Page 1
Alternators And Starting Motors—Use CTM77
For additional information, the component technical
manual (CTM) is also required.
Use the CTM in conjunction with this machine manual.
Group 20
References
TS225 –UN–17JAN89
TX,20,111114 –19–04SEP96–1/1
9015
20
1
TM1637 (15JAN04)
9015-20-1
644H and 644H MH Loader
011504
PN=391
Page 2
References
Diagnostic Trouble Code Quick Reference List
CCU SERVICE CODES
• F0275 CCU Power Dissipation Excessive
TRANSMISSION SYSTEM CODES:
• F0300 Oil Temperature High Long
• F0305 TCU Output Speed Zero
• F0306 TCU Voltage Low
• F0307 TCU Voltage High
• F0308 TCU Valve Solenoid Power
• F0309 TCU Park Brake Solenoid Power
• F0315 Oil Filter Circuit Short-to-Power
• F0320 1st Gear Clutch Slippage
9015
• F0321 2nd Gear Clutch Slippage
20
• F0322 3rd Gear Clutch Slippage
2
• F0323 4th Gear Clutch Slippage
• F0324 Forward Gear Clutch Slippage
• F0325 Reverse Gear Clutch Slippage
• F0330 Clutch Cut-Off Circuit Voltage Low
• F0331 Clutch Cut-Off Circuit Voltage High
• F0336 TCU Configuration Bad
• F0337 TCU Memory Bad
• F0339 Temperature Sensor Voltage Short-to-Ground
• F0340 Temperature Sensor Voltage Short-to-Power
• F0341 Output Speed Signal Bad
• F0342 Output Speed Circuit Short-to-Ground
• F0343 Output Speed Circuit Short-to-Power
• F0344 Internal Clutch Speed Signal Bad
• F0345 Internal Clutch Speed Circuit Short-to-Ground
• F0346 Internal Clutch Speed Circuit Short-to-Power
• F0347 Turbine Speed Signal Bad
• F0348 Turbine Speed Circuit Short-to-Ground
• F0349 Turbine Speed Circuit Short-to-Power
• F0350 Input Speed Signal Bad
• F0351 Input Speed Circuit Short-to-Ground
• F0352 Input Speed Circuit Short-to-Power
• F0353 FWD High Range Clutch Pack Solenoid
Open
• F0354 FWD High Range Clutch Pack Solenoid Short
to Ground
• F0355 FWD High Range Clutch Pack Solenoid Short
to Power
• F0356 Third Speed Clutch Pack Solenoid Open
• F0357 Third Speed Clutch Pack Solenoid
Short-to-Ground
• F0358 Third Speed Clutch Pack Solenoid
Short-to-Power
• F0359 Second Speed Clutch Pack Solenoid Open
• F0360 Second Speed Clutch Pack Solenoid
Short-to-Ground
• F0361 Second Speed Clutch Pack Solenoid
Short-to-Power
• F0362 First Speed Clutch Pack Solenoid Open
• F0363 First Speed Clutch Pack Solenoid
Short-to-Ground
• F0364 First Speed Clutch Pack Solenoid
Short-to-Power
• F0365 Reverse Clutch Pack Solenoid Open
• F0366 Reverse Clutch Pack Solenoid
Short-to-Ground
• F0367 Reverse Clutch Pack Solenoid
Short-to-Power
• F0368 FWD Low Range Clutch Pack Solenoid Open
• F0369 FWD Low Range Clutch Pack Solenoid
Short-to-Ground
• F0370 FWD Low Range Clutch Pack Solenoid
Short-to-Power
• F0375 Gear Selector
• F0377 Oil Temperature Circuit Short-to-Power
• F0378 Oil Temperature Circuit Open
• F0379 FNR Selector Switch Open
• F0380 Oil Filter Restricted
• F0384 Reverse Alarm Relay Short-to-Power
• F0385 Reverse Alarm Relay Short-to-Ground
• F0386 Reverse Alarm Relay Open
• F0387 Park Brake Solenoid Short-to-Power
• F0388 Park Brake Solenoid Short-to-Ground
• F0389 Park Brake Solenoid Open
• F0396 Oil Temperature High
TM1637 (15JAN04)
Continued on next page
9015-20-2
CED,TX17864,29 –19–30MAR99–1/3
644H and 644H MH Loader
011504
PN=392
Page 3
References
NOTE: Some engine codes are listed more than once.
Access codes with Service ADVISOR to
determine SPN.FMI number. If using monitor
both diagnostic procedure should be followed.
Fuel injection system will be Level 3 or Level 9
Electronic fuel injection system. The term level is
simply a means to identify fuel systems. Level 3
system meters the fuel at the injection pump. Level 9
system uses a High Pressure Common Rail (HPCR)
and meters fuel at the injectors. See Distinguishing
ECUs on 8.1 L Engines in CTM134.
ENGINE SYSTEM CODES:
• F0400 Oil Pressure Low Long
• F0411 Analog Throttle (A) Input High
• F0412 Analog Throttle (A) Input Low
• F0413 PWM Throttle Input Too High
• F0414 PWM Throttle Input Too Low
• F0415 CCU Throttle Circuit Voltage Low
• F0416 CCU Throttle Circuit Voltage High
• F0419 ECU Sensor Voltage High
• F0420 ECU Sensor Voltage Low
• F0423 Ambient Air Temperature Input Voltage High
(Level 3 ECU)
• F0423 Ambient Air Temperature Input Voltage High
(Level 9 ECU)
• F0424 Ambient Air Temperature Input Voltage Low
(Level 3 ECU)
• F0424 Ambient Air Temperature Input Voltage Low
(Level 9 ECU)
• F0425 Engine Coolant Temperature Input Voltage
High (Level 3 ECU)
• F0425 Engine Coolant Temperature Input Voltage
High (Level 9 ECU)
• F0426 Engine Coolant Temperature Input Voltage
Low (Level 3 ECU)
• F0426 Engine Coolant Temperature Input Voltage
Low (Level 9 ECU)
• F0431 Cylinder #1 EI Circuit Open
• F0431 Cylinder #1 EI Circuit Shorted
• F0432 Cylinder #2 EI Circuit Open
• F0432 Cylinder #2 EI Circuit Shorted
• F0433 Cylinder #3 EI Circuit Open
• F0433 Cylinder #3 EI Circuit Shorted
• F0434 Cylinder #4 EI Circuit Open
• F0434 Cylinder #4 EI Circuit Shorted
• F0435 Cylinder #5 EI Circuit Open
• F0435 Cylinder #5 EI Circuit Shorted
• F0436 Cylinder #6 EI Circuit Open
• F0436 Cylinder #6 EI Circuit Shorted
• F0437 Fuel Temperature Input Voltage Too High
(Level 3 ECU)
• F0437 Fuel Temperature Input Voltage High (Level 9
ECU)
• F0438 Fuel Temperature Input Voltage Too Low
(Level 3 ECU)
• F0438 Fuel Temperature Input Voltage Too Low
(Level 9 ECU)
• F0439 Pump Control Valve #1 Error
• F0440 Pump Control Valve #2 Error
• F0441 Crank Position Input Missing
• F0442 Crank Position Input Noise
• F0442 Crank Position Input Pattern Error
• F0443 Pump Position Sensor Input Missing
• F0444 Pump Position Sensor Input Noise
• F0444 Pump Position Sensor Input Pattern Error
• F0445 Crank Position/Pump Position Timing
Moderately Out of Sync
• F0446 Rack Measurement Error
• F0447 Rack Position Error
• F0448 Rack Position Voltage High
• F0449 Rack Position Voltage Low
• F0450 Fuel Rail Pressure Input Voltage High
• F0451 Fuel Rail Pressure Input Voltage Low
• F0453 Water in Fuel Signal Voltage High
• F0454 Water in Fuel Signal Voltage Low
• F0455 Manifold Air Temperature Moderately High
• F0456 Pump Control Valve #2 Fuel Flow Not
Detected
• F0462 ECU Primary Speed Error
• F0463 ECU Start Signal Missing
• F0464 Engine Overspeed
• F0465 ECU Auxiliary Speed Error
• F0466 ECU Speed Signal Mismatch
• F0467 ECU Start Signal Active
• F0468 Fuel Shutoff Fault
• F0469 Pump Control Valve #1 Fuel Flow Not
Detected
• F0470 Fuel Rail Pressure Control Error
9015
20
3
TM1637 (15JAN04)
Continued on next page
9015-20-3
CED,TX17864,29 –19–30MAR99–2/3
644H and 644H MH Loader
011504
PN=393
Page 4
References
• F0471 Fuel Rail Pressure Sensor Supply Voltage
Low
• F0478 Oil Pressure Circuit Voltage Low
• F0479 Oil Pressure Circuit Voltage High
• F0485 Water in Fuel Detected
• F0499 Engine Oil Pressure Low
• F0500 Engine Coolant Temperature High Long
• F0515 Engine Air Filter Restriction Circuit
