31 – EGR Valve Fault…167
ECU 015930.31 – DOC Outlet Temperature Sensor Fault…167
ECU 015978.31 – DEF Heating Unit Backflow Line Supply Voltage Error…167
ECU 016026.31 – DEF Heating Unit Supply Line Supply Voltage Error…167
ECU 016234.31 – DEF Heating Unit Pressure Line Supply Voltage Error…167
ECU 016282.31 – DEF Dosing Valve Fault, Voltage Too Low…167
ECU 016658.31 – Camshaft Position Sensor Fault…167
ECU 016677.31 – Fuel Rail Pressure Sensor Fault…167
ECU 016725.31 – High Pressure Fuel Control Valve Fault…167
ECU 016914.31 – Camshaft Position Sensor Fault…167
ECU 017318.31 – Injector No. 1, Incorrect Calibration Code…167
ECU 017358.31 – Outlet NOx Sensor Error…167
ECU 017426.31 – Camshaft Position Sensor Signal Invalid…167
ECU 017429.31 – Water-in-Fuel detected…167
ECU 017509.31 – High Pressure Fuel System Fault…167
ECU 017574.31 – Injector No. 3, Incorrect Calibration Code…167
ECU 017682.31 – Crankshaft Position Sensor Fault…167
ECU 017830.31 – Injector No. 4, Incorrect Calibration Code…167
ECU 017998.31 – DEF Quality Sensor Error…167
ECU 018002.31 – Glow Plug Control Unit Fault…167
ECU 018017.31 – Main Relay, Voltage Too High…167
ECU 018086.31 – Injector No. 2, Incorrect Calibration Code…167
ECU 018318.31 – Inlet NOx Sensor Signal Short Circuit…168
ECU 018842.31 – DEF Tank Level Sensor CAN Message Fault…168
ECU 018858.31 – DEF Sensor Temperature CAN message Error…168
ECU 018886.31 – DEF Dosing Unit Pump Communication Error…168
ECU 019086.31 – Outlet NOx Sensor Signal Short Circuit…168
ECU 019402.31 – DEF Quality Sensor Concentration Error…168
ECU 019534.31 – DEF Quality Sensor Error…168
ECU 019658.31 – DEF Quality Sensor Wrong Fluid Error…168
ECU 019678.31 – NH3 Sensor Error…168
ECU 019934.31 – NH3 Sensor Error…168
ECU 020190.31 – NH3 Sensor Error…168
ECU 020245.31 – Water-in-Fuel detected…168
ECU 020346.31 – DEF Heating Unit Supply Voltage Error…168
ECU 020826.31 – DEF Dosing Unit Pump, Current Too Low…168
ECU 020917.31 – Fuel Filter Heater Fault…168
ECU 021077.31 – High Pressure Fuel Control Valve Fault…168
ECU 021270.31 – Injector No. 1 Fault…168
ECU 021430.31 – DEF Heating Unit Supply Line Supply Voltage Error…168
ECU 021462.31 – DEF Back Flow Pump Fault…168
ECU 021526.31 – Injector No. 2 Fault…168
ECU 021608.31 – Turbocharger Wastegate Valve Fault…168
ECU 021782.31 – Injector No. 4 Fault…168
ECU 022038.31 – Injector No. 3 Fault…168
ECU 022170.31 – DEF Tank Heater, Current Too Low…168
ECU 022198.31 – SCR Relay, Current Too Low…168
ECU 022074.31 – DEF Supply Module Heater, Current Too Low…168
ECU 022375.31 – EGR Valve Fault…168
ECU 022458.31 – DEF Heating Unit, Current Too Low…168
ECU 022610.31 – Indicator Light for Glow Plug Fault…168
ECU 023482.31 – DEF Pressure Line Heater, Current Too Low…168
ECU 023990.31 – DEF Dosing Valve Fault…168
ECU 024890.31 – DEF Dosing Unit Pump, Voltage Too High…168
ECU 024936.31 – Turbocharger Wastegate Valve, Voltage Too High…168
ECU 025060.31 – Actuator for Throttle, Voltage Too High…169
ECU 025126.31 – Injector No. 1, Short Circuit…169
ECU 025166.31 – DEF Quality Sensor, Voltage Too High…169
ECU 025316.31 – Actuator for Throttle, Voltage Too High…169
ECU 025382.31 – Injector No. 3, Short Circuit…169
ECU 025525.31 – Fuel Filter Heater, Voltage Too High…169
ECU 025638.31 – Injector No. 4, Short Circuit…169
ECU 025658.31 – DEF Dosing Unit Heater, Voltage Too High…169
ECU 025754.31 – DEF Tank Heater, Voltage Too High…169
ECU 025894.31 – Injector No. 2, Short Circuit…169
ECU 026042.31 – DEF Heating Unit, Voltage Too High…169
ECU 026070.31 – DEF Back Flow Pump, Voltage Too High…169
ECU 026197.31 – High Pressure Fuel Control Valve, Voltage Too High…169
Section 212: Observable Symptoms…912
Group 20: Engine…912
Engine Soot Load Too High…918
Group 30: Fuel and Air Intake System…912
Fuel and Air Intake Problems…912
Group 40: Electrical System…912
Electrical System (Summary of References)…926
Starting System Diagnostics…912
Charging System Diagnostics…912
Lighting System Diagnostics…912
Group 45: Electronic Control Units…912
Vehicle CAN Bus Check…938
Group 50: Power Train…912
Drive System Diagnostics…912
Group 60: Steering and Brakes…912
Problems with the Brakes…912
Problems with the Steering System…912
Group 70: Hydraulic System…912
Problems with the Hydraulic System…912
Group 80: Front-Wheel Drive…912
Problems with the Front-Wheel Drive…912
Group 90: Air-Conditioning System…912
Problems with the Air-Conditioning System…912
Section 220: Engine…956
Group 05: Engine – General Information…3761
General Information – Engine Overview…958
Group 10: Engine – Operational Checks…956
Operational Check-Out (Summary of References)…960
Engine Safety Precautions…3690
Preliminary Engine Tests…962
Group 20: Engine – Aftertreatment System General Information…3761
Summary of References – Aftertreatment System…964
DPF Regeneration – Operating Modes…965
Group 50: Engine – Diagnostic Tests/Adjustments…956
Tests and Adjustments (Summary of References)…967
Dynamometer Test…968
Section 230: Fuel, Air Intake and Cooling Systems…969
Group 20: Fuel, Air Intake and Cooling System – Theory of Operation…969
Summary of References – Theory of Operation…3748
Fuel System – Description…972
Fuel System – Description – Auxiliary Fuel Tank (Optional)…974
Air Intake System – Theory of Operation…976
Engine Cooling System Operation…980
Cooling System Radiator – Description…982
Viscous Clutch of Fan – Theory of Operation…983
Automatic Drive Belt Tensioner – Theory of Operation…985
Cold Weather Starting Aid – Theory of Operation…986
SCR Inducement – Theory of Operation…987
Group 50: Fuel, Air Intake and Cooling Systems – Diagnostic Tests/Adjustments…969
Summary of References – Tests and Adjustments…990
Essential or Recommended Tools…3767
General Information – Fuel, Air Intake and Cooling Systems…993
Explanation of Checks…994
Safety…995
Specifications…3691
Test Air Intake System…997
Test the Low-Pressure Switch in Air Intake System…999
Check the Cooling System for Leaks…1002
Testing the Temperature at Which the Thermostat Opens…1004
Checking the Viscous Clutch of the Fan…1006
Checking the Mechanical Feed Pump…1007
Hand and Foot Throttle Adjustments…1008
Section 240A: Electrical System (5G VNF)…1009
Group 05: General Information (5G VNF)…1009
Essential or Recommended Tools…3767
General – Electrical System, Faults, and Circuit Tests…1018
General – Electrical System, Test for Open Circuit Under Load…1023
Relay Test (10—20 A)…1028
Relay Test (20—40 A)…1030
Group 05A: Summary of References of Diagnostic Schematics (5G VNF)…1009
Diagnostic Schematics, Summary of References…1033
Group 50AA: Starting Motor and Charging System (5G VNF)…1009
Essential or Recommended Tools…3767
50AA – Starting Motor and Charging System for Engine F5G (DOC/SCR), Diagnostic Schematic…1036
50AA – Starting Motor and Charging System for Engine F5D (DOC/DPF), Diagnostic Schematic…1037
50AA – Starting Motor and Charging System for Engine F5G (DOC/SCR), Circuit Test…1038
50AA – Starting Motor and Charging System for Engine F5D (DOC/DPF), Circuit Test…1041
50AA – G02 – Alternator, Circuit Test…1044
50AA – M01 – Starting Motor, Circuit Test…1047
Group 50BA: Head and Tail Lights (5G VNF)…1009
Essential or Recommended Tools…3767
50BA – Head Lights, Diagnostic Schematic…1053
E01 – Right Headlight, Circuit Test…1055
E02 – Left Headlight, Circuit Test…1060
S09 – Multi-Function Lever, Circuit Test (High and Low Beam Function)…1065
50BA – Tail Lights, Diagnostic Schematic…1070
E14 – Right-hand Side Tail Light, Circuit Test…1072
E13 – Left-hand Side Tail Light, Circuit Test…1075
Group 50CA: Horn (5G VNF)…1009
Essential or Recommended Tools…3767
50CA – Horn, Diagnostic Schematic…1080
H01 – Horn, Circuit Test…1082
Group 50FA: Electronic Engine Control Unit (5G VNF)…1009
Essential or Recommended Tools…3767
50FA – Electronic Engine Control Unit, Summary of References…1087
50FA – Engine F5D (DOC/DPF), Diagnostic Schematic…1088
50FA – Engine F5G (DOC/SCR), Diagnostic Schematic…1090
50FA – A052 – Engine Can Bus Terminator for Engine F5G (DOC/SCR), Circuit Test…1092
50FA – A500 – Engine Control Unit (ECM) F5D (DOC/DPF), Circuit Test…1095
50FA – A500 – Engine Control Unit (ECM) F5G (DOC/SCR), Circuit Test…1100
50FA – A510 – Glow Plug Control Unit (GCU), Circuit Test…1105
50FA – A520 – High Pressure Pump, Circuit Test…1108
50FA – A530 – Actuator for Throttle, Circuit Test…1112
50FA – A540 – DEF Dosing Unit for Engine F5G (DOC/SCR), Circuit Test…1117
50FA – A541 – DEF Heating Unit for Engine F5G (DOC/SCR), Circuit Test…1121
50FA – B500 – Coolant Temperature Sensor, Circuit Test…1125
50FA – B501 – Oxygen Sensor for Engine F5D (DOC/DPF), Circuit Test…1128
50FA – B502 – Camshaft Position Sensor, Circuit Test…1131
50FA – B503 – Fuel Temperature Sensor, Circuit Test…1135
50FA – B504 – Turbocharger Pressure Sensor, Circuit Test…1138
50FA – B505 – Engine Oil Pressure Sensor, Circuit Test…1142
50FA – B506 – Fuel Rail Pressure Sensor, Circuit Test…1145
50FA – B507 – Exhaust Gas Temperature Sensor, Circuit Test…1149
