Description
Introduction
Foreword
Contents
General Information
Safety
Recognize Safety Information
Understand Signal Words
Practice Safe Maintenance
Use Proper Tools
Handle Fluids Safely—Avoid Fires
Prevent Acid Burns
Prevent Battery Explosions
Handling Batteries Safely
Prepare for Emergencies
Park Machine Safely
Support Machine Properly
Wear Protective Clothing
Work in Clean Area
Service Machines Safely
Work In Ventilated Area
Illuminate Work Area Safely
Replace Safety Signs
Use Proper Lifting Equipment
Follow Tire Recommendations
Protect Against High Pressure Spray
Decommissioning—Proper Recycling and Disposal of Fluids and Components
Live With Safety
General Specifications
Service Recommendations for O-Ring Boss Fittings
Straight Fitting
Angle Fitting
Service Recommendations For Flat Face O-Ring Seal Fittings
Metric Cap Screw Torque Values—Grade 7
Metric Bolt and Screw Torque Values
Unified Inch Bolt and Screw Torque Values
Fuel and Lubricants
Diesel Fuel—North America
Required fuel properties
Sulfur content
Handling and Storing Diesel Fuel
Diesel Fuel—Europe
Diesel Fuel Storage
4-Cycle Diesel Engine Oil—North America
Diesel Engine Oil—Europe
Oil Filters
Transmission and Hydraulic Oil
Grease
Mixing of Lubricants
Alternative and Synthetic Lubricants
Lubricant Storage
Operating in Warm Temperature Climates
Diesel Engine Coolant (engine without wet sleeve cylinder liners)
Preferred Coolants
Additional Recommended Coolants
Other Coolants
Water Quality
Coolant Drain Intervals
John Deere COOL-GARD™ II Coolant Extender
Testing Diesel Engine Coolant
Coolant Test Strips
When Using John Deere COOL-GARD II
When Using Nitrite-Containing Coolants
Coolant Analysis
Machine Specifications
Machine Specifications
Product Identification Number Location
Engine Repair
Engine
Summary of References
Essential or Recommended Tools
Service Equipment and Tools
Other Material
Specifications
Remove Engine
Install Engine
Remove and Install Muffler
Removal:
Installation:
Remove and Install Exhaust Manifold
Removal:
Installation:
Remove and Install Rocker Arm Cover
Remove and Install Rocker Arm and Push Rods
Rocker Arm Removal:
Rocker Arm Disassembly:
Rocker Arm Inspection:
Push Rod Inspection:
Rocker Arm Assembly:
Rocker Arm Installation:
Remove and Install Cylinder Head
Removal:
Installation:
Recondition Cylinder Head
Disassembly:
Assembly:
Inspection/Replacement:
Cylinder Head:
Intake and Exhaust Valves:
Valve Guides:
Valve Guide Replacement:
Valve Stem Seal Installation:
Valve Springs:
Valve Seat Grinding:
Valve Lapping:
Remove and Install Rear Crankshaft Oil Seal
Rear Oil Seal Case:
Remove and Install Front Crankshaft Oil Seal
Remove and Install Timing Gear Cover
Check Camshaft End Play
Reason:
Procedure:
Results:
Check Timing Gear Backlash
Reason:
Procedure:
Results:
Remove and Install Idler Gear
Removal and Installation:
Inspection/Replacement:
Remove and Install Cam Followers
Removal:
Installation:
Inspection:
Remove and Install Camshaft
Camshaft Removal:
Camshaft Installation:
Camshaft Side Gap Measurement:
Camshaft Gear Removal:
Camshaft Gear Installation:
Camshaft Inspection:
Remove and Install Oil Pan and Strainer
Removal:
Installation:
Check Connecting Rod Side Play
Reason:
Equipment:
Procedure:
Results:
Check Crankshaft End Play
Reason:
Equipment:
Procedure:
Results:
Check Connecting Rod Bearing Clearance
Reason:
Procedure:
Results:
Check Crankshaft Main Bearing Clearance
Reason:
Procedure:
Results:
Remove, Inspect, and Install Connecting Rod
Removal:
Inspection/Replacement:
Installation:
Disassemble and Assemble Pistons
Disassembly:
Assembly:
Bore Cylinder
Inspection:
Results:
Deglazing:
Reboring:
Remove and Install Crankshaft and Main Bearings
Removal:
Installation:
Inspection/Replacement:
Remove and Install Flywheel
Removal:
Installation:
Remove and Install Flywheel Plate
Removal:
Installation:
Remove and Install Timing Gear Housing
Removal:
Installation:
Remove and Install Oil Pump
Remove and Install Coolant Temperature Sensor
Removal:
Installation:
Remove and Install Thermostat
Removal:
Installation:
Remove and Install Oil Pressure Regulating Valve
Removal:
Inspection:
Installation:
Remove and Install Water Pump
Removal:
Installation:
Remove and Install Fuel Filter
Remove and Install Fuel Filter Assembly
Removal:
Installation:
Remove and Install Fuel Transfer Pump
Removal:
Installation:
Remove and Install Fuel Injection Nozzle
Removal:
Installation:
Repair:
Cleaning and Inspection:
Remove and Install Fuel Injection Pump
Removal:
Installation:
Remove and Install Fuel Control and Governor Linkage
Removal:
Installation:
Summary of References
Repair Starting Motor
Removal
Installation
Analyze Condition
Disassembly
Assembly
Inspection and Test
Repair Alternator
Removal:
Equipment:
Disassembly:
Inspection:
Assembly:
Installation:
Electrical Repair
Wiring Harnesses
Summary of References
Load Center and Wire Table – E Series
Load Center – E Series
Wire Table – E Series
Load Center and Wire Table – M Series
Load Center – M Series
Wire Table – M Series
Load Center and Wire Table – M Series (w/HVAC) and R Series
Load Center – M Series (w/HVAC) and R Series
Wire Table – M Series (w/HVAC) and R Series
Main Harness – E Series
Main Harness – E Series (2/5)
Main Harness – E Series (3/5)
Main Harness – E Series (4/5)
Main Harness – E Series (5/5)
Main Harness Splices – E Series
Main Harness Color Codes – E Series
Main Harness – M Series (without A/C)
Main Harness – M Series (without A/C) (2/6)
Main Harness – M Series (without A/C) (3/6)
Main Harness – M Series (without A/C) (4/6)
Main Harness – M Series (without A/C) (5/6)
Main Harness – M Series (without A/C) (6/6)
Main Harness Splices – M Series (without A/C)
Main Harness Color Codes – M Series (without A/C)
Main Harness – R, M Series (with A/C)
Main Harness – R, M Series (with A/C) (2/7)
Main Harness – R, M Series (with A/C) (3/7)
Main Harness – R, M Series (with A/C) (4/7)
Main Harness – R, M Series (with A/C) (5/7)
Main Harness – R, M Series (with A/C) (6/7)
Main Harness – R, M Series (with A/C) (7/7)
Main Harness Splices – R, M Series (with A/C)
Summary of References
Wheel Speed Sensor Adapter Harness
Power Train Repair
Transmission
Summary of References
Specifications
Essential or Recommended Tools
Other Material
Change Transmission Oil
Clean Drive Clutch
Remove and Install Clutch Housing
Clutch Housing Removal
Clutch Housing Installation
Remove and Install Clutch
Required Tool:
Drive Clutch Removal
Drive Clutch Installation
Driven Clutch Removal
Driven Clutch Installation
Repair Drive Clutch
Disassembly
Assembly
Repair Driven Clutch
Disassembly
Assembly
Remove Transmission
Summary of References
Disassemble Transmission
Disassembly:
Shift Shaft Disassembly:
Differential Disassembly:
AssembleTransmission
Differential Assembly
Assembly:
Axles and Driveshaft
Summary of References
Service Equipment and Tools
Specifications
Remove and Install EMFWD Driveshaft
Remove Driveshaft
Install Driveshaft
Replace EMFWD Driveshaft Boot
Removal
Replacement
Remove and Install Rear Axle Half Shaft
Removal
Installation
Remove and Install Front Axle Half Shaft
Removal
Installation
Summary of References
Repair CV Joint and Boots—Rear Axle Half Shafts
Required Tool:
Disassembly:
Assembly:
Mechanical Front Wheel Drive
Summary of References