• F0516 Engine Fuel Level Circuit Voltage Low
• F0517 Engine Fuel Level Circuit Open
• F0575 Engine Coolant Level Circuit
• F0576 Engine Coolant Temperature Circuit Noisy
• F0577 Engine Coolant Temperature Circuit
Short-to-Ground
• F0578 Engine Coolant Temperature Circuit Open
• F0580 Engine Air Filter Restricted
9015
• F0588 Engine Coolant Level Low
20
• F0599 Engine Coolant Temperature High
4
STEERING SYSTEM CODES:
• F0998 Steering Pressure Circuit
• F0999 Steering Pressure Low
BRAKE SYSTEM CODES:
• F1637 CCU Timer Reset
• F1638 Proportional Fan Drive Solenoid Circuit Error
• F1639 Reverse Fan Drive Solenoid Circuit Error
• F1641 Drive Light Switch Circuit Open
• F1644 MDU Memory Bad
• F1645 CCU Memory Bad
• F1647 Machine Odometer Bad
• F1648 Machine Hourmeter Bad
• F1649 CCU Hourmeter Bad
• F1651 No ECU CAN Transmit
• F1653 No CCU CAN Transmit
• F1655 No TCU CAN Transmit
• F1658 Power Voltage Balance
• F1660 Alternator Voltage High
• F1661 Alternator Voltage Low
• F1662 Power Voltage High
• F1663 Power Voltage Low
• F1664 Brake Light Pressure Circuit
• F1665 Drive Light Switch Circuit
• F1667 Turn Switch Circuit Short
• F1668 Hazard Switch Circuit
• F1671 Return to Carry Detent Solenoid Circuit Error
• F1672 Boom Height Kickout Detent Solenoid Circuit
Error
• F1699 Configuration Bad
• F1097 Service Brake Pressure Circuit
• F1099 Service Brake Pressure Low
ELECTRICAL SYSTEM CODES:
• F1620 CCU Spare Relay #1 Short
• F1621 CCU Spare Relay #3 Short
• F1622 CCU Spare Relay #4 Short
• F1623 CCU Spare Relay #5 Short
• F1624 Air Preheat Driver Short Ground
• F1625 Detent Enable Driver Short-to-Ground
• F1626 Ride Control Boom Driver Short-to-Ground
• F1628 Ride Control On Driver Short-to-Ground
• F1629 Left Turn Driver Short-to-Ground
• F1630 Right Turn Driver Short-to-Ground
• F1633 Secondary Steering Driver Short-to-Ground
• F1634 Rear Wiper Driver Short-to-Ground
• F1635 Front Wiper Driver Short-to-Ground
• F1636 CCU Relay Driver Overtemp
HYDRAULIC SYSTEM CODES:
• F2100 Oil Temperature High Long
• F3115 Oil Filter Restriction Circuit Short-to-Ground
• F3150 Oil Filter Restriction Circuit Short-to-Power
• F3160 Ride Control Circuit Short-to-Power
• F3161 Ride Control Auto Circuit Short-to-Ground
• F3162 Ride Control On Circuit Short-to-Ground
• F3163 Boom Position Voltage Low
• F3165 Boom Position Voltage High
• F3171 Hydraulic Oil Pressure Circuit Voltage Low
• F3172 Hydraulic Oil Pressure Circuit Voltage High
• F3173 LPM Mode Circuit
• F3174 LPM Enable Circuit Short-to-Ground
• F3175 Hydraulic Oil Temperature Circuit
Short-to-Ground
• F3176 Hydraulic Oil Temperature Circuit Open
• F3177 Hydraulic Oil Temperature Circuit Noisy
• F3199 Hydraulic Oil Temperature High
TM1637 (15JAN04)
9015-20-4
CED,TX17864,29 –19–30MAR99–3/3
644H and 644H MH Loader
011504
PN=394
Page 5
References
Transmission Diagnostic Trouble Codes
(DTCs)
IMPORTANT: Whenever a Transmission Control Unit
(TCU), a Chassis Computer Unit (CCU),
or Monitor Display Unit (MDU) is
replaced, the MDU must be
reconfigured in the Service Menu. See
Monitor Display Unit Reconfiguration
Access Service Menu, Machine Model
(S 01), Tire Size (S 03), Enable Options
(S 06), and Delete Diagnostic Trouble
Codes in Group 9015—15.
NOTE: A Diagnostic Trouble Code (DTC) is the same as
a Service Code. The term DTC conforms with the
standards set by the Society of Automotive
Engineers (SAE).
References:
See System Functional Schematic
9015
20
5
Symptom Problem
Solution
F0275 CCU Power Dissipation CCU (A2) CCU (Replace)
Excessive
MDU (Reconfigure). See Monitor
Display Unit Reconfiguration Access
Service Menu, Machine Model (S
01), Tire Size (S 03), Enable Options
(S 06), and Delete Diagnostic
Trouble Codes in Group 9015—15.
F0300 Transmission Oil Transmission Oil Type Wrong Transmission Oil Type
Temperature High Long* (Check/Replace)
Tell-Tale Code displayed in MDU
“Service” menu. See Monitor
Display Unit —Service Menu—
Tell-Tale Diagnostic Trouble
Codes (S 02) in Group 9015-15.
Transmission Oil Level Too High or Transmission Oil Level
Too Low (Check/Adjust)
TM1637 (15JAN04)
Continued on next page
9015-20-5
TX,9015,111902 –19–30MAR99–1/32
644H and 644H MH Loader
011504
PN=395
Page 6
References
Symptom Problem
9015
20
6
Solution
Transmission Oil Cooler Internal Transmission Oil Cooler Internal
Restriction Restriction (Check/Repair)
Transmission Oil Cooler Air Flow Transmission Oil Cooler Air Flow
Restriction Restriction (Check/Repair)
Transmission Oil Cooler Air Flow
Restriction (Check/Clean)
Transmission Oil Temperature Transmission Oil Temperature
Sensor (B32) Short-To-Ground Sensor (B32) Short-To-Ground
(Check/Replace)
Transmission Main Pressure Transmission Main Pressure
Regulating Valve Spring Broken Regulating Valve Spring Broken
(Check/Replace)
Transmission Oil Pump Inlet Screen Transmission Oil Pump Inlet Screen
Plugged (Check/Clean)
Transmission Control Valve Gasket Transmission Control Valve Gasket
(Check/Replace)
Torque Converter Relief Valve Stuck Torque Converter Relief Valve
Open (Check/Repair)
Transmission Oil Cooler Bypass Transmission Oil Cooler Bypass
Valve Stuck Open Valve Stuck Open (Check/Repair)
Transmission Oil Pump Worn Transmission Oil Pump Worn
(Check/Replace)
F0305 TCU Output Speed Zero Rocker, Restriction, Radio Switches Rocker, Restriction, Radio Switches
5A fuse (F23) 5A fuse (F23), Check/Replace
Transmission Output Shaft Speed Transmission Output Shaft Speed
Sensor (B31) Sensor (B31), Check/Replace
Wire M10 (Purple) Harness (W10) Transmission Harness (W10)—M10
Short-To-Power (Purple) Short-To-Power
(Check/Repair)
Wire R22 (Black) Harness (W10) Transmission Harness (W10)—R22
Short-To-Battery (Black) Short-To-Battery
(Check/Repair)
TM1637 (15JAN04)
Continued on next page
9015-20-6
TX,9015,111902 –19–30MAR99–2/32
644H and 644H MH Loader
011504
PN=396
Page 7
References
Symptom Problem
Solution
TCU (A3) TCU (Replace)
F0306 TCU Voltage Low Batteries Batteries (Recharge/Replace)
Alternator Alternator (G4), Check/Repair
F0307 TCU Voltage High Batteries Batteries (Recharge/Replace)
Alternator Alternator (G4), Check/Repair
F0308 TCU Valve Solenoid Power TCU (A3) TCU (Replace)
F0309 TCU Park Brake Solenoid TCU (A3) TCU (Replace)
Power
F0315 Transmission Oil Filter Transmission Oil Filter Restriction Transmission Oil Filter Restriction
Circuit Short-To-Power Switch (B20) Short-To-Power Switch (B20) Short-To-Power
(Check/Replace)
Wire N03 (Yellow) Harness (W10) Transmission Harness (W10) - N03
Short-To-Power (Yellow) Short-To-Power
(Check/Repair)
9015
20
7
Wire N03 (Yellow) Harness (W3) Load Center Harness (W3) - N03
Short-To-Power (Yellow) Short-To-Power
(Check/Repair)
CCU (A2) CCU (Replace)
MDU (Reconfigure). See Monitor
Display Unit Reconfiguration Access
Service Menu, Machine Model (S
01), Tire Size (S 03), Enable Options
(S 06), and Delete Diagnostic
Trouble Codes in Group 9015—15.