50FA – B508 – Crankshaft Position Sensor, Circuit Test…1152
50FA – B509 – Ambient Temperature Sensor, Circuit Test…1155
50FA – B510 – Water-in-Fuel Sensor, Circuit Test…1158
50FA – B511 – DPF Differential Pressure Sensor for Engine F5D (DOC/DPF), Circuit Test…1162
50FA – B512 – DOC Inlet Temperature Sensor for Engine F5D (DOC/DPF), Circuit Test…1165
50FA – B513 – DOC Outlet Temperature Sensor for Engine F5D (DOC/DPF), Circuit Test…1168
50FA – B514 – Aftertreatment Outlet NH3 Sensor for Engine F5G (DOC/SCR), Circuit Test…1171
50FA – B515 – Aftertreatment Outlet NOx Sensor for Engine F5G (DOC/SCR), Circuit Test…1175
50FA – B516 – Aftertreatment Inlet NOx Sensor for Engine F5G (DOC/SCR), Circuit Test…1179
50FA – B517 – SCR Outlet Temperature Sensor for Engine F5G (DOC/SCR), Circuit Test…1183
50FA – B518 – DOC Outlet Temperature Sensor for Engine F5G (DOC/SCR), Circuit Test…1186
50FA – B519 – DOC Inlet Temperature Sensor for Engine F5G (DOC/SCR), Circuit Test…1189
50FA – B520 – Aftertreatment Diesel Exhaust Fluid (DEF) Sensor for Engine F5G (DOC/SCR), Circuit Test…1192
50FA – R501 – Glow Plug for Cylinder 1, Circuit Test…1196
50FA – R502 – Glow Plug for Cylinder 2, Circuit Test…1200
50FA – R504 – Glow Plug for Cylinder 4, Circuit Test…1204
50FA – R505 – Fuel Filter Heater, Circuit Test…1208
50FA – Y501 – Injection Valve for Cylinder 1, Circuit Test…1212
50FA – Y502 – Injection Valve for Cylinder 2, Circuit Test…1217
50FA – Y503 – Injection Valve for Cylinder 3, Circuit Test…1222
50FA – Y504 – Injection Valve for Cylinder 4, Circuit Test…1227
50FA – Y510 – Turbocharger Wastegate Valve, Circuit Test…1232
50FA – Y520 – High Pressure Fuel Control Valve, Circuit Test…1237
50FA – Y530 – EGR Valve, Circuit Test…1242
50FA – Y540 – DEF Tank Heater Valve for Engine F5G (DOC/SCR), Circuit Test…1247
50FA – Y541 – DEF Dosing Valve for Engine F5G (DOC/SCR), Circuit Test…1252
Group 50CB: Wiper and Washer System (5G VNF)…1011
Essential or Recommended Tools…3767
50CB – Windshield Wiper and Washer System, Diagnostic Schematic…1258
50CB – Rear Window Wiper and Washer System, Diagnostic Schematic…1260
50CB – M03 – Windshield Wiper, Circuit Test…1262
50CB – M05 – Pump of Washer System, Circuit Test…1265
50CB – M04 – Rear Wiper Motor, Circuit Test…1267
Group 50GD: Differential Lock (5G VNF)…1011
Essential or Recommended Tools…3767
50GD – Differential Lock (Mechanical Transmission), Diagnostic Schematic…1272
50GD – Differential Lock (PowrReverser™ Transmission), Diagnostic Schematic…1273
50GD – Y05 – Differential Lock Solenoid Valve (Mechanical Transmission), Circuit Test…1275
50GD – Differential Lock (PowrReverser™ Transmission), Circuit Test…1278
Group 50BC: Work Lights, Turn-Signal Lights/Amber Warning and Hazard Warning Light (5G VNF)…1011
Essential or Recommended Tools…3767
50BC – Work Lights, Turn-Signal Lights/Amber Warning and Hazard Warning Light (Cab), Diagnostic Schematic…1286
50BC – E11/L – Left Rear Worklight (Cab), Circuit Test…1287
50BC – E11/R – Right Rear Worklight (Cab), Circuit Test…1290
50BC – E18/L – Left Front Work Light (Cab), Circuit Test…1293
50BC – E18/R – Right Front Work Light (Cab), Circuit Test…1296
50BC – S09 – Multi-Function Lever, Circuit Test (Lights Function)…1299
50BC – S106 – Hazard Warning Light Switch (Cab), Circuit Test…1301
50BC – S61 – Rear Worklight Switch (Open Operator Platform), Diagnostic Schematic…1303
50BC – S61 – Rear Worklight Switch (Open Operator Platform), Circuit Test…1305
Group 50FB: Electronic Engine Controls (5G VNF)…1012
Essential or Recommended Tools…3767
50FB – Cruise Control, Diagnostic Schematic…1310
50FB – S992 – Cruise Control Switch (ON/OFF/Save), Circuit Test…1312
50FB – S993 – Cruise Control Switch (Decrease RPM), Circuit Test…1315
50FB – S994 – Cruise Control Switch (Increase RPM), Circuit Test…1318
50FB – B998 – Hand Throttle Sensor, Diagnostic Schematic…1321
50FB – B998 – Hand Throttle Sensor, Circuit Test…1323
50FB – B999 – Foot Throttle Potentiometer, Diagnostic Schematic…1326
50FB – B999 – Foot Throttle Potentiometer, Circuit Test…1327
Group 50GG: Rear PTO System (5G VNF)…1012
Essential or Recommended Tools…3767
50GG – Rear PTO System, Diagnostic Schematic…1332
50GG – S350 – PTO Switch (PowrReverser™ Transmission), Circuit Test…1334
50GG – B07/1 – PTO Switch (540 rpm), Circuit Test (PTO engaged signal under threshold)…1338
50GG – B07/1 – PTO Switch (540 rpm), Circuit Test (PTO engaged signal inconsistent)…1341
50GG – B07/1 – PTO Switch (540 rpm), Circuit Test (PTO engaged signal over threshold)…1345
50GG – B07/2 – PTO Switch (540E/1000 rpm), Circuit Test (PTO engaged signal under threshold)…1348
50GG – B07/2 – PTO Switch (540E/1000 rpm), Circuit Test (PTO engaged signal inconsistent)…1351
50GG – B07/2 – PTO Switch (540E/1000 rpm), Circuit Test (PTO engaged signal over threshold)…1355
50GG – Rear PTO Speed Selection Switches, Circuit Test (detection failure)…1358
50GG – S21/2 – Independent Rear PTO Selector Switch, Circuit Test (PTO engaged signal under threshold)…1361
50GG – S21/2 – Independent Rear PTO Selector Switch, Circuit Test (PTO engaged signal inconsistent)…1364
50GG – S21/2 – Independent Rear PTO Selector Switch, Circuit Test (PTO engaged signal over threshold)…1368
50GG – S21/1 – Ground Drive PTO Selector Switch, Circuit Test (PTO engaged signal under threshold)…1371
50GG – S21/1 – Ground Drive PTO Selector Switch, Circuit Test (PTO engaged signal inconsistent)…1374
50GG – S21/1 – Ground Drive PTO Selector Switch, Circuit Test (PTO engaged signal over threshold)…1378
50GG – S21/2 – Independent Rear PTO and S21/1 – Ground Drive PTO Selector Switches, Circuit Test (detection failure)…1381
50GG – B989 – PTO Shaft Output Speed Sensor 2 with IPM (PTO Side Sensor), Circuit Test…1384
50GG – B980 – PTO Shaft Output Speed Sensor 2 with IPM (Engine Side Sensor), Circuit Test…1388
50GG – PTO Shaft Output Speed Sensors, Circuit Test (signal not consistent)…1392
50GG – B350 – PTO Pressure Sensor, Circuit Test (open signal failure)…1396
50GG – B350 – PTO Pressure Sensor, Circuit Test (closed signal failure)…1400
50GG – Y350 – PTO Shut-Off Solenoid Valve, Circuit Test…1403
50GG – Y04 – PTO Solenoid Valve, Circuit Test…1406
50GG – B350 – PTO Pressure Sensor, Circuit Test (low pressure)…1409
B980 – PTO Shaft Output Speed Sensor 2 with IPM (Engine Side Sensor), Circuit Test (signal failure)…1412
Group 50CC: Air Conditioning System (5G VNF)…1013
Essential or Recommended Tools…3767
50CC – Air-Conditioning Condenser, Diagnostic Schematic…1418
50CC – Air-Conditioning System, Diagnostic Schematic…1420
50CC – M02 – Air-Conditioning Compressor Clutch, M08 and M09 – Air-Conditioning Condenser Fan Motors, Circuit Test…1422
50CC – M02 – Air-Conditioning Compressor Clutch and M07 – Cab Blower Motor (Air-Conditioning System), Circuit Test…1430
50CC – E28 – Heater and Air-Conditioning Control Panel Backlighting (Air-Conditioning System), Circuit Test…1436
Group 50CE: Radio, Dome, and Spot Light (5G VNF)…1013
Essential or Recommended Tools…3767
50CE – Radio, Dome, and Spot Light, Diagnostic Schematic…1441
50CE – A010 – Radio, Circuit Test…1443
50CE – E12 – Dome Light, Circuit Test…1446
Group 50CF: Beacon Light (5G VNF)…1013
Essential or Recommended Tools…3767
50CF – Beacon Light (Cab), Diagnostic Schematic…1451
50CF – Beacon Light (ROPS), Diagnostic Schematic…1452
50CF – E27 – Beacon Light (Cab), Circuit Test…1453
50CF – E27 – Beacon Light (ROPS), Circuit Test…1456
Group 50CG: Trailer Socket (5G VNF)…1014
Essential or Recommended Tools…3767
50CG – 7-Terminal Trailer Socket, Diagnostic Schematic…1461
50CG – X21W30 – 7-Terminal Trailer Socket, Circuit Test…1463
Group 50GA: Transmission Control Unit (5G VNF)…1014
Essential or Recommended Tools…3767
50GA – Hi-Lo Shifting, Diagnostic Schematic…1470
50GA – Transmission Control Unit, Diagnostic Schematic…1471
50GA – A320 – Transmission Control Unit Supply Voltage Circuit Test…1475
50GA – A320 – 5 – Volt Supply Voltage Circuit Test…1479
50GA – B64 – Reverse Drive Lever Switch Circuit Test…1483
50GA – B65 – Clutch Pedal Potentiometer, Circuit Test…1489
50GA – B73 – Transmission Oil Filter Restricted Sensor, Circuit Test…1493
50GA – B104 – Transmission Top Shaft Speed Sensor, Circuit Test…1497
50GA – B300 – Forward High Clutch Pressure Sensor, Circuit Test…1502
50GA – B301 – Forward Low Clutch Pressure Sensor, Circuit Test…1506
50GA – B302 – Reverse Clutch Pressure Sensor, Circuit Test…1511
50GA – B303 – Transmission Oil Pressure Sensor, Circuit Test…1516
50GA – S300/1 – Hi/Lo Switch (Hi) and S300/2 – Hi/Lo Switch (Lo), Circuit test…1521
50GA – S300/1 – Hi/Lo Switch (Hi), Circuit Test…1524
50GA – S300/2 – Hi/Lo Switch (Lo), Circuit Test…1527
50GA – X9W31 – CAN-Bus Circuit Test…1530
50GA – Y51 – Reverse Clutch Solenoid Valve, Circuit Test…1533
50GA – Y52 – Forward Low Clutch Solenoid Valve, Circuit Test…1540
50GA – Y53 – Forward High Clutch Solenoid Valve, Circuit Test…1547
50GA – Y300 – Main Ring Valve Solenoid Valve, Circuit Test…1553
Group 50GE: Front Wheel Drive and Park Brake (5G VNF)…1014
