John Deere Troubleshooting - 31200371

Service Manual
John Deere
Tier II Engine
Troubleshooting
31200371
Original
February 2, 2007
EFFECTIVITY PAGE
February 2, 2007 - A - Original Issue Of Manual
31200371 John Deere Engine i

EFFECTIVITY PAGE
-ii John Deere Engine 31200371

SECTION CONTENTS
Section Subject Page
Section 1
Safety Practices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.1
1.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2
1.2 Disclaimer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2
1.3 Operation & Safety Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2
1.4 Do Not Operate Tags . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2
1.5 Safety Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.3
1.6 Safety Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.3
1.7 Safety Decals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.4
Section 2
General Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.1
2.1 Basic Engine Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.2
2.2 Pre-Troubleshooting Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.2
2.3 Electronic Control System Terminology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.3
2.4 Electronic Control System Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.4
2.5 Monitoring Engine Parameters. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.4
2.6 Electronic Control System Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.4
2.7 ECU Connector Legend . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.5
2.8 OEM Trim Option Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.6
Section 3
Function Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.1
3.1 Troubleshooting Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.2
3.2 Retrieving Fault Codes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.3
3.3 Engine Derate Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.5
3.4 Engine Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.6
3.5 ECU Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.12
3.6 CAN Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.14
3.7 Electrical Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.15
Section 4
Electrical Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.1
4.1 Wiring Schematics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.2
John Deere Engine i

Section Subject Page
ii John Deere Engine

Section 1
Safety Practices
Contents
PARAGRAPH TITLE PAGE

1.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2
1.2 Disclaimer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2
1.3 Operation & Safety Manual. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2
1.4 Do Not Operate Tags. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2
1.5 Safety Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.3
1.5.1 Safety Alert System and Signal Words . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.3
1.6 Safety Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.3
1.6.1 Personal Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.3
1.6.2 Equipment Hazards. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.3
1.6.3 General Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.4
1.6.4 Operational Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.4
1.7 Safety Decals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.4
John Deere Engine 1.1

Safety Practices
1.1 INTRODUCTION 1.2 DISCLAIMER

This manual provides general directions for All information in this manual is based on the latest
accomplishing service and repair procedures. Following product information available at the time of publication.
the procedures in this manual will help assure safety and JLG reserves the right to make changes and
equipment reliability. improvements to its products, and to discontinue the
Read, understand and follow the information in this manufacture of any product, at its discretion at any time
manual, and obey all locally approved safety practices, without public notice or obligation.
procedures, rules, codes, regulations and laws.
These instructions cannot cover all details or variations in
the equipment, procedures, or processes described, nor 1.3 OPERATION & SAFETY MANUAL
provide directions for meeting every possible contingency
during operation, maintenance, or testing. When additional The mechanic must not operate the machine until the
information is desired consult the local JLG distributor. Operation & Safety Manual has been read & understood,
training has been accomplished and operation of the
Many factors contribute to unsafe conditions: carelessness, machine has been completed under the supervision of an
fatigue, overload, inattentiveness, unfamiliarity, even experienced and qualified operator.
drugs and alcohol, among others. For optimal safety,
encourage everyone to think, and to act, safely. An Operation & Safety Manual is supplied with each
machine and must be kept in the manual holder located
Appropriate service methods and proper repair in the cab. In the event that the Operation & Safety
procedures are essential for the safety of the individual Manual is missing, consult the local JLG distributor before
doing the work, for the safety of the operator, and for the proceeding.
safe, reliable operation of the machine. All references to
the right side, left side, front and rear are given from the
operator’s seat looking in a forward direction.
Supplementary information is available from JLG in the
1.4 DO NOT OPERATE TAGS
form of Service Bulletins, Service Campaigns, Service
Place Do Not Operate Tags on the ignition key switch and
Training Schools, the JLG website, other literature, and
the steering wheel before attempting to perform any
through updates to the manual itself.
service or maintenance. Remove key and disconnect
battery leads.
1.2 John Deere Engine

Safety Practices
1.5 SAFETY INFORMATION 1.6 SAFETY INSTRUCTIONS

To avoid possible death or injury, carefully read, Following are general safety statements to consider before
understand and comply with all safety messages. performing maintenance procedures on the telehandler.
In the event of an accident, know where to obtain medical Additional statements related to specific tasks and
assistance and how to use a first-aid kit and fire procedures are located throughout this manual and are
extinguisher/fire suppression system. Keep emergency listed prior to any work instructions to provide safety
telephone numbers (fire department, ambulance, rescue information before the potential of a hazard occurs.
squad/paramedics, police department, etc.) nearby. If For all safety messages, carefully read, understand and
working alone, check with another person routinely to follow the instructions before proceeding.
help assure personal safety.
1.6.1 Personal Hazards
1.5.1 Safety Alert System and Signal Words PERSONAL SAFETY GEAR: Wear all the protective
clothing and personal safety gear necessary to perform
DANGER the job safely. This might include heavy gloves, safety
glasses or goggles, filter mask or respirator, safety shoes
or a hard hat.
DANGER indicates an imminently hazardous situation LIFTING: NEVER lift a heavy object without the help of at
which, if not avoided, will result in death or serious injury. least one assistant or a suitable sling and hoist.
1.6.2 Equipment Hazards

WARNING LIFTING OF EQUIPMENT: Before using any lifting
equipment (chains, slings, brackets, hooks, etc.), verify
that it is of the proper capacity, in good working order, and
WARNING indicates a potentially hazardous situation is properly attached.
which, if not avoided, could result in death or serious
NEVER stand or otherwise become positioned under a
injury.
suspended load or under raised equipment. The load or
equipment could fall or tip.
DO NOT use a hoist, jack or jack stands only to support
equipment. Always support equipment with the proper
capacity blocks or stands properly rated for the load.
HAND TOOLS: Always use the proper tool for the job;
keep tools clean and in good working order, and use
special service tools only as recommended.

Safety Practices
1.6.3 General Hazards appropriate container and dispose of in accordance with

prevailing environmental regulations.
SOLVENTS: Only use approved solvents that are known
to be safe for use. RADIATOR CAP: Always wear steam-resistant, heat
protective gloves when opening the radiator cap. Cover
HOUSEKEEPING: Keep the work area and operator’s
the cap with a clean, thick cloth and turn slowly to the first
cab clean, and remove all hazards (debris, oil, tools, etc.).
stop to relieve pressure.
FIRST AID: Immediately clean, dress and report all injuries
FLUID FLAMABILTITY: DO NOT service the fuel or
(cuts, abrasions, burns, etc.), no matter how minor the
hydraulic systems near an open flame, sparks or smoking
injury may seem. Know the location of a First Aid Kit, and
materials.
know how to use it.
NEVER drain or store fluids in an open container. Engine
CLEANLINESS: Wear eye protection, and clean all
fuel and hydraulic fluid are flammable and can cause a
components with a high-pressure or steam cleaner
fire and/or explosion.
before attempting service.
DO NOT mix gasoline or alcohol with diesel fuel. The
When removing hydraulic components, plug hose ends
mixture can cause an explosion.
and connections to prevent excess leakage and
contamination. Place a suitable catch basin beneath the PRESSURE TESTING: When conducting any test, only
machine to capture fluid run-off. use test equipment that is correctly calibrated and in good
condition. Use the correct equipment in the proper
Check and obey all Federal, State and/or Local
manner, and make changes or repairs as indicated by the
regulations regarding waste storage, disposal and
test procedure to achieve the desired result.
recycling.
LEAVING MACHINE: Lower the forks or attachment to
1.6.4 Operational Hazards the ground before leaving the machine.
ENGINE: Stop the engine before performing any service TIRES: Always keep tires inflated to the proper pressure
unless specifically instructed otherwise. to help prevent tipover. DO NOT over-inflate tires.
VENTILATION: Avoid prolonged engine operation in NEVER use mismatched tire types, sizes or ply ratings.
enclosed areas without adequate ventilation. Always use matched sets according to machine
specifications.
SOFT SURFACES AND SLOPES: NEVER work on a
machine that is parked on a soft surface or slope. The MAJOR COMPONENTS: Never alter, remove, or
machine must be on a hard level surface, with the wheels substitute any items such as counterweights, tires,
blocked before performing any service. batteries or other items that may reduce or affect the
overall weight or stability of the machine.
FLUID TEMPERATURE: NEVER work on a machine
when the engine, cooling or hydraulic systems are hot. BATTERY: DO NOT charge a frozen battery.Charging a
Hot components and fluids can cause severe burns. frozen battery may cause it to explode. Allow the battery
Allow systems to cool before proceeding. to thaw before jump-starting or connecting a battery
charger.
FLUID PRESSURE: Before loosening any hydraulic or
diesel fuel component, hose or tube, turn the engine
1.7 SAFETY DECALS
OFF. Wear heavy, protective gloves and eye protection.
NEVER check for leaks using any part of your body; use Check that all safety decals are present and readable on
a piece of cardboard or wood instead. If injured, seek the machine. Refer to the Operation & Safety Manual
medical attention immediately. Diesel fluid leaking under supplied with machine for information.
pressure can explode. Hydraulic fluid and diesel fuel
leaking under pressure can penetrate the skin, cause
infection, gangrene and other serious personal injury.
Relieve all pressure before disconnecting any
component, part, line or hose. Slowly loosen parts and
allow release of residual pressure before removing any
part or component. Before starting the engine or applying
pressure, use components, parts, hoses and pipes that
are in good condition, connected properly and are
tightened to the proper torque. Capture fluid in an

Section 2
General Troubleshooting
Contents

2.1 Basic Engine Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.2
2.2 Pre-Troubleshooting Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.2
2.3 Electronic Control System Terminology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.3
2.4 Electronic Control System Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.4
2.5 Monitoring Engine Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.4
2.6 Electronic Control System Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.4
2.7 ECU Connector Legend . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.5
2.8 OEM Trim Option Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.6

2.1 BASIC ENGINE CHECKS • Crank position sensor that is not giving consistent
readings can cause hard starting, shutdown, erratic
throttle issues. This is a John Deere isssue. Just be aware
If the engine will not run or is running erratically, the fault may of the effect this sensor can have.
not be related to the electronic system. Ensure that the following
Check critical connectors for signs of looseness, corrosion,
points are checked before ECU troubleshooting.
damage, etc. The following connectors are critical:
• Travel Select Lever is in the (N) NEUTRAL position
• ECU Connector
• Park brake is set
• Crank position sensor at front of engine
• Throttle pedal has free range of motion without interuption
• Fuel pump solenoid connector
• Sufficient fuel in the fuel tank for engine operation
• Cam position sensor on block
• Fuel quality is of an acceptable rating
• ECU water temperature sensor on thermostat housing (not
• Battery power and ground connections are secure to be confused with the JLG/Gradall installed water
temperature sensor)
• Fuel tank vent hose is clear of obstructions
The order in which the steps should be taken are as follows:
• No restrictions in the exhaust or intake system
1. Check all fuel and air filters, water ingression into this
• No broken fins on turbo equipped models
system will promote fault codes. Daily draining of the fuel/
• No restrictions in fuel filters water separator is recommended.
• No water in the fuel system 2. Check the condition of the fuel lines from the tank to the
engine.
2.2 PRE-TROUBLESHOOTING CHECKS 3. Check the fuel tank cap vent.
The following is a basic checklist of items to check when 4. Check all engine fault codes and record them. Refer to
troubleshooting engine ECU issues on John Deere engines. Section 3.2, “Retrieving Fault Codes.”
Some of the reported issues have been engine shutdown, 5. Check all wiring and socket conditions. A check for ground
erratic running, and erratic throttle position. This list is not for and positive voltage supply at the John Deere, 9 pin
actual ECU troubleshooting, but rather external factors that may connector is also recommended. This would also detect a
affect ECU operation. Check fault codes prior to checking the harness issue on the JLG side.
following items. Refer to Section 3.2, “Retrieving Fault Codes,” 6. After all JLG/Gradall supplied items have been inspected,
for more information on fault codes. Some of the items below repaired, corrected and/or replaced, then the John Deere
may not show a fault code. Dealer should be called to install the latest version of ECU
• Check the female sockets in the engine harness plug that software. Refer to Section 2.8, “OEM Trim Option
attaches to the engine’s ECU. Use the proper tension Settings.”. The John Deere Dealer will need to file a
gauge or a male pin to ensure that the female socket is in DETAC case and request, the “OEM Trim Options”
good condition. If it is not, the socket will have to be payload replacement software.
replaced. Usage of dielectric grease on all connections is
required. 7. If the problem comes back, then the ECU will have to be
• Check bolt used to retain harness connector to ECU. If replaced with a new one that has been updated.
loose, it needs to be tightened. Check operation after
tightening bolt. Loctite® 242 should be applied to threads if
bolt is loose.
• Verify brass insert in ECU is not loose. In addition, it may
be possible in some situations that the brass insert may
not allow full seating of the connector bolt. If the connector
bolt is tight, and you are able to “wiggle” the connector, the
brass insert in the ECU is suspect. Contact your local John
Deere service dealer with full details.
• Verify ground cable attachment on engine and frame.
Check that bolts are tight; verify ground is clean and bare
for contact between ground connection and frame. ECU
primary supply ground wire must be properly secured in
the wedge connector.
• Verify positive cables are clean and tight. Primary ECU
power supply at the battery post is tight within the wedge
connection, that the fuse is supplied and working properly.
• Check the overall condition of the engine harness
including heat related damage and routing. Harness tie off
locations should leave a small amount of slack to the
individual sensors or ECU.

2.3 ELECTRONIC CONTROL SYSTEM

TERMINOLOGY
Term Definition
Actuator A device controlled by the (ECU) to perform a certain function.
Analog Signal which has a continuous range of possible voltages. Usually 0 to 5 volt or 0 to 12 volt
signals.
Boost Air charge pressure in the intake manifold.
CAN Controller Area Network. The electronic pathway network on vehicles that allows communication
between controllers.
DTC Diagnostic Trouble Code. A code which is stored in the ECU’s memory when the ECU detects a
problem in the electronic control system.
DST Diagnostic Scan Tool. This is a diagnostic software that is used to read engine parameters, check
DTC’s and run special tests. The DST consists of a Windows (‘95, ‘98, 2000) or NT compatible
computer and a hardware kit available from John Deere Distribution Service Center (DSC):
JDIS121 - ECU Communication Hardware Kit. The software is available to download from your
John Deere home page.
Digital A signal which consists of only two-volt levels - usually 0 volts and +5 volts.
ECT Engine Coolant Temperature (sensor). Measures the temperature of the engine coolant.
ECU Engine Control Unit. The computer which controls the fuel, air, and ignition systems on the engine.
FMI Failure Mode Identifier. The second part of a two-part code that identifies control system trouble
codes according to the SAE J1939 standard. The FMI identifies the type of failure that has
occurred. The first half of the code is the Suspect Parameter Number (SPN).
J1587-J1708 The Society of Automotive Engineers (SAE) standard for the electronic components of heavy duty
vehicles. J1587 is the software standard. J1708 is the hardware standard.
MAT Manifold Air Temperature (sensor). Measures the temperature of the air in the intake manifold.
PDM Parallel Data Module. Device used as part of the DST that allows communication with the ECU.
PROM Programmable, Read-Only Memory. The computer chip which contains the calibration information
for the engine control system.
PWM Pulse Width Modulation. A digital signal (not analog) which consists of a pulse generated at a fixed
frequency. When an actuator is controlled by a PWM signal, the on time of the signal is increased
or decreased (modulated) to increase or decrease the output of the actuator.
RAM Random Access Memory. The portion of computer memory within the ECU which changes as the
engine is running and is stored while the engine is off.
SAE Society of Automotive Engineers. Working with society to promote vehicle safety and maintenance
and energy resource conservation.
Sensor Device used by the ECU to monitor various engine parameters.
SPN Suspect Parameter Number. The first half of a two-part code that identifies control system fault
codes according to the SAE J1939 Standard. The SPN identifies the system of component that
has the failure. The second half of the code is the Failure Mode Identifier (FMI).
VBAT Battery voltage or unswitched voltage.
VSW Switch voltage

2.4 ELECTRONIC CONTROL SYSTEM 2.6 ELECTRONIC CONTROL SYSTEM

OPERATION OVERVIEW
Engine Starting Mode Note: Some of the components shown are optional and not
When the key is turned to the “ON” position, a switched power used on all applications.
voltage is sent to the Engine Control Unit (ECU). This energizes The electronic control system serves as an engine governor by
the ECU and allows it to “boot-up” and ready itself for engine controlling the pump control valve through a solenoid so that
start. fuel is delivered according to a given set of engine conditions, in
Note: If a wiring problem prevents the key ON signal from precise amounts, and at a precise time in relation to piston
getting to the ECU, the engine will not start. position. In order to achieve this, the engine control system
performs the following functions:
As soon as the ECU receives an input from the crankshaft
position sensor that the engine is cranking, it will move the • Constantly monitors engine operating conditions
pump control valve to the “pressure” position, which will allow • Delivers an optimum amount of fuel for operating
injection pressure to be developed. The fuel is delivered to all of conditions
the cylinders. To provide cold temperature enrichment, the • Provides multiple control modes
amount of fuel injected is based on the temperature measured • Performs self-diagnosis
by the Engine Coolant Temperature (ECT) sensor. At this point,
the engine will start and the ECU will go into the running mode. Connection Check
Engine Running Mode IMPORTANT: Do not force probes into connector terminals or
damage will result. Use JT07328 Connector Adapter Test Kit to
In the running mode, the ECU monitors information from the make measurements in connectors. This will ensure that
various sensors, then determines the optimum amount of fuel to terminal damage does not occur.
inject and the optimum injection timing in order to allow the
engine to develop high power while maintaining low exhaust Perform a preliminary inspection of the ECU connector, the
emission output. The ECU controls fuel delivery by energizing Engine Coolant Temperature (ECT) connector, and any
and de-energizing the pump control valve solenoid. When the connectors in between them. Look for dirty, damaged, or poorly
ECU energizes the solenoid, the pump control valve closes and positioned terminals.
injection begins. When the correct amount of fuel has been
injected, the ECU de-energizes the solenoid, causing the pump
control valve to open, and fuel injection to stop.
2.5 MONITORING ENGINE PARAMETERS

In order for the electronic control system to deliver fuel
according to a given set of operating conditions, the following
parameters are monitored by the ECU:
• Engine Coolant Temperature (ECT)
• Loss of Coolant Temperature
• Manifold Air Temperature (MAT)
• Oil Pressure
• Fuel Temperature
• Throttle Position
• Crankshaft Position Sensor

2.7 ECU CONNECTOR LEGEND Pin Wire Designation

A1 941 (Brn, 16)
A2 012B (Red, 16)
A3 493 (Org, 16)
A3 B3 C3 D3 E3 F3 G3 H3 J3 K3
B1 461, (Brn, 18)
A2 B2 C2 D2 E2 F2 G2 H2 J2 K2
A1 B1 C1 D1 E1 F1 G1 H1 J1 K1 B2 447 (Purple, 18)
B3 918 (Gray, 16)
MAN0150 C1 947 (Purple, 18)

C2
C3 428 (Gray, 18)
D1 463 (Org, 18)
D2 448 (Gray, 18)
D3 914E (Yllw, 16)
E1 915 (Dk Grn, 16)
E2 911E (Brn, 16)
E3
F1 905E (Dk Grn, 18)
F2
F3 467 (Pur, 16)
G1 904E (Yllw, 18)
G2
G3 473 (Org, 16) Eng Over ride Light
H1
H2
H3
J1
J2 050G (Blk, 16) > 050F > Btry Neg
J3
K1 022C (Red, 16 >002B >Fuse >
002A > Btry Pos
K2 491 (Brn, 16)
K3

2.8 OEM TRIM OPTION SETTINGS External Shutdown

Enable - OFF
Note: The following setting can only be accessed by John External Shutdown Input - Normally Open Switch
Deere service personnel.
External Shutdown Timer - Immediate
Digital Throttle Override External Shutdown at Engine Start - OFF
Enable - OFF Override External Shutdown Time - 30 seconds
3 - state Throttle - selected Oil Pressure Sensor - Enable
Primary Analog Throttle Cruise Control - No Change
Enable - ON Enable - OFF
Self Calibration Enable - ON On/Off Input - Normally Open Switch
Secondary Analog Throttle Accel Input - Normally Open Switch
Enable - OFF Decel Input - Normally Open Switch
Throttle Adjustments - No Change Brake Input - Normally Closed Switch
Throttle Out of Range Recovery - Resume Recovery Turnaround Input - Normally Open Switch
Min Throttle Offset - 0 rpm Tachometer Output - Enable
Maximum Throttle Offset - 0 rpm Low Idle Warm-Up - OFF
Throttle Rate - Standard (Maximum) CAN Wait-to-Start Message - Enable
Ramp Rate - 1.6% Governor Gains
Combination Throttle - No Change Low Speed Governor Gain - Use Default Governor Gain
Enable OFF All Speed Governor Gain - Use Default Governor Gain
Master Input - Primary Analog selected Selected Alternate Gain - Alternate Gain #1
2nd Input - Secondary Analog selected, Gain Adjustment Percentage - 100
Input Type - Accelerator
3rd Input - Digital selected,
Type - Accelerator
Torque Speed Control - No Change
Enable TSC Source 1 - OFF
Enable TSC Source 2 - OFF
Source Address 1 - 3
Source Address 2 - 4
Governor
Single Governor - Selected
Harness Selectable Governor - OFF
RPM of Droop - 150
Standard Derates and Standard Shutdowns
Enable Derates - Selected
Standard Shutdowns
Oil Pressure, Coolant and Fuel temperature Shutdown - Enable
Shutdown Timer - 30 seconds
External Derate
Enable - OFF
External Derate Input - Normally Open Switch
External Derate Rate - 20% Derate over 10 minutes