F0320 Transmission 1st Gear Transmission Oil Pump Inlet Screen Transmission Oil Pump Inlet Screen
Clutch Slippage Plugged (Clean)
Transmission Oil Type Wrong Transmission Oil Type
(Check/Replace)
Transmission Control Valve Transmission Control Valve
(Check/Replace)
TM1637 (15JAN04)
Continued on next page
9015-20-7
TX,9015,111902 –19–30MAR99–3/32
644H and 644H MH Loader
011504
PN=397
Page 8
References
Symptom Problem
9015
20
8
Solution
Transmission Control Valve Gasket Transmission Control Valve Gasket
Leaking (Replace)
Transmission Oil Pump Worn Transmission Oil Pump Worn
(Check/Replace)
Transmission Control Solenoid (Y1) Transmission Control Solenoid (Y1)
Malfunction (Replace)
Transmission Control Solenoid (Y2) Transmission Control Solenoid (Y2)
Malfunction (Replace)
Transmission Control Solenoid (Y3) Transmission Control Solenoid (Y3)
Malfunction (Replace)
Transmission Control Solenoid (Y4) Transmission Control Solenoid (Y4)
Malfunction (Replace)
Transmission Control Solenoid (Y5) Transmission Control Solenoid (Y5)
Malfunction (Replace)
Transmission Control Solenoid (Y6) Transmission Control Solenoid (Y6)
Malfunction (Replace)
Transmission Output Speed Shaft Transmission Output Speed Shaft
Sensor (B31) Open Sensor (B31) Open (Check/Repair)
Wire M10 (Purple) Harness (W10) Transmission Harness (W10) - M10
Open (Purple) Open (Check/Repair)
Wire M10 (Purple) Harness (W3) Load Center Harness (W3) - M10
Open (Purple) Open (Check/Repair)
F0321 Transmission 2nd Gear Transmission Oil Pump Inlet Screen Transmission Oil Pump Inlet Screen
Clutch Slippage Plugged (Clean)
Transmission Oil Type Wrong Transmission Oil Type
(Check/Replace)
Transmission Control Valve Transmission Control Valve
(Check/Replace)
Transmission Control Valve Gasket Transmission Control Valve Gasket
Leaking (Replace)
TM1637 (15JAN04)
Continued on next page
9015-20-8
TX,9015,111902 –19–30MAR99–4/32
644H and 644H MH Loader
011504
PN=398
Page 9
References
Symptom Problem
Transmission Oil Pump Worn Transmission Oil Pump Worn
Transmission Control Solenoid (Y1) Transmission Control Solenoid (Y1)
Malfunction (Replace)
Transmission Control Solenoid (Y2) Transmission Control Solenoid (Y2)
Malfunction (Replace)
Transmission Control Solenoid (Y3) Transmission Control Solenoid (Y3)
Malfunction (Replace)
Transmission Control Solenoid (Y4) Transmission Control Solenoid (Y4)
Malfunction (Replace)
Transmission Control Solenoid (Y5) Transmission Control Solenoid (Y5)
Malfunction (Replace)
Transmission Control Solenoid (Y6) Transmission Control Solenoid (Y6)
Malfunction (Replace)
Transmission Output Speed Shaft Transmission Output Speed Shaft
Sensor (B31) Open Sensor (B31) Open (Check/Repair)
Solution
(Check/Replace)
9015
20
9
Wire M10 (Purple) Harness (W10) Transmission Harness (W10) - M10
Open (Purple) Open (Check/Repair)
Wire M10 (Purple) Harness (W3) Load Center Harness (W3) - M10
Open (Purple) Open (Check/Repair)
F0322 Transmission 3rd Gear Transmission Oil Pump Inlet Screen Transmission Oil Pump Inlet Screen
Clutch Slippage Plugged (Clean)
Transmission Oil Type Wrong Transmission Oil Type
(Check/Replace)
Transmission Control Valve Transmission Control Valve
(Check/Replace)
Transmission Control Valve Gasket Transmission Control Valve Gasket
Leaking (Replace)
Transmission Oil Pump Worn Transmission Oil Pump Worn
(Check/Replace)
TM1637 (15JAN04)
Continued on next page
9015-20-9
TX,9015,111902 –19–30MAR99–5/32
644H and 644H MH Loader
011504
PN=399
Page 10
References
Symptom Problem
9015
20
10
Solution
Transmission Control Solenoid (Y1) Transmission Control Solenoid (Y1)
Malfunction (Replace)
Transmission Control Solenoid (Y2) Transmission Control Solenoid (Y2)
Malfunction (Replace)
Transmission Control Solenoid (Y3) Transmission Control Solenoid (Y3)
Malfunction (Replace)
Transmission Control Solenoid (Y4) Transmission Control Solenoid (Y4)
Malfunction (Replace)
Transmission Control Solenoid (Y5) Transmission Control Solenoid (Y5)
Malfunction (Replace)
Transmission Control Solenoid (Y6) Transmission Control Solenoid (Y6)
Malfunction (Replace)
Transmission Output Speed Shaft Transmission Output Speed Shaft
Sensor (B31) Open Sensor (B31) Open (Check/Repair)
Wire M10 (Purple) Harness (W10) Transmission Harness (W10) - M10
Open (Purple) Open (Check/Repair)
Wire M10 (Purple) Harness (W3) Load Center Harness (W3) - M10
Open (Purple) Open (Check/Repair)
F0323 Transmission 4th Gear Transmission Oil Pump Inlet Screen Transmission Oil Pump Inlet Screen
Clutch Slippage Plugged (Clean)
Transmission Oil Type Wrong Transmission Oil Type
(Check/Replace)
Transmission Control Valve Transmission Control Valve
(Check/Replace)
Transmission Control Valve Gasket Transmission Control Valve Gasket
Leaking (Replace)
Transmission Oil Pump Worn Transmission Oil Pump Worn
(Check/Replace)
Transmission Control Solenoid (Y1) Transmission Control Solenoid (Y1)
Malfunction (Replace)
TM1637 (15JAN04)
Continued on next page
9015-20-10
TX,9015,111902 –19–30MAR99–6/32
644H and 644H MH Loader
011504
PN=400
Page 11
References
Symptom Problem
Transmission Control Solenoid (Y2) Transmission Control Solenoid (Y2)
Malfunction (Replace)
Transmission Control Solenoid (Y3) Transmission Control Solenoid (Y3)
Malfunction (Replace)
Transmission Control Solenoid (Y4) Transmission Control Solenoid (Y4)
Malfunction (Replace)
Transmission Control Solenoid (Y5) Transmission Control Solenoid (Y5)
Malfunction (Replace)
Transmission Control Solenoid (Y6) Transmission Control Solenoid (Y6)
Malfunction (Replace)
Transmission Output Speed Shaft Transmission Output Speed Shaft
Sensor (B31) Open Sensor (B31) Open (Check/Repair)
Wire M09 (Purple) Harness (W10) Transmission Harness (W10) - M09
Open (Purple) Open (Check/Repair)
Wire M09 (Purple) Harness (W3) Load Center Harness (W3) - M09
Open (Purple) Open (Check/Repair)
Solution
9015
20
11
F0324 Transmission Forward Transmission Oil Pump Inlet Screen Transmission Oil Pump Inlet Screen
Gear Clutch Slippage Plugged (Clean)
Transmission Oil Type Wrong Transmission Oil Type
(Check/Replace)
Transmission Control Valve Transmission Control Valve
(Check/Replace)
Transmission Control Valve Gasket Transmission Control Valve Gasket
Leaking (Replace)
Transmission Oil Pump Worn Transmission Oil Pump Worn
(Check/Replace)
Transmission Control Solenoid (Y1) Transmission Control Solenoid (Y1)
Malfunction (Replace)
Transmission Control Solenoid (Y2) Transmission Control Solenoid (Y2)
Malfunction (Replace)
TM1637 (15JAN04)
Continued on next page
9015-20-11
TX,9015,111902 –19–30MAR99–7/32
644H and 644H MH Loader
011504
PN=401
Page 12
References
Symptom Problem
Solution
Transmission Control Solenoid (Y3) Transmission Control Solenoid (Y3)
Malfunction (Replace)
Transmission Control Solenoid (Y4) Transmission Control Solenoid (Y4)
Malfunction (Replace)
Transmission Control Solenoid (Y5) Transmission Control Solenoid (Y5)
Malfunction (Replace)
Transmission Control Solenoid (Y6) Transmission Control Solenoid (Y6)
Malfunction (Replace)
Transmission Internal Clutch Speed Transmission Internal Clutch Speed
9015
20
12
Sensor (B30) Open Sensor (B30) Open (Check/Repair)
Wire M09 (Purple) Harness (W10) Transmission Harness (W10) - M09
Open (Purple) Open (Check/Repair)
Wire M09 (Purple) Harness (W3) Load Center Harness (W3) - M09
Open (Purple) Open (Check/Repair)
F0325 Transmission Reverse Transmission Oil Pump Inlet Screen Transmission Oil Pump Inlet Screen
Gear Clutch Slippage Plugged (Clean)
Transmission Oil Type Wrong Transmission Oil Type
(Check/Replace)
Transmission Control Valve Transmission Control Valve
(Check/Replace)
Transmission Control Valve Gasket Transmission Control Valve Gasket
Leaking (Replace)
Transmission Oil Pump Worn Transmission Oil Pump Worn
(Check/Replace)
Transmission Control Solenoid (Y1) Transmission Control Solenoid (Y1)
Malfunction (Replace)
Transmission Control Solenoid (Y2) Transmission Control Solenoid (Y2)
Malfunction (Replace)
Transmission Control Solenoid (Y3) Transmission Control Solenoid (Y3)
Malfunction (Replace)
TM1637 (15JAN04)
Continued on next page
9015-20-12
TX,9015,111902 –19–30MAR99–8/32
644H and 644H MH Loader
011504
PN=402
Page 13
References
Symptom Problem
Solution
Transmission Control Solenoid (Y4) Transmission Control Solenoid (Y4)
Malfunction (Replace)
Transmission Control Solenoid (Y5) Transmission Control Solenoid (Y5)
Malfunction (Replace)
Transmission Control Solenoid (Y6) Transmission Control Solenoid (Y6)
Malfunction (Replace)
Transmission Internal Clutch Speed Transmission Internal Clutch Speed
Sensor (B30) Open Sensor (B30) Open (Check/Repair)
Wire M09 (Purple) Harness (W10) Transmission Harness (W10) - M09
Open (Purple) Open (Check/Repair)
Wire M09 (Purple) Harness (W3) Load Center Harness (W3) - M09
Open (Purple) Open (Check/Repair)
F0330 Transmission Clutch Clutch Cut-off Sensor (B33) Open Or Clutch Cut-off Sensor (B33)
Cut-off Circuit Voltage Low Short-To-Ground Open/Short-To-Ground
(Check/Replace)
Wire T20 (Blue) Harness (W3) Open Load Center Harness (W3) - T20
Or Short-To-Ground (Blue) Open or Short-To-Ground
(Check/Repair)
9015
20
13
TCU (A3) TCU (Replace)
MDU (Reconfigure). See Monitor
Display Unit Reconfiguration Access
Service Menu, Machine Model (S
01), Tire Size (S 03), Enable Options
(S 06), and Delete Diagnostic
Trouble Codes in Group 9015—15.