Essential or Recommended Tools…3767
50GE – Front Wheel Drive and Park Brake, Diagnostic Schematic…1558
50GE – B988 – Front Wheel Drive Pressure Switch, Circuit test…1560
50GE – S63 – Front-Wheel Drive Switch, Circuit Test…1563
50GE – Y03 – Front wheel drive solenoid valve, Circuit Test…1565
Group 50GF: Brake System (5G VNF)…1014
Essential or Recommended Tools…3767
50GF – Brake System (Mechanical Transmission), Diagnostic Schematic…1570
50GF – E13 – Left-hand and E14 – Right-hand side Tail Lights, Circuit Test…1572
50GF – Brake System (PowrReverser™ Transmission), Diagnostic Schematic…1575
50GF – B112/1 – Right Brake Pedal and B112/2 – Left Brake Pedal Switch, Circuit Test…1577
Group 50IA: Instrument Unit (5G VNF)…1015
Essential or Recommended Tools…3767
50IA – Instrument Unit, Diagnostic Schematic…1583
50IA – A330 – Instrument Unit, Circuit Test…1585
50IA – A330 – Instrument Unit – SPI and CAN fail, Circuit Test…1600
Group 50JA: CAN Bus System (5G VNF)…1015
Essential or Recommended Tools…3767
50JA – Vehicle CAN (Controller Area Network) Bus System, Diagnostic Schematic…1606
50JA – Controller Area Network (CAN), Circuit Test…1608
Section 240B: Electrical System (5GL)…1612
Group 05: Electrical System – General Information (5GL)…1612
Essential or Recommended Tools…3767
General – Electrical System, Faults, and Circuit Tests (5GL)…1619
General – Electrical System, Test for Open Circuit Under Load (5GL)…1624
Relay Test (10—20 A) (5GL)…1629
Relay Test (20—40 A) (5GL)…1631
Group 30: Electrical System – Schematics (5GL)…1612
30A – Electrical System (5GL) – Summary of Schematics…1634
Group 50AA: Starting Motor and Charging System (5GL)…1612
50AA – Starter Motor and Charging System (5GL), Summary of References…1636
Essential or Recommended Tools…3767
SE01 – Starting Motor and Charging System (PowrReverser™ Transmission) (5GL), Diagnostic Schematic…1638
G02 – Alternator (5GL), Circuit Test…1641
M01 – Starting Motor (5GL), Circuit Test…1644
R1 – Starter Motor Relay (5GL), Circuit Test…1648
Group 50BA: Vehicle Lights (5GL)…1612
50BA – Vehicle Lights (5GL), Summary of References…1652
Essential or Recommended Tools…3767
SE04 – Head Lights (Open Operator Platform) (5GL), Diagnostic Schematic…1654
SE10 – Beacon Light (Open Operator Platform) (5GL), Diagnostic Schematic…1655
SE13/1 – Clearance, Tail Lights and 7-Terminal Power Outlet Socket (Open Operator Platform) (5GL), Diagnostic Schematic…1656
SE13/2 – Brake Lights and 7-Terminal Power Outlet Socket (Open Operator Platform) (5GL), Diagnostic Schematic…1657
SE13/3 – Turn-Signal, Hazard Warning Lights and 7-Terminal Power Outlet Socket (Open Operator Platform) (5GL), Diagnostic Schematic…1658
E01 – Right Headlight (5GL), Circuit Test…1660
E02 – Left Headlight (5GL), Circuit Test…1664
E13 – Left-Hand Side Tail Light (Position Light) (5GL), Circuit Test…1668
E13 – Left-Hand Side Tail Light (Stop Light) (5GL), Circuit Test…1671
E13 – Left-Hand Side Tail Light (Rear Turn/Warn Light) (5GL), Circuit Test…1674
E14 – Right-Hand Side Tail Light (Position Light) (5GL), Circuit Test…1677
E14 – Right-Hand Side Tail Light (Stop Light) (5GL), Circuit Test…1680
E14 – Right-Hand Side Tail Light (Rear Turn/Warn Light) (5GL), Circuit Test…1683
E27 – Beacon Light (5GL), Circuit Test…1686
E30 – Right Front Turn-Signal/Amber Warning Lights (5GL), Circuit Test…1689
E31 – Left Front Turn-Signal/Amber Warning Lights (5GL), Circuit Test…1692
E32 – Right Rear Turn-Signal/Amber Warning Lights (5GL), Circuit Test…1695
E33 – Left Rear Turn-Signal/Amber Warning Lights (5GL), Circuit Test…1698
H01 – Horn (5GL), Circuit Test…1701
S09 – Multi-Function Lever (5GL), Circuit Test…1703
S106 – Hazard Warning Light Switch (5GL), Circuit Test…1705
Group 50CA: Operator's Seat (5GL)…1613
50CA – Operator's Seat (5GL), Summary of References…1708
Essential or Recommended Tools…3767
SE20 – Air Suspension Seat (5GL), Diagnostic Schematic…1710
M06 – Air Suspension Seat Compressor Motor (5GL), Circuit Test…1712
Group 50CB: Power Outlet Sockets (5GL)…1613
50CB – Power Outlet Sockets (5GL), Summary of References…1716
SE23 – Power Outlet Sockets (Open Operator Platform) (5GL), Diagnostic Schematic…1717
Group 50FA: Electronic Engine Control Unit (5GL)…1613
50FA – Electronic Engine Control (5GL), Summary of References…1719
Essential or Recommended Tools…3767
50FA – Engine F5D (DOC/DPF) (5GL), Diagnostic Schematic…1721
SE98 – Hand, Foot throttle, Cruise Control and Transmission Speed Sensor (PowrReverser™ Transmission) (Open Operator Platform) (5GL), Diagnostic Schematic…1723
50FA – A500 – Engine Control Unit (ECM) F5D (DOC/DPF) (5GL), Circuit Test…1724
50FA – A510 – Glow Plug Control Unit (GCU) (5GL), Circuit Test…1729
50FA – A520 – High Pressure Pump (5GL), Circuit Test…1732
50FA – A530 – Actuator for Throttle (5GL), Circuit Test…1736
B06 – Transmission Speed Sensor (5GL), Circuit Test…1741
50FA – B500 – Coolant Temperature Sensor (5GL), Circuit Test…1745
50FA – B501 – Oxygen Sensor for Engine F5D (DOC/DPF) (5GL), Circuit Test…1748
50FA – B502 – Camshaft Position Sensor (5GL), Circuit Test…1751
50FA – B503 – Fuel Temperature Sensor (5GL), Circuit Test…1754
50FA – B504 – Exhaust Manifold Pressure Sensor (5GL), Circuit Test…1757
50FA – B505 – Engine Oil Pressure Sensor (5GL), Circuit Test…1761
50FA – B506 – Fuel Rail Pressure Sensor (5GL), Circuit Test…1764
50FA – B507 – Exhaust Gas Temperature Sensor (5GL), Circuit Test…1767
50FA – B508 – Crankshaft Position Sensor (5GL), Circuit Test…1770
50FA – B509 – Ambient Temperature Sensor (5GL), Circuit Test…1773
50FA – B510 – Water-in-Fuel Sensor (5GL), Circuit Test…1776
50FA – B511 – DPF Differential Pressure Sensor for Engine F5D (DOC/DPF) (5GL), Circuit Test…1780
50FA – B512 – DOC Inlet Temperature Sensor for Engine F5D (DOC/DPF) (5GL), Circuit Test…1783
50FA – B513 – DOC Outlet Temperature Sensor for Engine F5D (DOC/DPF) (5GL), Circuit Test…1786
B998 – Hand Throttle Sensor (5GL), Circuit Test…1789
B999 – Foot Throttle Potentiometer (5GL), Circuit Test…1792
50FA – R501 – Glow Plug for Cylinder 1 (5GL), Circuit Test…1795
50FA – R502 – Glow Plug for Cylinder 2 (5GL), Circuit Test…1799
50FA – R503 – Glow Plug for Cylinder 3 (5GL), Circuit Test…1803
50FA – R504 – Glow Plug for Cylinder 4 (5GL), Circuit Test…1807
50FA – R505 – Fuel Filter Heater (5GL), Circuit Test…1811
S40 – Presence Sensor Switch (5GL), Circuit Test…1815
S992/1 – Cruise Control Switch (ON/OFF/Save) (5GL), Circuit Test…1818
S992/2 – Cruise Control Switch (ON/OFF/Save) (5GL), Circuit Test…1821
S993 – Cruise Control Switch (Decrease RPM) (5GL), Circuit Test…1824
S994 – Cruise Control Switch (Increase RPM) (5GL), Circuit Test…1827
50FA – Y501 – Injection Valve for Cylinder 1 (5GL), Circuit Test…1830
50FA – Y502 – Injection Valve for Cylinder 2 (5GL), Circuit Test…1834
50FA – Y503 – Injection Valve for Cylinder 3 (5GL), Circuit Test…1838
50FA – Y504 – Injection Valve for Cylinder 4 (5GL), Circuit Test…1842
50FA – Y510 – Turbocharger Wastegate Valve (5GL), Circuit Test…1846
50FA – Y520 – High Pressure Fuel Control Valve (5GL), Circuit Test…1851
50FA – Y530 – EGR Valve (5GL), Circuit Test…1855
Group 50GA: PowrReverser™ Transmission (5GL)…1614
50GA – PowrReverser™ Transmission (5GL), Summary of References…1861
Essential or Recommended Tools…3767
SE90 – Transmission Control Unit (5GL), Diagnostic Schematic…1863
A320 – Transmission Control Unit (5GL), Circuit Test…1865
B60 – Transmission Oil Temperature Sensor (5GL), Circuit Test…1872
B63 – Hi/Lo Switch on Transmission (5GL), Circuit Test…1877
B64 – Reverse Drive Lever Switch (5GL), Circuit Test…1881
B65 – Clutch Pedal Potentiometer (5GL), Circuit Test…1887
B73 – Transmission Oil Filter Restriction Sensor (5GL), Circuit Test…1891
B104 – Transmission Top Shaft Speed Sensor (5GL), Circuit Test…1896
B300 – Forward High Clutch Pressure Sensor (5GL), Circuit Test…1903
B301 – Forward Low Clutch Pressure Sensor (5GL), Circuit Test…1907
B302 – Reverse Clutch Pressure Sensor (5GL), Circuit Test…1911
B303 – Transmission Oil Pressure Switch (5GL), Circuit Test…1915
R15 – PWM Enabler (5GL), Circuit Test…1919
S20 – Calibration Switch of Instrument Unit (5GL), Circuit Test…1925
S72 – Clutch Pedal Switch (5GL), Circuit Test…1928
S300 – Hi/Lo Switch (5GL), Circuit Test…1930
Y51 – Reverse Clutch Solenoid Valve (5GL), Circuit Test…1933
Y52 – Forward Low Clutch Solenoid Valve (5GL), Circuit Test…1937
Y53 – Forward High Clutch Solenoid Valve (5GL), Circuit Test…1941
Y300 – Main Ring Valve Solenoid Valve (5GL), Circuit Test…1945
Group 50GC: Differential Lock (5GL)…1615
50GC – Differential Lock (5GL), Summary of References…1949
Essential or Recommended Tools…3767
SE16 – Differential Lock (Open Operator Platform) (5GL), Diagnostic Schematic…1951
B987 – Differential Lock Pressure Switch (5GL), Circuit Test…1952
S22 – Differential Lock Switch (5GL), Circuit Test…1955
Y05 – Differential Lock Solenoid Valve (5GL), Circuit Test…1958
Group 50GD: Front Wheel Drive and Park Brake (5GL)…1615
50GD – Front Wheel Drive and Park Brake (5GL), Summary of References…1962