Section 3
Function Troubleshooting
Contents

3.1 Troubleshooting Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.2
3.2 Retrieving Fault Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.3
3.3 Engine Derate Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.5
3.4 Engine Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.6
3.4.1 Engine Cranks, Will Not Start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.6
3.4.2 Engine Will Not Crank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.8
3.4.3 Engine Over Speed. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.9
3.4.4 Engine Misfires/Runs Irregularly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.11
3.5 ECU Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.12
3.5.1 ECU Switched Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.12
3.5.2 ECU Power Down Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.13
3.6 CAN Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.14
3.7 Electrical Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.15
3.7.1 Manifold Air Temperature Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.15
3.7.2 Fuel Temperature Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.17
3.7.3 Analog Throttle Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.19
3.7.4 Crank Position Sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.21
3.7.5 Pump Solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.22
3.7.6 Oil Pressure Sender . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.23
3.7.7 Oil Pressure Switch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.24
3.7.8 Coolant Temperature Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.25
3.7.9 Loss of Engine Coolant Sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.27

3.1 TROUBLESHOOTING PROCEDURE

The procedures outlined in this section should be completed in
succession as listed. Once the step is completed, retest for
correction of the problem. If the problem is not corrected, move
onto the next step.
Manifold Air
Temperature (MAT)
Sensor
ECT Sensor
Loss of Coolant
Fuel Temperature Sensor
Sensor
Crank Position
Sensor
Electronic Control
Unit (ECU)
Pump Control
Solenoid Oil Pressure
Sensor

3.2 RETRIEVING FAULT CODES flash code 33 if there are any “stored” fault codes. If there
are no “stored” codes, the system will flash code 88.
1. Park the machine on a firm, level surface, level the 4. Once the code is retrieved, turn the ignition OFF.
machine, fully retract the boom, lower the boom, place the
Note: When the engine sensor inputs exceed normal
transmission control lever in (N) NEUTRAL and engage
operating ranges, the ECU will derate the amount of fuel that is
the park brake.
delivered to the engine. A fault code will always accompany a
2. Turn the ignition switch to “ON”. fuel derate. If the engine is running at a much lower rate, check
3. Push down and hold the reset button on the dash for 3-5 the fault codes first to see if the engine is experiencing an
seconds. The fault lamp will begin to flash a code number. internal problem.
The light will flash the first digit then pause for a short time
and then flash the second digit. If there are “active” codes,
the system will first flash code 32. If there are no “active”
codes, the system will flash code 88. The system will then
Fault Codes SPN Codes FMI Codes Definition

11 N/A N/A Analog Throttle (A) Input High
12 N/A N/A Analog Throttle (B) Input High
18 110 3 Engine Coolant Temperature Input Voltage High
19 110 4 Engine Coolant Temperature Input Voltage Low
21 620 3 Sensor Supply Voltage High
1079 3 Sensor Supply Voltage High
22 620 4 Sensor Supply Voltage Low
1079 4 Sensor Supply Voltage Low
23 100 3 Engine Oil Pressure Input Voltage High
24 100 4 Engine Oil Pressure Input Voltage Low
25 105 3 Manifold Air Temperature Input Voltage High
26 105 4 Manifold Air Temperature Input Voltage Low
28 629 13 ECU Error
32 N/A N/A Signifies Start of Active Fault Codes
33 N/A N/A Signifies Start of Previously Active Fault Codes
37 174 3 Fuel Temperature Input Voltage High
38 174 4 Fuel Temperature Input Voltage Low
39 637 2 Crank Position Input Noise
10 Crank Position Input Pattern Error
42 190 0 Engine Overspeed Extreme
16 Engine Overspeed Moderate
54 158 17 ECU Power Down Error
55 639 13 CAN Error
62 110 15 Engine Coolant Temperature High Least Service
63 110 16 Engine Coolant Temperature High Moderately Service
64 100 18 Engine Oil Pressure Moderately Low
65 100 1 Engine Oil Pressure Extremely Low

66 105 16 Manifold Air Temperature Moderately High

68 1569 31 Fuel Derate
69 110 0 Engine Coolant Temperature High Most Severe
71 1076 0 Pump Control Valve Closure Too Long
72 1076 1 Pump Control Valve Closure Too Short
73 1076 5 Pump Solenoid Circuit Open
74 1076 6 Pump Solenoid Circuit Severely Shorted
75 1076 7 Pump Control Valve Closure Not Detected
76 1076 10 Pump Solenoid Circuit Moderately Shorted
77 1076 3 Pump Solenoid Current High
78 200 13 Security Violation
79 2000 6 Internal ECU Error
81 174 16 Fuel Temperature Moderately High
82 1110 31 Engine Protection Shutdown
83 970 31 Auxiliary Engine Shutdown Switch Active
Note: If 5VDC is detected on circuit K2 there is a short in the system. If 5VDC is not
detected, John Deere assistance is required. JLG does not currently use this shutdown.
84 158 17 ECU Power Down Error

971 31 External Derate Switch Active
88 N/A N/A Signifies No Fault Codes Are In Buffer

3.3 ENGINE DERATE CHART
Sensor Measured Sensor Out of Range Value Derate

Parameter
Analog Throttle (A) High Input Voltage Above 4.7 Volts If no other throttle is available, engine
will run at idle speed
Low Input Voltage Below 0.3 Volts If no other throttle is available, engine
will run at idle speed
Oil Pressure Switch Low Input Voltage Input circuit is grounded at No derate
key ON with no engine
speed
Extremely Low Input circuit is grounded No derate
Pressure when engine is running at a
minimum engine speed
Manifold Air Temperature High Input Voltage Above 4.9 Volts High MAT engine protection is disabled
(MAT)
Low Input Voltage Below 0.1 Volts High MAT engine protection is disabled
Engine Coolant High Input Voltage Exceeds 4.9 Volts High ECT engine protection is disabled
Temperature
Low Input Voltage Below 0.1 Volts High ECT engine protection is disabled
Most Severe Exceeds 244°F (118°C) ECU derates engine 20% per minute
Temperature until engine runs at 40% of full power
Moderately Severe Exceeds 235°F (113°C) ECU derates engine 2% per minute
Fuel Temperature High Input Voltage Above 4.9 Volts High fuel temperature engine
protection is disabled
Low Input Voltage Below 0.1 Volts High fuel temperature engine
protection is disabled
Moderately High Exceeds 248°F (120°C) ECU derates engine 2% per minute

3.4 ENGINE TROUBLESHOOTING
3.4.1 Engine Cranks, Will Not Start

IGNITION
SWITCH
BATTERY
VSW
30A
VBAT
12VDC
012D, RED
022C, RED
K1 A2
J2
A3 B3 C3 D3 E3 F3 G3 H3 J3 K3
050G, BLK
A2 B2 C2 D2 E2 F2 G2 H2 J2 K2
A1 B1 C1 D1 E1 F1 G1 H1 J1 K1
MAN0010 ECU HARNESS CONNECTOR

1. Refer to Section 2, “General Troubleshooting” for initial for continuity with pin K1 on the harness end of the
checks before moving on to the following steps. connector.
2. Loosen one fuel line connection on the injection nozzles, • If continuity is found, repeat this step for the A2 and
crank engine over while monitoring the loose connection J2 circuits of the ECU connector.
for consistent supply of fuel. Be sure no air is coming out • If continuity is not found, there is a faulty ECU
of the connection. If air is present, bleed the entire fuel connector.
system as required starting at the lift pump and the fuel/ • If continuity is found on all circuits, proceed to next
water separator moving to the injection pump, followed by step.
the injectors. Torque fuel lines to 20 lb-ft after testing. Note: If proper voltage is not found on the A2 circuit, the
3. Recover any fault codes. Refer to Section 3.2, “Retrieving problem may exist earlier in the circuit. Refer to Section 4.1,
Fault Codes.” “Wiring Schematics” for schematic information on a specific
machine.
4. Check the ECU Power Wiring
a. Ignition OFF 6. Test the Engine Cranking Speed
b. Disconnect ECU connector. IMPORTANT: Cranking speed specifications are for OEM
c. Backprobe wire K1 and wire J2 and check for 12 VDC. engines only.
Make sure that batteries are fully charged before performing
• If the required voltage is found, test the A2 circuit
this test.
• If voltage is not found, there is an open in the ECU
Power wiring a. Disable the fuel supply system at the injection pump
so fuel delivery is in the OFF position.
d. Backprobe wire A2 and wire J2 and check for 12 VDC b. If not using the machine tachometer, install a photo
with the ignition ON. tach or TIME TRAC®.
• If the required voltage is found, test the Engine c. Crank engine for 15 seconds and record engine
Cranking Speed speed.
• If the required voltage is not found, there is an open d. Compare recorded engine speed to the following
in the ECU Power wiring chart:
5. Test the ECU connector
a. Ignition OFF
b. ECU connector still disconnected
c. Backprobe wire K1 on the ECU connector and check

If pressure is high, worn or stuck rings are indicated,

220 replace piston rings or install new piston and liner set
as needed.
200
If pressure is low, valves could be worn or sticking.
Recondition cylinder head as required.
180
g. Measure compression pressure in all remaining
cylinders and compare readings. Recondition
MINIMUM 160 cylinders and valves as required.
CRANKING
SPEED
(RPM) 140 8. If all checks are completed and the engine still does not
operate properly, contact your local John Deere service
120 distributor.
100
80
-40°F -20°F -0°F 20°F 40°F 60°F 80°F 100°F 120°F

-40°C -29°C -18°C -7°C 4°C 16°C 16°C 38°C 49°C
AMBIENT AIR TEMPERATURE
MAN0140
Cranking speed should meet or exceed specified engine rpm for

a given ambient air temperature. For example, at 29°C (85°F)
ambient air temperature, cranking speed should be at least 200
rpm.
If cranking speed is below specifications, check the following:

• Starting system problems (low battery, loose or
defective wiring, defective starter, etc.)
• Excessive engine loads (thick hydraulic oil, thick
engine oil, etc.).
7. Test the Engine Compression Pressure.
IMPORTANT: Compression pressures are affected by the
cranking speed of the engine. Before beginning test, ensure
that batteries are fully charged and injection nozzle area is
thoroughly cleaned.
Note: Engines equipped with Level 4 Electronic Fuel Systems
with VP44 Pump provide the ability to perform an electronic
compression test.
a. Install a test gauge adapter to an engine cylinder
injector nozzle.
b. Move throttle lever to “STOP” position. Turn crankshaft
for 10 - 15 seconds with starter motor (minimum
cranking speed - 150 rpm cold/200 rpm hot).
c. Test the remaining cylinders.
d. Compare readings from all cylinders. Compression
pressure is set to be
2379-2792 kPa (24-28 bar)(345-405 psi). The
maximum difference between cylinders should be no
more than 350 kPa (3.5 bar)(50 psi).
Note: Pressure given was taken at 183 m (600 ft) above sea
level. A 3.6 percent reduction in gauge pressure will result for
each additional 300 m (1000 ft) rise in altitude.
e. If pressure is much lower than shown, remove gauge
and apply oil to ring area of piston through injection
nozzle or glow plug bore. Do not use too much oil. Do
not get oil on the valves.
f. Test compression pressure again.

3.4.2 Engine Will Not Crank
IGNITION
SWITCH
BATTERY
VSW
30A
VBAT
12VDC
012D, RED
022C, RED
K1 A2
J2
A3 B3 C3 D3 E3 F3 G3 H3 J3 K3
050G, BLK
A2 B2 C2 D2 E2 F2 G2 H2 J2 K2
A1 B1 C1 D1 E1 F1 G1 H1 J1 K1

1. Refer to Section 2, “General Troubleshooting” for initial 4. Recover any fault codes. Refer to Section 3.2, “Retrieving
checks before moving on to the following steps. Fault Codes.”
2. Check the ECU Power Wiring 5. Check the starter circuit. If the starter solenoid operates,
a. Ignition OFF replace the starter motor.
b. Disconnect ECU connector. Note: Remove starter motor providing engine compression is
c. Backprobe wire K1 and wire J2 and check for 12 VDC. preventing turning over of assembly. To check, place proper
• If the required voltage is found, test the A2 circuit size socket over crank dampner pulley and rotate engine.
• If voltage is not found, there is an open in the ECU 6. During starter replacement, turn the engine over by hand
Power wiring to check for possible starter ring gear damage, chipped or
d. Backprobe wire A2 and wire J2 and check for 12 VDC damaged teeth.
with the ignition ON. 7. If all checks are completed and the engine still does not
• If the required voltage is found, test the Engine operate properly, contact your local John Deere service
Cranking Speed distributor.
• If the required voltage is not found, there is an open
in the ECU Power wiring
a. Ignition OFF
for continuity with pin K1 on the harness end of the
connector.
• If continuity is found, repeat this step for the A2 and
J2 circuits of the ECU connector.
• If continuity is not found, there is a faulty ECU
connector.
• If continuity is found on all circuits, proceed to next
step.
Note: If proper voltage is not found on the A2 circuit, the
problem may exist earlier in the circuit. Refer to Section 4.1,
“Wiring Schematics” for schematic information on a specific
machine.

3.4.3 Engine Over Speed
Crank Sensor
Crank Position Connector
Sensor
Crank Position Return
B B
A A Crank Position Input
447, PURPLE
448, GRAY
B2 D2
A3 B3 C3 D3 E3 F3 G3 H3 J3 K3
A2 B2 C2 D2 E2 F2 G2 H2 J2 K2
A1 B1 C1 D1 E1 F1 G1 H1 J1 K1
The crank position sensor is located on the front of the c. Backprobe Terminal A and test for continuity between
crankshaft behind the pressed-on crank gear. It is an inductive Pin A on the same side of the connector.
type pickup sensor that detects teeth on the crank timing wheel. • If continuity is found, repeat step for the other
The ECU uses the crank position input to determine engine terminals of the connector
speed and precise piston position in relation to the firing order. • If continuity is not found, repair or replace the
The crank timing wheel is composed of 46 evenly spaced teeth connector
and 2 missing teeth. The missing teeth help the ECU to • If continuity is found on all terminals and both sides of
determine “Top-Dead-Center” (TDC). the connector, proceed to next step
1. Refer to Section 2, “General Troubleshooting” for initial 6. Check Crank Position sensor Input and Return Wiring
checks before moving on to the following steps. a. Ignition OFF
2. Recover any fault codes. Refer to Section 3.2, “Retrieving b. Crank Position sensor connector still disconnected
Fault Codes.” A fault code will result if the ECU detects that c. Disconnect ECU connector
engine speed exceeds 3400 rpm. The ECU will shut fuel d. Backprobe wire B2 on the ECU connector and test for
off until engine speed is below 2800 rpm. continuity between Terminal A of the Crank Position
3. Inspect the Crank Position sensor and Timing Wheel sensor connector.
a. Remove crank position sensor from injection pump. • If continuity is found, check the sensor return wire
b. Inspect sensor for cracks, corrosion, or any foreign • If continuity is not found, there is an open in the
material on the end of the sensor. sensor input wiring OR a faulty ECU connector.
c. Inspect the crank timing wheel notches for burrs or e. Backprobe wire D2 on the ECU connector and test for
chips. continuity between Terminal B of the ECT sensor
• If a fault is found in a part, repair or replace the part. connector.
4. Test the Crank Position sensor. • If continuity is found, proceed to next step.
a. Ignition OFF • If continuity is not found, there is an open in the

sensor return wiring OR a faulty ECU connector.
b. Disconnect crank position sensor connector
c. Measure resistance between both terminals of the
crank position sensor.
• If voltage is between 2500 and 3500 ohms, proceed
to next step.
• If voltage is below 2500 ohms or above
3500 ohms, repair or replace the sensor.
5. Test Crank Position sensor connector
a. Ignition OFF
b. Crank position sensor connector still disconnected


a. Ignition OFF
c. Backprobe wire B2 on the ECU connector and check
for continuity with pin B2 on the harness end of the
connector.
• If continuity is found, repeat this step for the D2 circuit
of the ECU connector.
• If continuty is not found, there is a faulty ECU
connector.
step.
8. Check Gear Timing
a. Ignition OFF
b. Remove timing cover
c. Check timing between camshaft, crankshaft, and
injection pump gears.
• If all gears are in time, proceed to next step.
• If one or more gears are out of time, make the
necessary adjustments to ensure correct timing.
9. If all checks are completed and the engine still does not
distributor.

3.4.4 Engine Misfires/Runs Irregularly 10. With engine running at a moderate engine rpm, loosen the
injector fuel supply hard lines one at a time. A drop in the
engine rpm would indicate the cylinder is OK. If there is no
change in engine rpm, contact your local John Deere
service distributor.
distributor.
MY1030
1. Refer to Section 2, “General Troubleshooting” for initial

checks before moving on to the following steps.
2. Check for air intake system leaks, air in the fuel system.
• If air intake leak is found, investigate entry of dirt.
• Sample oil
• Refer to John Deere engine service manual.
3. Recover any DTC’s from the Engine Shutdown Override
System. Refer to Section 3.2, “Retrieving Fault Codes.”
4. Check the individual engine cylinders for misfire by
loosening one injector nozzle at a time to determine which
cylinder is affected. Once the cylinder is located, check for
an adequate fuel supply. If there is blockage in the hard
line, disconnect both ends and blow pressurized air
through the line.
5. Check for proper engine RPM’s. The engine should run
smoothly at low idle.
6. Check that the transmission and hydraulic systems do not
have problems preventing full high idle operation.
7. Check that all system pressures are adjusted properly.
8. Insure that the throttle linkage and/or analog pedal are
functioning properly.
9. Bring engine to operating temperature, determine the color
of smoke from the exhaust system.
• Heavy white smoke - make sure engine is up to
operating temperature. Fuel quality is good, min of
CETANE 45.
• Heavy gray or black smoke - check fuel quality,
CETANE of 45, make sure engine is up to operating
temperature, engine is not under excessive load and
that air filters are not restricted. Ensure the turbo is
operating correctly (on equipped machines).
• Small amounts or no exhaust smoke - Contact John
Deere if misfiring.

3.5 ECU TROUBLESHOOTING
3.5.1 ECU Switched Power
IGNITION
SWITCH
BATTERY
VSW
30A
VBAT
12VDC
012D, RED
022C, RED
K1 A2
J2
A3 B3 C3 D3 E3 F3 G3 H3 J3 K3
050G, BLK
A2 B2 C2 D2 E2 F2 G2 H2 J2 K2
A1 B1 C1 D1 E1 F1 G1 H1 J1 K1

This error occurs when the ECU does not detect battery voltage. If proper voltage is not found on the A2 circuit, the problem may
In this scenario, the engine will not start or run. exist earlier in the circuit. Refer to Section 4.1, “Wiring
1. Check the ECU Power Wiring Schematics” for schematic information on a specific machine.
a. Ignition OFF
b. Disconnect ECU connector.
c. Backprobe wire K1 and wire J2 and check for 12 VDC.
Power wiring
d. Backprobe wire A2 and wire J2 and check for 12 VDC
with the ignition ON.
• If the required voltage is found, test the Engine
Cranking Speed
a. Ignition OFF
connector.
connector.

3.5.2 ECU Power Down Error
IGNITION
SWITCH
BATTERY
VSW
30A
VBAT
12VDC
012D, RED
022C, RED
K1 A2
J2
A3 B3 C3 D3 E3 F3 G3 H3 J3 K3
050G, BLK
A2 B2 C2 D2 E2 F2 G2 H2 J2 K2
A1 B1 C1 D1 E1 F1 G1 H1 J1 K1
1. Refer to Section 2, “General Troubleshooting” for initial 5. If all checks are completed and the engine still does not
checks before moving on to the following steps. operate properly, contact your local John Deere service
2. Recover any fault codes. Refer to Section 3.2, “Retrieving distributor.
Fault Codes.” A fault code will result if the ECU detects
voltage is on the switched voltage input wire to the ECU.
3. Check the ECU Power Wiring
a. Ignition OFF
b. Disconnect ECU connector.
c. Backprobe wire K1 and wire J2 and check for 12 VDC.
Power wiring
d. Backprobe wire A2 and wire J2 and check for 12 VDC
with the ignition ON.
• If the required voltage is found, test the Engine
Cranking Speed
a. Ignition OFF
connector.
connector.
step.