Other Material
Specifications
Change EMFWD Front Differential Oil
Disassemble and Assemble Front Drive Gearbox
Disassembly:
Assembly:
Remove and Install Front Differential
Removal
Installation
Disassemble Front Differential
Inspection:
Summary of References
Steering and Brake Repair
Steering
Summary of References
Other Material
Specifications
Remove and Install Steering Knuckle
Removal
Installation
Remove and Replace Front Wheel Bearing
Removal
Installation
Remove and Install Ball Joint
Removal
Installation
Remove and Install Steering Wheel (Standard)
Removal
Installation
Remove and Install Steering Wheel (Sport)
Removal
Installation
Remove and Install Electric Power Assisted Steering (EPAS) Module
Removal:
Installation:
Remove and Install Steering Shaft
Removal:
Steering Shaft Installation:
Remove and Install Steering Shaft (EPAS)
Upper Steering Shaft Removal:
Lower Steering Shaft Removal:
Steering Shaft Installation:
Replace Steering Shaft Bearing
Remove and Install Steering Gearbox
Steering Gearbox Removal:
Tie Rod Boot Replacement:
Steering Gearbox Installation:
Remove and Install Front Shock Absorber
Removal:
Installation:
Remove and Install Rear Shock Absorber
Removal:
Installation:
Remove and Install Tie Rod End
Removal:
Installation:
Remove and Install Front Suspension Arm
Removal:
Installation:
Rear Axle Bearing Carrier
Bearing Carrier Removal
Bearing Carrier Disassembly
Bearing Carrier Assembly
Bearing Carrier Installation
Remove and Install Rear Suspension Arm
Upper Suspension Arm Removal:
Upper Suspension Arm Installation:
Lower Suspension Arm Removal
Lower Suspension Arm Installation
Remove and Install Stabilizer Bar
Stabilizer Bar Removal
Stabilizer Bar Installation
Brakes
Summary of References
Essential or Recommended Tools
Other Material
Specifications
Replace Brake Pad
Removal
Installation
Remove and Install Master Cylinder
Removal:
Installation:
Remove Front Brake Hose
Install Front Brake Hose
Remove Rear Brake Hose
Front
Rear
Install Rear Brake Hose
Front
Rear
Remove and Install Rear Brake Line—Front
Remove and Install Rear Brake Line—Rear
Remove and Install Brake Caliper
Removal
Installation
Remove and Install Brake Rotor
Removal
Installation
Remove and Install Brake Pedal
Installation:
Remove and Install Park Brake Pedal
Installation:
Summary of References
Replace Park Brake Release Cable
Removal:
Installation:
Remove, Service, and Replace Park Brake
Special or Required Tools:
Park Brake Removal
Park Brake Disassembly
Park Brake Assembly
Park Brake Installation:
Operator ` s Station Repair
Operator ` s Station
Summary of References
Specifications
Remove and Install Seats
Remove and Install Bucket Seat
Remove and Install Bench Seat
Summary of References
Install Door
Replace Cabin Air Filter
Miscellaneous Repair
Wheels
Summary of References
Specifications
Remove and Install Wheels
Removal:
Installation:
Hood, Cargo Box, and Bumper
Summary of References
Remove and Install Hood
Removal:
Installation:
Remove and Install Front Bumper/Skid Plate
Removal:
Installation:
Remove and Install Cargo Box
Removal:
Installation:
Summary of References
Miscellaneous Repair
Summary of References
Remove and Install Standard Headlights
Remove and Install Dual Beam Headlights
Summary of References
Remove and Install Battery
Removal
Installation
Engine Operation, Tests, and Adjustments
Component Location
Summary of References
Fuel Filter Components
Engine Fuel System
Engine Mounts
Fuel System Components
Exhaust System Components
Coolant System Components
Theory of Operation
Summary of References
Cooling System Operation
Function:
Theory of Operation:
Lubrication System Operation