Essential or Recommended Tools…3767
SE15 – Front Wheel Drive and Park Brake (Open Operator Platform) (5GL), Diagnostic Schematic…1964
B05 – Park Brake Switch (5GL), Circuit Test…1965
B988 – Front Wheel Drive Pressure Switch (5GL), Circuit Test…1967
S63 – Front-Wheel Drive Switch (5GL), Circuit Test…1970
Y03 – Front-Wheel Drive Solenoid Valve (5GL), Circuit Test…1972
Group 50GE: PTO System (5GL)…1616
50GE – PTO System (5GL), Summary of References…1976
Essential or Recommended Tools…3767
SE94 – Front and Rear PTO System (PowrReverser™ Transmission) (5GL), Diagnostic Schematic…1978
B07/1 – PTO Switch (540 rpm) (5GL), Circuit Test…1980
B07/2 – PTO Switch (540E/1000 rpm) (5GL), Circuit Test…1984
B36 – Neutral Start Switch (5GL), Circuit Test…1988
B350 – PTO Pressure Sensor (5GL), Circuit Test…1991
B980 – PTO Shaft Output Speed Sensor (5GL), Circuit Test…1995
R998 – Resistor for Ground Drive PTO Presence (5GL), Circuit Test…1999
R999 – Resistor for Independent Rear PTO Presence (5GL), Circuit Test…2003
S350 – Rear PTO Switch (PowrReverser™ Transmission) (5GL), Circuit Test…2007
Y04 – PTO Solenoid Valve (5GL), Circuit Test…2011
Y350 – PTO Shutoff Solenoid Valve (5GL), Circuit Test…2014
Group 50IA: Instrument Unit (5GL)…1616
50IA – Instrument Unit (5GL), Summary of References…2018
Essential or Recommended Tools…3767
SE02 – Instrument Unit (PowrReverser™ Transmission) (5GL), Diagnostic Schematic…2020
A330 – Instrument Unit (5GL), Circuit Test…2021
B02 – Air Filter Restriction Sensor (5GL), Circuit Test…2025
B03 – Fuel Level Sensor (5GL), Circuit Test…2028
B69 – Brake Oil Level Sensor (5GL), Circuit Test…2031
B112/1 – Right Brake Pedal Switch (5GL), Circuit Test…2034
B112/2 – Left Brake Pedal Switch (5GL), Circuit Test…2037
S990 – Programming Switch (Menu) (5GL), Circuit Test…2040
S991 – Programming Switch (Save) (5GL), Circuit Test…2043
Group 50JA: CAN Bus System (5GL)…1616
50JA – CAN Bus System (5GL), Summary of References…2047
Essential or Recommended Tools…3767
SE19 – CAN Bus Vehicle (PowrReverser™ Transmission) (5GL), Diagnostic Schematic…2049
50JA – Controller Area Network (CAN) (5GL), Circuit Test…2050
Section 245: Electronic Control Units…2053
Group 05: Operation and General Information on Diagnostics…2053
Operation and General Information on Diagnostics (Summary of References)…2057
Procedure for Dealing with Diagnostic Trouble Codes…2058
Digital Display Onboard Functionality…2060
Group 10C: Information on How to Reprogram Control Units…2053
Information on How to Reprogram Control Units – Summary of References…2062
General Information on How to Reprogram Control Units…2063
Software Data Files Available for Downloading…2064
Procedure When Replacing Control Units…2066
Important Notes on Programming…2067
Procedure When Programming Control Units…2068
Procedure in the Event of a Programming Problem…2070
Group ECU-F5D: ECU – Engine Control Unit for Engine F5D (DOC/DPF)…2053
ECU – Engine Control Unit for Engine F5D (DOC/DPF), Summary of References…2072
Control Unit Information and Overview Test…2073
Engine Control Unit Replacement…2074
Engine Replacement…2075
Service ADVISOR™ Readings (Datapoint) list for Engine F5D (DOC/DPF)…2076
Engine Oil and Filter Replacement Calibration…2079
DPF Differential Pressure Sensor Calibration for Engine F5D (DOC/DPF)…2080
Oxygen Sensor Calibration for Engine F5D (DOC/DPF)…2081
DPF Calibration for Engine F5D (DOC/DPF)…2082
DOC Calibration for Engine F5D (DOC/DPF)…2083
DPF Ash Service Calibration for Engine F5D (DOC/DPF)…2084
Injector Calibration for Engine F5D (DOC/DPF)…2085
Fuel Rail Pressure Relief Valve Counter Reset for Engine F5D (DOC/DPF)…2087
EGR Valve Calibration for Engine F5D (DOC/DPF)…2088
Glow Plug System Test for Engine F5D (DOC/DPF)…2089
Service Regeneration for Engine F5D (DOC/DPF)…2090
Cylinder Cutout Test for Engine F5D (DOC/DPF)…2091
Group ECU-F5G: ECU – Engine Control Unit for Engine F5G (DOC/SCR)…2053
ECU – Engine Control Unit, Summary of References for Engine F5G (DOC/SCR)…2094
Service ADVISOR™ Readings (Datapoint) list for Engine F5G (DOC/SCR)…2095
DOC Calibration for Engine F5G (DOC/SCR)…2098
EGR Cooler Calibration for Engine F5G (DOC/SCR)…2099
EGR Valve Calibration for Engine F5G (DOC/SCR)…2100
Fuel Rail Pressure Relief Valve Counter Reset for Engine F5G (DOC/SCR)…2101
Fuel Rail Pressure Sensor Calibration for Engine F5G (DOC/SCR)…2102
Injector Calibration for Engine F5G (DOC/SCR)…2103
NOx Sensor Calibration for Engine F5G (DOC/SCR)…2105
SCR Catalyst Calibration for Engine F5G (DOC/SCR)…2106
Actuator Test for Engine F5G (DOC/SCR)…2107
Control Unit Information and Overview for Engine F5G (DOC/SCR)…2108
Cylinder Cutout Test for Engine F5G (DOC/SCR)…2109
Cylinder Electronic Compression Test for Engine F5G (DOC/SCR)…2111
Cylinder Misfire Test for Engine F5G (DOC/SCR)…2112
DEF Dosing System Test for Engine F5G (DOC/SCR)…2113
DEF High Flow Rate Test for Engine F5G (DOC/SCR)…2119
DEF Pump Diagnostic Test for Engine F5G (DOC/SCR)…2120
DEF Quantity Test for Engine F5G (DOC/SCR)…2121
Glow Plug System Test for Engine F5G (DOC/SCR)…2122
High Pressure Fuel System Test for Engine F5G (DOC/SCR)…2123
SCR Catalyst Cleaning Procedure for Engine F5G (DOC/SCR)…2125
SCR System Reset for Engine F5G (DOC/SCR)…2126
SCR Catalyst Cleaning Counter Reset…2127
Group TCU: TCU – Transmission Control Unit…2054
TCU – Transmission Control Unit – Summary of References…2129
Transmission Control Unit – On-Board Configuration…2130
Transmission Control Unit – On-Board Configuration – Vehicle type configuration…2134
Transmission Control Unit – On-Board Configuration – Clutch pedal calibration…2137
Transmission Control Unit – On-Board Configuration – Clutches pressure sensors calibration…2141
Transmission Control Unit -On-Board Configuration – FNR lever comfort parameterization…2144
Transmission Control Unit – On-Board Configuration – Hi/Lo comfort parameterization…2147
Transmission Control Unit – On-Board Configuration – Clutch pedal comfort parameterization…2150
Transmission Control Unit – On-Board Configuration – Limp home mode activation…2153
Transmission Control Unit – On-Board Configuration – On board diagnostic…2156
Transmission Control Unit – On-Board Configuration and Calibration Values…2158
Digital Display – TCU Message and Diagnostic Trouble Code (DTC) Overview…2159
Transmission Control Unit – Software Information…2172
Clutch Pedal, Operational Check…2173
Reverse Drive Lever, Operational Check…2174
Forward High Clutch, Operational Check…2175
Forward Low Clutch, Operational Check…2176
Reverse Clutch, Operational Check…2177
TCU Main Ring Pressure, Operational Check…2178
Power Take-Off (PTO), Operational Check…2179
Group VCU: VCU – Vehicle Control Unit…2055
Changing Display and User Menu…2188
User Menu…2188
Initial Setup…2203
Oil Reset…2215
Digital Display – Message and Diagnostic Trouble Code (DTC) Overview…2217
VCU Operational Checks – Diagnostic Trouble Code (DTC)…2223
Section 249A: Electrical System – Component Information (5G VNF)…2227
Group 05: Summary of Electrical Components and Harnesses (5G VNF)…2227
Summary of References of Electrical Components, Assemblies…2239
Summary of References of Electrical Components, Sensors…2240
Summary of References of Electrical Components, Lights…2242
Summary of References of Electrical Components, Fuses, Relays, and Diodes…2243
Summary of References of Electrical Components, Power Supply and Alternator…2244
Summary of References of Electrical Components, Monitoring and Signaling Devices…2245
Summary of References of Electrical Components, Electrical Motors…2246
Summary of References of Electrical Components, Resistors…2247
Summary of References of Electrical Components, Switches…2248
Summary of References of Electrical Components, Wiring Harnesses…2249
Summary of References of Electrical Components, Wiring Diagrams…2250
Summary of References of Electrical Components, Connector Information…2251
Summary of References of Electrical Components, Ground Points…2253
Summary of References of Electrical Components, Solenoids and Solenoid Valves…2254
Summary of References of Electrical Components, Other…2255
Group 40A: Electrical Components – Assemblies (5G VNF)…2227
A005 – Right Speaker, Component Information…2258
A006 – Left Speaker, Component Information…2260
A010 – Radio, Component Information…2262
A050 – CAN Bus Terminator (Vehicle CAN Bus), Component Information…2264
A052 – CAN Bus Terminator (Engine CAN Bus) for Engine F5G (DOC/SCR), Component Information…2266
A320 – Transmission Control Unit, Component Information…2268
A330 – Instrument Unit, Component Information…2272
A500 – Engine Control Unit (ECM) for Engine F5D (DOC/DPF), Component Information…2276
A500 – Engine Control Unit (ECM) for Engine F5G (DOC/SCR), Component Information…2283
A510 – Glow Plug Control Unit (GCU), Component Information…2290
A520 – High Pressure Pump, Component Information…2292
A530 – Actuator for Throttle, Component Information…2294
A540 – DEF Dosing Unit for Engine F5G (DOC/SCR), Component Information…2296