3.6 CAN TROUBLESHOOTING
CAN Low 905E, Dark Green F1 A1 A2 A3
ECU HARNESS CONNECTOR

B1 B2 B3
CAN High 904E, Yellow G1 C1 C2 C3
D1 D2 D3
CAN Shield E1 E2 E3
F1 F2 F3
D D G1G2 G3
E C
C H1 H2 H3
J1 J2 J3
F A B E K1 K2 K3
G B SWITCHED VOLTAGE
J
H A STATIC GROUND
DIAGNOSTIC
CONNECTOR
B A
B
A
C
C MAN0020
CAN (Controller Area Network) throttle is information sent to the

ECU by another controller over CAN of the desired throttle
position.
This code will set if:
• The ECU either does not receive throttle information
over CAN, or the information received is not valid.
If this code sets, the following will occur:
• If more than one throttle is available, the ECU will
ignore the input from the CAN throttle, and will use
the input values from another throttle.
• If the CAN throttle is the only throttle or all additional
throttles are also faulted, the ECU will use a default
“limp-home” throttle value that will only allow idle
engine speed.
If a problem is found to be within the CAN throttle system,
contact your local John Deere service distributor.

3.7 ELECTRICAL TROUBLESHOOTING
3.7.1 Manifold Air Temperature Sensor

MAT Sensor
MAT Sensor Connector
Sensor Ground
t B B
A A MAT Input
463, Orange
914E, Yellow
D1 D3
A3 B3 C3 D3 E3 F3 G3 H3 J3 K3
A2 B2 C2 D2 E2 F2 G2 H2 J2 K2
A1 B1 C1 D1 E1 F1 G1 H1 J1 K1
The Manifold Air Temperature (MAT) sensor is a thermistor • If measurement is between 2500 and 3500 ohms,
(temperature sensitive resistor) mounted in the intake manifold. proceed to next step.
The MAT sensor is used to measure the temperature of the • If measurement is below 2500 ohms or above
intake air. The MAT sensor’s variable resistance causes the 3500 ohms, repair or replace the sensor.
input voltage to the ECU to vary. Higher intake air temperatures 4. Test MAT sensor connector
result in lower MAT input voltages to the ECU; lower
a. Ignition OFF
temperatures result in higher voltages.
b. MAT connector still disconnected
Note: For OEM applications, the high manifold air temperature c. Backprobe Terminal A and test for continuity between
input voltage specification is 4.9 volts. Low manifold air Pin A on the same side of the connector.
temperature voltage specification is 0.1 volts. • If continuity is found, repeat step for the other
Check the following items that can cause high intake air terminals of the connector
temperatures: • If continuity is not found, repair or replace the
connector
• Excessively high ambient air temperature
• If continuity is found on all terminals and both sides of
• Restricted, dirty, or damaged charge air cooler the connector, proceed to next step
• Loose cooling fan belt 5. Check MAT Sensor Input and Return Wiring
• Malfunctioning cooling fan a. Ignition OFF
• Restricted or damaged intake air piping b. MAT connector still disconnected
• Damaged cooling fan shroud c. Disconnect ECU connector
d. Backprobe wire D1 on the ECU connector and test for
1. Refer to Section 2, “General Troubleshooting” for initial continuity between Terminal A of the MAT sensor
checks before moving on to the following steps. connector.
2. Recover any fault codes. Refer to Section 3.2, “Retrieving • If continuity is found, check the sensor return wire
Fault Codes.” A fault code will result if the manifold air
• If continuity is not found, there is an open in the
temperature input voltage exceeds or goes below the sensor input wiring OR a faulty ECU connector.
sensor’s voltage specification.
e. Backprobe wire D3 on the ECU connector and test for
3. Check the MAT sensor continuity between Terminal B of the MAT sensor
a. Ignition OFF connector.
b. Disconnect MAT sensor connector • If continuity is found, proceed to next step.
c. Measure resistance between both terminals of the • If continuity is not found, there is an open in the
MAT sensor sensor return wiring OR a faulty ECU connector.


a. Ignition OFF
c. Backprobe wire D1 on the ECU connector and check
for continuity with pin D1 on the harness end of the
connector.
connector.
step.
distributor.

3.7.2 Fuel Temperature Sensor
Fuel Temp
Fuel Temp Connector
Sensor
Sensor Ground
t B B
A A Fuel Temp Input
428, Gray
914E, Yellow
C3 D3
A3 B3 C3 D3 E3 F3 G3 H3 J3 K3
A2 B2 C2 D2 E2 F2 G2 H2 J2 K2
A1 B1 C1 D1 E1 F1 G1 H1 J1 K1
The fuel temperature sensor is a thermistor (temperature 4. Test Fuel Temperature sensor connector
sensitive resistor) located on the injection pump fuel outlet a. Ignition OFF
housing. The fuel temperature sensor’s variable resistance b. Fuel Temperature connector still disconnected
causes the input voltage to the ECU to vary. Higher fuel
c. Backprobe Terminal A and test for continuity between
temperatures result in lower fuel temperature input voltages to Pin A on the same side of the connector.
the ECU; lower temperatures result in higher voltages. The ECU
• If continuity is found, repeat step for the other
uses the fuel temperature sensor input to adjust the fuel delivery terminals of the connector
for the variations in fuel density caused by varying fuel
temperatures. • If continuity is not found, repair or replace the
connector
Note: For OEM engine applications, the high fuel temperature • If continuity is found on all terminals and both sides of
input voltage specification is 4.9 volts. Low manifold air the connector, proceed to next step
temperature voltage specification is 0.1 volts. The ECU will use 5. Check Fuel Temperature sensor Input and Return Wiring
a “limp-home” fuel temperature value of -20° C (-4° F) during
cranking, and 40° C (104° F) during running. a. Ignition OFF
b. Fuel Temperature connector still disconnected
1. Refer to Section 2, “General Troubleshooting” for initial c. Disconnect ECU connector
d. Backprobe wire C3 on the ECU connector and test for
2. Recover any fault codes. Refer to Section 3.2, “Retrieving continuity between Terminal A of the Fuel Temperature
Fault Codes.” A fault code will result if the fuel temperature sensor connector.
input voltage goes above the sensor’s high voltage • If continuity is found, check the sensor return wire
specification. This voltage corresponds to a temperature • If continuity is not found, there is an open in the
that is lower than what is physically possible for fuel sensor input wiring OR a faulty ECU connector.
temperature.
3. Check the Fuel Temperature sensor continuity between Terminal B of the Fuel Temperature
sensor connector.
a. Ignition OFF
b. Disconnect Fuel Temperature sensor connector • If continuity is found, proceed to next step.
Fuel Temperature sensor sensor return wiring OR a faulty ECU connector.
• If measurement is between 2500 and 3500 ohms,
proceed to next step.
• If measurement is below 2500 ohms or above


a. Ignition OFF
c. Backprobe wire C3 on the ECU connector and check
for continuity with pin C3 on the harness end of the
connector.
connector.
step.
distributor.

3.7.3 Analog Throttle Sensor
Analog Throttle (C)

Sensor Connector
Sensor Ground
A 914E, Yllw
Analog B
Throttle (C) Analog Throttle (C) Input to ECU
Sensor C 915, Grn
5V Supply
D 911E, Brn
E2 E1 D3
A3 B3 C3 D3 E3 F3 G3 H3 J3 K3
A2 B2 C2 D2 E2 F2 G2 H2 J2 K2
A1 B1 C1 D1 E1 F1 G1 H1 J1 K1
The analog throttle position sensor is a variable resistor • If continuity is not found, there is an open in the
(potentiometer) used to measure the position of the throttle. The sensor supply circuit OR a faulty sensor connector
throttle input voltage normally varies between 1.0 and 4.0 volts OR a faulty ECU connector
depending on the throttle position. Analog throttle voltage at low 4. Check the Sensor Connector
idle will be approximately 0.500-1.0 VDC to 4.0-4.80 VDC at a. Ignition OFF
high idle. The ECU has the ability to learn different voltages for b. Disconnect the sensor connector
low and high idle, so the voltage range may change slightly c. Backprobe Terminal A and test for continuity between
between applications. Pin A on the same side of the connector.
1. Refer to Section 2, “General Troubleshooting” for initial • If continuity is found, repeat step for the other
checks before moving on to the following steps. terminals of the connector
2. Recover any fault codes. Refer to Section 3.2, “Retrieving • If continuity is not found, repair or replace the
Fault Codes.” connector
3. Check the Sensor Wiring • If continuity is found on all terminals and both sides of
the connector, proceed to next step
a. Ignition OFF
5. Check the Sensor Input and Return Wiring
b. Disconnect the ECU connector
c. Backprobe wire E2 on the ECU connector and check a. Ignition OFF
for continuity with Terminal D on the sensor side of the b. ECU connector still disconnected
connector. c. Backprobe wire E2 on the ECU connector and test for
• If continuity is found, proceed to step D. continuity between Terminal D of the sensor
connector.
sensor supply circuit OR a faulty sensor connector • If continuity is found, check the Analog Throttle Input
OR a faulty ECU connector to ECU wiring
d. Backprobe wire E1 on the ECU connector and check • If continuity is not found, there is an open in the
for continuity with Terminal C on the sensor side of the sensor supply wiring OR a faulty ECU connector
connector. d. Backprobe wire E1 on the ECU connector and test for
• If continuity is found, proceed to step E. continuity between Terminal C of the sensor
connector.
sensor supply circuit OR a faulty sensor connector • If continuity is found, check the sensor ground wiring
OR a faulty ECU connector • If continuity is not found, there is an open in the
e. Backprobe wire D3 on the ECU connector and check sensor Input to ECU wiring OR a faulty ECU
for continuity with Terminal A on the sensor side of the connector
connector.
• If continuity is found, repair or replace the Analog
Throttle sensor


continuity between Terminal A of the sensor
connector.
• If continuity is found, check the ECU connector
sensor ground wiring OR a faulty ECU connector
6. Check the ECU connector
a. Ignition OFF
c. Backprobe wire E2 on the ECU connector and check
for continuity with pin E2 on the harness end of the
connector
• If continuity is found, repeat this step for the E1 and
D3 circuits of the ECU connector
connector
step
distributor.

3.7.4 Crank Position Sensor
Crank Sensor
Crank Position Connector
Sensor
Crank Position Return
B B
A A Crank Position Input
447, PURPLE
448, GRAY
B2 D2
A3 B3 C3 D3 E3 F3 G3 H3 J3 K3
A2 B2 C2 D2 E2 F2 G2 H2 J2 K2
A1 B1 C1 D1 E1 F1 G1 H1 J1 K1

The crank position sensor is located on the front of the 5. Check Crank Position sensor Input and Return Wiring
crankshaft, behind the pressed-on crank gear. It is an inductive a. Ignition OFF
type pickup sensor that detects teeth on the crank timing wheel. b. Crank Position sensor connector still disconnected
1. Refer to Section 2, “General Troubleshooting” for initial c. Disconnect ECU connector
checks before moving on to the following steps. d. Backprobe wire B2 on the ECU connector and test for
2. Recover any fault codes. Refer to Section 3.2, “Retrieving continuity between Terminal A of the Crank Position
Fault Codes.” A fault code will result if the ECU detects that sensor connector.
engine speed exceeds 3400 rpm. The ECU will shut fuel • If continuity is found, check the sensor return wire
off until engine speed is below 2800 rpm. • If continuity is not found, there is an open in the
3. Test the Crank Position sensor. sensor input wiring OR a faulty ECU connector.
a. Ignition OFF e. Backprobe wire D2 on the ECU connector and test for
continuity between Terminal B of the ECT sensor
b. Disconnect crank position sensor connector connector.
c. Measure resistance between both terminals of the
crank position sensor. • If continuity is found, proceed to next step.
• If voltage is between 2500 and 3500 ohms, proceed • If continuity is not found, there is an open in the
to next step. sensor return wiring OR a faulty ECU connector.
• If voltage is below 2500 ohms or above 6. Test the ECU connector

3500 ohms, repair or replace the sensor. a. Ignition OFF
4. Test Crank Position sensor connector b. ECU connector still disconnected
a. Ignition OFF c. Backprobe wire B2 on the ECU connector and check
b. Crank position sensor connector still disconnected connector.
Pin A on the same side of the connector. • If continuity is found, repeat this step for the D2 circuit
terminals of the connector • If continuty is not found, there is a faulty ECU
connector.
• If continuity is not found, repair or replace the
connector 7. If all checks are completed and the engine still does not
• If continuity is found on all terminals and both sides of distributor.

3.7.5 Pump Solenoid
Pump
Solenoid Pump Solenoid
Connector
Solenoid Return
B B
A A Solenoid Input
491, Brown
493, Orange
K2 A3
A3 B3 C3 D3 E3 F3 G3 H3 J3 K3
A2 B2 C2 D2 E2 F2 G2 H2 J2 K2
A1 B1 C1 D1 E1 F1 G1 H1 J1 K1

The stanadyne DE10 injection pump has an internal solenoid 5. Check Pump Solenoid Input and Return Wiring
that is controlled by the ECU. The ECU switches current on and a. Ignition OFF
off in order to change the solenoid. When the current to the b. Pump Solenoid connector still disconnected
solenoid is increased, it moves a pump control valve into a
c. Disconnect ECU connector
position that allows for injection pressure to be developed.
d. Backprobe wire K2 on the ECU connector and test for
When the current to the solenoid is decreased, the pump control continuity between Terminal A of the Pump Solenoid
valve will return to a position that ends injection pressure. By connector.
controlling current to the solenoid, the ECU has the ability to
• If continuity is found, check the solenoid return wire
manage the quality of the timing of fuel delivery to the engine.
1. Refer to Section 2, “General Troubleshooting” for initial solenoid input wiring OR a faulty ECU connector.
e. Backprobe wire A3 on the ECU connector and test for
2. Recover any fault codes. Refer to Section 3.2, “Retrieving continuity between Terminal B of the Pump Solenoid
Fault Codes.” connector.
3. Check the Pump Solenoid • If continuity is found, proceed to next step.
b. Disconnect Pump Solenoid connector solenoid return wiring OR a faulty ECU connector.
c. Measure resistance between both terminals of the 6. Test the ECU connector
Pump Solenoid a. Ignition OFF
• If measurement is between 2500 and 3500 ohms, b. ECU connector still disconnected
proceed to next step. c. Backprobe wire K2 on the ECU connector and check
• If measurement is below 2500 ohms or above for continuity with pin K2 on the harness end of the
3500 ohms, repair or replace the solenoid. connector.
4. Test Pump Solenoid connector • If continuity is found, repeat this step for the A3 circuit
a. Ignition OFF
b. Pump Solenoid connector still disconnected • If continuty is not found, there is a faulty ECU
connector.
Pin A on the same side of the connector. • If continuity is found on all circuits, proceed to next
step.
terminals of the connector 7. If all checks are completed and the engine still does not
connector distributor.

3.7.6 Oil Pressure Sender
B 5V Supply
B A C Oil Pressure Input
C A Sensor Ground
914E, Yellow
467, Purple
911E, Brown
Oil Pressure Sender
D3 F3 E2
A3 B3 C3 D3 E3 F3 G3 H3 J3 K3
A2 B2 C2 D2 E2 F2 G2 H2 J2 K2
A1 B1 C1 D1 E1 F1 G1 H1 J1 K1
The oil pressure sender is a pressure transducer connected to • If continuity is not found, there is an open in the
the main oil galley. As engine oil pressure increases, the oil Supply Wiring
pressure sender input voltage increases. The ECU monitors oil 4. Check the ECU connector
pressure in order to protect the engine in case of a low oil a. Ignition OFF
pressure condition.
Note: ECU uses a default oil pressure of 260 kPa (2.6 bar) c. Backprobe wire D3 on the ECU connector and check
(37.5 psi). For OEM applications, the high oil pressure input for continuity with pin D3 on the harness end of the
voltage is 4.9 volts. The low oil pressure input voltage connector
specification is 0.3 volts. • If continuity is found, repeat this step for the F3 and
E2 circuits of the ECU connector.
checks before moving on to the following steps. • If continuity is not found, there is a faulty ECU
connector
2. Recover any fault codes. Refer to Section 3.2, “Retrieving
Fault Codes.” A fault code will result if: step
• The oil pressure input voltage exceeds or drops 5. If all checks are completed and the engine still does not
below the sender’s voltage specification. operate properly, contact your local John Deere service
• ECU’s low oil pressure engine protection feature distributor.
disabled.
3. Check the Sender Wiring
a. Ignition OFF
b. Disconnect the ECU connector
c. Backprobe wire D3 on the ECU connector and check
for continuity between Terminal A on the Oil Pressure
Sender
• If continuity is found, check the Sender Input Wiring
circuit wiring OR a faulty ECU connector
d. Backprobe wire F3 on the ECU connector and check
for continuity between Terminal C on the Oil Pressure
Sender
• If continuity is found, check Sender Input Wiring
circuit wiring OR a faulty ECU connector
e. Backprobe wire E2 on the ECU connector and check
for continuity between Terminal B on the Oil Pressure
Sender
• If continuity is found, repair or replace the Oil
Pressure Sender

3.7.7 Oil Pressure Switch
A1 A2 A3
ECU HARNESS CONNECTOR

B1 B2 B3
Oil Pressure C1 C2 C3
Switch
D1 D2 D3
E1 E2 E3
Oil Pressure Input C1
947, Purple
F1 F2 F3
G1G2 G3
H1 H2 H3
J1 J2 J3
K1 K2 K3
MAN0040
The oil pressure switch is used to detect a loss of oil pressure.

A lack of oil pressure causes the contacts in the switch to close
when oil pressure drops below the minimum oil pressure
threshold. The switch is open when the engine is not running
and engine is running with sufficient oil pressure.
2. Recover any fault codes. Refer to Section 3.2, “Retrieving
Fault Codes.”
3. Check the Oil Pressure Switch Input and Ground Wiring
a. Ignition OFF
b. Disconnect ECU connector
c. Backprobe wire C1 on the ECU connector and test for
continuity between the input wire at the Oil Pressure
Switch.
• If continuity is found, check the Oil Pressure Switch
Ground Wiring
• If continuity is not found, there is an open in the Input
Wiring OR a faulty ECU connector.
d. Probe the Oil Pressure Switch Ground wire and test
for continuity between the switch ground chassis
connection.
• If continuity is found, repair or replace the Oil
Pressure Switch.
Ground Wiring circuit.
4. Check the ECU connector
a. Ignition OFF
c. Backprobe wire C1 on the ECU connector and check
for continuity with pin C1 on the harness end of the
connector.
• If continuity is found, proceed to next step.
connector.
distributor.

3.7.8 Coolant Temperature Sensor
ECT Sensor
ECT Sensor Connector
ECT Ground
t B B
A A ECT Input
461, Brown
914E, Yellow
B1 D3
A3 B3 C3 D3 E3 F3 G3 H3 J3 K3
A2 B2 C2 D2 E2 F2 G2 H2 J2 K2
A1 B1 C1 D1 E1 F1 G1 H1 J1 K1
The engine coolant temperature (ECT) is a thermistor 4. Test ECT sensor connector
(temperature sensitive resistor) mounted on the thermostat a. Ignition OFF
housing or in the rear of the cylinder head. It is used to measure b. ECT connector still disconnected
the coolant temperature. The ECT’s variable resistance causes
the input voltage to the ECU to vary. Higher coolant Pin A on the same side of the connector.
temperatures result in lower ECT input voltages to the Engine
Control Unit (ECU); lower temperatures result in higher terminals of the connector
voltages.
The ECU senses ECT on OEM applications about 118° C connector
(244° F).
Note: This engine is equipped with Engine protection with the connector, proceed to next step
different features: 5. Check ECT Sensor Input and Return Wiring
• With Shutdown Feature: The derate feature will go a. Ignition OFF
into effect when the code is set, and the engine will b. ECT connector still disconnected
shut down after 30 seconds.
• With Derate Feature: On OEM applications, the d. Backprobe wire B1 on the ECU connector and test for
engine derates 60% per minute until the engine is continuity between Terminal A of the ECT sensor
running at 40% full power. connector.
1. Refer to Section 2, “General Troubleshooting” for initial • If continuity is found, check the sensor return wire
2. Recover any fault codes. Refer to Section 3.2, “Retrieving sensor input wiring OR a faulty ECU connector.
Fault Codes.” e. Backprobe wire D3 on the ECU connector and test for
3. Check the ECT Sensor continuity between Terminal B of the ECT sensor
connector.
a. Ignition OFF
b. Disconnect ECT sensor connector • If continuity is found, proceed to next step.
ECT sensor sensor return wiring OR a faulty ECU connector.
• If measurement is between 2500 and 3500 ohms,
proceed to next step.
• If measurement is below 2500 ohms or above


a. Ignition OFF
c. Backprobe wire B1 on the ECU connector and check
connector.
connector.
step.
distributor.