Function:
Theory of Operation:
Fuel System Operation
Function:
Theory of Operation:
Air System Operation
Function:
Theory of Operation:
Diagnosis
Engine Troubleshooting and Diagnostics
Diagnose Engine Oil
Diagnose Excessive Fuel Consumption
Diagnose Incorrect Manifold Pressure
Diagnose Low Engine Compression
Diagnose Engine Starting Problem
Diagnose Poor Engine Operation
Summary of References
Diagnose Coolant in Oil or Oil in Coolant
Diagnose Engine
Tests and Adjustments
Summary of References
Essential or Recommended Tools
Service Equipment and Tools
Other Material
Specifications
Test Air Restriction Indicator
Reason:
Procedure (Normal Operation):
Results:
Procedure (Simulated Excess Restriction):
Results:
Adjust Fast Idle Speed
Reason:
Equipment:
Procedure:
Results:
Adjust Slow Idle
Reason:
Equipment:
Procedure:
Results:
Adjust Throttle Cable
Reason:
Equipment:
Procedure
To Adjust Cable:
Reason:
Equipment:
Adjust Valve Clearance
Reason:
Equipment:
Procedure:
Check Valve Lift
Reason:
Equipment:
Procedure:
Results:
Test Cylinder Compression
Reason:
Equipment:
Procedure:
Results:
Adjust Water Pump/Alternator Drive Belt
Reason:
Equipment:
Procedure:
Results:
Test Thermostat
Reason:
Equipment:
Procedure:
Results:
Test Radiator Bubble
Reason:
Equipment:
Procedure:
Results:
Test Cooling System Pressure
Reason:
Equipment:
Procedure:
Results:
Test Radiator Cap Pressure
Reason:
Equipment:
Procedure:
Results:
Test Engine Oil Pressure
Reason:
Equipment:
Procedure:
Results:
Test Fuel Injection System
Reason:
Equipment:
Procedure:
Results:
Test Fuel Injection Nozzle
Adjust Injection Pump Timing
Check Injection Pump Static Timing
Reason:
Equipment:
Procedure:
Results:
Bleed Fuel System Air
Reason:
Procedure:
Test Fuel Transfer Pump Flow
Reason:
Equipment:
Procedure:
Results:
Summary of References
Electrical Operation, Tests, and Adjustments
General Information
Summary of References
Operation and Diagnostics
Diagnostic Information
Summary of References
Component Location
Summary of References
Connector Location – E Series
Connector Location – M Series (without A/C)
M Series (without A/C)
Connector Location – R, M Series (with A/C)
R, M Series (with A/C)
Summary of References
ICC Pinout
ICC Signal Locations
Theory of Operation
Summary of References
Power Circuit Operation (Switched)
Power Circuit Operation (Unswitched)
Charging and Tachometer Circuit Operation
Fuel Level Circuit Operation
Seat Belt Circuit Operation
Park Brake Light and Warning Buzzer Circuit Operation
Cranking, Glow Plug, Fuel Gauge Circuit Operation
4WD and Speedometer Circuit Operation
EPAS Circuit Operation
Engine Cooling Circuit Operation
Light Circuit Operation
Summary of References
Loadshed Power Circuit Operation
CAN Bus Circuit Operation
Schematics
Summary of References
Wheel Speed Sensor Adapter Schematic
Battery Cable (+ve)
Summary of References
Engine Ground Cable
Schematics, Kits
Summary of References
Homologation Front Harness Schematic, AM147613 (M Spec)
Homologation Dash Harness Schematic, AM147614 (M Spec)
Deluxe Front Harness Schematic, AM147902
Deluxe Dash Harness Schematic, AM147903
Attachment Chassis Harness Schematic, AM148118 (E Spec)
Attachment Dash Harness Schematic, AM148119 (E Spec)
Box Lift Harness Schematic , AM136637
Front Cab Harness Schematic, AUC13795
Rear Cab Harness Schematic, AM147542
Cab Pillar Harness Schematic, AM146898
Speaker Harness Schematic, AM147719
Summary of References
Attachment Port Harness Schematic, AM148350
Connector Information
Summary of References
XA5-1 ICC J1 Connector
XA5-2 ICC J2 Connector
XA25 HVAC Controller Connector
XY24 HVAC Top Side Actuator Connector