F0331 Transmission Clutch Clutch Cut-off Sensor (B33) Short To Clutch Cut-off Sensor (B33) Short To
Cut-off Circuit Voltage High Power Or Open Power or Open (Check/Replace)
Wire T20 (Blue) Harness (W3) Short Load Center Harness (W3) - T20
to Power or Open (Blue) Short-To-Power or Open
(Check/Repair)
TCU (A3) TCU (Replace)
TM1637 (15JAN04)
Continued on next page
9015-20-13
TX,9015,111902 –19–30MAR99–9/32
644H and 644H MH Loader
011504
PN=403
Page 14
References
Symptom Problem
Solution
MDU (Reconfigure). See Monitor
Display Unit Reconfiguration Access
Service Menu, Machine Model (S
01), Tire Size (S 03), Enable Options
(S 06), and Delete Diagnostic
Trouble Codes in Group 9015—15.
F0336 TCU Configuration Bad MDU Configuration Incorrect MDU (Reconfigure). See Monitor
Display Unit Reconfiguration Access
Service Menu, Machine Model (S
01), Tire Size (S 03), Enable Options
(S 06), and Delete Diagnostic
Trouble Codes in Group 9015—15.
9015
20
14
TCU (A3) TCU (Replace)
MDU (Reconfigure)
CCU (A2) CCU (Replace)
MDU (Reconfigure)
F0337 TCU Memory Bad TCU (A3) TCU (Replace)
MDU (Reconfigure). See Monitor
Display Unit Reconfiguration Access
Service Menu, Machine Model (S
01), Tire Size (S 03), Enable Options
(S 06), and Delete Diagnostic
Trouble Codes in Group 9015—15.
F0339 Transmission Temperature Transmission Oil Temperature Transmission Oil Temperature
Sensor Voltage Short-To- Ground Sensor (B32) Short-To-Ground Sensor (B32) Short-To-Ground
(Check/Replace)
Wire P23 (Red) Harness (W3) Load Center Harness (W3) - P23
Short-To-Ground (Red) Short-To-Ground
(Check/Repair)
Wire P23 (Red) Harness (W10) Transmission Harness (W10) - P23
Short-To-Ground (Red) Short-To-Ground
(Check/Repair)
Transmission Clutch Cutoff Sensor Transmission Clutch Cutoff Sensor
(B33) Short-To-Ground (B33) Short-To-Ground
(Check/Replace)
TM1637 (15JAN04)
Continued on next page
9015-20-14
TX,9015,111902 –19–30MAR99–10/32
644H and 644H MH Loader
011504
PN=404
Page 15
References
Symptom Problem
Solution
Wire P60 (Red) Harness (W3) Load Center Harness (W3) - P60
Short-To-Ground (Red) Short-To-Ground
(Check/Repair)
TCU (A3) TCU (Replace)
MDU (Reconfigure). See Monitor
Display Unit Reconfiguration Access
Service Menu, Machine Model (S
01), Tire Size (S 03), Enable Options
(S 06), and Delete Diagnostic
Trouble Codes in Group 9015—15.
F0340 Transmission Temperature Transmission Oil Temperature Transmission Oil Temperature
Sensor Voltage Short-To- Power Sensor (B32) Short-To-Power Sensor (B32) Short-To-Power
(Check/Replace)
Wire P23 (Red) Harness (W3) Load Center Harness (W3) - P23
Short-To-Power (Red) Short-To-Power Check/Repair)
Wire P23 (Red) Harness (W10) Transmission Harness (W10) - P23
Short-To-Ground (Red) Short-To-Power
(Check/Repair)
9015
20
15
F0341 Transmission Output Transmission Output Shaft Speed Transmission Output Shaft Speed
Speed Signal Bad Sensor (B31) Open Sensor (B31) Open (Check/Replace)
Wire M10 (Purple) Harness (W10) Transmission Harness (W10) - M10
Open (Purple) Open (Check/Repair)
Wire M10 (Purple) Harness (W3) Load Center Harness (W3) - M10
Open (Purple) Open (Check/Repair)
TCU (A3) TCU (Replace)
MDU (Reconfigure). See Monitor
Display Unit Reconfiguration Access
Service Menu, Machine Model (S
01), Tire Size (S 03), Enable Options
(S 06), and Delete Diagnostic
Trouble Codes in Group 9015—15.
F0342 Transmission Output Transmission Output Shaft Speed Transmission Output Shaft Speed
Speed Circuit Short-To- Ground Sensor (B31) Short-To-Ground Sensor (B31) Short-To-Ground
(Check/Replace)
TM1637 (15JAN04)
Continued on next page
9015-20-15
TX,9015,111902 –19–30MAR99–11/32
644H and 644H MH Loader
011504
PN=405
Page 16
References
Symptom Problem
Solution
Wire M10 (Purple) Harness (W10) Transmission Harness (W10) - M10
Short-To-Ground (Purple) Short-To-Ground
(Check/Repair)
Wire M10 (Purple) Harness (W3) Load Center Harness (W3) - M10
Short-To-Ground (Purple) Short-To-Ground
(Check/Repair)
TCU (A3) TCU (Replace)
MDU (Reconfigure). See Monitor
Display Unit Reconfiguration Access
Service Menu, Machine Model (S
9015
20
16
01), Tire Size (S 03), Enable Options
(S 06), and Delete Diagnostic
Trouble Codes in Group 9015—15.
F0343 Transmission Output F2—Start Aid, Converter and Check fuse F2. See Fuse
Speed Circuit Short-To- Power Secondary Steering 10A Fuse Specifications..
Suspect fuse F2 only for Serial
Number (578660—- )
Transmission Output Shaft Speed Transmission Output Shaft Speed
Sensor (B31) Short-To-Power Sensor (B31) Short-To-Power
(Check/Replace)
Wire M10 (Purple) Harness (W10) Transmission Harness (W10) - M10
Short-To-Power (Purple) Short-To-Power
(Check/Repair). See System
Functional Schematic. See
Transmission Harness (W10)
Component Location.
Wire M10 (Purple) Harness (W3) Load Center Harness (W3) - M10
Short-To-Power (Purple) Short-To-Power
(Check/Repair). See System
Functional Schematic. See Load
Center Harness (W3) Component
Location..
TM1637 (15JAN04)
Continued on next page
9015-20-16
TX,9015,111902 –19–30MAR99–12/32
644H and 644H MH Loader
011504
PN=406
Page 17
References
Symptom Problem
Wire P04 Red Open Check P04 Wire. See System
Wire P27 Red Open Check P27 Wire. See System
TCU (A3) TCU (Replace)
Solution
Functional Schematic. See
Transmission Harness (W10)
Component Location.
Suspect wire P04 only for Serial
Number (578660—- )
Functional Schematic. See
Transmission Harness (W10)
Component Location.
Suspect wire P27 only for Serial
Number ( —578659)
MDU (Reconfigure). See Monitor
Display Unit Reconfiguration Access
Service Menu, Machine Model (S
01), Tire Size (S 03), Enable Options
(S 06), and Delete Diagnostic
Trouble Codes in Group 9015—15.
9015
20
17
F0344 Transmission Internal Transmission Internal Clutch Speed Transmission Internal Clutch Speed
Clutch Speed Signal Bad Sensor (B30) Open Sensor (B30) Open (Check/Replace)
Wire M09 (Purple) Harness (W10) Transmission Harness (W10) - M09
Open (Purple) Open (Check/Repair)
Wire M09 (Purple) Harness (W3) Load Center Harness (W3) - M09
Open (Purple) Open (Check/Repair)
TCU (A3) TCU (Replace)
MDU (Reconfigure). See Monitor
Display Unit Reconfiguration Access
Service Menu, Machine Model (S
01), Tire Size (S 03), Enable Options
(S 06), and Delete Diagnostic
Trouble Codes in Group 9015—15.
TM1637 (15JAN04)
Continued on next page
9015-20-17
TX,9015,111902 –19–30MAR99–13/32
644H and 644H MH Loader
011504
PN=407
Page 18
References
Symptom Problem
Solution
F0345 Transmission Internal Transmission Internal Clutch Speed Transmission Internal Clutch Speed
Speed Circuit Short-To- Ground Sensor (B30) Short-To-Ground Sensor (B30) Short-To-Ground
(Check/Replace)
Wire M09 (Purple) Harness (W10) Transmission Harness (W10) - M09
Short-To-Ground (Purple) Short-To-Ground
(Check/Repair)
Wire M09 (Purple) Harness (W3) Load Center Harness (W3) - M09
Short-To-Ground (Purple) Short-To-Ground
(Check/Repair)
TCU (A3) TCU (Replace)
9015
20
18
MDU (Reconfigure). See Monitor
Display Unit Reconfiguration Access
Service Menu, Machine Model (S
01), Tire Size (S 03), Enable Options
(S 06), and Delete Diagnostic
Trouble Codes in Group 9015—15.
F0346 Transmission Internal Transmission Internal Clutch Speed Transmission Internal Clutch Speed
Speed Circuit Short-To- Power Sensor (B30) Short-To-Power Sensor (B30) Short-To-Power
(Check/Replace)
Wire M09 (Purple) Harness (W10) Transmission Harness (W10) - M09
Short-To-Power (Purple) Short-To-Power
(Check/Repair)
Wire M09 (Purple) Harness (W3) Load Center Harness (W3) - M09
Short-To-Power (Purple) Short-To-Power
(Check/Repair)
TCU (A3) TCU (Replace)
MDU (Reconfigure). See Monitor
Display Unit Reconfiguration Access
Service Menu, Machine Model (S
01), Tire Size (S 03), Enable Options
(S 06), and Delete Diagnostic
Trouble Codes in Group 9015—15.