3.7.9 Loss of Engine Coolant Sensor
Loss of Coolant
Loss of Coolant Temperature Sensor
Temperature Connector
Sensor
Sensor Ground
t B B
A A Input
947, Purple
914E, Yellow
C1 D3
A3 B3 C3 D3 E3 F3 G3 H3 J3 K3
A2 B2 C2 D2 E2 F2 G2 H2 J2 K2
A1 B1 C1 D1 E1 F1 G1 H1 J1 K1
The loss of coolant temperature sensor is a thermistor 5. If continuity is found on all terminals and both sides of the
(temperature sensitive resistor) mounted in the rear of the connector, proceed to next stepCheck Loss of Coolant
cylinder head. It is used to measure the coolant temperature Temperature Sensor Input and Return Wiring
and to detect whether there is a loss of coolant. The sensor’s a. Ignition OFF
variable resistance causes the input voltage to the ECU to vary. b. Loss of Coolant sensor connector still disconnected
Higher coolant temperatures result in lower loss of coolant
temperature input voltages to the ECU; lower temperatures
d. Backprobe wire C1 on the ECU connector and test for
result in higher voltages. continuity between Terminal A of the Loss of Coolant
1. Refer to Section 2, “General Troubleshooting” for initial Temperature sensor connector.
checks before moving on to the following steps. • If continuity is found, check the sensor return wire
2. Recover any fault codes. Refer to Section 3.2, “Retrieving • If continuity is not found, there is an open in the
Fault Codes.” A fault code will result if the loss of coolant sensor input wiring OR a faulty ECU connector.
temperature input voltage drops below 0.1 volts. This e. Backprobe wire D3 on the ECU connector and test for
voltage corresponds to a temperature that is higher than continuity between Terminal B of the Loss of Coolant
what is physically possible for engine coolant. Temperature sensor connector.
3. Check the Loss of Coolant Sensor • If continuity is found, proceed to next step.
b. Disconnect Loss of Coolant sensor connector sensor return wiring OR a faulty ECU connector.
c. Measure resistance between both terminals of the 6. Test the ECU connector
Loss of Coolant sensor a. Ignition OFF
• If measurement is between 2500 and 3500 ohms, b. ECU connector still disconnected
proceed to next step. c. Backprobe wire C1 on the ECU connector and check
• If measurement is below 2500 ohms or above for continuity with pin C1 on the harness end of the
3500 ohms, repair or replace the sensor. connector.
4. Test Loss of Coolant Temperature sensor connector • If continuity is found, repeat this step for the D3 circuit
a. Ignition OFF
b. Loss of Coolant sensor connector still disconnected • If continuty is not found, there is a faulty ECU
connector.
Pin A on the same side of the connector. • If continuity is found on all circuits, proceed to next
step.
terminals of the connector 7. If all checks are completed and the engine still does not
connector distributor.

This Page Intentionally Left Blank

Section 4
Electrical Wiring
Contents

4.1 Wiring Schematics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.2
4.1.1 Models 534D-9 Tier II & 534D-10 Tier II . . . . . . . . . . . . . . . . . . . . . . . . 4.2
4.1.2 Model 544D Tier II. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.4
4.1.3 Models G10-55A & G12-55A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.6
4.1.4 Model 1044C-54 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.10

4.2
4.1
N START
15 AMP
FUSE
A A BAT-HN HN-AC
B B 15 AMP
GND-3 FUSE
C C
START 15 AMP
D D IGN-A FUSE
RELAY
OIL PRESS. FUEL
IGN-C PRK IGN PRK BRK 4X4 PWR
GAUGE GAUGE FWD/N/REV ENGINE SHUTDOWN
BAT
REV
FWD
SWITCH START-C 2/4 WHEEL SHUTDOWN OVERRIDE THROTTLE
IGN-A
BAT-HN
SHT IGN
SWITCH
START-A
DRIVE SWITCH LIGHT PEDAL
15 AMP
FUSE GND-3 473
GAUGE START-B
I ACC-A ACC-B PB LHT
LIGHT WATER TEMP. B A
VOLTMETER START-B
IGN-B
START-A AL
GAUGE PRK IGN
915
ST TE
918
OIL GAG
4X4 LHT
911A
911B
914C
XC
GND-6 -A
4X4
IGNITION PARK BRAKE
IGN-B SWITCH 4X4
LIGHT
GAUGE
LIGHT GND-3
ACC-C
OPEN
AUXLT
FUL GAG
CLT TMP
OPEN
ACC-C
Electrical Wiring
911A
915
914C
START-B
473
911B
918
534D-9 Tier II:
HOUR
534D-10 Tier II:
PRK IGN
START-C
CLT TMP
PRK BRK
OIL GAG
ALT EXC-A
GND-3
4X4
ACC-C
FUL GAG
HR MTR
ALT EXC-B
METER
ALT EXC-B
PB LHT
GND-3 OPEN GND-3
HR MTR
A B C D E F G H J K L M N P SPL-ACC ALTERNATOR C B A 6 5 4 3 2 1
WARNING LIGHT
GND-3
PS IGN
PARK BRAKE
OPEN
Before S/N 0160013979
LIGHT
ACC-B
SPL-ACC2
A B C D E F G H J K L M N P C B A 6 5 4 3 2 1
4X4
918
473
915
ALT EXC-A
911B
911A
914C
GND-3
WIRING SCHEMATICS
ACC-C
PRK IGN
OIL GAG
START-B
CLT TMP
60
ALT EXC-B
HR MTR
FUL GAG
START-C
ALT EXC-A
PRK BRK
SPL-ACC RESISTOR
SPL-ACC-2 HORN
BUTTON
ACC-C
HN-AC
4X4
TRC LOK
OPEN
GND-3
GND-2
GND-6
HORN
941
Before S/N 0160014009 (excluding S/N 0160013513)
B A
OPT.
SHUT
PRK BRK
GND-2
DOWN
B A
941
914C
911B
473
915
918
911A
CLT TMP
REV
OIL GAG
ALT EXC-B
PS IGN
4X4
FWD
HR MTR
HORN
BAT
FUL GAG
START-C
DIODE 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 P N M L K J H G F E D C B A
A B 4X4 TRC LOK
050C 050C
012C 012C
TRACTION LOCK 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 P N M L K J H G F E D C B A 904B 904B
SWITCH BAT 905B 905B
4X4
A B
REV
473
915
918
941
FWD
911A
914C
911B
HORN
020C 020C CAN
PS IGN
TRC LOK
HR MTR
DIAGNOSTIC
OIL GAG
START-C
CLT TMP
BACK-UP
FUL GAG
ALT EXC-B
ALARM 85 86
GND-10 START-C
GND-4 STRT SOL
911B
473
915
918
941
012B
911A
914C
B 30 87
J H G F E D C B A
J H G F E D C B A
A DIODE
HORN
FUL GAG
8 7 6 5 4 3 2 1
FUEL HORN STARTER
(#10)
LEVEL ST RELAY
A B
TRACTION SENDER RT
LOCK SO 914D 914D
BAT L 8 7 6 5 4 3 2 1 OIL
911D 911D
REV
VALVE
012C
(#000) PRESSURE
GND-5
473
915
918
941
SIGNAL
REV-B
PARK BRAKE 467 467
C B A
C B A
911B
911A
914C
012B
SOLENOID VALVE SNSR STARTER

BATTERY MOTOR
4X4 (#000) STARTER 012B
- +
4.1.1
SOLENOID
(#12)
B 10 AMP
A 904C 904C
ALT BAT
(#000)
GND-3 FUSE
012D
050F
002A 002B CAN
(#12)
905C 905C
GND-4
914C
050F TERMINATOR
GND-5
914E 914D 020D 020D 020D
C B A
C B A
D-2
-1
A B
GND-3
D
911A
911B
GN
G
ALT EXC-B 911D
NEG POS
PS IGN
DIODE
GND-10 491 491 FUEL
4X4 493 493 INJECTION
B A
B A
VALVE CONTROL
911E
#1
050D
022A
012B
ALT BAT ALTERNATOR 39
BATT #2
904B
904C
905B
905C
020D
HR MTR
RESISTOR
SNSR 904E 904D
022C 904D 904D
947
GND-1 GND-2 905E 905D 905D 905D CAN

FWD TERMINATOR
050C 020F 020F 020F
C B A
C B A
050D
OIL PRESSURE SWITCH 020E 020E
OIL GAG
(ON ENGINE)
CLT TMP
050G
DIODE 447 447

CRANK
448 448
B A
B A
POSITION
DIODE
FORWARD
REVERSE
OIL
REV-B
VALVE
WATER PRESSURE
TEMP. GAUGE
SENDER
STAB-PWR 428 428

STAB-SW1 FUEL
415 415 TMP
B A
B A
491
022C
050G
473
904E
467
905E
911E
915
914E
448
428
947
918
447
461
493
012D
941
K3 K2 K1 J3 J2 J1 H3 H2 H1 G3 G2 G1 F3 F2 F1 E3 E2 E1 D3 D2 D1 C3 C2 C1 B3 B2 B1 A3 A2 A1
461 461
GND-8 COOLANT
415 415
B A
B A
TEMP
STAB-SW2
B
A ECU CONNECTOR
A B C D
A B C D
B
A
WHITE
BLUE
BLACK
RED
ORANGE
DIODE
+ -
STABILIZER
N.C.
N.O.
PROXIMITY
SENSOR
GND-7
STABILIZER
VALVE
MAN0180
Models 534D-9 Tier II & 534D-10 Tier II
John Deere Engine

N START
15 AMP
FUSE
A A BAT-HN HN-AC
B B 15 AMP
GND-3 FUSE
C C
START 15 AMP
D D IGN-A FUSE
RELAY
OIL PRESS. FUEL
IGN-C PRK IGN PRK BRK 4X4 PWR
GAUGE GAUGE FWD/N/REV ENGINE SHUTDOWN
BAT
REV
FWD
SWITCH START-C 2/4 WHEEL OVERRIDE THROTTLE
IGN-A
SHUTDOWN
BAT-HN
SHT IGN
START-A
DRIVE SWITCH LIGHT SWITCH PEDAL
15 AMP
John Deere Engine

FUSE GND-3 473
GAUGE START-B
I ACC-A ACC-B PB LHT
LIGHT WATER TEMP. B A
VOLTMETER START-B
IGN-B
START-A AL
GAUGE PRK IGN
915
ST TE
918
OIL GAG
4X4 LHT
911A
911B
914C
XC
GND-6 -A
4X4
IGNITION PARK BRAKE
IGN-B SWITCH 4X4
LIGHT
GAUGE
LIGHT GND-3
ACC-C
OPEN
AUXLT
FUL GAG
CLT TMP
OPEN
ACC-C
534D-9 Tier II:
911A
915
914C
START-B
534D-10 Tier II:
473
911B
918
HOUR
PRK IGN
START-C
CLT TMP
PRK BRK
OIL GAG
ALT EXC-A
GND-3
4X4
ACC-C
FUL GAG
HR MTR
ALT EXC-B
ALT EXC-B
METER
PB LHT
GND-3 OPEN GND-3
HR MTR
A B C D E F G H J K L M N P SPL-ACC ALTERNATOR C B A 6 5 4 3 2 1
WARNING LIGHT
GND-3
PS IGN
S/N 0160013979 & After
PARK BRAKE
OPEN LIGHT
ACC-B
SPL-ACC2
4X4
918
473
915
ALT EXC-A
911B
911A
914C
GND-3
ACC-C
PRK IGN
OIL GAG
START-B
CLT TMP
ALT EXC-B
60
HR MTR
FUL GAG
START-C
ALT EXC-A
PRK BRK
SPL-ACC RESISTOR
SPL-ACC-2 HORN
BUTTON
ACC-C
HN-AC
4X4
TRC LOK
S/N 0160014009 & After (including S/N 0160013513)
OPEN
GND-3
GND-2
GND-6
HORN
B A 941
OPT.
SHUT
PRK BRK
GND-2
DOWN
B A
941
914C
911B
473
915
918
911A
CLT TMP
REV
OIL GAG
ALT EXC-B
PS IGN
4X4
FWD
HR MTR
HORN
BAT
FUL GAG
START-C
A B 4X4 TRC LOK
050C 050C
012C 012C
SWITCH BAT 905B 905B
4X4
A B
REV
473
915
918
941
FWD
911A
914C
911B
HORN
020C 020C CAN
PS IGN
HR MTR
TRC LOK DIAGNOSTIC
OIL GAG
START-C
CLT TMP
FUL GAG
BACK-UP
ALT EXC-B
ALARM 85 86
GND-10 START-C
GND-4 STRT SOL
911B
473
915
918
941
012B
911A
914C
B 30 87
J H G F E D C B A
J H G F E D C B A
A DIODE
HORN
FUL GAG
8 7 6 5 4 3 2 1
FUEL HORN STARTER
(#10)
LEVEL ST RELAY
A B
TRACTION SENDER RT
LOCK SO 914D 914D
BAT L 8 7 6 5 4 3 2 1 OIL
911D 911D
REV
VALVE
012C
(#000) PRESSURE
GND-5
473
915
918
941
SIGNAL
REV-B
PARK BRAKE 467 467
C B A
C B A
911B
911A
914C
012B
SOLENOID VALVE SNSR STARTER

BATTERY MOTOR
4X4 (#000) STARTER 012B
- + SOLENOID
(#12)
B 10 AMP
A 904C 904C
ALT BAT
(#000)
FUSE
012D
GND-3
050F
002A 002B CAN
(#12)
905C 905C
GND-4
914C
050F TERMINATOR
GND-5
914E 914D 020D 020D 020D
C B A
C B A
D-2
-1
914B
GND-3
A B
D
911A
911B
GN
914A
G
ALT EXC-B 911D
NEG POS
PS IGN
DIODE
GND-10 491 491 FUEL
B A
B A
CONTROL
911E
VALVE #1
050D
022A
012B
ALT BAT ALTERNATOR 39
BATT #2
904B
904C
905B
905C
020D
HR MTR
RESISTOR
SNSR 904E 904D
022C 904D 904D
947
GND-1 GND-2 905E 905D 905D 905D CAN

FWD TERMINATOR
050C 020F 020F 020F
C B A
C B A
050D
OIL PRESSURE SWITCH 020E 020E
OIL GAG
(ON ENGINE)
CLT TMP
050G
DIODE 447 447

CRANK
448 448
B A
B A
POSITION
DIODE
FORWARD
REVERSE
OIL
REV-B
VALVE
WATER PRESSURE
TEMP. GAUGE
SENDER
STAB-PWR 428 428

STAB-SW1 FUEL
914B 415 TMP
B A
B A
491
022C
050G
473
904E
467
905E
911E
915
914E
448
428
947
918
447
461
493
012D
941
461 461
GND-8 COOLANT
914A 415
B A
B A
TEMP
STAB-SW2
B
A ECU CONNECTOR
A B C D
A B C D
B
A
WHITE
BLUE
BLACK
RED
ORANGE
DIODE
+ -
Electrical Wiring
STABILIZER
N.C.
N.O.
PROXIMITY
SENSOR
GND-7
STABILIZER
VALVE
MAN0190
4.3
4.4
4.1.2
N START
15 AMP
FUSE
A A BAT-HN HN-AC
B B 15 AMP
GND-3 FUSE
C C 15 AMP
START
D D RELAY IGN-A FUSE
OIL PRESS. FUEL
IGN-C PRK IGN PRK BRK 4X4 PWR SHUTDOWN
GAUGE GAUGE FWD/N/REV ENG.
BAT
SWITCH START-C SHUTDOWN OVERRIDE THROTTLE
BAT-HN
FWD
REV
2/4 WHEEL
SWITCH PEDAL
START-A
LIGHT
IGN-A
SHT IGN
15 AMP DRIVE SWITCH
FUSE GND-3 473
GAUGE ACC-A ACC-B START-B
LIGHT I
WATER TEMP. B A PB LHT
VOLTMETER START-B START-A
AL
IGN-B
GAUGE PRK IGN
915
918
TE
ST
4X4 LHT
911B
911A
914C
XC
4X4
GND-6 -A
IGNITION PARK BRAKE 4X4
IGN-B SWITCH LIGHT
GAUGE
OIL GAG
LIGHT GND-3
ACC-C
OPEN
AUXLT
FUL GAG
CLT TMP
OPEN
CLT TMP
ACC-C
Electrical Wiring
Before S/N 0160013976

Model 544D Tier II
START-B
918
473
911B
915
914C
911A
HOUR
ALT EXC-B
PRK IGN
START-C
PRK BRK
ACC-C
FUL GAG
ALT EXC-A
4X4
GND-3
CLT TMP
ALT EXC-B
OIL GAG
HR MTR
METER OPEN
PB LHT
GND-3 GND-3
HR MTR
SPL-ACC
PS IGN
A B C D E F G H J K L M N P ALTERNATOR C B A 6 5 4 3 2 1
WARNING LIGHT
GND-3
PARK BRAKE
OPEN LIGHT
SPL-ACC2
ACC-B
4X4
918
473
915
60
ALT EXC-A
911B
911A
914C
GND-3
ACC-C
RESISTOR
PRK IGN
START-B
OIL GAG
START-C
ALT EXC-B
CLT TMP
PRK BRK
ALT EXC-A
HR MTR
FUL GAG
SPL-ACC
SPL-ACC-2 HORN
BUTTON
ACC-C
HN-AC
4X4
TRC LOK
OPEN
GND-2
GND-6
GND-3
B A 941
PRK BRK
HORN
OPT.
GND-2
SHUT
DOWN
B A
473
915
941
911A
914C
918
911B
ALT EXC-B
OIL GAG
PS IGN
REV
CLT TMP
BAT
4X4
FWD
FUL GAG
HORN
START-C
HR MTR
A B 4X4 TRC LOK
050C 050C
012C 012C
SWITCH BAT
A B 905B 905B
941
918
915
473
4X4
REV
FWD
911A
914C
911B
CAN
HORN
020C 020C
PS IGN
TRC LOK DIAGNOSTIC
HR MTR
BACK-UP
OIL GAG
START-C
CLT TMP
FUL GAG
ALT EXC-B
ALARM 85 86
GND-10 START-C
GND-4 STRT SOL
012B
914C
918
941
915
911A
30 87
473
911B
A B
J H G F E D C B A
J H G F E D C B A
DIODE
HORN
FUL GAG
8 7 6 5 4 3 2 1
FUEL HORN STARTER
(#10)
A B ST RELAY
LEVEL RT
TRACTION SENDER SO 914D 914D
LOCK BAT L OIL
REV
8 7 6 5 4 3 2 1
012C
VALVE 911D 911D PRESSURE

(#000)
SIGNAL
473
915
941
918
PARK BRAKE 467 467

C B A
C B A
911A
012B
911B
914C
REV-B
STARTER
GND-5
SOLENOID VALVE SNSR
BATTERY MOTOR
4X4 (#000) STARTER 012B
- +
020C
SOLENOID
(#12)
B 10 AMP
ALT BAT
A
(#000)
GND-3 904C 904C
012D
FUSE
050F
(#12)
002A 002B 905C 905C CAN
GND-4
914C
TERMINATOR
050F
GND-5
914E 020D 020D 020D
C B A
914D
C B A
D-2
-1
911B
911A
GND-3
A B
D
N
914F
GN
G
GND-7 ALT EXC-B NEG POS 911D
GND-8 PS IGN
DIODE
GND-10 491 491 FUEL
B A
B A
VALVE CONTROL
#1
012B
ALTERNATOR
050D
022A
911E
ALT BAT 390

904B
904C
905B
905C
HR MTR
BATT #2
020D
RESISTOR
SNSR 904E 904D
022C 904D 904D
947
GND-1 GND-2 905E 905D 905D 905D CAN

FWD TERMINATOR
050C 020F 020F 020F
050D
C B A
C B A
OIL 020E 020E
STAB-SW1
STAB-PWR
PRESSURE SWITCH
CLT TMP
(ON ENGINE)
OIL GAG
050G
DIODE 447 447

GND-8 STAB-SW2 CRANK
448 448
B A
B A
B POSITION
DIODE
A B C D A
FORWARD
REVERSE OIL
REV-B
VALVE 463 463
WATER PRESSURE A B C D CHARGE AIR
914F 914F
B A
B A
TEMP. GAUGE TEMP

B
SENDER
A
WHITE
BLUE
BLACK
RED
ORANGE
DIODE
+ - 428 428
FUEL
415 415
B A
B A
TMP
N.O.
N.C.
491
022C
050G
473
904E
467
905E
911E
915
914E
448
463
428
947
918
447
461
493
012D
941
STABILIZER
PROXIMITY K3 K2 K1 J3 J2 J1 H3 H2 H1 G3 G2 G1 F3 F2 F1 E3 E2 E1 D3 D2 D1 C3 C2 C1 B3 B2 B1 A3 A2 A1
SENSOR
STABILIZER 461 461
VALVE COOLANT
415 415
B A
B A
TEMP
MAN0200
ECU CONNECTOR
John Deere Engine