XY25 HVAC Bottom Side Actuator Connector
XB1 Fuel Level Sensor Connector
XA33 Box Lift Connector
XE10 Left Tail Light Connector
XE9 Right Tail Light Connector
XY29 MFWD Solenoid Connector
XX3 Glove Box Power Port
XX1 Dash Power Port
XE1 Left Headlight Connector
XE2 Right Headlight Connector
XF7 EPAS Fuse
XF36 Rear Attachment Fuse
XH1 Buzzer
XA28-1 EPAS Control Connector
XA28-2 EPAS Power Connector
XK16 Load Shed Relay
XM11 Left Fan Connector
XM9 HVAC Fan Connector
XM10 HVAC Compressor Connector
XR3 CAN2 Termination Resistor 1 Connector
XR4 CAN2 Termination Resistor 2 Connector
XS1 Key Switch Connector
XS38 Box Lift Switch Connector
XS21 Neutral Switch Connector
XS36 Reverse Switch Connector
XS49 Throttle Switch Connector
XS33 MFWD Switch Connector
XS34 Service Brake Switch Connector
XS50 HVAC Mid Pressure Switch
XS51 HVAC High Pressure Switch
XS41 Wiper Switch Connector
XS48 Headlight Switch Connector
XS13 Front Cab Work Light Switch Connector
XS14 Rear Cab Work Light Switch Connector
XS16 Beacon Light Switch Connector
XV1 Key Switch Diode Connector
XV2 Load Shed Diode Connector
XX4 HVAC Interface-1 Connector
XX5 HVAC Interface-2 Connector
XX13 Diagnostic Interface Connector
XA35 Winch Controller Power Connector
XA34 Winch Controller Connector
XX31 Dash Attachment Port Rear Connector
XB2 Coolant Temp Sensor Connector
XA24 Radio Connector
XK46 Radio Relay Connector
XB39-1 Right Front Speaker (+) Connector
XB39-2 Right Front Speaker (-) Connector
XB38-1 Left Front Speaker (+) Connector
XB38-2 Left Front Speaker (-) Connector
XS18 Brush Guard Light Switch Connector
XS10 Delux Headlight Switch Connector
XM1 Starter Motor Connector
XE12 Front Left Work Light Connector
XE13 Front Right Work Light Connector
XE14 Rear Left Work Light Connector
XE15 Rear Right Work Light Connector
XE22 Beacon Light Connector
XE23 Dome Light Connector
XM13 Wiper Motor Connector
XE24 Left Brush Guard Light Connector
XE25 Right Brush Guard Light Connector
XX9 Marker Interface Connector
XA36 Wireless Winch GND Connector
XA26 GS 2630 Display Connector
XA27 Starfire Receiver Connector
XX30 Dash Attachment Port Front Connector
XA37 Canbus Gateway Connector
XG1 Battery Connector
XG6-1 HVAC Load Center 1 Connector
XS35 Seat Belt Switch Connector
XS44 Supervisor Mode Switch Connector
XS46 Brake Float Switch Connector
XW4 Front Chassis Ground Connector
XX7 Tail Light Jumper Connector
XX11 Front Attachment Connector
XX12 Rear Attachment Connector
XX14 Front Attachment Power Connectors
X22 Marker Jumper Connector
XB36-1 Right Rear Speaker (+) Connector
XB36-2 Right Rear Speaker (-) Connector
XB37-1 Left Rear Speaker (+) Connector
XB37-2 Left Rear Speaker (-) Connector
XE20 Left Front Marker Connector
XE21 Right Front Marker Connector
ANT Radio Connector
XX15 Rear Attachment Power Connector
XX16 Dash Attachment Power Connector
XY1 Washer Bottle Connector
XY30 Front Winch Solenoid Connector
XS5-1 Park Brake Switch Connector
XS5-2 Park Brake Switch Connector
XY31 Front Winch Solenoid Connector
XE28-1 Trailor Integrity Light Connector
XE28-2 Trailor Integrity Light Connector
XG7 Homologation Load Center Connector
XR5 Flasher Module Resistor Connector
XS12 High Beam Switch Connector
XE7 Left Turn Light Connector
XE8 Right Turn Light Connector
XE31 Left Deluxe Headlight Connector
XE32 Right Deluxe Headlight Connector
XH2-1 Horn Connector
XH2-2 Horn Connector
S06 Speed Sensor Connector
C1 Deluxe Light Interconnect
C2 Deluxe Light Chassis Connection Interconnect
C3 Dash Interconnect
C4 Deluxe Light Chassis Interconnect
C5 Radio Harness Interconnect
C6 Dash Interconnect
C7 Attachment Harness Interconnect
C16 Attachment Port Harness Interconnect