F0347 Transmission Turbine Torque Converter Output Speed Torque Converter Output Speed
Speed Signal Bad Sensor (B29) Open Sensor (B29) Open (Check/Replace)
TM1637 (15JAN04)
Continued on next page
9015-20-18
TX,9015,111902 –19–30MAR99–14/32
644H and 644H MH Loader
011504
PN=408
Page 19
References
Symptom Problem
Solution
Torque Converter Output Speed Torque Converter Output Speed
Sensor (B29) Loose Sensor (B29) Open (Check/Replace)
Wire M08 (Purple) Harness (W10) Transmission Harness (W10) - M08
Open (Purple) Open (Check/Repair)
Wire M08 (Purple) Harness (W3) Load Center Harness (W3) - M08
Open (Purple) Open (Check/Repair)
TCU (A3) TCU (Replace)
MDU (Reconfigure). See Monitor
Display Unit Reconfiguration Access
Service Menu, Machine Model (S
01), Tire Size (S 03), Enable Options
(S 06), and Delete Diagnostic
Trouble Codes in Group 9015—15.
F0348 Transmission Turbine Torque Converter Output Speed Torque Converter Output Speed
Speed Short-To-Ground Sensor (B29) Short-To-Ground Sensor (B29) Short-To-Ground
(Check/Replace)
Wire M08 (Purple) Harness (W10) Transmission Harness (W10) - M08
Short-To-Ground (Purple) Short-To-Ground
(Check/Repair)
9015
20
19
Wire M08 (Purple) Harness (W3) Load Center Harness (W3) - M08
Short-To-Ground (Purple) Short-To-Ground
(Check/Repair)
TCU (A3) TCU (Replace)
MDU (Reconfigure). See Monitor
Display Unit Reconfiguration Access
Service Menu, Machine Model (S
01), Tire Size (S 03), Enable Options
(S 06), and Delete Diagnostic
Trouble Codes in Group 9015—15.
F0349 Transmission Turbine Torque Converter Output Speed Torque Converter Output Speed
Speed Short-To- Power Sensor (B29) Short-To-Power Sensor (B29) Short-To-Power
(Check/Replace)
Wire M08 (Purple) Harness (W10) Transmission Harness (W10) - M08
Short-To-Power (Purple) Short-To-Power
(Check/Repair)
TM1637 (15JAN04)
Continued on next page
9015-20-19
TX,9015,111902 –19–30MAR99–15/32
644H and 644H MH Loader
011504
PN=409
Page 20
References
Symptom Problem
Solution
Wire M08 (Purple) Harness (W3) Load Center Harness (W3) - M08
Short-To-Power (Purple) Short-To-Power
(Check/Repair)
TCU (A3) TCU (Replace)
MDU (Reconfigure). See Monitor
Display Unit Reconfiguration Access
Service Menu, Machine Model (S
01), Tire Size (S 03), Enable Options
(S 06), and Delete Diagnostic
Trouble Codes in Group 9015—15.
F0350 Transmission Input Speed Torque Converter Input Speed Torque Converter Input Speed
9015
Signal Bad Sensor (B28) Open Sensor (B28) Open (Check/Replace)
20
20
Wire M07 (PUR) Harness (W10) Transmission Harness (W10) - M07
Open (PUR) Open (Check/Repair)
Wire M07 (PUR) Harness (W3) Load Center Harness (W3) - M07
Open (PUR) Open (Check/Repair)
TCU (A3) TCU (Replace)
MDU (Reconfigure). See Monitor
Display Unit Reconfiguration Access
Service Menu, Machine Model (S
01), Tire Size (S 03), Enable Options
(S 06), and Delete Diagnostic
Trouble Codes in Group 9015—15.
F0351 Transmission Input Speed Torque Converter Input Speed Torque Converter Input Speed
Circuit Short-To-Ground Sensor (B28) Short-To-Ground Sensor (B28) Short-To-Ground
(Check/Replace)
Wire M07 (Purple) Harness (W10) Transmission Harness (W10) - M07
Short-To-Ground (Purple) Short-To-Ground
(Check/Repair)
Wire M07 (Purple) Harness (W3) Load Center Harness (W3) - M07
Short-To-Ground (Purple) Short-To-Ground
(Check/Repair)
TCU (A3) TCU (Replace)
TM1637 (15JAN04)
Continued on next page
9015-20-20
TX,9015,111902 –19–30MAR99–16/32
644H and 644H MH Loader
011504
PN=410
Page 21
References
Symptom Problem
Solution
MDU (Reconfigure). See Monitor
Display Unit Reconfiguration Access
Service Menu, Machine Model (S
01), Tire Size (S 03), Enable Options
(S 06), and Delete Diagnostic
Trouble Codes in Group 9015—15.
F0352 Transmission Input Speed Torque Converter Input Speed Torque Converter Input Speed
Circuit Short-to-Power Sensor (B28) Short-To-Power Sensor (B28) Short-To-Power
(Check/Replace)
Wire M07 (Purple) Harness (W10) Transmission Harness (W10) - M07
Short-To-Power (Purple) Short-To-Power
(Check/Repair)
Wire M07 (Purple) Harness (W3) Load Center Harness (W3) - M07
Short-To-Power (Purple) Short-To-Power
(Check/Repair)
TCU (A3) TCU (Replace)
MDU (Reconfigure). See Monitor
Display Unit Reconfiguration Access
Service Menu, Machine Model (S
01), Tire Size (S 03), Enable Options
(S 06), and Delete Diagnostic
Trouble Codes in Group 9015—15.
9015
20
21
F0353 Transmission FWD High Transmission Control Solenoid (Y1) Transmission Control Solenoid (Y1)
Range Clutch Pack Solenoid Open Open (Check/Replace)
Open
Wire T04 (Blue) Harness (W3) Open Load Center Harness (W3) - T04
(Blue) Open (Check/Repair)
Wire T04 (Blue) Harness (W10) Transmission Harness (W10) - T04
Open (Blue) Open (Check/Repair)
Wire T04 (Blue) Control Valve Transmission Control Valve Internal
Internal Harness Open Harness - T04 (Blue) Open
(Check/Repair)
TCU (A3) TCU (Replace)
TM1637 (15JAN04)
Continued on next page
9015-20-21
TX,9015,111902 –19–30MAR99–17/32
644H and 644H MH Loader
011504
PN=411
Page 22
References
Symptom Problem
Solution
MDU (Reconfigure). See Monitor
Display Unit Reconfiguration Access
Service Menu, Machine Model (S
01), Tire Size (S 03), Enable Options
(S 06), and Delete Diagnostic
Trouble Codes in Group 9015—15.
F0354 Transmission FWD High Transmission Control Solenoid (Y1) Transmission Control Solenoid (Y1)
Range Clutch Pack Solenoid Short-To-Ground Short-To-Ground (Check/Replace)
Short-To-Ground
Wire T04 (Blue) Harness (W3) Load Center Harness (W3) - T04
Short-To-Ground (Blue) Short-To-Ground
9015
20
22
Wire T04 (Blue) Harness (W10) Transmission Harness (W10) - T04
(Check/Repair)
Short-To-Ground (Blue) Short-To-Ground
(Check/Repair)
Wire T04 (Blue) Control Valve Transmission Control Valve Internal
Internal Harness Short-To-Ground Harness - T04 (Blue)
Short-To-Ground (Check/Repair)
TCU (A3) TCU (Replace)
MDU (Reconfigure). See Monitor
Display Unit Reconfiguration Access
Service Menu, Machine Model (S
01), Tire Size (S 03), Enable Options
(S 06), and Delete Diagnostic
Trouble Codes in Group 9015—15.
F0355 Transmission FWD High Transmission Control Solenoid (Y1) Transmission Control Solenoid (Y1)
Range Clutch Pack Solenoid Short-To-Power Short-To-Power (Check/Replace)
Short-To-Power
Wire T04 (Blue) Harness (W3) Short Load Center Harness (W3) - T04
to Power (Blue) Short-To-Power
(Check/Repair)
Wire T04 (Blue) Harness (W10) Transmission Harness (W10) - T04
Short-To-Power (Blue) Short-To-Power
(Check/Repair)
TM1637 (15JAN04)
Continued on next page
9015-20-22
TX,9015,111902 –19–30MAR99–18/32
644H and 644H MH Loader
011504
PN=412
Page 23
References
Symptom Problem
Solution
Wire T04 (Blue) Control Valve Transmission Control Valve Internal
Internal Harness Short-To-Power Harness - T04 (Blue)
Short-To-Power (Check/Repair)
TCU (A3) TCU (Replace)
MDU (Reconfigure). See Monitor
Display Unit Reconfiguration Access
Service Menu, Machine Model (S
01), Tire Size (S 03), Enable Options
(S 06), and Delete Diagnostic
Trouble Codes in Group 9015—15.
F0356 Transmission Third Speed Transmission Control Solenoid (Y4) Transmission Control Solenoid (Y4)
Clutch Pack Solenoid Open Open Open (Check/Replace)
Wire T06 (Blue) Harness (W3) Open Load Center Harness (W3) - T06
(Blue) Open (Check/Repair)
Wire T06 (Blue) Harness (W10) Transmission Harness (W10) - T06
Open (Blue) Open (Check/Repair)
Wire T06 (Blue) Control Valve Transmission Control Valve Internal
Internal Harness Open Harness - T06 (Blue) Open
(Check/Repair
9015
20
23
TCU (A3) TCU (Replace)
MDU (Reconfigure). See Monitor
Display Unit Reconfiguration Access
Service Menu, Machine Model (S
01), Tire Size (S 03), Enable Options
(S 06), and Delete Diagnostic
Trouble Codes in Group 9015—15.