A541 – DEF Heating Unit for Engine F5G (DOC/SCR), Component Information…2298
Group 40B: Electrical Components – Sensors (5G VNF)…2228
B02 – Air Filter Restriction Sensor, Component Information…2304
B03 – Fuel Level Sensor, Component Information…2307
B05 – Park Brake Switch, Component Information…2309
B06 – Transmission Speed Sensor, Component Information…2311
B07/1 – PTO Switch (540 rpm), Component Information…2313
B07/2 – PTO Switch (540E/1000 rpm), Component Information…2315
B08 – PTO Neutral Start Switch, Component Information…2318
B36/1 – Neutral Start Switch, Component Information…2321
B60 – Transmission Oil Temperature Sensor, Component Information…2323
B63 – Hi/Lo Switch on Transmission, Component Information…2325
B64 – Reverse Drive Lever Switch, Component Information…2327
B65 – Clutch Pedal Potentiometer, Component Information…2329
B69 – Brake Oil Level Sensor, Component Information…2331
B73 – Transmission Oil Filter Restriction Sensor, Component Information…2333
B104 – Transmission Top Shaft Speed Sensor, Component Information…2335
B112/1 – Right Brake Pedal Switch, Component Information…2338
B112/2 – Left Brake Pedal Switch, Component Information…2340
B150 – Thermostat, Component Information…2342
B151 – Fan Resistor, Component Information…2344
B300 – Forward High Clutch Pressure Sensor, Component Information…2346
B301 – Forward Low Clutch Pressure Sensor, Component Information…2348
B302 – Reverse Clutch Pressure Sensor, Component Information…2350
B303 – Transmission Oil Pressure Switch, Component Information…2352
B304 – Refrigerant Pressure Sensor, Component Information…2354
B350 – PTO Pressure Sensor, Component Information…2356
B500 – Coolant Temperature Sensor, Component Information…2358
B501 – Oxygen Sensor for Engine F5D (DOC/DPF), Component Information…2360
B502 – Camshaft Position Sensor, Component Information…2362
B503 – Fuel Temperature Sensor, Component Information…2364
B504 – Exhaust Manifold Pressure Sensor, Component Information…2366
B505 – Engine Oil Pressure Sensor, Component Information…2368
B506 – Fuel Rail Pressure Sensor, Component Information…2370
B507 – Exhaust Gas Temperature Sensor, Component Information…2372
B508 – Crankshaft Position Sensor, Component Information…2374
B509 – Ambient Temperature Sensor, Component Information…2376
B510 – Water in Fuel Sensor, Component Information…2378
B511 – DPF Differential Pressure Sensor for Engine F5D (DOC/DPF), Component Information…2380
B512 – DOC Inlet Temperature Sensor for Engine F5D (DOC/DPF), Component Information…2382
B513 – DOC Outlet Temperature Sensor for Engine F5D (DOC/DPF), Component Information…2384
B514 – Aftertreatment Outlet NH3 Sensor for Engine F5G (DOC/SCR), Component Information…2386
B515 – Aftertreatment Outlet NOx Sensor for Engine F5G (DOC/SCR), Component Information…2388
B516 – Aftertreatment Inlet NOx Sensor for Engine F5G (DOC/SCR), Component Information…2390
B517 – SCR Outlet Temperature Sensor for Engine F5G (DOC/SCR), Component Information…2392
B518 – DOC Outlet Temperature Sensor for Engine F5G (DOC/SCR), Component Information…2394
B519 – DOC Inlet Temperature Sensor for Engine F5G (DOC/SCR), Component Information…2396
B520 – Aftertreatment Diesel Exhaust Fluid (DEF) Sensor for Engine F5G (DOC/SCR), Component Information…2398
B980 – PTO Shaft Output Speed Sensor 2 with IPM (Engine Side Sensor), Component Information…2400
B988 – Front Wheel Drive Pressure Switch, Component Information…2403
B989 – PTO Shaft Output Speed Sensor 2 with IPM (PTO Side Sensor), Component Information…2405
B998 – Hand Throttle Sensor, Component Information…2407
B999 – Foot Throttle Potentiometer, Component Information…2409
Group 40E: Electrical Components – Lights (5G VNF)…2229
E01 – Right Headlight, Component Information…2413
E02 – Left Headlight, Component Information…2415
E05 – Cigarette Lighter, Component Information…2417
E07 – Left-Hand H4 Farm Headlight, Component Information…2420
E08 – Right-Hand H4 Farm Headlight, Component Information…2422
E11/L – Left Rear Worklight, Component Information…2424
E11/R – Right Rear Worklight, Component Information…2426
E12 – Dome Light, Component Information…2428
E13 – Left-hand Side Tail Light, Component Information…2430
E14 – Right-Hand Tail Light, Component Information…2432
E18/L – Left Front Work Light, Component Information…2435
E18/R – Right Front Work Light, Component Information…2437
E27 – Beacon Light (ROPS), Component Information…2439
E27 – Beacon Light (Cab), Component Information…2441
E28 – Heater and Air-Conditioning Control Panel Backlighting, Component Information…2443
E30 – Right Front Turn-Signal/Amber Warning Lights, Component Information…2445
E31 – Left Front Turn-Signal/Amber Warning Lights, Component Information…2448
E32 – Right Rear Turn-Signal/Amber Warning Lights, Component Information…2451
E33 – Left Rear Turn-Signal/Amber Warning Lights, Component Information…2454
Group 40F: Electrical Components – Fuses, Relays, and Diodes (5G VNF)…2230
X3.FW29 – F1-F16 (Fuse Box), Component Information…2459
X4W04 – Fuse Box F1—F6 (Cab Wiring Harness)…2461
X100W02B – Fuse/Relay Box F1-F10/K1-K5 for Engine F5G (DOC/SCR), Component Information…2463
F1 – ECU Sensor Fuse (7.5A) for Engine F5D (DOC/DPF), Component Information…2466
F2 – ECU Protection Fuse (20A) for Engine F5D (DOC/DPF), Component Information…2468
F3 – ECU Protection Fuse (7.5A) for Engine F5D (DOC/DPF), Component Information…2470
F4 – Fuel Heater Fuse (20A) for Engine F5D (DOC/DPF), Component Information…2472
X3.RW29 – K1—K7 (Relay Box), Component Information…2474
F3 – 70 Amp Main Fuse, Component Information…2476
F1 – 50 Amp Main Harness Fuse, Component Information…2478
F2 – 50 Amp Glow Plug Fuse, Component Information…2480
F3 – 70 Amp Engine ECU Fuse, Component Information…2482
F25 – Fan Motor I Fuse, Component Information…2484
F26 – Fan Motor I and II Fuse, Component Information…2486
K01 – Starter Motor Relay, Component Information…2488
K01 – ECU Main Relay, Component Information…2490
K02 – Fuel Heater Relay, Component Information…2492
K1 – PWM Enabler, Component Information…2494
K08 – Turn-Signal Relay, Component Information…2496
K22 – Power Supply Relay, Component Information…2499
K23 – Front Work Light Relay, Component Information…2501
K24 – Rear Work Light Relay, Component Information…2503
K25 – Air-Conditioning Compressor Clutch Relay, Component Information…2505
K28 – Fan Speed Relay, Component Information…2507
K29 – Relay for Air-Conditioning Condenser Fan Motor I, Component Information…2509
K30 – Relay for Air-Conditioning Condenser Fan Motor I and II, Component Information…2511
K31 – Relay for Air-Conditioning Condenser Fan Motor I and II, Component Information…2513
K1000 – ECU Keep Alive Relay for Engine F5G (DOC/SCR), Component Information…2515
D1 – Suppressor Diode (A/C Compressor)…2517
D25 – Diode for End Stroke (PowrReverser™ Transmission Safety), Component Information…2519
D26 – Diode for Neutral Signal (PowrReverser™ Transmission Safety), Component Information…2521
Group 40G: Electrical Components – Power Supply and Alternator (5G VNF)…2231
G01 – Battery, Component Information…2528
G02 – Alternator, Component Information…2533
Group 40H: Electrical Components – Monitoring and Signaling Devices (5G VNF)…2231
H01 – Horn, Component Information…2538
Group 40M: Electrical Components – Electrical Motors (5G VNF)…2231
M01 – Starting Motor, Component Information…2543
M02 – Air-Conditioning Compressor Clutch, Component Information…2546
M03 – Windshield Wiper Motor, Component Information…2548
M04 – Rear Wiper Motor with Switch, Component Information…2550
M05 – Pump of Washer System, Component Information…2552
M06 – Air Suspension Seat Compressor Motor, Component Information…2554
M07 – Cab Blower Motor, Component Information…2556
M08 – Air-Conditioning Condenser Fan Motor I, Component Information…2558
M09 – Air-Conditioning Condenser Fan Motor II, Component Information…2560
Group 40R: Electrical Components – Resistors (5G VNF)…2231
R501 – Glow Plug for Cylinder 1, Component Information…2564
R502 – Glow Plug for Cylinder 2, Component Information…2566
R503 – Glow Plug for Cylinder 3, Component Information…2568
R504 – Glow Plug for Cylinder 4, Component Information…2570
R505 – Fuel Filter Heater, Component Information…2572
Group 40S: Electrical Components – Switches (5G VNF)…2231
S01 – Main Switch, Component Information…2576
S09 – Multi-Function Lever, Component Information…2578
S14 – Fan Switch, Component Information…2581
S15 – Switch for Windshield Wiper and Pump of Washer System, Component Information…2583
S20 – Calibration Switch of Instrument Unit, Component Information…2585
S21/1 – Ground Drive PTO Selector Switch, Component Information…2587
S21/2 – Independent Rear PTO Selector Switch, Component Information…2589
S22 – Differential Lock Switch, Component Information…2591
S36 – Beacon Light Switch, Component Information…2595
S40 – Presence Sensor Switch (PowrReverser™ Transmission)…2597
S61 – Rear Worklight Switch, Component Information…2600
S63 – Front-Wheel Drive Switch, Component Information…2602