N START
15 AMP
FUSE
A A BAT-HN HN-AC
B B 15 AMP
GND-3 FUSE
C C 15 AMP
START
D D RELAY IGN-A FUSE
John Deere Engine

OIL PRESS. FUEL
IGN-C PRK IGN PRK BRK 4X4 PWR SHUTDOWN
GAUGE GAUGE FWD/N/REV ENG.
BAT
START-C OVERRIDE THROTTLE
BAT-HN
SHUTDOWN
FWD
REV
SWITCH 2/4 WHEEL
SWITCH PEDAL
START-A
LIGHT
IGN-A
SHT IGN
15 AMP DRIVE SWITCH
FUSE GND-3 473
GAUGE ACC-A ACC-B START-B
LIGHT I
WATER TEMP. B A PB LHT
VOLTMETER START-B START-A
AL
IGN-B
GAUGE PRK IGN
915
918
TE
ST
4X4 LHT
911B
911A
914C
XC
4X4
GND-6 -A
IGNITION PARK BRAKE 4X4
IGN-B SWITCH LIGHT
GAUGE
OIL GAG
LIGHT GND-3
ACC-C
OPEN
AUXLT
FUL GAG
S/N 0160013976 & After
CLT TMP
OPEN
CLT TMP
ACC-C
START-B
918
473
911B
915
914C
911A
HOUR
ALT EXC-B
PRK IGN
START-C
PRK BRK
ACC-C
FUL GAG
ALT EXC-A
4X4
GND-3
CLT TMP
ALT EXC-B
OIL GAG
HR MTR
METER OPEN
PB LHT
GND-3 GND-3
HR MTR
SPL-ACC
PS IGN
A B C D E F G H J K L M N P ALTERNATOR C B A 6 5 4 3 2 1
WARNING LIGHT
GND-3
PARK BRAKE
OPEN LIGHT
SPL-ACC2
ACC-B
4X4
918
473
915
60
ALT EXC-A
911B
911A
914C
GND-3
ACC-C
RESISTOR
PRK IGN
START-B
OIL GAG
START-C
ALT EXC-B
CLT TMP
PRK BRK
ALT EXC-A
HR MTR
FUL GAG
SPL-ACC
SPL-ACC-2 HORN
BUTTON
ACC-C
HN-AC
4X4
TRC LOK
OPEN
GND-2
GND-6
GND-3
B A 941
PRK BRK
HORN
OPT.
GND-2
SHUT
DOWN
B A
473
915
941
911A
914C
918
911B
ALT EXC-B
OIL GAG
PS IGN
REV
CLT TMP
BAT
4X4
FWD
FUL GAG
HORN
START-C
HR MTR
A B 4X4 TRC LOK
050C 050C
012C 012C
SWITCH BAT
A B 905B 905B
941
918
915
473
4X4
REV
FWD
911A
914C
911B
CAN
HORN
020C 020C
PS IGN
TRC LOK DIAGNOSTIC
HR MTR
BACK-UP
OIL GAG
START-C
CLT TMP
FUL GAG
ALT EXC-B
ALARM 85 86
GND-10 START-C
GND-4 STRT SOL
012B
914C
918
941
915
911A
30 87
473
911B
A B
J H G F E D C B A
J H G F E D C B A
DIODE
HORN
FUL GAG
8 7 6 5 4 3 2 1
FUEL HORN STARTER
(#10)
A B ST RELAY
LEVEL RT
TRACTION SENDER SO 914D 914D
LOCK BAT L OIL
REV
8 7 6 5 4 3 2 1
012C
VALVE 911D 911D PRESSURE

(#000)
SIGNAL
473
915
941
918
PARK BRAKE 467 467

C B A
C B A
911A
012B
911B
914C
REV-B
STARTER
GND-5
SOLENOID VALVE SNSR
BATTERY MOTOR
4X4 (#000) STARTER 012B
- +
020C
SOLENOID
(#12)
B 10 AMP
ALT BAT
A
(#000)
GND-3 904C 904C
012D
FUSE 914B
050F
(#12)
002A 002B 905C 905C CAN
GND-4
914A
914C
TERMINATOR
050F
GND-5
914E 020D 020D 020D
C B A
914D
C B A
D-2
-1
911B
911A
GND-3
A B
D
N
914F
GN
G
GND-7 ALT EXC-B NEG POS 911D
GND-8 PS IGN
DIODE
GND-10 491 491 FUEL
B A
B A
VALVE CONTROL
#1
012B
ALTERNATOR
050D
022A
911E
ALT BAT 390

904B
904C
905B
905C
HR MTR
BATT #2
020D
RESISTOR
SNSR 904E 904D
022C 904D 904D
947
GND-1 GND-2 905E 905D 905D 905D CAN

FWD TERMINATOR
050C 020F 020F 020F
050D
C B A
C B A
OIL 020E 020E
STAB-SW1
STAB-PWR
PRESSURE SWITCH
CLT TMP
(ON ENGINE)
OIL GAG
050G
DIODE 447 447

GND-8 STAB-SW2 CRANK
448 448
B A
B A
B POSITION
DIODE
A B C D A
FORWARD
REVERSE OIL
REV-B
VALVE 463 463
WATER PRESSURE A B C D CHARGE AIR
914F 914F
B A
B A
TEMP. GAUGE TEMP

B
SENDER
A
WHITE
BLUE
BLACK
RED
ORANGE
DIODE
+ - 428 428
FUEL
914B 415
B A
B A
TMP
N.O.
N.C.
491
022C
050G
473
904E
467
905E
911E
915
914E
448
463
428
947
918
447
461
493
012D
941
STABILIZER
PROXIMITY K3 K2 K1 J3 J2 J1 H3 H2 H1 G3 G2 G1 F3 F2 F1 E3 E2 E1 D3 D2 D1 C3 C2 C1 B3 B2 B1 A3 A2 A1
SENSOR
MAN0210
STABILIZER 461 461
VALVE COOLANT
914A 415
B A
B A
TEMP
Electrical Wiring
ECU CONNECTOR
4.5
MY1060 KEY BAT PWR
S
B
KEY IGN
FUL LVL (D BLU, 18 GA GXL)
I
A
OIL PSI (D BLU, 18 GA GXL)

KEY/IGN
DASH GND
4
1
(BLK, 18 GA GXL)
CLT TMP (D BLU, 18 GA GXL)
GAGE PWR (RED, 18 GA GXL)
G
KEY BAT PWR (ORG, 18 GA GXL)

B+
FAULT LT/473
BEEDE GAUGE
(D BLU, 18 GA GXL)
3
2
KEY IGN TRANS TMP SW

KEY ACC KEY ACC HR MTR (ORG, 18 GA GXL)
1 2 3 4 5 6 7 8
KEY START KEY START

DASH GND
GAGE PWR
HORN PWR HORN PWR
STEER/SWAY PWR HORN
STR AW OVR SUP/911
STR CRB OVR SGN/918
HORN
FUL LVL
3
2
3
2
(RED, 18 GA GXL)
TRANS TMP SW
(RED, 18 GA GXL)
ST RLY
ON
SHIFT PWR 1
OFF
ON
HORN
(BLK, 18 GA GXL)
OFF
PK BRK SOL
HR MTR
SHTDN OVR
CHECK ENG
HD34-24-31ST
OIL PSI
LEFT DASH PANEL
TRANS TMP WRN
CLT TMP STR CRB

DASH PANEL HARNESS
OVR SUP/911
STEER/SWAY PWR
OVR SGN/918 STR AW
FAULT LT/473
TRAN/BRK PWR TRAN/BRK PWR
PLUGGED
PLUGGED
3
2
1
3
2
1
PLUGGED
+
PLUGGED
OFF
CRAB
ON
ALL WHL
PLUGGED
-
6
5
4
7
PLUGGED
HR MTR
6
5
4
7
PK BRK SOL
PARK BRAKE
STEER MODE
PLUGGED ST RLY
PLUGGED PK BRK SOL
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31
SHIFT PWR 1
DASH GND
DASH GND
F4
F3
F2
F1
N4
N3
N2
N1
R4
R3
R2
R1
GEAR
SW3
SW1
R
F
1
4
N
TRANS SOL Y1
2
3
TRANS SOL Y3
TRANS SOL Y5
TRANS SOL Y4
SHIFT PWR 1
KEY START
Y2, Y6
Y1, Y6
TRANS SOL Y2
Y2, Y3, Y6
Y1, Y3, Y6
Y2, Y3, Y5, Y6

Y2, Y3, Y4, Y6
Y1, Y3, Y5, Y6
Y1, Y3, Y4, Y6
PK BRK SOL
3
2
HOBBS
1 2 3 4 5 6 7 8
4
1
N
R
F
TRANSMISSION LEGEND
Y6 (ONLY IF PARK BRAKE OFF)

ACTIVATED TRANS SOLENOIDS
TRANSMISSION SHIFTER
SW4
SW2
TO CHASSIS ASSEMBLY
THR SGN/915
THR RTN/914
OVR SUP/911
PLUGGED
PLUGGED
WILLIAMS
PLUGGED
A B C D E F
(SUSPENDED)
TWIST
THROTTLE
12 TURNS
PER FOOT
TRANS SOL Y1
TRANS SOL Y2
TRANS SOL Y3
TRANS SOL Y4
TRANS SOL Y5
PLUGGED PLUGGED 3 87a
KEY START TRAN/BRK PWR 1 30
SHIFT PWR 1 REVERSE 4 87
PK BRK SOL TRANS SOL Y2 5 86
RELAY
REVERSE SHIFTER GND 2 85

REVERSE
TRAN/BRK PWR
SHIFTER GND
OVR SUP/911
THR SGN/915
THR RTN/914
SP BAT PWR
SP ACCY PWR
SP CAB GND 1 PLUGGED 3 87a
SP CAB GND 2 SHIFTER GND 1 30
HD34-24-31PT
SP-1 TRANS TMP SW 4 87
SHIFTER HARNESS
SP-2 KEY START 5 86
SP-3 SHIFTER GND 2 85
TRANS TMP SW
TEST RELAY
WARN LIGHT
AC CLUTCH
STAB/TILT PWR
TILT UP
TILT DN
SP BAT PWR
STAB/TILT PWR
PLUGGED
PLUGGED STD JOY PWR
TILT
RED YEL
PLUGGED
SPEED
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31
STAB/TILT PWR
SHIFTER GND
TILT UP
TILT DN TILT UP RED
1 2 3 4
DT06-4S
TILT
UP
STD JOY PWR BLK

STD JOY PWR GRY
ROLLER OPTION
SHIFTER HARNESS
TILT DN BLU
TO TILT ON JOYSTICK
TILT
JOYSTICK
DOWN
PLUGGED PLUG
STANDARD
PLUGGED PLUG
1 2 3 4 5 6
SP BAT PWR
SP ACCY PWR
SP-3
SP-2
SP-1
SP CAB GND 2
SP CAB GND 1
SEE AC CLUTCH
SHEET 2
Cab Schematic
Models G10-55A & G12-55A 4.1.3
Electrical Wiring
John Deere Engine
WINDSHIELD
CAB LIGHTS WASHER DASH BLOWER HEATER M WIPER MOTOR
STOPLIGHT DOME
BEACON LEFT RIGHT MOTOR FAN MOTOR VALVE RIGHT DASH PANEL
AUX HYD PANEL OPTIONS VEC SWITCH LIGHT M
WIPER HEATER/BLOWER M M
F1 20 WIPER PWR M WORKLIGHTS BEACON WIPER
A
F5 20 HEATER PWR 1 2 3 4 5 6 7 8 9 10 OFF OFF
87a
87
86
85
30
87a
30
87
86
85
B
KEY ACC 1 4
C H
F7 10 BCN PWR 2 5 2 L
D W B
F8 10 D FAN PWR 3 6 3
AUX ELEC E P
AUX ELEC
GREEN-4
LIGHTS BCN/FAN F6 20
F
DOME LT A A B A B A B ON ON
SWING 7 MAST
7 CAB LT PWR A B A B C D
G
EMPTY
EMPTY
EMPTY
EMPTY
EMPTY
EMPTY
EMPTY
1 4 1
87a
30
87
86
85
4
87a
30
87
86
85
H
S/W LT PWR
2 5 2 5
BCN LT
AUX ELEC1
CAB LTS
WORK LT
BCN PWR
3 6 3 6
S/W LT PWR
SW1 86
CAB LT PWR
HEATER GND
HTR CNTRL B
HEATER PWR
A
EMPTY
EMPTY
87a
30
87
86
85
OPTION (15A) OPTION (25A) HEATER GND
WIPER HI
B
WASHER
WIPER HI
WIPER LO
WIPER LO
EXTRA SIDESHIFT CAB LT GND

WIPER PWR
WIPER PARK
87a
30
87
86
85
87a
30
87
86
85
WIPER PARK
D
DOME/BCN GND
AUX ELEC2
AUX RLYS PWR
BLUE-3
E
STOP LT
S/W LT PWR
DOME/BCN GND
DOME LT
BCN LT
DOME/BCN GND
CAB LTS
CAB LT GND
CAB LTS
CAB LT GND
WASHER
HEATER HI
HEATER MED
HEATER LOW
HEATER GND
D FAN PWR
D FAN GND
SW1 87A
87a
30
87
86
85
F
F4
F3
F2
G
SW2 86
H
SW2 87A
25
15
15
BLACK-1 GRAY-2 HEATER HI
H G F E D C B A H G F E D C B A HEATER MED
HEATER LOW
HTR TEMP BLOWER
8K OHM
M H
L B
24 KOHM,1W
SWING
EXTRA
SW2 87A
SW2 86
MAST
SW1 87A
SIDESHIFT
SW1 86
AUX SW GND
PLUGGED
PLUGGED
PLUGGED
RESISTOR LOCATED
25A OPT
C
STOP LT
S/W LT PWR
BCN PWR
DOME LT
DOME/BCN GND
CAB LT PWR
CAB LT GND
WORK LT
PLUGGED
PLUGGED
15A OPT 2
15A OPT 1
OPT GND 1
OPT GND 2
APPROX 10" BEHIND
OPT PWR 1
OPT PWR 2
OPT PWR 3
OPT PWR 4
D FAN GND
AUX
AUX SW GND
25A OPT GND
WORKLIGHT/ HEATER TEMP SWITCH A B C
15A OPT 2 GND

15A OPT 1 GND
ELECTRIC 1 2 3 4 5 6 7 8 9 10 11 12 1 2 3 4 5 6 7 8 BEACON CONNECTION IN
OPTION OPTION ENCLOSED CAB
D FAN PWR
HEATER PWR
WIPER PWR
HEATER GND
D FAN GND
PLUGGED
OPTIONS HARNESS
FAN SW C
15A OPT 1
HEATER PWR
A OPTION 1
15A OPT 1 GND B 15 A
MAST
EXTRA
SWING
SW2 86
SW1 86
A B C D E F ENCLOSED CAB
SW2 87A
SW1 87A
HEATER GND
HTR CNTRL A
15A OPT 2
HEATER PWR
PLUGGED
PLUGGED
PLUGGED
STOP LT
A OPTION 2 OPTION
DOME LT
WORK LT
SIDESHIFT
BCN PWR
15A OPT 2 GND
(RED)
S/W LT PWR
CAB LT PWR
B 15 A
CAB LT GND
AUX SW GND
DOME/BCN GND
25A OPT A
25A OPT GND B
OPTION
25 A
PLUGGED
D FAN GND
D FAN PWR
WIPER PWR
HEATER GND
HEATER PWR
A/C SWITCH
(BLACK)
Options Schematic
(RED/WHITE)
OPTIONS
FUSE LEGEND
F1 20A WIPER PWR THERMOSTATIC
F2 15A 15A OPTION 1 PWR SWITCH A/C PRESSURE SWITCH
F3 15A 15A OPTION 2 PWR
PRS SW AC SW
F4 25A 25A OPTION PWR
F5 20A HEATER/BLOWER PWR
F6 20A LIGHT PWR
F7 10A BEACON PWR
F8 10A DASH FAN PWR
25A OPT GND
KEY ACC
AUX RLYS PWR
STOP LT
WORK LT
PLUGGED
PLUGGED
MAST
OPT PWR 1
SIDESHIFT
OPT PWR 2
SWING
OPT PWR 3
EXTRA
OPT PWR 4
PLUGGED
OPT GND 1
PLUGGED
OPT GND 2
PLUGGED
RLY 87
AC SW
A
RLY 87
B
25A OPT GND
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 86 87a 87
OPTIONS HARNESS CONDENSER FANS
A/C M 17A M
AC CLUTCH
HD36-24-19PE (ON ROOF)
RELAY
TO CHASSIS ASSEMBLY 85 30
25A OPT GND
25A OPT
MY1070
SEE SHEET 1
Electrical Wiring
4.7
4.8
(OPT)
(OPT) (OPT) REVERSE (OPT) AUXILIARY
TAIL LIGHT ALARM TO OPTIONS HARNESS A/C TILT-ON ELECTRIC
FRONT RIGHT HORN TO DASH PANEL HARNESS TO CAB ASSEMBLY
WORKLIGHT 8-SHT3-REV BLK AND BOM COMPRESSOR JOYSTICK A S LT RT TM FUEL
BU STOP TAIL HD36-24-31PT TO SHIFTER HARNESS
VALVE SNDR
CHASSIS HARNESS HD36-24-31ST HD34-24-19SE
CHASSIS HARNESS CHASSIS HARNESS M
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19
BLK
YEL
BLU
RED
ORG
POWER DISTRIBUTION
(-)
EMPTY
A B
BLK
GRN
RED
A B A B A B
PLUGGED
FUSE/BREAKER LEGEND
Electrical Wiring
CB1 20A OPTIONS POWER 3
SP-1
SP-2
SP-3
A B A B C D
SP-3
SP-2
SP-1
HORN
MAST
HORN
ST RLY
OIL PSI
A B C D E F
SWING
EXTRA
STR AW
TILT UP
TILT DN
FUL LVL
HR MTR
KEY IGN
LT GND
CLT TMP
KEY ACC
STR CRB
STOP LT
KEY ACC
WORK LT
PLUGGED
PLUGGED
PLUGGED
PLUGGED
PLUGGED
PLUGGED
PLUGGED
PLUGGED
REVERSE
PLUGGED
PLUGGED
PLUGGED
PLUGGED
SP GND 1
SP GND 2
REVERSE
PLUGGED
PLUGGED
PLUGGED
PLUGGED
PLUGGED
DASH GND
GAGE PWR
SIDESHIFT
KEY START
HORN PWR
OPT GND 1
OPT GND 2
OPT PWR 1
OPT PWR 2
OPT PWR 3
OPT PWR 4
AC CLUTCH
PK BRK SOL
KEY START
PK BRK SOL
AC CLUTCH
SP BAT PWR
SP BAT PWR
SHIFT PWR 1
OVR SUP/911
SHIFT PWR 1
THR RTN/914
OVR SGN/918
FAULT LT/473
OVR SUP/911
THR SGN/915
SP BAT PWR
KEY BAT PWR