F0357 Transmission Third Speed Transmission Control Solenoid (Y4) Transmission Control Solenoid (Y4)
Clutch Pack Solenoid Short-To-Ground Short-To-Ground (Check/Replace)
Short-to-Ground
Wire T06 (Blue) Harness (W3) Load Center Harness (W3) - T06
Short-To-Ground (Blue) Short-To-Ground
(Check/Repair)
Wire T06 (Blue) Harness (W10) Transmission Harness (W10) - T06
Short-To-Ground (Blue) Short-To-Ground
(Check/Repair)
TM1637 (15JAN04)
Continued on next page
9015-20-23
TX,9015,111902 –19–30MAR99–19/32
644H and 644H MH Loader
011504
PN=413
Page 24
References
Symptom Problem
Solution
Wire T06 (Blue) Control Valve Transmission Control Valve Internal
Internal Harness Short-To-Ground Harness - T06 (Blue)
Short-To-Ground (Check/Repair)
TCU (A3) TCU (Replace)
MDU (Reconfigure). See Monitor
Display Unit Reconfiguration Access
Service Menu, Machine Model (S
01), Tire Size (S 03), Enable Options
(S 06), and Delete Diagnostic
Trouble Codes in Group 9015—15.
F0358 Transmission Third Speed Transmission Control Solenoid (Y4) Transmission Control Solenoid (Y4)
9015
Clutch Pack Solenoid Short-To- Short-To-Power Short-To-Power (Check/Replace)
20
Power
24
Wire T06 (Blue) Harness (W3) Load Center Harness (W3) - T06
Short-To-Power (Blue) Short-To-Power
(Check/Repair)
Wire T06 (Blue) Harness (W10) Transmission Harness (W10) - T06
Short-To-Power (Blue) Short-To-Power
(Check/Repair)
Wire T06 (Blue) Control Valve Transmission Control Valve Internal
Internal Harness Open Harness - T06 (Blue) Open
(Check/Repair)
TCU (A3) TCU (Replace)
MDU (Reconfigure). See Monitor
Display Unit Reconfiguration Access
Service Menu, Machine Model (S
01), Tire Size (S 03), Enable Options
(S 06), and Delete Diagnostic
Trouble Codes in Group 9015—15.
F0359 Transmission Second Transmission Control Solenoid (Y6) Transmission Control Solenoid (Y6)
Speed Clutch Pack Solenoid Open Open (Check/Replace)
Open
Wire T08 (Blue) Harness (W3) Open Load Center Harness (W3) - T08
(Blue) Open (Check/Repair)
TM1637 (15JAN04)
Continued on next page
9015-20-24
TX,9015,111902 –19–30MAR99–20/32
644H and 644H MH Loader
011504
PN=414
Page 25
References
Symptom Problem
Solution
Wire T08 (Blue) Harness (W10) Transmission Harness (W10) - T08
Open (Blue) Open (Check/Repair)
Wire T08 (Blue) Control Valve Transmission Control Valve Internal
Internal Harness Open Harness - T08 (Blue) Open
(Check/Repair)
TCU (A3) TCU (Replace)
MDU (Reconfigure). See Monitor
Display Unit Reconfiguration Access
Service Menu, Machine Model (S
01), Tire Size (S 03), Enable Options
(S 06), and Delete Diagnostic
Trouble Codes in Group 9015—15.
F0360 Transmission Second Transmission Control Solenoid (Y6) Transmission Control Solenoid (Y6)
Speed Clutch Pack Solenoid Short-To-Ground Short-To-Ground (Check/Replace)
Short-To-Ground
Wire T08 (Blue) Harness (W3) Load Center Harness (W3) - T08
Short-To-Ground (Blue) Short-To-Ground
(Check/Repair)
9015
20
25
Wire T08 (Blue) Harness (W10) Transmission Harness (W10) - T08
Short-To-Ground (Blue) Short-To-Ground
(Check/Repair)
Wire T08 (Blue) Control Valve Transmission Control Valve Internal
Internal Harness Short-To-Ground Harness - T08 (Blue)
Short-To-Ground (Check/Repair)
TCU (A3) TCU (Replace)
MDU (Reconfigure). See Monitor
Display Unit Reconfiguration Access
Service Menu, Machine Model (S
01), Tire Size (S 03), Enable Options
(S 06), and Delete Diagnostic
Trouble Codes in Group 9015—15.
F0361 Transmission Second Transmission Control Solenoid (Y6) Transmission Control Solenoid (Y6)
Speed Clutch Pack Solenoid Short-To-Power Short-To-Power (Check/Replace)
Short-To-Power
TM1637 (15JAN04)
Continued on next page
9015-20-25
TX,9015,111902 –19–30MAR99–21/32
644H and 644H MH Loader
011504
PN=415
Page 26
References
Symptom Problem
Solution
Wire T08 (Blue) Harness (W3) Load Center Harness (W3) - T08
Short-To-Power (Blue) Short-To-Power
(Check/Repair)
Wire T08 (Blue) Harness (W10) Transmission Harness (W10) - T08
Short-To-Power (Blue) Short-To-Power
(Check/Repair)
Wire T08 (Blue) Control Valve Transmission Control Valve Internal
Internal Harness Short-To-Power Harness - T08 (Blue)
Short-To-Power (Check/Repair)
TCU (A3) TCU (Replace)
9015
20
26
MDU (Reconfigure). See Monitor
Display Unit Reconfiguration Access
Service Menu, Machine Model (S
01), Tire Size (S 03), Enable Options
(S 06), and Delete Diagnostic
Trouble Codes in Group 9015—15.
F0362 Transmission First Speed Transmission Control Solenoid (Y3) Transmission Control Solenoid (Y3)
Clutch Pack Solenoid Open Open Open (Check/Replace)
Wire T05 (Blue) Harness (W3) Open Load Center Harness (W3) - T05
(Blue) Open (Check/Repair)
Wire T05 (Blue) Harness (W10) Transmission Harness (W10) - T05
Open (Blue) Open (Check/Repair)
Wire T05 (Blue) Control Valve Transmission Control Valve Internal
Internal Harness Open Harness - T05 (Blue) Open
(Check/Repair)
TCU (A3) TCU (Replace)
MDU (Reconfigure). See Monitor
Display Unit Reconfiguration Access
Service Menu, Machine Model (S
01), Tire Size (S 03), Enable Options
(S 06), and Delete Diagnostic
Trouble Codes in Group 9015—15.
F0363 Transmission First Speed Transmission Control Solenoid (Y3) Transmission Control Solenoid (Y3)
Clutch Pack Solenoid Short-To-Ground Short-To-Ground (Check/Replace)
Short-To-Ground
TM1637 (15JAN04)
Continued on next page
9015-20-26
TX,9015,111902 –19–30MAR99–22/32
644H and 644H MH Loader
011504
PN=416
Page 27
References
Symptom Problem
Solution
Wire T05 (Blue) Harness (W3) Load Center Harness (W3) - T05
Short-To-Ground (Blue) Short-To-Ground
(Check/Repair)
Wire T05 (Blue) Harness (W10) Transmission Harness (W10) - T05
Short-To-Ground (Blue) Short-To-Ground
(Check/Repair)
Wire T06 (Blue) Control Valve Transmission Control Valve Internal
Internal Harness Short-To-Ground Harness - T05 (Blue)
Short-To-Ground (Check/Repair)
TCU (A3) TCU (Replace)
MDU (Reconfigure). See Monitor
Display Unit Reconfiguration Access
Service Menu, Machine Model (S
01), Tire Size (S 03), Enable Options
(S 06), and Delete Diagnostic
Trouble Codes in Group 9015—15.
F0364 Transmission First Transmission Control Solenoid (Y3) Transmission Control Solenoid (Y3)
Solenoid Speed Clutch Pack Short-To-Power Short-To-Power (Check/Replace)
Short-To-Power
9015
20
27
Wire T05 (Blue) Harness (W3) Short Load Center Harness (W3) - T05
to Power (Blue) Short-To-Power
(Check/Repair)
Wire T05 (Blue) Harness (W10) Transmission Harness (W10) - T05
Short-To-Power (Blue) Short-To-Power
(Check/Repair)
Wire T05 (Blue) Control Valve Transmission Control Valve Internal
Internal Harness Short-To-Ground Harness - T05 (Blue)
Short-To-Ground (Check/Repair)
TCU (A3) TCU (Replace)
MDU (Reconfigure). See Monitor
Display Unit Reconfiguration Access
Service Menu, Machine Model (S
01), Tire Size (S 03), Enable Options
(S 06), and Delete Diagnostic
Trouble Codes in Group 9015—15.
TM1637 (15JAN04)
Continued on next page
9015-20-27
TX,9015,111902 –19–30MAR99–23/32
644H and 644H MH Loader
011504
PN=417
Page 28
References
Symptom Problem
Solution
F0365 Transmission Reverse Transmission Control Solenoid (Y2) Transmission Control Solenoid (Y2)
Clutch Pack Solenoid Open Open Open (Check/Replace)
Wire T03 (Blue) Harness (W3) Open Load Center Harness (W3) - T03
(Blue) Open (Check/Repair)
Wire T03 (Blue) Control Valve Transmission Harness (W10) - T03
Harness Open (Blue) Open (Check/Repair)
Wire T03 (Blue) Control Valve Transmission Control Valve Internal
Internal Harness Open Harness - T03 (Blue) Open
(Check/Repair)
9015
20
28
TCU (A3) TCU (Replace)
MDU (Reconfigure). See Monitor
Display Unit Reconfiguration Access
Service Menu, Machine Model (S
01), Tire Size (S 03), Enable Options
(S 06), and Delete Diagnostic
Trouble Codes in Group 9015—15.