S72 – Clutch Pedal Switch, Component Information…2605
S92/1 – Front Worklight Switch, Component Information…2607
S92/2 – Rear Worklight Switch, Component Information…2609
S93 – Heating and Air-Conditioning System Switch, Component Information…2611
S106 – Hazard Warning Light Switch, Component Information…2613
S300/1 – Hi/Lo Switch (Hi), Component Information…2615
S300/2 – Hi/Lo Switch (Lo), Component Information…2617
S300/3 – Declutch Switch, Component Information…2619
S350 – PTO Switch (PowrReverser™ Transmission), Component Information…2621
S900 – Battery Cut-Off Switch for Engine F5G (DOC/SCR), Component Information…2624
S900 – Battery Cut-Off Switch for Engine F5D (DOC/DPF), Component Information…2626
S990 – Programming Switch (Menu), Component Information…2628
S991 – Programming Switch (Save), Component Information…2630
S992 – Cruise Control Switch (ON/OFF/Save), Component Information…2632
S993 – Cruise Control Switch (Decrease RPM), Component Information…2634
S994 – Cruise Control Switch (Increase RPM), Component Information…2636
Group 40WA: Wiring Harnesses (5G VNF)…2232
W02A – Engine Wiring Harness for Engine F5D (DOC/DPF)…2641
W02B – Engine Wiring Harness for Engine F5G (DOC/SCR)…2644
W04 (W19, W35) – Cab Wiring Harness…2647
W05 (W52) – Hood Wiring Harness (Cab)…2650
Section 249B: Electrical System – Component Information (5GL)…2948
Group 05: Summary of Electrical Components and Harnesses (5GL)…2948
List of Summary of References (5GL)…2955
Summary of References of Electrical Components, Assemblies (5GL)…2956
Summary of References of Electrical Components, Sensors (5GL)…2957
Summary of References of Electrical Components, Lights (5GL)…2958
Summary of References of Electrical Components, Fuses, Relays, and Diodes (5GL)…2959
Summary of References of Electrical Components, Power Supply and Alternator (5GL)…2960
Summary of References of Electrical Components, Monitoring and Signaling Devices (5GL)…2961
Summary of References of Electrical Components, Electrical Motors (5GL)…2962
Summary of References of Electrical Components, Resistors (5GL)…2963
Summary of References of Electrical Components, Switches (5GL)…2964
Summary of References of Electrical Components, Wiring Harnesses (5GL)…2965
Summary of References of Electrical Components, Connector Information (5GL)…2966
Summary of References of Electrical Components, Ground Points (5GL)…2967
Summary of References of Electrical Components, Solenoids and Solenoid Valves (5GL)…2968
Group 40A: Electrical Components – Assemblies (5GL)…2948
A320 – Transmission Control Unit (5GL), Component Information…2972
A330 – Instrument Unit (5GL), Component Information…2975
A500 – Engine Control Unit (ECM) for Engine F5D (DOC/DPF) (5GL), Component Information…2979
A510 – Glow Plug Control Unit (ECU) (5GL), Component Information…2986
A520 – High Pressure Pump (5GL), Component Information…2988
A530 – Actuator for Throttle (5GL), Component Information…2990
Group 40B: Electrical Components – Sensors (5GL)…2948
B02 – Air Filter Restriction Sensor (5GL), Component Information…2994
B03 – Fuel Level Sensor (5GL), Component Information…2996
B05 – Park Brake Switch (5GL), Component Information…2998
B06 – Transmission Speed Sensor (5GL), Component Information…3000
B07/1 – PTO Switch (540 rpm) (5GL), Component Information…3002
B07/2 – PTO Switch (540E/1000 rpm) (5GL), Component Information…3004
B36 – Neutral Start Switch (5GL), Component Information…3006
B60 – Transmission Oil Temperature Sensor (5GL), Component Information…3008
B63 – Hi/Lo Switch on Transmission (5GL), Component Information…3010
B64 – Reverse Drive Lever Switch (5GL), Component Information…3012
B65 – Clutch Pedal Potentiometer (5GL), Component Information…3014
B69 – Brake Oil Level Sensor (5GL), Component Information…3016
B73 – Transmission Oil Filter Restriction Sensor (5GL), Component Information…3018
B104 – Transmission Top Shaft Speed Sensor (5GL), Component Information…3020
B112/1 – Right Brake Pedal Switch (5GL), Component Information…3022
B112/2 – Left Brake Pedal Switch (5GL), Component Information…3024
B300 – Forward High Clutch Pressure Sensor (5GL), Component Information…3026
B301 – Forward Low Clutch Pressure Sensor (5GL), Component Information…3028
B302 – Reverse Clutch Pressure Sensor (5GL), Component Information…3030
B303 – Transmission Oil Pressure Switch (5GL), Component Information…3032
B350 – PTO Pressure Sensor (5GL), Component Information…3034
B500 – Coolant Temperature Sensor (5GL), Component Information…3036
B501 – Oxygen Sensor for Engine F5D (DOC/DPF) (5GL), Component Information…3038
B502 – Camshaft Position Sensor (5GL), Component Information…3040
B503 – Fuel Temperature Sensor (5GL), Component Information…3042
B504 – Exhaust Manifold Pressure Sensor (5GL), Component Information…3044
B505 – Engine Oil Pressure Sensor (5GL), Component Information…3046
B506 – Fuel Rail Pressure Sensor (5GL), Component Information…3048
B507 – Exhaust Gas Temperature Sensor (5GL), Component Information…3050
B508 – Crankshaft Position Sensor (5GL), Component Information…3052
B509 – Ambient Temperature Sensor (5GL), Component Information…3054
B510 – Water-in-Fuel Sensor (5GL), Component Information…3056
B511 – DPF Differential Pressure Sensor for Engine F5D (DOC/DPF) (5GL), Component Information…3058
B512 – DOC Inlet Temperature Sensor for Engine F5D (DOC/DPF) (5GL), Component Information…3060
B513 – DOC Outlet Temperature Sensor for Engine F5D (DOC/DPF) (5GL), Component Information…3062
B980 – PTO Shaft Output Speed Sensor (5GL), Component Information…3064
B987 – Differential Lock Pressure Switch (5GL), Component Information…3066
B988 – Front Wheel Drive Pressure Switch (5GL), Component Information…3068
B998 – Hand Throttle Sensor (5GL), Component Information…3070
B999 – Foot Throttle Potentiometer (5GL), Component Information…3072
Group 40E: Electrical Components – Lights (5GL)…2950
E01 – Right Headlight (5GL), Component Information…3076
E02 – Left Headlight (5GL), Component Information…3078
E05 – Cigarette Lighter (5GL), Component Information…3080
E13 – Left-hand Side Tail Light (5GL), Component Information…3082
E14 – Right-Hand Side Tail Light (5GL), Component Information…3084
E27 – Beacon Light (5GL), Component Information…3086
E30 – Right Front Turn-Signal/Amber Warning Lights (5GL), Component Information…3088
E31 – Left Front Turn-Signal/Amber Warning Lights (5GL), Component Information…3090
E32 – Right Rear Turn-Signal/Amber Warning Lights (5GL), Component Information…3092
E33 – Left Rear Turn-Signal/Amber Warning Lights (5GL), Component Information…3094
Group 40F: Electrical Components – Fuses, Relays, and Diodes (5GL)…2950
F1 – 120 Amp Main Harness Fuse (5GL), Component Information…3098
F2 – 60 Amp Glow Plug Fuse (5GL), Component Information…3100
F3 – 70 Amp Engine ECU Fuse (5GL), Component Information…3102
F100 – Load Center (5GL), Component Information…3104
K08 – Turn-Signal Relay (5GL), Component Information…3114
P17 – Power Supply, Fuse/Relay Box F1-F10/K1-K5 for Engine F5D (DOC/DPF) (5GL)…3116
P18 – Fuse/Relay Box F1-F10/K1-K5 for Engine F5D (DOC/DPF) (5GL)…3118
Group 40G: Electrical Components – Power Supply and Alternator (5GL)…2950
G01 – Battery (5GL), Component Information…3124
G02 – Alternator (5GL), Component Information…3127
Group 40H: Electrical Components – Monitoring and Signaling Devices (5GL)…2950
H01 – Horn (5GL), Component Information…3131
Group 40M: Electrical Components – Electrical Motors (5GL)…2950
M01 – Starting Motor (5GL), Component Information…3135
M06 – Air Suspension Seat Compressor Motor (5GL), Component Information…3137
Group 40R: Electrical Components – Resistors (5GL)…2950
R501 – Glow Plug for Cylinder 1 (5GL), Component Information…3141
R502 – Glow Plug for Cylinder 2 (5GL), Component Information…3143
R503 – Glow Plug for Cylinder 3 (5GL), Component Information…3145
R504 – Glow Plug for Cylinder 4 (5GL), Component Information…3147
R505 – Fuel Filter Heater (5GL), Component Information…3149
R998 – Resistor for Ground Drive PTO Presence (5GL), Component Information…3151
R999 – Resistor for Independent Rear PTO Presence (5GL), Component Information…3153
Group 40S: Electrical Components – Switches (5GL)…2951
S01 – Main Switch (5GL), Component Information…3157
S09 – Multi-Function Lever (5GL), Component Information…3159
S20 – Calibration Switch of Instrument Unit (5GL), Component Information…3161
S22 – Differential Lock Switch (5GL), Component Information…3163
S36 – Beacon Light Switch (5GL), Component Information…3165
S40 – Presence Sensor Switch (5GL), Component Information…3167
S61 – Rear Worklight Switch (5GL), Component Information…3169
S63 – Front-Wheel Drive Switch (5GL), Component Information…3171
S72 – Clutch Pedal Switch (5GL), Component Information…3173
S106 – Hazard Warning Light Switch (5GL), Component Information…3175
S300 – Hi/Lo Switch (5GL), Component Information…3177
S350 – Rear PTO Switch (5GL), Component Information…3179
S900 – Battery Cut-Off Switch for Engine F5D (DOC/DPF) (5GL), Component Information…3181