SHIFTER GND
SP ACCY PWR
SP CAB GND 2
SP CAB GND 1
F1 15A TRANS/PARK BRK PWR
TRANS SOL Y1
TRANS SOL Y2
TRANS SOL Y3
TRANS SOL Y4
TRANS SOL Y5
SP ACCY PWR
TRANS TMP SW
TRAN/BRK PWR
STAB/TILT PWR
TRAN/BRK PWR
TRANS TMP SW
AUX RLYS PWR
FUL LVL
F2 5A ALTERNATOR EXCITE
FUL/STAB GND
REMOVE DIODES
STEER/SWAY PWR
LT GND
REVERSE
STOP LT
WORK LT
LT GND
WORK LT
F3 10A ENGINE ECU IGN PWR FOR OPTIONAL
ROLLER TILT NEGATIVE CABLE
ON JOYSTICK TO CAB FIREWALL
F4 10A GAGE (INST PANEL) PWR AND INSTALL
"EMPTY" PLUG
TILT DN
TILT UP
F5 15A SPARE ACCESSORY PWR
MAST
SIDESHIFT
AUX ELEC GND
SWING
EXTRA
PLUGGED
FUL/STAB GND
FUL/STAB GND
F6 10A AUX ELECTRIC PWR
F7 15A HORN PWR
F8 25A SPARE BATTERY PWR
F9 10A ENGINE ECU BAT PWR
F10 10A STEER/SWAY PWR
F11 10A R. AXLE STAB/TILT PWR
F12 15A KEY BATTERY PWR
+ -
12 VDC
ALL WHEEL 1
STR AW BATTERY
STEER 2
STR/SWAY GND
MODE POSITIVE CABLE
1
STR CRB
VALVE TO STARTER
2
STR/SWAY GND
CRAB AND ALTERNATOR
NEGATIVE CABLE
TO ENG BLOCK
NEGATIVE CABLE
FLAG TO
12 TURNS CHASSIS FRAME
PER FOOT
TWIST ECU IGN/012 1
ECU BAT/022 2
BAT GND
BAT GND
BAT POS
BAT POS
ECU GND/050 3
ENG GND 4
CLT TMP 5
PK BRK SOL 6
POWER DIST OVR SGN/918 7
A C A C FAULT LT/473 8
BLACK-6 GRAY-5 VEC ALT EXC 9
OVR SUP/911 10
THR SGN/915 11
A
DASH GND
THR RTN/914 12
F2 5 ALT EXC
B ST RLY
ACCY-2 IGNITION-2 F5 15 SP ACCY PWR 13
C HR MTR
F6 10 AUX RLYS PWR 14
87a
30
87
86
85
87a
30
87
86
85
D OIL PSI
OPT GND 1 15
E GAGE PWR
KEY ACC 16
GREEN-4
F TRANS TMP SW
F1 15 TRAN/BRK PWR 17
HD34-24-29PE
G PLUGGED
OPT GND 2 18
IGNITION-1 ACCY-1
CHASSIS HARNESS
H TRANS SOL Y1 19
PLUGGED
87a
30
87
86
85
87a
30
87
86
85
SP CAB GND 1 20
Chassis/Boom Schematic
A TRANS SOL Y2
SP CAB GND 2 21
B TRANS SOL Y3
TO POWER UNIT ASSEMBLY
SP GND 1 22
C PLUGGED
SP GND 2 23
D PLUGGED
AUX ELEC GND 24
E
CB4
F8
F3
CB3
F4
F9
CB1
F7
F10
CB2
F11
F12
TRANS SOL Y4
BLUE-3
LT GND 25
F TRANS SOL Y5
STR/SWAY GND 26
20
20
20
20
G PLUGGED
25
10
10
10
15
10
10
15
FUL/STAB GND 27
H PLUGGED 28
PLUGGED 29
BLACK-1 GRAY-2
H G F E D C B A H G F E D C B A
6A 6A
KEY IGN
ENG GND
OPT PWR 2
OPT PWR 1
GAGE PWR
OPT PWR 3
OPT PWR 4
HORN PWR
STAB/TILT PWR
STAB/TILT PWR
STAB VLV
FUL/STAB GND
ECU IGN/012
SP BAT PWR
ECU BAT/022
ECU GND/050
SHIFTER GND
KEY BAT PWR
STAB VLV
FUL/STAB GND
STAB VLV
FUL/STAB GND
STAB/TILT PWR
STEER/SWAY PWR
A B C D
STEER/SWAY PWR
STEER/SWAY PWR
SWAY ENABLE
STR/SWAY GND
SWAY ENABLE
MINUS 15
PLUG
STR/SWAY GND
SWAY ENABLE
PLUG
PLUS 15
STR/SWAY GND
SWAY LT
STR/SWAY GND
SWAY LOCK
STR/SWAY GND
SWAY LOCK
STR/SWAY GND
SWAY LOCK
STR/SWAY GND
SWAY RT
STR/SWAY GND
BLU
WHT
RED
ORG
BLK
A B C D
1 2 3 4 1 2 3 4 A B A B
STR/SWAY GND
MINUS 15
SWAY RT
STEER/SWAY PWR
STR/SWAY GND
PLUS 15
SWAY LT
STEER/SWAY PWR
1 2 1 2 1 2 1 2 1 2
BLU
BLK
RED
WHT
ORG
+
1
3
1
3
RED
YELLOW
GREEN
BLACK
RED
YELLOW
GREEN
BLACK
STABILIZER PROXIMITY
85 2
86 5
87 4
30
85 2
86 5
87 4
30
STABILIZER
87a
87a
ENGINE SIDE CAB SIDE VALVE SWITCH

+ SV2 SV1 SV4 SV5 SV3
(-)15 DEG (+)15 DEG
LT
SWAY PILOT
RT LAT TILT LAT TILT
VALVE SWITCH SWITCH
MY1080
(-)15 DEG RLY (+)15 DEG RLY
SWAY PROXIMITY
SWITCH
John Deere Engine

John Deere Engine
TRANSMISSION LEGEND
MANIFOLD AIR COOLANT TEMP GEAR ACTIVATED TRANS SOLENOIDS

FUEL TEMP CRANK OIL PRESSURE INJECTOR
TEMP SENSOR SENSOR SENSOR SENSOR SENSOR PUMP
F1 Y1, Y3, Y4, Y6
F2 Y1, Y3, Y5, Y6

NEGATIVE CABLE
TO BATTERY (3/0 AWG, BLACK)
F3 Y1, Y3, Y6
A B A B A B A B A B C A B
F4 Y1, Y6
POSITIVE CABLE
TO BATTERY (3/0 AWG, RED)
R1 Y2, Y3, Y4, Y6
R2 Y2, Y3, Y5, Y6 STARTER
CLT/461
RELAY
INJ A/491
INJ B/493
30
R3 Y2, Y3, Y6 ST RLY PWR
OIL PRS/467
THR RTN/914
THR RTN/914
MAN TMP/463
THR RTN/914
THR RTN/914
CRANK A/447
OVR SUP/911
FUEL TMP/428
CRANK B/448
STRT SOL 87
R4 Y2, Y6 ST RLY 86
ENG GND 85
12 TURNS
PER FOOT N1 Y6 (ONLY IF PARK BRAKE OFF)
TWIST (3/0 AWG, RED)
N2 Y6 (ONLY IF PARK BRAKE OFF) (3/0 AWG, BLACK)
N3 Y6 (ONLY IF PARK BRAKE OFF)

STARTER
1
ECU IGN/012
N4 Y6 (ONLY IF PARK BRAKE OFF)
2
ECU BAT/022
3
ECU GND/050 STRT SOL M
4
ENG GND
5
CLT TMP
6
PK BRK SOL
ST RLY PWR
7
OVR SGN/918
(3/0 AWG, RED)
8
FAULT LT/473
6A/400V
(4 AWG, RED)
9
ALT EXC
10
OVR SUP/911
11
THR SGN/915
12
THR RTN/914
13
ST RLY
ALTERNATOR
14
HR MTR (4 AWG, RED)
OIL PSI B+
15
HD36-24-29SE
G
16
GAGE PWR ALT EXC A
TRANS TMP SW A D+
6A/400V
POWER UNIT HARNESS

17
18
PLUGGED
TO CHASSIS ASSEMBLY
19
TRANS SOL Y1
20
PLUGGED
21
TRANS SOL Y2
TRANS SOL Y3 GAGE PWR 5 PSI ENGINE OIL
22 A
PLUGGED HR MTR PRESSURE
23 B
PLUGGED SWITCH
24
25
TRANS SOL Y4
26
TRANS SOL Y5
27
PLUGGED
28
PLUGGED
29
PLUGGED CLT TMP CLT TEMP
RESISTOR LOCATED SENDER
Power Unit Schematic
390 OHM, 1W AT SPLIT OF CRANK

SHTDN/941 SENSOR WIRES A/447& OIL PSI OIL PRESS
B/448 IN ENGINE SENDER
SHIELDED
ECU HARNESS
CAN TERMINATOR CABLE PK BRK SOL 1 PARK
ENG GND 2 BRAKE
A
(CAN H/904, YELLOW)
(CAN L/905, GREEN) VALVE
B
120 OHM C
(SHIELD/020)
SHIELDED
CAN TERMINATOR
CABLE
A
(CAN H/904, YELLOW)
B
(CAN L/905, GREEN)
120 OHM C
(SHIELD/020)
12 TURNS
PER FOOT
TWIST
SHIELDED
CABLE
TRANS SOL Y1
ENG GND
TRANS SOL Y2
ENG GND
TRANS SOL Y3
ENG GND
TRANS SOL Y4
ENG GND
TRANS SOL Y5
ENG GND
PK BRK SOL
ENG GND
TRANS TMP SW
ENG GND
SHTDN/941
ECU IGN/012
INJ B/493
CLT/461
CRANK A/447
OVR SGN/918
HI LO/947
PLUGGED
FUEL TMP/428
MAN TMP/463
CRANK B/448
THR RTN/914
THR SGN/915
OVR SUP/911
PLUGGED
CAN L/905
PLUGGED
OIL PRS/467
CAN H/904
PLUGGED
FAULT LT/473
PLUGGED
PLUGGED
PLUGGED
PLUGGED
ECU GND/050
PLUGGED
ECU BAT/022
INJ A/491
PLUGGED
A B A B A B A B A B A B A B
J1
A1
F1
E1
C1
G1
J2
J3
A2
A3
B1
D1
K1
H1
F2
F3
E2
E3
C2
C3
G2
G3
B2
B3
D2
D3
K2
K3
H2
H3
ECU GND/050
ECU IGN/012
(CAN H/904, YELLOW)
(CAN L/905, GREEN)
(SHIELD/020)
PLUGGED
PLUGGED
PLUGGED
PLUGGED
Y1 Y2 Y3 Y4 Y5 Y6 250 F
DEERE ENGINE ECU
TRANSMISSION
A B C D E F G H J
DIAGNOSTIC
MY1090
CONNECTOR
Electrical Wiring
4.9
4.10
FUEL
H
9 8
CHECK
5 6
36830B
CLUSTER GAUGE
ORANGE-16
BLACK-16
P
A
B
A
B
ORANGE-16
BLACK-16
38200C-4
GROUND
ENGINE TO
MAINFRAME
PIN 86 IS GROUND
ON ALL RELAYS 4.1.4
6 7 BOOM ENGINE ENGINE FUEL INCLUDED IN UPPER INCLUDED IN INTERMEDIATE FUEL LEVEL 30
TRANS
WATER FAULT EXTEND PARK WATER I G HARNESS 66944D HARNESS 66961D GA SEND CONNECT BATT GRD
LOCK BRAKE TEMP CONNECTS UNDER SEAT BOX CONNECTS UNDER SEAT BOX TO LOWER STARTER
5 8 P29317
7 TRANS OIL MOUNTING BOLT
36804X POWER
HOURMETER TEMP
4 9 12 1 4 S STARTER 65724A
LAMPS BRAKE MOTOR
REAR PRESS
ENGINE BATTERY NEG. CABLE 2/0 BLACK 86 85
3 10 OSC OIL VOLTAGE 66982A 87A
LOCK TRANS
GRD DISC PRESSURE D TRANSMISSION TEMP 4923233 DASH HARNESS 'O' 4923232 ENGINE HARNESS 'A'
10 CONNECTS TO ENGINE HARNESS CONNECTS UNDER SEAT BOX 38200C-3
2 11 11 SOLENOID GROUND
87
OIL UNDER THE SEAT BOX PINS 18 - 29 PLUGGED 35646A
HOUR + BATTERY - OPER COMP TO
METER 1 12 POS. CABLE 12V MAINFRAME
G R B G Y V W T P O
+ - R E L R E I H A I R BLACK-10 2/0 RED
1 SEE SHEET 3
E D A A L O I N N A RELAY SOCKE
E 1 C Y L L T 1 K N 2 SEE SHEET 3
F N 6 K 1 O E E 6 1 G 3 SEE SHEET 3 TOP VIEW
1 1 6 W T 1 6 E 4 PLUGGED WHITE-10
6 6 1 1 6 1
5 SEE SHEET 3 38200C-5
6 6 6
6 PLUGGED R
SEE SHEET 3 E
7
STARTER D RED-12
8 SEE SHEET 3 YELLOW-14
RELAY 6 >> A (SHEET 4)
9 67789A
10 SEE SHEET 3
RED-12
>> B (SHEET 4)
11 SEE SHEET 3 RED-14 S B+
12 SEE SHEET 3 RED-12
13 PLUGGED ALTERNATOR >> C (SHEET 4)
Electrical Wiring
BOSCH
14 SEE SHEET 3
Model 1044C-54
95 AMP RED-12
15 SEE SHEET 3 D+ >> D (SHEET 4)
16 SEE SHEET 3
17 SEE SHEET 3 4923247
RED-12
WIRE W/DIODE >> E (SHEET 4)
PINS 4,
ENGINE 38094A THROTTLE
WILLIAMS 6, 13 &
3 3
FAULT O/R TRANSMISSION (SUSPENDED) 18 - 29
2 (RESET) 2 DISCONNECT
R PLUGGED
A WHITE-12
SWITCH 7 SWITCH B
C - + 66679A SPST-N.O., 250 PSI 67062A SPST-N.O., 250 PSI RED-12
Q B D PLUGGED BRAKE PRESSURE SWITCH ON MACHINES W/ROADWAY LIGHTS
E PLUGGED
F PLUGGED N ON DIAGNOSTIC PANEL
OPTION
67063A SPST-N.O., 1000 PSI 67064A SPST-N.O., 1000 PSI BACK-UP
TAN-16 B BLACK-16 CIRCUIT LIGHT
ON MACHINES W/DRY DISC BRAKES ON MACHINES W/DRY DISC BRAKES BREAKERS
RED-16 A RED-16
& ROADWAY LIGHTS 40 AMP
P29694
T
WHITE-16 D BLUE-16 BACK-UP
66680A DPST-N.C. SWITCH, 850 PSI ALARM
RED-16 C BLACK-16 P13774
LOW BRAKE PRESSURE SWITCH
BLACK-16 B YELLOW-16
- ON DIAGNOSTIC PANEL + -
YELLOW-16 A BROWN-16 +
USE 67065A SPST-N.C. SWITCH, 1800 PSI A
+ -
ON MACHINES WITH DRY DISC BRAKES B
M 66891C (10366981)
CIRCUIT BOARD 38329A COIL
10 AMP
2-WAY SOLENOID VALVE ON
A BOOM ANGLE GREATER THAN 40° NO
VIOLET-14 SV3 REAR AXLE STABILIZER VALVE
BLACK-14 ON REAR STABILIZER CYLINDER BOOM ANGLE LESS THAN 40° NC
A IGN. P11092 B
ENERGIZED W/BOOM BELOW 40° 37115X PROXIMITY SENSOR IS N. O.
ACC. IGNITION ON TRANSFER CARRIAGE
ST. SWITCH
10 AMP BAT.
VIOLET-16 1 STAB. SOL. SV3 (1.2 AMP INRUSH) VIOLET-16
38329A COIL
PINK-16 2 BACK-UP ALARM (.6 AMPS) PINK-16 SOLENOID VALVE ON BROWN BLACK
TO PARKING BRAKE J14 A REAR AXLE STABILIZER
BLACK-16 3 GROUND (9.6 AMPS AT INRUSH) BLACK-16 POWER
RELAY TERM 85 SV1 POWER
CONTROL VALVE(ENERGIZED IN
(SEE SHEET 2). B OUT
YELLOW-14 4 START RELAY(.41-.48 AMPS) YELLOW-14 W/BOOM BELOW 20°)
E2 BLACK-14
ORANGE-16 5 STAB. SOL. SV1 (1.2 AMP INRUSH) ORANGE-16 GROUND
RED-16 A 38329A COIL BLUE
BLACK-16 6 GROUND (2.4 AMPS) BLACK-16
BLUE-16 B J15 A 3-WAY SOLENOID VALVE ON
BLUE-16 7 STAB. SOL. SV2 (1.2 AMP INRUSH) BLUE-16 REAR AXLE STABILIZER CONTROL
66941A DPST-N.C. SWITCH,100 PSI - + SV2
VALVE ON VALVE PLATE
GRAY-14 8 HORN (6 AMPS MAX.) GRAY-14 B
PARKING BRAKE PRESSURE SWITCH ENERGIZED W/BOOM BELOW 40° OR
UNDER DASH PANEL GREEN-16 9 40° SWITCH POWER OUT BLACK-14 BOOM ABOVE 40° & FOOT BOOM ANGLE GREATER THAN 20° NO
+ - BOOM ANGLE LESS THAN 20° NC
SWITCH DEPRESSED
PINK-16 A TRANSMISSION BOOM/ TRANSFER RED-16 10 12 VOLTS 37115X PROXIMITY SENSOR IS N. O.
REAR OSC.
EXTEND LOCKOUT J2 ON TRANSFER CARRIAGE
BLACK-16 B LOCK DISCONNECT BLACK-16 11 PROXIMITY SWITCH GROUND
TO PARKING BRAKE 4 SECTION BOOM ONLY HORN
WHITE-16 12 20° SWITCH POWER OUT P13707
E1 RELAY TERM 86
(SEE SHEET 2). 13 BROWN BLACK
LAMP #10 LAMP #11 LAMP #9 14 POWER
POWER
IN
OUT
WHITE-16 A LAMP #10 A WHITE-16 GREEN-16 D GREEN-16 D
RED-16 C RED-16 C GROUND
VIOLET-16 B LAMP #11 B VIOLET-16 INTERMEDIATE HARNESS, 66961D
BLACK-16 B BLACK-16 B BLUE
TAN-16 C LAMP #9 C TAN-16 CONNECTS UNDER SEAT BOX
WHITE-16 A WHITE-16 A
BLUE-16 D DECLUTCH D BLUE-16
65923A PROXIMITY 65924A PROXIMITY SWITCH HARNESS

'K' J8 SWITCH HARNESS,THRU ON TRANSFER CARRIAGE BOOM EXTEND GREATER THAN 20' NO
4923233 DASH HARNESS TRANSFER CARRIAGE BOOM EXTEND LESS THAN 20' NC
CONNECTS TO CIRCUIT 37115X PROXIMITY SENSOR IS N. O.
BOARD UNDER THE DASH BOOM BOOM FOOT ON OUTER BOOM
OVER 20° OVER 40° SWITCH
BACK-UP BOOM/TRANSFER EXTEND
NEUTRAL CUTOUT HARNESS, 66809C
ALARM
START CONNECTS UNDER SEAT BOX BROWN BLACK
66906A HARNESS 39351A PROXIMITY
66466X J1 SWITCH HARNESS,THRU POWER POWER
FOOT SWITCH,CONNECTS 86 30 86 30 86 30 R 86 30 R 86 30
MOMENTARY SWITCH BOOM TRANSFER CARRIAGE IN OUT
UNDER DASH D D YELLOW-16
TRANSMISSION ENGAGE/ EXTEND YELLOW-16
AXLE UNLOCK RED-16 C C RED-16 RED-16 C RED-16 C
85 87A 87 85 87A 87 85 87A 87 85 87A 87 85 87A 87 R
J9
R BLACK-16 B B BLACK-16 BLACK-16 B BLACK-16 B BLUE GROUND
WHITE-16 A A WHITE-16 WHITE-16 A WHITE-16 A
YELLOW-16 B ~1.5 AMPS B YELLOW-16
R
WHITE-16 A ~1.5 AMPS A WHITE-16 85 30 E 38329A COIL 38231A PROXIMITY SWITCH HARNESS
D WHITE-16
A ON OUTER BOOM
YELLOW-16
86
SV4
87A 87 BLACK-16 SOLENOID VALVE
B
85 30 BLACK-16 BOOM/TRANSFER EXTEND CUTOUT
85 30
R VALVE ON VALVE PLATE
4TH SPEED ENERGIZED WITH BOOM EXTENDED LESS
(USED ON 4 SECTION ONLY) A B B A THAN 20' OR OUTRIGGERS DOWN
86 87A 87
LOCKOUT RELAY
TRANS. 86 87A 87 REMOVE RELAY ON ALL
CUT-OUT OTHER MACHINES BLACK WHITE BLACK
TO CIRCUIT BOARD &
SHIFTER HARNESS J10
(SEE SHT 2)
A RED-16 BLACK-16 A
B YELLOW-16 YELLOW-16 B
C PINK-16 PINK-16 C
BLUE-16 D TO CIRCUIT BOARD RIGHT LEFT
D GRAY-16
GRAY-16 E & SHIFTER HARNESS
GREEN-16 F (SEE SHT 2) 68441A SPST-NO
A BROWN-16
B GREEN-16 DIFFERENTIAL PRESSURE SWITCH
TO CIRCUIT BOARD & C BLUE-16 J3 OUTRIGGER CYLINDERS-BASE END
SHIFTER HARNESS D VIOLET-16 CLOSED ABOVE 92 PSI DIFFERENTIAL
(SEE SHT 2) OPEN BELOW 92 PSI DIFFERENTIAL
J11
J16
WHITE-12 FROM ENGINE HARNESS, UNSWITCHED POWER
WHITE-14
L STUD ON BOARD
YELLOW-16 A NEUTRAL START RELAY .41-.48 AMPS A YELLOW-16

VIOLET-16 B IGN. SWITCH RELAY RELAY CURRENT B VIOLET-16
FUSES FOR CIRCUIT BOARD RELAYS FOR CIRCUIT BOARD J5
BLACK-16 C HORN RELAY RELAY CURRENT C
7.5 AMP: BROWN-LULL#66827X ALL ARE THE SAME RED-12 FROM ENGINE HARNESS, UNSWITCHED POWER
B IGN.
J12 85 30 10 AMP: RED-LULL#66828X 30/40 AMP-LULL#66820X
L SWITCH 15 AMP: BLUE-LULL#66829X
I A R RELAY S PUSHBUTTON
C
4923233 DASH HARNESS K 86 87A 87
SWITCH
HORN BUTTON CONNECTS TO CIRCUIT 1 P31598
KIT P18141 BOARD UNDER THE DASH 6
15 AMP FRONT REAR
F2 JOYSTICK JOYSTICK
7.5 AMP HORN
86 F3 (OPTION ON
30 R
10 AMP
HORN 6K MACHINES)
TRANS. & PROXIMITY SWITCHES.
RELAY
F 85 87A 87
10 AMP
F4 RED-16
R BACK-UP ALARM
J7 STUD ON BOARD BLUE-16
15 AMP SWITCHED POWER FOR OPTIONS A B A B
F5 39510B HARNESS
R
BOOM PROX. SWITCH RELAYS
J J4 38329A COIL
RED-16 A A RED-16 10 AMP 10 AMP