F0366 Transmission Reverse Transmission Control Solenoid (Y2) Transmission Control Solenoid (Y2)
Clutch Pack Solenoid Short-To- Short-To-Ground Short-To-Ground (Check/Replace)
Ground
Wire T03 (Blue) Harness (W3) Load Center Harness (W3) - T03
Short-To-Ground (Blue) Short-To-Ground
(Check/Repair)
Wire T03 (Blue) Harness (W10) Transmission Harness (W10) - T03
Short-To-Ground (Blue) Short-To-Ground
(Check/Repair)
Wire T03 (Blue) Control Valve Transmission Control Valve Internal
Internal Harness Short-To-Ground Harness - T03 (Blue)
Short-To-Ground (Check/Repair)
TCU (A3) TCU (Replace)
MDU (Reconfigure). See Monitor
Display Unit Reconfiguration Access
Service Menu, Machine Model (S
01), Tire Size (S 03), Enable Options
(S 06), and Delete Diagnostic
Trouble Codes in Group 9015—15.
TM1637 (15JAN04)
Continued on next page
9015-20-28
TX,9015,111902 –19–30MAR99–24/32
644H and 644H MH Loader
011504
PN=418
Page 29
References
Symptom Problem
Solution
F0367 Transmission Reverse Transmission Control Solenoid (Y2) Transmission Control Solenoid (Y2)
Clutch Pack Solenoid Short-To-Power Short-To-Power (Check/Replace)
Short-To-Power
Wire T03 (Blue) Harness (W3) Short Load Center Harness (W3) - T03
to Power (Blue) Short-To-Power
(Check/Repair)
Wire T03 (Blue) Harness (W10) Transmission Harness (W10) - T03
Short-To-Power (Blue) Short-To-Power
(Check/Repair)
Wire T03 (Blue) Control Valve Transmission Control Valve Internal
Internal Harness Short-To-Power Harness - T03 (Blue)
Short-To-Power (Check/Repair)
TCU (A3) TCU (Replace)
MDU (Reconfigure). See Monitor
Display Unit Reconfiguration Access
Service Menu, Machine Model (S
01), Tire Size (S 03), Enable Options
(S 06), and Delete Diagnostic
Trouble Codes in Group 9015—15.
9015
20
29
F0368 Transmission FWD Low Transmission Control Solenoid (Y5) Transmission Control Solenoid (Y5)
Range Clutch Pack Solenoid Open Open (Check/Replace)
Open
Wire T07 (Blue) Harness (W3) Open Load Center Harness (W3) - T07
(Blue) Open (Check/Repair)
Wire T07 (Blue) Harness (W10) Transmission Harness (W10) - T07
Open (Blue) Open (Check/Repair)
Wire T07 (Blue) Control Valve Transmission Control Valve Internal
Internal Harness Open Harness - T07 (Blue) Open
(Check/Repair)
TCU (A3) TCU (Replace)
Continued on next page
TX,9015,111902 –19–30MAR99–25/32
TM1637 (15JAN04)
9015-20-29
644H and 644H MH Loader
011504
PN=419
Page 30
References
Symptom Problem
Solution
MDU (Reconfigure). See Monitor
Display Unit Reconfiguration Access
Service Menu, Machine Model (S
01), Tire Size (S 03), Enable Options
(S 06), and Delete Diagnostic
Trouble Codes in Group 9015—15.
F0369 Transmission FWD Low Transmission Control Solenoid (Y5) Transmission Control Solenoid (Y5)
Range Clutch Pack Solenoid Short-To-Ground Short-To-Ground (Check/Replace)
Short-To-Ground
Wire T07 (Blue) Harness (W3) Load Center Harness (W3) - T07
Short-To-Ground (Blue) Short-To-Ground
9015
20
30
Wire T07 (Blue) Harness (W10) Transmission Harness (W10) - T07
(Check/Repair)
Short-To-Ground (Blue) Short-To-Ground
(Check/Repair)
Wire T07 (Blue) Control Valve Transmission Control Valve Internal
Internal Harness Short-To-Ground Harness - T07 (Blue)
Short-To-Ground (Check/Repair)
TCU (A3) TCU (Replace)
MDU (Reconfigure). See Monitor
Display Unit Reconfiguration Access
Service Menu, Machine Model (S
01), Tire Size (S 03), Enable Options
(S 06), and Delete Diagnostic
Trouble Codes in Group 9015—15.
F0370 Transmission FWD Clutch Transmission Control Solenoid (Y5) Transmission Control Solenoid (Y5)
Pack Solenoid Short-To-Power Short-To-Power Short-To-Power (Check/Replace)
Wire T07 (Blue) Harness (W3) Short Load Center Harness (W3) - T07
to Power (Blue) Short-To-Power
(Check/Repair)
Wire T07 (Blue) Harness (W10) Transmission Harness (W10) - T07
Short-To-Power (Blue) Short-To-Power
(Check/Repair)
Wire T07 (Blue) Control Valve Transmission Control Valve Internal
Internal Harness Short-To-Power Harness - T07 (Blue)
Short-To-Power (Check/Repair)
TM1637 (15JAN04)
Continued on next page
9015-20-30
TX,9015,111902 –19–30MAR99–26/32
644H and 644H MH Loader
011504
PN=420
Page 31
References
Symptom Problem
Solution
TCU (A3) TCU (Replace)
MDU (Reconfigure). See Monitor
Display Unit Reconfiguration Access
Service Menu, Machine Model (S
01), Tire Size (S 03), Enable Options
(S 06), and Delete Diagnostic
Trouble Codes in Group 9015—15.
F0375 Transmission Gear Shifter Switch (Gear Selector) (S10) Shifter Switch (S10) (Gear Selector)
Selector Open Open (Check/Repair)
Wire P24 (Red) Harness (W4) Open Front Console Harness (W4) P24
(Red) Open (Check/Repair)
Wire P24 (Red) Harness (W3) Open Load Center Harness (W3) P24
(Red) Open (Check/Repair)
TCU (A3) TCU (Replace)
F0377 Transmission Oil Transmission Oil Temperature Transmission Oil Temperature
Temperature Circuit Sensor (B32) Short-To-Power Sensor (B32) Short-To-Power
Short-To-Power (Check/Replace)
9015
20
31
Wire X06 (Yellow) Harness (W3) Load Center Harness (W3) - X06
Short-To-Power (Yellow) Short-To-Power
(Check/Repair)
Wire X06 (Yellow) Harness (W10) Transmission Harness (W10) - X06
Short-To-Power (Yellow) Short-To-Power
(Check/Repair)
F0378 Transmission Oil Transmission Oil Temperature Transmission Oil Temperature
Temperature Circuit Open Sensor (B32) Open Sensor (B32) Open (Check/Replace)
Wire X06 (Yellow) Harness (W3) Load Center Harness (W3) - X06
Open (Yellow) Open (Check/Repair)
Wire X06 (Yellow) Harness (W10) Transmission Harness (W10) - X06
Open (Yellow) Open (Check/Repair)
TCU (A3) TCU (Replace)
TM1637 (15JAN04)
Continued on next page
9015-20-31
TX,9015,111902 –19–30MAR99–27/32
644H and 644H MH Loader
011504
PN=421
Page 32
References
Symptom Problem
Solution
MDU (Reconfigure). See Monitor
Display Unit Reconfiguration Access
Service Menu, Machine Model (S
01), Tire Size (S 03), Enable Options
(S 06), and Delete Diagnostic
Trouble Codes in Group 9015—15.
F0379 Transmission FNR Shifter Switch (FNR) (S10) Open Shifter Switch (S10) Replace
Selector Switch Open
Wire P23 (Red) Harness (W4) Open Front Console Harness (W4) - P23
(Red) Open (Check/Repair)
9015
20
32
Wire T13 (Blue) Harness (W4) Open Front Console Harness (W4) - T13
(Blue) Open (Check/Repair)
Wire T14 (Blue) Harness (W4) Open Front Console Harness (W4) - T14
(Blue) Open (Check/Repair)
Wire E02 (White) Harness (W4) Front Console Harness (W4) - E02
Open (White) Open (Check/Repair)
TCU (A3) TCU (Replace)
MDU (Reconfigure). See Monitor
Display Unit Reconfiguration Access
Service Menu, Machine Model (S
01), Tire Size (S 03), Enable Options
(S 06), and Delete Diagnostic
Trouble Codes in Group 9015—15.
F0380 Transmission Oil Filter Transmission Oil Filter Restriction Transmission Oil Filter Restriction
Restricted Switch (B20) Short-To-Ground Switch (B20) Short-To-Ground
(Check/Replace)
Wire N03 (Yellow) Harness (W10) Transmission Harness (W10) — N03
Short-To-Ground (Yellow) Short-To-Ground
(Check/Repair)
Wire N03 (Yellow) Harness (W3) Load Center Harness (W3) - N03
Short-To-Ground (Yellow) Short-To-Ground
(Check/Repair)
CCU (A2) CCU (Replace)
TM1637 (15JAN04)
Continued on next page
9015-20-32
TX,9015,111902 –19–30MAR99–28/32
644H and 644H MH Loader
011504
PN=422
Page 33
References
Symptom Problem
Solution
MDU (Reconfigure). See Monitor
Display Unit Reconfiguration Access
Service Menu, Machine Model (S
01), Tire Size (S 03), Enable Options
(S 06), and Delete Diagnostic
Trouble Codes in Group 9015—15.
F0384 Reverse Alarm Relay Back-up Alarm Relay (K10) Back-up Alarm Relay (K10)
Short-To- Power Short-To-Power Short-To-Power (Check/Replace)
Wire M28 (Purple) Harness (W3) Load Center Harness (W3) - M28
Short-To-Power (Purple) Short-To-Power
(Check/Repair)
TCU (A3) TCU (Replace)
MDU (Reconfigure). See Monitor
Display Unit Reconfiguration Access
Service Menu, Machine Model (S
01), Tire Size (S 03), Enable Options
(S 06), and Delete Diagnostic
Trouble Codes in Group 9015—15.