S990 – Programming Switch (Menu) (5GL), Component Information…3184
S991 – Programming Switch (Save) (5GL), Component Information…3186
S992/1 – Cruise Control Switch (ON/OFF/Save) (5GL), Component Information…3188
S992/2 – Cruise Control Switch (ON/OFF/Save) (5GL), Component Information…3190
S993 – Cruise Control Switch (Decrease RPM) (5GL), Component Information…3192
S994 – Cruise Control Switch (Increase RPM) (5GL), Component Information…3194
Group 40W: Wiring Harnesses (5GL)…2951
W02 – Engine Wiring Harness for Engine F5D (DOC/DPF) (5GL)…3199
W05 – Hood Wiring Harness (5GL)…3202
W12 – Wiring Harness for Tail Lights (5GL)…3203
W17 – Wiring Harness for Beacon Light (5GL)…3204
W22 – Battery Cable (Negative) (5GL)…3205
W22/1 – Battery Cable (Negative) (Adapter) (5GL)…3206
W25 – Wiring Harness for Hi-Lo Shifting (PowrReverser™ Transmission) (5GL)…3207
W29 – Main Wiring Harness (Digital Display Side) (PowrReverser™ Transmission) (5GL)…3208
W29/1 – Wiring Harness for Brake Pedal Switch (5GL)…3209
W30 – Main Wiring Harness (Transmission Side) (PowrReverser™ Transmission) (Open Operator Platform) (5GL)…3210
W33/2 – Wiring Harness for PTO Switch (5GL)…3213
W38A – Engine Wiring Harness for Engine F5D (DOC/DPF) (5GL)…3214
W45 – Engine Power Supply Wiring Harness (5GL)…3217
W45/1 – Battery Cable (Positive) (5GL)…3219
W45/2 – Power Supply for Main Fuse (5GL)…3221
W53 – Wiring Harness for Turn-Signal/Amber Warning Lights (5GL)…3223
Group 40X: Connector Information (5GL)…2952
J3 / P56 – Connection point between harnesses W29 and W30 (5GL)…3226
J9 / P84 – Connection point between harnesses W29 and W30 (5GL)…3228
J10 / P85 – Connection point between harnesses W29 and W30 (5GL)…3233
J78 – Service Socket (CAN) (5GL), Component Information…3238
J79 / P369 – Connection point between harnesses W17 and W30 (5GL)…3240
J155 / P155 – Connection point between harnesses W25 and W30 (5GL)…3242
P3 / X8.1 – Connection point between harnesses W02 and W38A (5GL)…3245
P14 / X8.2 – Connection point between harnesses W02 and W38A (5GL)…3248
P16 / J5 – Connection point between harnesses W02 and W29 (5GL)…3254
P21 – Connector (5GL) (Not Used)…3258
P23 / J2 – Connection point between harnesses W02 and W45 (5GL)…3260
P25 – Connector (5GL) (Not Used)…3263
P88 / J13 – Connection point between harnesses W05 and W30 (5GL)…3265
P139 – Service Socket (Serial Connection) (5GL), Component Information…3268
P169 / J47 – Connection point between harnesses W30 and Jumper Plug (5GL)…3270
P177 – Connector (5GL) (Not Used)…3273
P320 – 6-Terminal Trailer Socket (5GL), Component Information…3275
P326 / X2 – Connection point between harnesses W30 and W53 (5GL)…3277
P328 / X2 – Connection point between harnesses W30 and W53 (5GL)…3279
P332 / P1 – Connection point between harnesses W30 and W33/2 (5GL)…3281
P382 / J85 – Connection point between harnesses W30 and Jumper Harness (5GL)…3283
J80 / P383 – Connection point between harnesses W30 and Jumper Harness (5GL)…3285
P600 / J600 – Connection point between harnesses W29 and W29/1 (5GL)…3287
X2 / P329 – Connection point between harnesses W12 and W30 (5GL)…3290
X2 / P330 – Connection point between harnesses W12 and W30 (5GL)…3293
X42 – 3-Terminal Power Outlet Socket (5GL), Component Information…3295
Group 40XGND: Ground Points (5GL)…2953
P83 – Ground Connection on Harness W30 (5GL)…3298
RT8 – Ground Connection on Harness W45 (5GL)…3299
RT9 – Ground Connection on Harness W22 (5GL)…3300
RT10 – Ground Connection on Harness W22/1 (5GL)…3301
RT11 – Ground Connection on Harness W22/1 (5GL)…3302
Group 40Y: Electrical Components – Solenoids and Solenoid Valves (5GL)…2953
Y03 – Front-Wheel Drive Solenoid Valve (5GL), Component Information…3305
Y04 – PTO Solenoid Valve (5GL), Component Information…3307
Y05 – Differential Lock Solenoid Valve (5GL), Component Information…3309
Y51 – Reverse Clutch Solenoid Valve (5GL), Component Information…3311
Y52 – Forward Low Clutch Solenoid Valve (5GL), Component Information…3313
Y53 – Forward High Clutch Solenoid Valve (5GL), Component Information…3315
Y300 – Main Ring Valve Solenoid Valve (5GL), Component Information…3317
Y350 – PTO Shutoff Solenoid Valve (5GL), Component Information…3319
Y501 – Injection Valve for Cylinder 1 (5GL), Component Information…3321
Y502 – Injection Valve for Cylinder 2 (5GL), Component Information…3323
Y503 – Injection Valve for Cylinder 3 (5GL), Component Information…3325
Y504 – Injection Valve for Cylinder 4 (5GL), Component Information…3327
Y510 – Turbocharger Wastegate Valve (5GL), Component Information…3329
Y520 – High Pressure Fuel Control Valve (5GL), Component Information…3331
Y530 – EGR Valve (5GL), Component Information…3333
Section 250A: Drive Train (without Transmission)…3335
Group 20A: Front-Wheel Drive – Theory of Operation…3335
Front-Wheel Drive – Theory of Operation, Summary of References…3338
Front-Wheel Drive Operation – Electro-Hydraulically Shifted…3339
Group 20B: Differential – Theory of Operation…3335
Differential – Theory of Operation, Summary of References…3344
Differential Power Flow…3345
Differential Lock Operation (Hydraulic Version)…3347
Group 20C: Final Drives – Theory of Operation…3335
Final Drives – Theory of Operation, Summary of References…3350
Final Drive Operation…3351
Group 20D: Rear PTO – Theory of Operation…3335
Rear PTO – Theory of Operation, Summary of References…3354
Operation of PTO Dry Clutch…3355
Electro-Hydraulic Rear PTO – Description…3356
Electro-Hydraulic Rear PTO – PTO Solenoid Valves…3358
Electro-Hydraulic Rear PTO – PTO Clutch and PTO Brake…3362
540/540E rpm Rear PTO Operation…3365
Group 40: Drive Train (without Transmission) – Component Information…3335
Drive Systems – Component Location, Summary of References…3368
Drive Systems – Component Location Information…3369
Front-Wheel Drive Components – Electro-Hydraulically Shifted…3370
Differential Components…3372
Differential Lock Components (Hydraulic Version)…3373
Final Drive Components…3374
Hydraulic PTO Clutch Components…3449
Rear PTO Components…3377
Group 50: Drive Train (without transmisson) – Diagnostic Tests/Adjustments…3335
Drive Systems – Tests and Adjustments, Summary of References…3379
Drive Systems – Tests and Adjustments, Test Ports and Test Equipment…3380
Pressure Relief Valve – Pressure Check…3382
Hydraulic Front-Wheel Drive Clutch – Pressure Check…3384
Hydraulic Differential Lock – Pressure Check…3386
Hydraulic Rear PTO Clutch – Pressure Check…3388
Hydraulic Rear PTO Brake – Pressure Check…3390
Lube Oil Pressure Check…3391
Drive Systems – Tests and Adjustments, Test Result Table…3393
Front-Wheel Drive Lever Will Not Stay in Off Position…3394
Problem with Noises when Driving with Front-Wheel Drive Engaged…3336
Unusual Vibrations when Driving with Front-Wheel Drive Engaged…3336
Excessive Differential Noise…3404
Differential Does Not Work…3405
Differential Lock Does Not Work…3406
Differential Chatters…3407
Axle Noise…3408
Axle Shaft Will Not Turn…3409
PTO Noisy…3410
PTO Will Not Operate…3411
PTO Will Not Stay Engaged…3413
PTO Clutch Lever Adjustment…3414
Section 250B: Mechanical Transmissions…3416
Group 20: Mechanical Transmissions – Theory of Operation…3416
Summary of References – Theory of Operation…3748
Theory of Operation Information – Mechanical Transmissions…3419
Clutch Operation…3420
Transmission Power Flow – Mechanical High-Low…3427
Transmission Power Flow – Electrohydraulic High-Low…3429
Transmission Synchronizer Operation – Mechanical High-Low…3431
Clutch Operation – Electrohydraulic High-Low…3433
Transmission Power Flow – Reverse Speed Gears…3435
Transmission Power Flow – Forward Speed Gears…3437
Transmission Synchronizer Operation – Reverse, Forward, 1st, 2nd, 3rd and 4th Gear…3439
Transmission Power Flow – Range Shift…3441
Group 40: Mechanical Transmissions – Component Information…3416
Summary of References – Component Location…3672
Mechanical Transmissions – Component Location Information…3445
Mechanical Power Train Components…3446
Clutch Components…3449
Transmission Components — 12/12-Speed Transmission…3451
Group 50: Drive Train (without transmisson) – Diagnostic Tests/Adjustments…3416
Summary of References – Diagnosis, Tests and Adjustments…3454
Specifications…3691
Diagnostic Information – Drive Train (without transmisson)…3456
Jerky or Rough Transmission…3457
Major Transmission Check…3458
Low Transmission Oil Level (Excessive Oil Leakage)…3463
Gears Clash, Shift Hard, or Will Not Engage…3464
Two Speeds Engage Together…3465
Transmission Will Not Stay in Gear…3466
Transmission Noisy…3467
Clutch Pedal Free Play Adjustment…3468
Section 250C: Power Reverser Transmission (24/12)…3471
Group 10: Power Reverser Transmission (24-12) – Operational Checks…3471
Transmission – Introductory Checks…3476
24/12-Speed Transmission – Operational Checks…3480
Group 20: Power Reverser Transmission (24-12) – Theory of Operation…3471
24/12-Speed Transmission – Theory of Operation, Summary of References…3486
24/12-Speed Transmission – Theory of Operation, Layout of Valves and Components…3487