C17 Attachment Dash Harness Interconnect
C18 Display Harness Interconnect
C19 Attachment Port Harness Interconnect
C20 Roof Harness Interconnect
C21 Chassis Harness Interconnect
C22 Front Roof Harness Interconnect
C23 Pillar Harness Interconnect
C24 Rear Roof Harness Interconnect
C25 Pillar Harness Interconnect
C26 Rear Speaker Harness Interconnect
C27 Pillar Harness Interconnect
C28 Wheel Speed Sensor Jumper
X06 Speed Sensor Connector
C30 Starfire Jumper Interconnect
C31 Rear Cab Interconnect
XB4 Engine Oil Pressure Sensor Connector
XB44 Air Filter Restriction Gauge Connector
XE37 Glow Plugs Connector
XG6-2 HVAC Load Center 2 Connector
XL Alternator Connector
XL HVAC Alternator Connector
XR1 Can1 Termination Resistor1 Connector
XS8 Radiator Tank Temp Switch Connector
XV3 Fuel Pull-in Diode Connector
XW HVAC Alternator Connector
XW3 Rear Chassis Ground Connector
Summary of References
Tests and Adjustments
Summary of References
Service Equipment and Tools
Other Material
Specifications
Common Circuit Tests
Ground Circuit Test
Reason:
Ohmmeter Procedure:
Voltmeter Procedure:
Results:
Charge Battery
Equipment:
Inspection:
Battery Charging:
Determining Battery State of Charge:
Battery, Charging, and Starting System Tests
Reason:
Out of Vehicle Battery Test-Procedure:
Out of Vehicle Battery Test-Results:
In Vehicle System Test-Procedure:
In Vehicle System Test-Results:
Amperage Draw Test-Procedure:
Load Test Battery
Results
Clean Battery
Fuse Test
Bulb Test
Reason:
Equipment:
Procedure:
Results:
Key Switch Test
Headlight Switch Test
Work Light Switch Test
Beacon Light Switch Test
4WD Switch Test
4WD Solenoid Test
Reason
Equipment:
Procedure
Results
Raise/Lower Switch Test
Wiper Switch Test
Brake Switch Test
Reason:
Test Connections:
Procedure:
Results:
Park Brake Switch Test
Reason:
Equipment:
Procedure
Results:
Troubleshooting Electronic Controllers
Problems Due to Specific Operating Conditions:
Problems Due to Intermittent Electrical Failures:
Problems Due to Control Unit Failures:
CAN Bus Terminator Test
Reason:
Equipment:
Procedure:
Results:
CAN Network Voltage Checks
Reason:
Check for proper voltage:
Check for Short Circuits to CAN Hi and CAN Lo:
Compare CAN Hi and CAN Lo Voltages:
Voltages Within Range but Out of Specification:
CAN Communication Fault Checks
Reason:
Equipment:
Procedure:
Condition 1:
Condition 2:
Condition 4:
Wiggle Test
Terminal Test
Summary of References
Coolant Temperature Sensor Test
Fuel Shutoff Solenoid Test
Reason
Equipment:
Procedure
Results
Control Unit Operation, Tests and Adjustments
Theory of Operation
Summary of References
Electric Power Assist Steering (EPAS) Operation
CAN Bus Message Structure
CAN Bus Operation
Data Bus Systems
CAN Trace
Control Unit Messaging Errors
Approved Software for Control Units
Erroneous Diagnostic Trouble Codes
Diagnostic Trouble Codes Overview
SPN.FMI Codes
Failure Modes:
Engine Speed and Tachometer Function
Coolant Fan Control
Starting Authorization and Protection
Load Dump Operation
Load Shed
Low Voltage Indicator
Engine Start and Stop Control
Starter Crank Protection
Fuel Level Display
Low Fuel Warning
HVAC Wide Open Throttle Operation
Air Filter Restriction Indicator
Brake MIL Operation (Homologated Only)
Engine Hour Operation
Engine Oil Pressure Monitor Operation
Parked Rollaway Alarm
Park Brake Indicator
Power On Self Test Operation (POST)
Seat Belt Indicator
Steering MIL
Engine Coolant Temperature
Engine RPM Bar Gauge Operation
Odometer Operation
4WD Operation
Ground Speed Limiting
Park Brake Drive Through Operation
Parked Drive Away Operation
Exit Lighting Operation
Signal Lighting Operation