WHITE-16 B F6 F1 SELECTOR VALVE
B WHITE-16 LOW BRAKE R JOYSTICK R
GAGE PANEL/ NEUTRAL START 39076C
PRESSURE
J13 BUZZER
4923233 DASH HARNESS
CONNECTS TO CIRCUIT
BOARD UNDER THE DASH
MAN0260
RED-16
>> F (SHEET 4)
Before S/N 0160016632
John Deere Engine

ON WHEN BOOM ON WHEN ON WHEN SHIFTER ON WHEN ON WHEN
ON WHEN BOOM ON WHEN BOOM OVER 20° AND SHIFTER Y5 IS OFF AND FORWARD REVERSE
John Deere Engine

OVER 40° OVER 40° NOT OVER 40° Y5 IS ON BOOM IS 21-40° SELECTED SELECTED
RELAY K11 RELAY K12 RELAY K13 RELAY K14 RELAY K15 RELAY K16 RELAY K17
NOTES:
MAN0270
1. DIODE MODULES #1 AND #2 ARE IN TRANS
SOLENOID HARNESS (4923243).
30
87
86
85
30
87
86
85
30
87
86
85
30
87
86
85
30
87
86
85
30
87
86
85
30
87
86
85
87a
87a
87a
87a
87a
87a
87a
2. DIODES D1-D9 ARE INCLUDED IN TRANS
RELAY HARNESS ASSY (4923246).
N/C
N/C
N/C
N/C
N/C
N/C
JUMPER 1
JUMPER 2
JUMPER 1
JUMPER 2
IGN POWER
RELAY GND
RELAY GND
IGN POWER
RELAY GND
RELAY GND
RELAY GND
IGN POWER
RELAY GND
IGN POWER
RELAY GND
BOOM 21-40
BOOM 21-40
SHIFTER Y5
SHIFTER PWR
SOLENOID Y6
SOLENOID Y1
FORWARD SGN
SOLENOID Y2
REVERSE SGN
SHIFT TO 1ST
BOOM OVER 40
BOOM OVER 20
BOOM OVER 40
SHIFTER Y6 A
'A' OF CIRCUIT
BOARD &
SHIFTER HARNESS)
D1 D2 D3 D4 D5
A PLUGGED
B PLUGGED
C PLUGGED
D IGN POWER UPPER KOSTAL
TRANSMISSION
CONNECTOR
FROM CIRCUIT
('B' OF TRANS
BOARD J11
SOLENOID HARNESS)
(SEE SHT 1)
SOLENOID Y1 1
SOLENOID Y2 2
'B' OF CIRCUIT SOLENOID Y3 3
BOARD & DASH GND
SHIFTER HARNESS) 7
RELAY GND ONLY 4 OF 16

A PINS SHOWN
B FORWARD SGN (OTHERS NOT USED)
C REVERSE SGN
D BOOM OVER 40
E PLUGGED
DIODE
F BOOM OVER 20 MODULE
#1
FROM CIRCUIT
BOARD J3
(SEE SHT 1)
RELAY K18
'E' OF CIRCUIT
BOARD &
SHIFTER HARNESS)
30
87
86
85
87a
A DIRECTION INPUT
B FORWARD
C REVERSE
D NEUTRAL A UPPER KOSTAL
D10 TRANSMISSION
FROM CIRCUIT CONNECTOR
BOARD J10 ('C' OF TRANS
(SEE SHT 1) SOLENOID HARNESS)
NEUTRAL
NEUTRAL A
SOLENOID Y4 4
SOLENOID Y5 5
SOLENOID Y6 6
DASH GND 7
'C' OF CIRCUIT
BOARD & ONLY 4 OF 16
SHIFTER HARNESS) PINS SHOWN
DIRECTION INPUT (OTHERS NOT USED)
1
FORWARD
FROM E2 A (SEE SHT. 1)

2
3 REVERSE
NEUTRAL DIODE
4 MODULE
5 SHIFTER Y5 D6 #2
6 SHIFTER Y4 D7
7 SHIFTER Y3 D8
8 SHIFTER Y6 D9
9 SHIFTER PWR
10 PLUGGED
11 PLUGGED
12 PLUGGED
FROM SHIFTER
CONNECTOR
(SEE SHT 1)
TO DASH
GND STUD
Electrical Wiring
Before S/N 0160016632
4.11
MANIFOLD AIR COOLANT TEMP FUEL TEMP CRANK OIL PRESSURE INJECTOR
4.12
MAN0280
NOTES:
1. ALL CONNECTOR DESIGNATOR LETTERS ON THIS SHEET REFER TO THE
R Q P N F E ENGINE ECU HARNESS (4923232).
CLT/461
INJ A/491
INJ B/493
MAN TMP/463
THR RTN/914
THR RTN/914
THR RTN/914
CRANK A/447
CRANK B/448
THR RTN/914
OVR SUP/911
OIL PRS/467
FUEL TMP/428
12 TURNS
PER FOOT
TWIST
Electrical Wiring
A
1 ECU IGN/012
2 ECU BAT/022
3 ECU GND/050
4 PLUGGED
5 CLT TMP CLT TMP CLT TEMP
6 PLUGGED SENDER Q
7 OVR SGN/918 P23222
8 FAULT LT/473
9 ALT EXC SEE SHT 1 OIL PSI OIL PRESS
10 OVR SUP/911 SENDER L
11 THR SGN/915 P23217
12 THR RTN/914
13 PLUGGED
14 HR MTR
15 OIL PSI
GAGE PWR GAGE PWR 5 PSI ENGINE OIL
16 A
TRANS TEMP HR MTR PRESSURE
HD36-24-29SE
17 B
SWITCH
18 PLUGGED
K
19 PLUGGED
20 PLUGGED
21 PLUGGED
22 PLUGGED TRANS TEMP TRANS TEMP
23 PLUGGED SENDER V
TO DASH HARNESS (UNDER SEAT)

24 PLUGGED P19472
25 PLUGGED
26 PLUGGED
27 PLUGGED
28 PLUGGED
29 PLUGGED
390 OHM, 1W
SHTDN/941
SHIELDED
CAN TERMINATOR CABLE
A (CAN H/904, YELLOW)

B (CAN L/905, GREEN)
D 120 OHM C (SHIELD/020)
SHIELDED

H 120 OHM C (SHIELD/020)
12 TURNS
PER FOOT SHIELDED
TWIST CABLE
CLT/461
PLUGGED
PLUGGED
PLUGGED
PLUGGED
PLUGGED
PLUGGED
PLUGGED
PLUGGED
PLUGGED
PLUGGED
SHTDN/941
INJ B/493
HI LO/947
CAN L/905
CAN H/904
INJ A/491
ECU IGN/012
CRANK A/447
OVR SGN/918
MAN TMP/463
CRANK B/448
THR RTN/914
THR SGN/915
OVR SUP/911
OIL PRS/467
ECU GND/050
ECU BAT/022
FUEL TMP/428
FAULT LT/473
ECU GND/050
ECU IGN/012
(SHIELD/020)
PLUGGED
PLUGGED
PLUGGED
PLUGGED
(CAN L/905, GREEN)

(CAN H/904, YELLOW)
J
A1
A2
A3
B1
B2
B3
C1
C2
C3
D1
D2
D3
E1
E2
E3
F1
F2
F3
G1
G2
G3
H1
H2
H3
J1
J2
J3
K1
K2
K3
G
A B C D E F G H J
Before S/N 0160016632
DEERE ENGINE ECU DIAGNOSTIC

CONNECTOR
John Deere Engine

1 ED
1 (VP1/TRANSMISSION
F (SHT 1)
A (SHT 1)
E (SHT 1)
B (SHT 1)
CUT-OFF)
D (SHT 1)
C (SHT 1)
MAN0290
S1
2 3
2 AD4 (FORWARD)
John Deere Engine

S2
3 AD5 (REVERSE)
N/C FORWARD REVERSE NEUTRAL
87a
RED-16
RED-12
RED-12
RED-12
RED-12
RED-12
PIN
POWER (SHT 1) 30 4 AD6 (NEUTRAL)
SOLENOID
1 2 3 4 1 2 3 4 1 2 3 4
BEACON FUSE 87
LIGHT
AD1 Y3 S3
BEACON
RELAY GND 5 AD3 (SHIFTER Y5)
RELAY K18
86
AD2 Y4
J7 SWITCHED PWR 85 D1
S5
AD3 Y5
6 AD2 (SHIFTER Y4)
AD4 Y1
10 AMP
S4 D2
BEACON
LIGHT FUSE
AD5 Y2 7 AD1 (SHIFTER Y3)
AD6 S6
TO 8 AD7 (SHIFTER Y6)
BEACON N/C AD7 Y6
LIGHT 87a
POWER (SHT 1) 30 9 ED2 (VP/FUSED POWER)
WIPER FUSE 87 10 PLUGGED

DW3 SHIFTER SCHEMATIC
WIPER
RELAY GND
RELAY K19
86 11 PLUGGED
CONTROLS
NOTE: SWITCHES S1-S6 ARE RATED FOR
J7 SWITCHED PWR 0.6 AMPS WITH DAMPING DIODE.
85
12 PLUGGED
FUSE
WIPER
25 AMP
TRANSMISSION CONTROL VALVE OPERATION
SHIFTER SELECTION ACTIVATED SOLENOIDS
TO BOOM NOT OVER 20 DEGREES
WIPER N/C 87a FORWARD-4TH Y1, Y4, Y6
POWER (SHT 1) 30 FORWARD-3RD Y1, Y3, Y4, Y6
WK LIGHTS FUSE 87 FORWARD-2ND Y1, Y3, Y4, Y5
FORWARD-1ST Y1, Y3, Y5, Y6
LIGHTS
WORK
RELAY GND
RELAY K20
86 REVERSE-4TH Y2, Y3, Y4, Y6
J7 SWITCHED PWR 85 REVERSE-3RD Y2, Y3, Y4, Y6
REVERSE-2ND Y2, Y3, Y4, Y5
REVERSE-1ST Y2, Y3, Y5, Y6
FUSE
20 AMP
BOOM OVER 20 DEGREES AND NOT OVER 40 DEGREES
WORK LIGHTS
FORWARD-4TH Y1, Y3, Y4, Y5 (2ND GEAR)
TO FORWARD-3RD Y1, Y3, Y4, Y5 (2ND GEAR)
WORK N/C FORWARD-2ND Y1, Y3, Y4, Y5
LIGHTS 87a
POWER (SHT 1) 30 FORWARD-1ST Y1, Y3, Y5, Y6
REVERSE-4TH Y2, Y3, Y4, Y5 (2ND GEAR)
RD LIGHTS FUSE 87 REVERSE-3RD Y2, Y3, Y4, Y5 (2ND GEAR)
ROAD
LIGHTS
RELAY GND REVERSE-2ND Y2, Y3, Y4, Y5
RELAY K21
86
J7 SWITCHED PWR 85
BOOM OVER 40 DEGREES
(TRANS DISABLED UNLESS FOOTSWITCH PRESSED)
FUSE
25 AMP
FORWARD-4TH Y1, Y3, Y5, Y6 (1ST GEAR)
ROAD LIGHTS
FORWARD-3RD Y1, Y3, Y5, Y6 (1ST GEAR)
FORWARD-2ND Y1, Y3, Y5, Y6 (1ST GEAR)
TO
ROAD N/C FORWARD-1ST Y1, Y3, Y5, Y6
LIGHTS 87a
REVERSE-4TH Y2, Y3, Y5, Y6 (1ST GEAR)
POWER (SHT 1) 30
REVERSE-3RD Y2, Y3, Y5, Y6 (1ST GEAR)
HEATER-A/C FUSE 87
AND A/C REVERSE-2ND Y2, Y3, Y5, Y6 (1ST GEAR)
HEATER
RELAY GND 86
RELAY K22
J7 SWITCHED PWR 85
25 AMP
HEATER
& A/C FUSE
Electrical Wiring
TO
HEATER
AND A/C
Before S/N 0160016632
4.13
4.14
ORANGE-16 A A ORANGE-16 PIN 86 IS GROUND
38200C-4
36830B BLACK-16 B B BLACK-16 ON ALL RELAYS
GROUND
H CLUSTER GAUGE ENGINE TO
FUEL 9 8 5 6 MAINFRAME
CHECK P
6 7 BOOM ENGINE ENGINE FUEL INCLUDED IN UPPER INCLUDED IN INTERMEDIATE FUEL LEVEL 30
TRANS
WATER FAULT EXTEND PARK WATER I G HARNESS 66944D HARNESS 66961D GA SEND CONNECT BATT GRD
LOCK BRAKE TEMP CONNECTS UNDER SEAT BOX CONNECTS UNDER SEAT BOX TO LOWER STARTER
5 8 P29317
7 TRANS OIL MOUNTING BOLT
36804X POWER
HOURMETER TEMP
4 9 12 1 4 S STARTER 65724A
LAMPS BRAKE MOTOR
REAR PRESS
ENGINE BATTERY NEG. CABLE 2/0 BLACK 86 85
3 10 OSC OIL VOLTAGE 66982A 87A
LOCK TRANS
GRD DISC PRESSURE D TRANSMISSION TEMP 4923233 DASH HARNESS 'O' 4923232 ENGINE HARNESS 'A'
10 CONNECTS TO ENGINE HARNESS CONNECTS UNDER SEAT BOX 38200C-3
2 11 11 SOLENOID GROUND
87
OIL UNDER THE SEAT BOX PINS 18 - 29 PLUGGED 35646A
HOUR + BATTERY - OPER COMP TO
METER 1 12 POS. CABLE 12V MAINFRAME
G R B G Y V W T P O
+ - R E L R E I H A I R BLACK-10 2/0 RED
1 SEE SHEET 3
E D A A L O I N N A RELAY SOCKE
E 1 C Y L L T 1 K N 2 SEE SHEET 3
F N 6 K 1 O E E 6 1 G 3 SEE SHEET 3 TOP VIEW
1 1 6 W T 1 6 E 4 PLUGGED WHITE-10
6 6 1 1 6 1
5 SEE SHEET 3 38200C-5
6 6 6
6 PLUGGED R
SEE SHEET 3 E
7
STARTER D RED-12
8 SEE SHEET 3 YELLOW-14
RELAY 6 >> A (SHEET 4)
9 67789A
10 SEE SHEET 3
RED-12
>> B (SHEET 4)
11 SEE SHEET 3 RED-14 S B+
12 SEE SHEET 3 RED-12
13 PLUGGED ALTERNATOR >> C (SHEET 4)
BOSCH
14 SEE SHEET 3 95 AMP RED-12
15 SEE SHEET 3 D+ >> D (SHEET 4)
16 SEE SHEET 3
4923247
RED-12
Electrical Wiring
17 SEE SHEET 3
WIRE W/DIODE >> E (SHEET 4)
PINS 4,
ENGINE 38094A THROTTLE
WILLIAMS 6, 13 &
3 3
FAULT O/R TRANSMISSION (SUSPENDED) 18 - 29
2 (RESET) 2 DISCONNECT
R PLUGGED
A WHITE-12
SWITCH 7 SWITCH B
C - + 66679A SPST-N.O., 250 PSI 67062A SPST-N.O., 250 PSI RED-12
Q B D PLUGGED BRAKE PRESSURE SWITCH ON MACHINES W/ROADWAY LIGHTS
E PLUGGED
F PLUGGED N ON DIAGNOSTIC PANEL
OPTION
67063A SPST-N.O., 1000 PSI 67064A SPST-N.O., 1000 PSI BACK-UP
TAN-16 B BLACK-16 CIRCUIT LIGHT
ON MACHINES W/DRY DISC BRAKES ON MACHINES W/DRY DISC BRAKES BREAKERS
RED-16 A RED-16
& ROADWAY LIGHTS 40 AMP
P29694
T
WHITE-16 D BLUE-16 BACK-UP
66680A DPST-N.C. SWITCH, 850 PSI ALARM
RED-16 C BLACK-16 P13774
LOW BRAKE PRESSURE SWITCH
BLACK-16 B YELLOW-16
- ON DIAGNOSTIC PANEL + -
YELLOW-16 A BROWN-16 +
USE 67065A SPST-N.C. SWITCH, 1800 PSI A
+ -
ON MACHINES WITH DRY DISC BRAKES B
M 66891C (10366981)
CIRCUIT BOARD 38329A COIL
10 AMP
2-WAY SOLENOID VALVE ON
A BOOM ANGLE GREATER THAN 40° NO
VIOLET-14 SV3 REAR AXLE STABILIZER VALVE
BLACK-14 ON REAR STABILIZER CYLINDER BOOM ANGLE LESS THAN 40° NC
A IGN. P11092 B
ENERGIZED W/BOOM BELOW 40° 37115X PROXIMITY SENSOR IS N. O.
ACC. IGNITION ON TRANSFER CARRIAGE
ST. SWITCH
10 AMP BAT.
VIOLET-16 1 STAB. SOL. SV3 (1.2 AMP INRUSH) VIOLET-16
38329A COIL
PINK-16 2 BACK-UP ALARM (.6 AMPS) PINK-16 SOLENOID VALVE ON BROWN BLACK
TO PARKING BRAKE J14 A REAR AXLE STABILIZER
BLACK-16 3 GROUND (9.6 AMPS AT INRUSH) BLACK-16 POWER
RELAY TERM 85 SV1 POWER
CONTROL VALVE(ENERGIZED IN
(SEE SHEET 2). B OUT
YELLOW-14 4 START RELAY(.41-.48 AMPS) YELLOW-14 W/BOOM BELOW 20°)
E2 BLACK-14
ORANGE-16 5 STAB. SOL. SV1 (1.2 AMP INRUSH) ORANGE-16 GROUND
RED-16 A 38329A COIL BLUE
BLACK-16 6 GROUND (2.4 AMPS) BLACK-16
BLUE-16 B J15 A 3-WAY SOLENOID VALVE ON
BLUE-16 7 STAB. SOL. SV2 (1.2 AMP INRUSH) BLUE-16 REAR AXLE STABILIZER CONTROL
66941A DPST-N.C. SWITCH,100 PSI - + SV2
VALVE ON VALVE PLATE
GRAY-14 8 HORN (6 AMPS MAX.) GRAY-14 B
PARKING BRAKE PRESSURE SWITCH ENERGIZED W/BOOM BELOW 40° OR
UNDER DASH PANEL GREEN-16 9 40° SWITCH POWER OUT BLACK-14 BOOM ABOVE 40° & FOOT BOOM ANGLE GREATER THAN 20° NO
+ - BOOM ANGLE LESS THAN 20° NC
SWITCH DEPRESSED
PINK-16 A TRANSMISSION BOOM/ TRANSFER RED-16 10 12 VOLTS 37115X PROXIMITY SENSOR IS N. O.
REAR OSC.
EXTEND LOCKOUT J2 ON TRANSFER CARRIAGE
BLACK-16 B LOCK DISCONNECT BLACK-16 11 PROXIMITY SWITCH GROUND
TO PARKING BRAKE 4 SECTION BOOM ONLY HORN
WHITE-16 12 20° SWITCH POWER OUT P13707
E1 RELAY TERM 86
(SEE SHEET 2). 13 BROWN BLACK
LAMP #10 LAMP #11 LAMP #9 14 POWER
POWER
IN
OUT
WHITE-16 A LAMP #10 A WHITE-16 GREEN-16 D GREEN-16 D
RED-16 C RED-16 C GROUND
VIOLET-16 B LAMP #11 B VIOLET-16 INTERMEDIATE HARNESS, 66961D
BLACK-16 B BLACK-16 B BLUE
TAN-16 C LAMP #9 C TAN-16 CONNECTS UNDER SEAT BOX
WHITE-16 A WHITE-16 A
BLUE-16 D DECLUTCH D BLUE-16
65923A PROXIMITY 65924A PROXIMITY SWITCH HARNESS