24/12-Speed Transmission – Theory of Operation, Power Flow…3490
24/12-Speed Transmission – Theory of Operation, Hydraulic Schematic…3493
24/12-Speed Transmission – Theory of Operation, EHM III Valves…3496
24/12-Speed Transmission – Theory of Operation, Additional Valves…3498
24/12-Speed Transmission – Theory of Operation, Cooling and Lube Circuit…3499
24/12-Speed Transmission – Theory of Operation, Air Pump…3501
Group 40: Power Reverser Transmission (24-12) – Component Information…3471
Power Reverser™ Train Components…3504
Group 50: Power Reverser Transmission (24-12) – Diagnostic Tests/Adjustments…3471
24/12-Speed Transmission, Tests and Adjustments – Summary of References…3507
Hydraulic System – Safety Measures for Hydraulic Checks…3508
Connect SensoControl Test Equipment…3510
24/12-Speed Transmission, Tests, and Adjustments – Test Ports…3511
24/12-Speed Transmission, Tests and Adjustments – System Check…3514
24/12-Speed Transmission, Tests and Adjustments – EHM III Circuit Pressure Check…3520
24/12-Speed Transmission, Tests and Adjustments – EHM III Pressure Relief Valve Check…3522
24/12-Speed Transmission, Tests and Adjustments – Forward High Clutch Pressure Check…3523
24/12-Speed Transmission, Tests and Adjustments – Forward Low Clutch Pressure Check…3525
24/12-Speed Transmission, Tests and Adjustments – Reverse Clutch Pressure Check…3527
24/12-Speed Transmission, Tests, and Adjustments – Oil Cooler Flow Test…3529
24/12-Speed Transmission, Tests, and Adjustments – Lube Relief Valve Check…3532
24/12-Speed Transmission, Tests, and Adjustments – Oil Cooler Bypass Valve Check…3534
24/12-Speed Transmission, Tests and Adjustments – Clutch Leakage Check…3537
24/12-Speed Transmission, Tests and Adjustments – Test Result Table…3541
Hydraulic System – Heat Up the Hydraulic Oil…3543
Section 260: Steering and Brake Systems…3544
Group 20: Steering and Brake Systems – Theory of Operation…3544
Summary of References – Steering and Brake Systems Theory of Operation…3547
Steering and Brake Systems – General Information…3761
Steering System Operation…3549
Steering Valve Operation – Neutral and Manual Turning…3552
Steering Valve Operation – Power Turning…3555
Brake System Operation…3557
Brake Cylinder Operation – Brake Pedal Depressed…3559
Brake Cylinder Operation – Brake Pedal Released…3560
Group 40: Steering and Brake Systems – Component Information…3544
Summary of References – Steering and Brake Systems Component Location…3562
Steering and Brake Systems – Component Location Information…3563
Steering System Components…3564
Brake System Components…3566
Group 50: Steering and Brake Systems – Diagnostic Tests/Adjustments…3544
Summary of References – Diagnosis, Tests, and Adjustments…3569
Essential or Recommended Tools…3767
Specifications…3691
Diagnostic Information – Steering and Brake Systems…3572
Steering System Operational Check…3573
Steering System Diagnosis…3574
Steering Sluggish or Loss of Steering…3579
Brake System Operational Check…3580
Brake System Diagnosis…3581
Excessive Brake Pedal Leak-Down…3583
Excessive Brake Chatter…3584
Steering Pump Flow Test…3717
Steering Valve Relief Test…3587
Steering Cylinder Leakage Test…3589
Steering Valve Leakage Test…3590
Check Toe-In…3592
Adjust Toe-In…3594
Steering Angle Adjustment…3596
Brake Pedal Adjustment…3598
Park Brake Adjustment…3600
Bleed Brake System…3603
Section 270: Hydraulic System…3607
Group 20: Hydraulic System – Theory of Operation…3607
Summary of References—Theory of Operation…3611
General Information – Hydraulic System Operation…3613
Hydraulic System Operation…3613
Oil Cooler Operation…3618
Hydraulic Filter Operation…3621
Transmission Oil Filters — II Pumps Configuration…3622
Transmission Oil Filters — III Pumps Configuration…3623
Hydraulic Pump Operation…3625
Hydraulic System Operation – Steering and Front-Wheel Drive (12/12-Speed Transmission)…3627
Hydraulic System Operation – Steering and Front-Wheel Drive with Power Reverser (24/12 – Speed Transmission)…3629
Rockshaft Control Valve Operation – Neutral Position…3634
Rockshaft Control Valve Operation – Raise Position…3636
Rockshaft Control Valve Operation – Lower Position…3638
Rockshaft Draft – Sensing Operation…3640
Double-Acting Selective Control Valve – Neutral Position…3642
Double-Acting Selective Control Valve – Position 1…3644
Double-Acting Selective Control Valve – Position 2…3646
Double-Acting Selective Control Valve – Float Position…3648
Double-Acting Selective Control Valve – DUAL ACTING/SINGLE CONVERSION…3650
Setting Detents and Operating SCV Control Levers…3652
Double-Acting Sleeve Coupler Operation…3654
Flow Divider Valve without Solenoid Valve Operation…3656
Group 30: Hydraulic System – Schematics…3607
Summary of References – Hydraulic System Schematics…3659
Hydraulic Symbols…3660
12/12-Speed Transmission – Steering System without Front-Wheel Drive…3663
Base Transmission Hydraulic Scheme Power Reverser 24/12…3664
SCV and Hitch with Flow Divider…3667
Group 40: Hydraulic System – Component Information…3607
Summary of References – Component Location…3672
Hydraulic System – Component Location Information…3673
Hydraulic System Components – Steering and Front-Wheel Drive (12/12-Speed Transmission)…3674
Hydraulic System Components – Steering and Front-Wheel Drive with Power Reverser (24/12 – Speed Transmission)…3676
Hitch Control Lever Linkage Components…3681
SCVs with Levers and Flow Divider Valve…3682
Group 50: Hydraulic System – Diagnostic Tests/Adjustments…3608
Summary of References – Diagnostic Tests/Adjustments…3687
Essential or Recommended Tools…3767
Safety Precautions…3690
Specifications…3691
Diagnostic Information – Hydraulic System…3692
Hydraulic Oil Warm-Up Procedure…3693
Hydraulic System Diagnosis…3694
Insufficient Pump Delivery…3700
Hydraulic Functions Too Slow…3701
Excessive Pump Pressure…3702
Slow Hydraulic Pump Response…3703
Excessive Pump Noise During Operation…3704
Rockshaft Does Not Lift or Lifts Slowly…3705
Rockshaft Does Not Lower or Lowers Slowly…3706
Neutral Position Unstable, Rockshaft Drops After Engine Shut-Down…3707
SCV Control Lever Does Not Return to Neutral Position…3708
SCV Does Not Return to Neutral Position – SCV With Detent Position…3709
SCV Does Not Remain In Detent Position – SCV With Detent Position…3710
Remote Cylinder Does Not Extend or Retract…3711
Remote Cylinder Settles Under Load…3712
Remote Cylinder Operates Too Fast or Too Slow…3713
Hydraulic System Tests – with SCV…3714
Hydraulic System Tests…3715
Transmission Hydraulic System…3716
Pump Flow Test…3717
SCV Relief Valve Test…3720
SCV Leakage Test…3721
EHS II Leakage Test…3722
Rockshaft Lift Cycle Test…3723
Rockshaft Control Lever Friction Adjustment…3725
Hitch Sensitivity Adjustment…3726
Rockshaft Position Control Adjustment…3728
Rockshaft Draft Control Adjustment…3730
Rockshaft Safety and Relief Valve Adjustment…3732
SCV Relief Valve Adjustment…3734
Flow Divider Valve Adjustment…3735
Section 280: Miscellaneous…3736
Group 10: Operational Checks…3736
Operational Test on Front-Wheel Drive Axle…3740
Checking Positive Front-Wheel Lead on Front-Wheel Drive Axle…3743
Section 290: Cab and Open Operator’s Station…3746
Group 20: Cab and Open Operator’s Station – Theory of Operation…3746
Summary of References – Theory of Operation…3748
Theory of Operation Information – Cab and Open Operator’s Station…3749
Principle of Heat Exchange…3750
R134a Refrigerant…3751
Operation of Air-Conditioning System – Air Flow…3752
Air-Conditioning System Operation…3754
Compressor…3756
Condenser…3757
Receiver-Drier…3758
Expansion Valve…3759
Group 40: Cab and Open Operator’s Station – Component Information…3746
General Information…3761
Air-Conditioning System Components…3762
Heating System Components…3764
Group 50: Cab and Open Operator’s Station – Diagnostic Tests/Adjustments…3746
Essential or Recommended Tools…3767
Summary of References — Diagnosis, Tests and Adjustments…3768
Safety Equipment…3769
In an Emergency…3770
Storage of Refrigerant Containers…3771
Important Note…3772
Diagnostic Information – Cab and Open Operator’s Station…3773
Air-Conditioning System Diagnosis…3774
Pressure Deviations…3783
Air-Conditioning System Troubleshooting…3785
Failure Of Mechanical Type…3789
Section 299: Special Tools…3791
Group 05: Special Tools (Dealer-Fabricated)…3791
Summary of References – Dealer-Manufactured Tools…3794
Draft Control Adjusting Tool…3795
Group 10: Special Tools (Available as Spare Parts)…3791
Special Tools (Available as Spare Parts) – Summary of References…3797
D05104ST…3798
FKM10002…3799
FKM10417…3800
KJD10148…3801
FKM10209…3802
JDG10466…3803
KJD10589…3805
JDG11863…3806
FKM10472-4…3807
JDG11668…3808
JDG1478…3809
JDG839…3810
JT02156A…3811
JT03110…3812
JT03123…3813
JT03041…3814
JT03345…3815
JT03364…3816
JT03367…3817
JT05709…3818
JT05719…3819
JT05791A…3820
JT05800…3821
JT05469…3822
FKM10475…3823
JDG11978…3824
JT02098…3825
JDG10975…3826
OTC7062A…3827
John Deere 5075GV, 5090GV, 5075GN, 5090GN, 5100GN, and 5075GL Tractors Diagnosis and Tests Service Technical Manual (TM409119)