ICC System Settings Menu
System Menu Settings
Reading ICC On-Borard DTCs
Diagnostic Trouble Codes, ICC
ICC Quick Reference
Diagnostic Trouble Codes, SCU
SCU Quick Reference
SCU 000084.08— Speed Signal
SCU 000168.00— Battery Voltage—High
SCU 000168.01— Battery Voltage—Low
SCU 520192.06— Internal Torque Sensor Circuit
SCU 520193.05— Internal Motor Circuit
SCU 520194.06— Internal Motor Circuit
SCU 520195.03— Internal Motor H-Bridge
SCU 520196.06— Internal Motor Circuit
SCU 520197.06— Internal Motor Circuit
SCU 520198.03— Main Torque Sensor
SCU 520199.04— Main Torque Sensor
SCU 520200.03— Secondary Torque Sensor
SCU 520201.04— Secondary Torque Sensor
SCU 520202.02— Internal Angle Sensor
SCU 520206.04— Internal Temperature Sensor
SCU 520207.03— Internal Temperature Sensor
SCU 520208.04— Internal Temperature Sensor
SCU 520209.05— Internal Temperature Sensor
SCU 520210.03— Internal Temperature Sensor
SCU 520211.03— Internal Current Sensor
Summary of References
Service ADVISOR Readings
Summary of References
ICC Readings
SCU EPAS Readings
Power Train Operation, Tests, and Adjustments
Component Location
Summary of References
Drive Shaft
Continuously Variable Transmission
Front Axle
Rear Axle
Front Drive Gear Box
EMFWD Front Differential
Transaxle Gear
Differential
Transaxle Input
Controls and Shift Linkages
Primary Clutch
Summary of References
Transmission Mounts
Theory of Operation
Summary of References
Power Transfer Operation
Drive Clutch:
Driven Clutch:
Transaxle:
Differential Lock:
Mechanical Four Wheel Drive (MFWD):
Drive Clutch Operation
Clutch Operation
Theory of Operation:
(1) Engine Idle Speed:
(2) Transition from Low to Intermediate Ratio:
(3) High Engine Speed, Light Load, High Output Speed:
(4) Engine Braking with Low Engine RPM, High Output Speed
EMFWD Operation
Function:
Operation:
Diagnosis
Diagnose Drive Train
Diagnose Primary Clutch
Summary of References
Tests and Adjustments
Summary of References
Specifications
Differential Lock Adjustment
Purpose:
Procedure:
Results:
Summary of References
Clutch Sheave Alignment
Steering and Brake Operation, Tests, and Adjustments
Component Location
Summary of References
Steering Components With EPAS
Front Suspension Heavy Duty
Summary of References
Brake Pedal and Park Brake Linkages
Theory of Operation
Summary of References
Steering System Operation
Function:
Theory of Operation:
Brake System Operation
Function:
Theory of Operation:
Diagnosis
Diagnose Steering Pulls in One Direction
Diagnose Steering Wanders or Vibrates
Diagnose Wheel Bearing Noise
Diagnose Steering Hard in Left, Right, or Both Directions
Diagnose Steering Locks in Hard Left or Right Turn
Diagnose Steering Wheel Pulls Upwards
Diagnose Steering Wheel Spins Freely
Diagnose Noise During Turns Over Rough Terrain
Diagnose Hydraulic Brakes
Diagnose Brakes Will Not Engage or Show Poor Response
Diagnose Brake Effort Excessive
Diagnose Brakes Will Not Release
Diagnose Brakes Are Noisy or Chattering
Diagnose Excessive Brake Pad Wear
Diagnose Excessive Brake Pedal Travel
Diagnose Brakes Pull Left or Right
Diagnose Pedal Feels Hard With Little Travel
Diagnose Park Brake Will Not Engage or Hold
Diagnose Park Brake Will Not Release
Tests and Adjustments
Summary of References
Other Material
Specifications
Center Steering Rack
Center Steering Wheel
Adjust Suspension
Adjust Toe-In
Adjust Rear Wheel Camber
Check Brake Fluid Level
Check Park Brake Lubricating Oil Level
Adjust Master Cylinder Rod
Adjust Park Brake Cable
Bleed Brakes
Bleed Master Cylinder
Burnish Brakes
Service Tools
Service Tools and Kits
Essential or Recommended Tools
Service Equipment and Tools
Other Material
Kits