'K' J8 SWITCH HARNESS,THRU ON TRANSFER CARRIAGE BOOM EXTEND GREATER THAN 20' NO
4923233 DASH HARNESS TRANSFER CARRIAGE BOOM EXTEND LESS THAN 20' NC
CONNECTS TO CIRCUIT 37115X PROXIMITY SENSOR IS N. O.
BOARD UNDER THE DASH BOOM BOOM FOOT ON OUTER BOOM
OVER 20° OVER 40° SWITCH
BACK-UP BOOM/TRANSFER EXTEND
NEUTRAL CUTOUT HARNESS, 66809C
ALARM
START CONNECTS UNDER SEAT BOX BROWN BLACK
66906A HARNESS 39351A PROXIMITY
66466X J1 SWITCH HARNESS,THRU POWER POWER
FOOT SWITCH,CONNECTS 86 30 86 30 86 30 R 86 30 R 86 30
MOMENTARY SWITCH BOOM TRANSFER CARRIAGE IN OUT
UNDER DASH D D YELLOW-16
TRANSMISSION ENGAGE/ EXTEND YELLOW-16
AXLE UNLOCK RED-16 C C RED-16 RED-16 C RED-16 C
85 87A 87 85 87A 87 85 87A 87 85 87A 87 85 87A 87 R
J9
R BLACK-16 B B BLACK-16 BLACK-16 B BLACK-16 B BLUE GROUND
WHITE-16 A A WHITE-16 WHITE-16 A WHITE-16 A
YELLOW-16 B ~1.5 AMPS B YELLOW-16
R
WHITE-16 A ~1.5 AMPS A WHITE-16 85 30 E 38329A COIL 38231A PROXIMITY SWITCH HARNESS
D WHITE-16
A ON OUTER BOOM
YELLOW-16
86
SV4
87A 87 BLACK-16 SOLENOID VALVE
B
85 30 BLACK-16 BOOM/TRANSFER EXTEND CUTOUT
85 30
R VALVE ON VALVE PLATE
4TH SPEED ENERGIZED WITH BOOM EXTENDED LESS
(USED ON 4 SECTION ONLY) A B B A THAN 20' OR OUTRIGGERS DOWN
86 87A 87
LOCKOUT RELAY
TRANS. 86 87A 87 REMOVE RELAY ON ALL
CUT-OUT OTHER MACHINES BLACK WHITE BLACK
TO CIRCUIT BOARD &
SHIFTER HARNESS J10
(SEE SHT 2)
A RED-16 BLACK-16 A
B YELLOW-16 YELLOW-16 B
C PINK-16 PINK-16 C
BLUE-16 D TO CIRCUIT BOARD RIGHT LEFT
D GRAY-16
GRAY-16 E & SHIFTER HARNESS
GREEN-16 F (SEE SHT 2) 68441A SPST-NO
A BROWN-16
B GREEN-16 DIFFERENTIAL PRESSURE SWITCH
TO CIRCUIT BOARD & C BLUE-16 J3 OUTRIGGER CYLINDERS-BASE END
SHIFTER HARNESS D VIOLET-16 CLOSED ABOVE 92 PSI DIFFERENTIAL
(SEE SHT 2) OPEN BELOW 92 PSI DIFFERENTIAL
J11
J16
WHITE-12 FROM ENGINE HARNESS, UNSWITCHED POWER
WHITE-14
L STUD ON BOARD
YELLOW-16 A NEUTRAL START RELAY .41-.48 AMPS A YELLOW-16

VIOLET-16 B IGN. SWITCH RELAY RELAY CURRENT B VIOLET-16
FUSES FOR CIRCUIT BOARD RELAYS FOR CIRCUIT BOARD J5
BLACK-16 C HORN RELAY RELAY CURRENT C
7.5 AMP: BROWN-LULL#66827X ALL ARE THE SAME RED-12 FROM ENGINE HARNESS, UNSWITCHED POWER
B IGN. 10 AMP: RED-LULL#66828X 30/40 AMP-LULL#66820X
J12 85 30
L SWITCH 15 AMP: BLUE-LULL#66829X
I A R RELAY S PUSHBUTTON
C
4923233 DASH HARNESS K 86 87A 87
SWITCH
HORN BUTTON CONNECTS TO CIRCUIT 1 P31598
KIT P18141 BOARD UNDER THE DASH 6
15 AMP FRONT REAR
F2 JOYSTICK JOYSTICK
7.5 AMP HORN
86 F3 (OPTION ON
30 R
10 AMP
HORN 6K MACHINES)
TRANS. & PROXIMITY SWITCHES.
RELAY
F 85 87A 87
10 AMP
F4 RED-16
R BACK-UP ALARM
J7 STUD ON BOARD BLUE-16
15 AMP SWITCHED POWER FOR OPTIONS A B A B
F5 39510B HARNESS
R
BOOM PROX. SWITCH RELAYS
J J4 38329A COIL
RED-16 A A RED-16 10 AMP 10 AMP

WHITE-16 B F6 F1 SELECTOR VALVE
B WHITE-16 LOW BRAKE R JOYSTICK R
GAGE PANEL/ NEUTRAL START 39076C
PRESSURE
J13 BUZZER
4923233 DASH HARNESS
CONNECTS TO CIRCUIT
BOARD UNDER THE DASH
S/N 0160016632 & After
MAN0220
RED-16
John Deere Engine

ON WHEN BOOM ON WHEN ON WHEN SHIFTER ON WHEN ON WHEN
ON WHEN BOOM ON WHEN BOOM OVER 20° AND SHIFTER Y5 IS OFF AND FORWARD REVERSE
OVER 40° OVER 40° NOT OVER 40° Y5 IS ON BOOM IS 21-40° SELECTED SELECTED NOTES:
John Deere Engine

1. DIODE MODULES #1 AND #2 ARE IN TRANS
RELAY K11 RELAY K12 RELAY K13 RELAY K14 RELAY K15 RELAY K16 RELAY K17 SOLENOID HARNESS (4923243).
2. DIODES D1-D9 ARE INCLUDED IN TRANS
MAN0230
RELAY HARNESS ASSY (4923246).
30
87
86
85
30
87
86
85
30
87
86
85
30
87
86
85
30
87
86
85
30
87
86
85
30
87
86
85
87a
87a
87a
87a
87a
87a
87a
N/C
N/C
N/C
N/C
N/C
N/C
JUMPER 1
JUMPER 2
JUMPER 1
JUMPER 2
IGN POWER
RELAY GND
RELAY GND
IGN POWER
RELAY GND
RELAY GND
RELAY GND
IGN POWER
RELAY GND
IGN POWER
RELAY GND
BOOM 21-40
BOOM 21-40
SHIFTER Y5
SHIFTER PWR
SOLENOID Y6
SOLENOID Y1
FORWARD SGN
SOLENOID Y2
REVERSE SGN
SHIFT TO 1ST
BOOM OVER 40
BOOM OVER 20
BOOM OVER 40
SHIFTER Y6 A
'A' OF CIRCUIT
BOARD &
SHIFTER HARNESS)
D1 D2 D3 D4 D5
A PLUGGED
B PLUGGED
C PLUGGED
D IGN POWER UPPER KOSTAL
TRANSMISSION
CONNECTOR
FROM CIRCUIT
('B' OF TRANS
BOARD J11
SOLENOID HARNESS)
(SEE SHT 1)
SOLENOID Y1 1
SOLENOID Y2 2
'B' OF CIRCUIT SOLENOID Y3 3
BOARD & DASH GND
SHIFTER HARNESS) 7
RELAY GND ONLY 4 OF 16

A PINS SHOWN
B FORWARD SGN (OTHERS NOT USED)
C REVERSE SGN
D BOOM OVER 40
E PLUGGED
DIODE
F BOOM OVER 20 MODULE
#1
FROM CIRCUIT
BOARD J3
(SEE SHT 1)
RELAY K18
'E' OF CIRCUIT
BOARD &
SHIFTER HARNESS)
30
87
86
85
87a
A DIRECTION INPUT
B FORWARD
C REVERSE
D NEUTRAL A UPPER KOSTAL
D10 TRANSMISSION
FROM CIRCUIT CONNECTOR
BOARD J10 ('C' OF TRANS
(SEE SHT 1) SOLENOID HARNESS)
NEUTRAL
NEUTRAL A
SOLENOID Y4 4
SOLENOID Y5 5
SOLENOID Y6 6
DASH GND 7
'C' OF CIRCUIT
BOARD & ONLY 4 OF 16
SHIFTER HARNESS) PINS SHOWN
DIRECTION INPUT (OTHERS NOT USED)
1
FORWARD

2
3 REVERSE
NEUTRAL DIODE
4 MODULE
5 SHIFTER Y5 D6 #2
6 SHIFTER Y4 D7
7 SHIFTER Y3 D8
8 SHIFTER Y6 D9
9 SHIFTER PWR
10 PLUGGED
11 PLUGGED
12 PLUGGED
FROM SHIFTER
CONNECTOR
(SEE SHT 1)
TO DASH
GND STUD
Electrical Wiring
S/N 0160016632 & After
4.15
4.16
MANIFOLD AIR COOLANT TEMP FUEL TEMP CRANK OIL PRESSURE INJECTOR
NOTES:
MAN0240
1. ALL CONNECTOR DESIGNATOR LETTERS ON THIS SHEET REFER TO THE
ENGINE ECU HARNESS (4923232).
R Q P N F E
CLT/461
INJ A/491
INJ B/493
MAN TMP/463
THR RTN/914
THR RTN/914
THR RTN/914
CRANK A/447
CRANK B/448
THR RTN/914
OVR SUP/911
OIL PRS/467
FUEL TMP/428
12 TURNS
PER FOOT
Electrical Wiring
TWIST
A
1 ECU IGN/012
2 ECU BAT/022
3 ECU GND/050
4 PLUGGED
5 CLT TMP CLT TMP CLT TEMP
6 PLUGGED SENDER Q
7 OVR SGN/918 P23222
8 FAULT LT/473
9 ALT EXC SEE SHT 1 OIL PSI OIL PRESS
10 OVR SUP/911 SENDER L
11 THR SGN/915 P23217
12 THR RTN/914
13 PLUGGED
14 HR MTR
15 OIL PSI
GAGE PWR GAGE PWR 5 PSI ENGINE OIL
16 A
TRANS TEMP HR MTR PRESSURE
HD36-24-29SE
17 B
SWITCH
18 PLUGGED
K
19 PLUGGED
20 PLUGGED
21 PLUGGED
22 PLUGGED TRANS TEMP TRANS TEMP
23 PLUGGED SENDER V
TO DASH HARNESS (UNDER SEAT)

24 PLUGGED P19472
25 PLUGGED
26 PLUGGED
27 PLUGGED
28 PLUGGED
29 PLUGGED
390 OHM, 1W
SHTDN/941
SHIELDED

D 120 OHM C (SHIELD/020)
SHIELDED

H 120 OHM C (SHIELD/020)
12 TURNS
PER FOOT SHIELDED
TWIST CABLE
CLT/461
PLUGGED
PLUGGED
PLUGGED
PLUGGED
PLUGGED
PLUGGED
PLUGGED
PLUGGED
PLUGGED
PLUGGED
SHTDN/941
INJ B/493
HI LO/947
CAN L/905
CAN H/904
INJ A/491
ECU IGN/012
CRANK A/447
OVR SGN/918
MAN TMP/463
CRANK B/448
THR RTN/914
THR SGN/915
OVR SUP/911
OIL PRS/467
ECU GND/050
ECU BAT/022
FUEL TMP/428
FAULT LT/473
ECU GND/050
ECU IGN/012
(SHIELD/020)
PLUGGED
PLUGGED
PLUGGED
PLUGGED
(CAN L/905, GREEN)

(CAN H/904, YELLOW)
A1
A2
A3
B1
B2
B3
C1
C2
C3
D1
D2
D3
E1
E2
E3
F1
F2
F3
G1
G2
G3
H1
H2
H3
J1
J2
J3
K1
K2
K3
G
A B C D E F G H J
S/N 0160016632 & After
DEERE ENGINE ECU DIAGNOSTIC

CONNECTOR
John Deere Engine

1 ED
1 (VP1/TRANSMISSION
F (SHT 1)
A (SHT 1)
E (SHT 1)
B (SHT 1)
CUT-OFF)
D (SHT 1)
C (SHT 1)
MAN0250
S1
John Deere Engine

2 3
2 AD4 (FORWARD)
S2
3 AD5 (REVERSE)
N/C FORWARD REVERSE NEUTRAL
87a
RED-16
RED-12
RED-12
RED-12
RED-12
RED-12
PIN
POWER (SHT 1) 30 4 AD6 (NEUTRAL)
SOLENOID
1 2 3 4 1 2 3 4 1 2 3 4
BEACON FUSE 87
LIGHT
AD1 Y3 S3
BEACON
RELAY GND 5 AD3 (SHIFTER Y5)
RELAY K18
86
AD2 Y4
J7 SWITCHED PWR 85 D1
S5
AD3 Y5
6 AD2 (SHIFTER Y4)
AD4 Y1
10 AMP
S4 D2
BEACON
LIGHT FUSE
AD5 Y2 7 AD1 (SHIFTER Y3)
AD6 S6
TO 8 AD7 (SHIFTER Y6)
BEACON N/C AD7 Y6
LIGHT 87a
POWER (SHT 1) 30 9 ED2 (VP/FUSED POWER)
WIPER FUSE 87 10 PLUGGED

DW3 SHIFTER SCHEMATIC
WIPER
RELAY GND
RELAY K19
86 11 PLUGGED
CONTROLS
NOTE: SWITCHES S1-S6 ARE RATED FOR
J7 SWITCHED PWR 0.6 AMPS WITH DAMPING DIODE.
85
12 PLUGGED
FUSE
WIPER
25 AMP
TRANSMISSION CONTROL VALVE OPERATION
SHIFTER SELECTION ACTIVATED SOLENOIDS
TO BOOM NOT OVER 20 DEGREES
WIPER N/C 87a FORWARD-4TH Y1, Y4, Y6
POWER (SHT 1) 30 FORWARD-3RD Y1, Y3, Y4, Y6
WK LIGHTS FUSE 87 FORWARD-2ND Y1, Y3, Y4, Y5
FORWARD-1ST Y1, Y3, Y5, Y6
LIGHTS
WORK
RELAY GND
RELAY K20
86 REVERSE-4TH Y2, Y3, Y4, Y6
J7 SWITCHED PWR 85 REVERSE-3RD Y2, Y3, Y4, Y6
REVERSE-2ND Y2, Y3, Y4, Y5
FUSE
20 AMP
BOOM OVER 20 DEGREES AND NOT OVER 40 DEGREES
WORK LIGHTS
FORWARD-4TH Y1, Y3, Y4, Y5 (2ND GEAR)
TO FORWARD-3RD Y1, Y3, Y4, Y5 (2ND GEAR)
WORK N/C FORWARD-2ND Y1, Y3, Y4, Y5
LIGHTS 87a
POWER (SHT 1) 30 FORWARD-1ST Y1, Y3, Y5, Y6
REVERSE-4TH Y2, Y3, Y4, Y5 (2ND GEAR)
RD LIGHTS FUSE 87 REVERSE-3RD Y2, Y3, Y4, Y5 (2ND GEAR)
ROAD
LIGHTS
RELAY GND REVERSE-2ND Y2, Y3, Y4, Y5
RELAY K21
86
J7 SWITCHED PWR 85
BOOM OVER 40 DEGREES
(TRANS DISABLED UNLESS FOOTSWITCH PRESSED)
FUSE
25 AMP
FORWARD-4TH Y1, Y3, Y5, Y6 (1ST GEAR)
ROAD LIGHTS
FORWARD-3RD Y1, Y3, Y5, Y6 (1ST GEAR)
FORWARD-2ND Y1, Y3, Y5, Y6 (1ST GEAR)
TO
ROAD N/C FORWARD-1ST Y1, Y3, Y5, Y6
LIGHTS 87a
REVERSE-4TH Y2, Y3, Y5, Y6 (1ST GEAR)
POWER (SHT 1) 30
REVERSE-3RD Y2, Y3, Y5, Y6 (1ST GEAR)
HEATER-A/C FUSE 87 REVERSE-2ND Y2, Y3, Y5, Y6 (1ST GEAR)
AND A/C
HEATER REVERSE-1ST Y2, Y3, Y5, Y6
RELAY GND
RELAY K22
86
J7 SWITCHED PWR 85
25 AMP
HEATER
& A/C FUSE
Electrical Wiring
TO
HEATER
AND A/C
S/N 0160016632 & After
4.17
Electrical Wiring
This Page Intentionally Left Blank

JLG Industries, Inc.
1 JLG Drive
McConnellsburg PA. 17233-9533
USA
Phone: (717) 485-5161
Customer Support Toll Free: (877) 554-5438
Fax: (717) 485-6417
JLG Worldwide Locations

JLG Industries (Australia) JLG Latino Americana Ltda. JLG Industries (UK) JLG EQS
P.O. Box 5119 Rua Eng. Carlos Stevenson, Unit 4 & 5 Z.I. De Beaulieu
11 Bolwarra Road 80-Suite 71 Bentley Avenue 47400 Fuillet
Port Macquarie 13092-310 Campinas-SP M24 2GP Middleton France
N.S.W. 2444 Brazil Stockport Phone: (33) 553 848 584
Australia Phone: (55) 193 295 0407 England Fax: (33) 553 848 588
Phone: (61) 265 811 111 Fax: (55) 193 295 1025 Phone: (44) 161 654 1000
Fax: (61) 265 810 122 Fax: (44) 161 654 1003
JLG Deutschland GmbH JLG Equipment Services Ltd. JLG Industries (Italia) JLG Europe B.V.
Max Planckstrasse 21 Rm 1107 Landmark North Via Po. 22 Polaris Avenue 63
D-27721 Ritterhude/lhlpohl 39 Lung Sum Avenue 20010 Pregnana Milanese - MI 2132 JH Hoofddorp
Bei Bremen Sheung Shui N.T. Italy The Netherlands
Germany Hong Kong Phone: (39) 029 359 5210 Phone: (31) 235 655 665
Phone: (49) 421 693 500 Phone: (852) 2639 5783 Fax: (39) 029 359 5845 Fax: (31) 235 572 493
Fax: (49) 421 693 5035 Fax: (852) 2639 5797
JLG Polska JLG Industries (Scotland) Plataformas Elevadoras JLG Industries (Sweden)
UI. Krolewska Wright Business Centre JLG Iberica, S.L. Enkopingsvagen 150
00-060 Warsawa 1 Lonmay Road Trapadella, 2 Box 704
Poland Queenslie, Glasgow G33 4EL P.I. Castellbisbal Sur SE - 17527 Jarfalla
Phone: (48) 914 320 245 Scotland 08755Castellbisbal, Barcelona Sweden
Fax: (48) 914 358 200 Phone: (44) 141 781 6700 Spain Phone: (46) 850 659 500
Fax: (44) 141 773 1907 Phone: (34) 937 724 700 Fax: (46) 850 659 534
Fax: (34) 937 711 762

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Service Manual

February 2, 2007 - A - Original Issue Of Manual

31200371 John Deere Engine i

-ii John Deere Engine 31200371

John Deere Engine i

ii John Deere Engine

PARAGRAPH TITLE PAGE

John Deere Engine 1.1

1.1 INTRODUCTION 1.2 DISCLAIMER

1.2 John Deere Engine

1.5 SAFETY INFORMATION 1.6 SAFETY INSTRUCTIONS

1.6.2 Equipment Hazards

John Deere Engine 1.3

1.6.3 General Hazards appropriate container and dispose of in accordance with

1.4 John Deere Engine

PARAGRAPH TITLE PAGE

John Deere Engine 2.1

2.2 John Deere Engine

2.3 ELECTRONIC CONTROL SYSTEM

John Deere Engine 2.3

2.4 ELECTRONIC CONTROL SYSTEM 2.6 ELECTRONIC CONTROL SYSTEM

2.5 MONITORING ENGINE PARAMETERS

2.4 John Deere Engine

2.7 ECU CONNECTOR LEGEND Pin Wire Designation

MAN0150 C1 947 (Purple, 18)

John Deere Engine 2.5

2.8 OEM TRIM OPTION SETTINGS External Shutdown

2.6 John Deere Engine

PARAGRAPH TITLE PAGE

John Deere Engine 3.1

3.1 TROUBLESHOOTING PROCEDURE

3.2 John Deere Engine

Fault Codes SPN Codes FMI Codes Definition

John Deere Engine 3.3

66 105 16 Manifold Air Temperature Moderately High

84 158 17 ECU Power Down Error

3.4 John Deere Engine

3.3 ENGINE DERATE CHART

Sensor Measured Sensor Out of Range Value Derate

John Deere Engine 3.5

3.4 ENGINE TROUBLESHOOTING

3.4.1 Engine Cranks, Will Not Start

MAN0010 ECU HARNESS CONNECTOR

3.6 John Deere Engine

If pressure is high, worn or stuck rings are indicated,

-40°F -20°F -0°F 20°F 40°F 60°F 80°F 100°F 120°F

Cranking speed should meet or exceed specified engine rpm for

If cranking speed is below specifications, check the following:

John Deere Engine 3.7

3.4.2 Engine Will Not Crank

MAN0010 ECU HARNESS CONNECTOR

3.8 John Deere Engine

3.4.3 Engine Over Speed

A A Crank Position Input

MAN0060 ECU HARNESS CONNECTOR

a. Ignition OFF • If continuity is not found, there is an open in the

John Deere Engine 3.9

7. Test the ECU connector

3.10 John Deere Engine

1. Refer to Section 2, “General Troubleshooting” for initial

John Deere Engine 3.11

3.5 ECU TROUBLESHOOTING

3.5.1 ECU Switched Power