9015
20
33
F0385 Reverse Alarm Relay Back-up Alarm Relay (K10) Back-up Alarm Relay (K10)
Short-to-Ground Short-To-Ground Short-To-Ground (Check/Replace)
Wire M28 (Purple) Harness (W3) Load Center Harness (W3) - M28
Short-To-Ground (Purple) Short-To-Ground
(Check/Repair)
TCU (A3) TCU (Replace)
MDU (Reconfigure). See Monitor
Display Unit Reconfiguration Access
Service Menu, Machine Model (S
01), Tire Size (S 03), Enable Options
(S 06), and Delete Diagnostic
Trouble Codes in Group 9015—15.
F0386 Reverse Alarm Relay Open Back-up Alarm Relay (K10) Open Back-up Alarm Relay (K10) Open
(Check/Replace)
Back-up Alarm Relay Fuse (F13) Park Brake And Back-up Alarm Fuse
Open (F13) Open (Check/Replace)
TM1637 (15JAN04)
Continued on next page
9015-20-33
TX,9015,111902 –19–30MAR99–29/32
644H and 644H MH Loader
011504
PN=423
Page 34
References
Symptom Problem
Solution
Wire M28 (Purple) Harness (W3) Load Center Harness (W3) - M28
Open (Purple) Open (Check/Repair)
TCU (A3) TCU (Replace)
MDU (Reconfigure). See Monitor
Display Unit Reconfiguration Access
Service Menu, Machine Model (S
01), Tire Size (S 03), Enable Options
(S 06), and Delete Diagnostic
Trouble Codes in Group 9015—15.
F0387 Park Brake Solenoid Transmission Park Brake Release Transmission Park Brake Release
Short-to- Power Solenoid (Y19) Short-To-Power Solenoid (Y19) Short-To-Power
9015
20
34
(Check/Replace)
Wire T09 (Blue) Harness (W2) Loader Frame Harness (W2) - T09
Short-To-Power (Blue) Short-To-Power
(Check/Repair)
Wire T09 (Blue) Harness (W3) Load Center Harness (W3) - T09
Short-To-Power (Blue) Short-To-Power
(Check/Repair)
TCU (A3) TCU (Replace)
MDU (Reconfigure). See Monitor
Display Unit Reconfiguration Access
Service Menu, Machine Model (S
01), Tire Size (S 03), Enable Options
(S 06), and Delete Diagnostic
Trouble Codes in Group 9015—15.
F0388 Park Brake Solenoid Transmission Park Brake Release Transmission Park Brake Release
Short-to- Ground Solenoid (Y19) Short-To-Ground Solenoid (Y19) Short-To-Ground
(Check/Replace)
Wire T09 (Blue) Harness (W2) Loader Frame Harness (W2) - T09
Short-To-Ground (Blue) Short-To-Ground
(Check/Repair)
Wire T09 (Blue) Harness (W3) Load Center Harness (W3) - T09
Short-To-Ground (Blue) Short-To-Ground
(Check/Repair)
TCU (A3) TCU (Replace)
TM1637 (15JAN04)
Continued on next page
9015-20-34
TX,9015,111902 –19–30MAR99–30/32
644H and 644H MH Loader
011504
PN=424
Page 35
References
Symptom Problem
Solution
MDU (Reconfigure). See Monitor
Display Unit Reconfiguration Access
Service Menu, Machine Model (S
01), Tire Size (S 03), Enable Options
(S 06), and Delete Diagnostic
Trouble Codes in Group 9015—15.
F0389 Park Brake Solenoid Open Engine Controller Switched 15A Engine Controller Switched 15A
Fuse Bad Fuse Check/Replace
Transmission Park Brake Release Transmission Park Brake Release
Solenoid (Y19) Open Solenoid (Y19) Open
(Check/Replace)
Wire T09 (Blue) Harness (W2) Open Loader Frame Harness (W2) - T09
(Blue) Open (Check/Repair)
Wire T09 (Blue) Harness (W3) Open Load Center Harness (W3) - T09
(Blue) Open (Check/Repair)
TCU (A3) TCU (Replace)
MDU (Reconfigure). See Monitor
Display Unit Reconfiguration Access
Service Menu, Machine Model (S
01), Tire Size (S 03), Enable Options
(S 06), and Delete Diagnostic
Trouble Codes in Group 9015—15.
9015
20
35
F0396 Transmission Oil Transmission Oil Type Wrong Transmission Oil Type
Temperature High (Check/Replace)
Transmission Oil Level Transmission Oil Level
(Check/Adjust)
Transmission Oil Cooler Internal Transmission Oil Cooler Internal
Restriction Restriction (Check/Repair)
Transmission Oil Cooler Air Flow Transmission Oil Cooler Air Flow
Restriction Restriction (Check/Repair)
Transmission Oil Pump Inlet Screen Transmission Oil Pump Inlet Screen
Plugged Plugged (Check/Replace)
Transmission Control Valve Gasket Transmission Control Valve Gasket
(Check/Replace)
TX,9015,111902 –19–30MAR99–31/32
644H and 644H MH Loader
TM1637 (15JAN04)
Continued on next page
9015-20-35
011504
PN=425
Page 36
References
Symptom Problem
9015
20
36
Solution
Converter Relief Valve Stuck Open Torque Converter Relief Valve
(Check/Repair)
Transmission Main Pressure Transmission Main Pressure
Regulating Valve Spring Broken Regulating Valve Spring Broken
(Check/Replace)
Transmission Oil Cooler Relief Transmission Oil Cooler Relief
Bypass Valve Stuck Open Bypass Valve Stuck Open
(Check/Repair)
Transmission Oil Pump Worn Transmission Oil Pump Worn
(Check/Replace)
Transmission Oil Temperature Transmission Oil Temperature
Sensor (B32) Short-To-Ground Sensor (B32) Short-To-Ground
(Check/Replace)
Wire X06 (Yellow) Harness (W3) Load Center Harness (W3) - X06
Short-To-Ground (Yellow) Short-To-Ground
(Check/Repair)
Wire X06 (Yellow) Harness (W10) Transmission Harness (W10) - X06
Short-To-Ground (Yellow) Short-To-Ground
(Check/Repair)
TCU (A3) TCU (Replace)
MDU (Reconfigure). See Monitor
Display Unit Reconfiguration Access
Service Menu, Machine Model (S
01), Tire Size (S 03), Enable Options
(S 06), and Delete Diagnostic
Trouble Codes in Group 9015—15.
TX,9015,111902 –19–30MAR99–32/32
TM1637 (15JAN04)
9015-20-36
644H and 644H MH Loader
011504
PN=426
Page 37
Engine Related Diagnostic Trouble Codes
(DTCs)
These DTCs are related to engine operation, but not
created by the Engine Control Unit (ECU).
References
Symptom Problem
Solution
F0400 Engine Oil Pressure Low Engine Oil Pressure Switch (B24) Engine Oil Pressure Switch (B24)
Long Short-To-Ground Short-To-Ground (Check/Replace)
Tell-Tale Code displayed in MDU
“Service” menu. See Monitor
Display Unit —Service Menu—
Tell-Tale Diagnostic Trouble
Codes (S 02) in Group 9015-15.
Engine Oil Pressure Sensor (B23) Engine Oil Pressure Sensor (B23)
Short-To-Ground (Check/Replace)
Wire N02 (Yellow) Harness (W6) Engine Harness (W6) - N02 (Yellow)
Short-To-Ground Short-To-Ground (Check/Repair)
Wire N02 (Yellow) Harness (W3) Load Center Harness (W3) - N02
Short-To-Ground (Yellow) Short-To-Ground
(Check/Repair)
CCU (A2) CCU (Replace)
MDU (Reconfigure). See Monitor
Display Unit Reconfiguration Access
Service Menu, Machine Model (S
01), Tire Size (S 03), Enable Options
(S 06), and Delete Diagnostic
Trouble Codes in Group 9015—15.
9015
20
37
F0415 CCU Throttle Circuit (CCU) (CCU) Analog Throttle Position
Voltage Low Sensor (B14) Short To Ground
Analog Throttle Position Sensor (Check/Replace)
(B14) Shorted to Ground
Wire E12 (Yellow) Harness (W3) Load Center Harness (W3) - E12
Short to Ground (White) Short To Ground
(Check/Repair)
CCU (A2) CCU (Replace)
TX17961,0000006 –19–12AUG02–1/9
644H and 644H MH Loader
TM1637 (15JAN04)
Continued on next page
9015-20-37
011504
PN=427
Page 38
References
Symptom Problem
Solution
F0416 CCU Throttle Circuit (CCU) Analog Throttle Position (CCU) Analog Throttle Position
Voltage High Sensor (B14) Shorted to Battery Sensor (B14) Short To Battery
(Check/Replace)
Wire E12 (White) Harness (W3) Load Center Harness (W3) - E12
Short to Battery (White) Short To Battery
(Check/Repair)
ECU (A1) ECU (Replace)
ECU (Reprogram)
F0478 Engine Oil Pressure Engine Oil Pressure Sensor (B23) Engine Oil Pressure Sensor (B23)
Circuit Voltage Low Short-To-Ground (Check/Replace)
9015
20
38
Wire N02 (Yellow) Harness (W6) Engine Harness (W6) - N02 (Yellow)
Short-To-Ground Short-To-Ground (Check/Repair)
Wire N02 (Yellow) Harness (W3) Load Center Harness (W3) - N02
Short-To-Ground (Yellow) Short-To-Ground
(Check/Repair)
CCU (A2) CCU (Replace)
MDU (Reconfigure). See Monitor
Display Unit Reconfiguration Access
Service Menu, Machine Model (S
01), Tire Size (S 03), Enable Options
(S 06), and Delete Diagnostic
Trouble Codes in Group 9015—15.
F0479 Engine Oil Pressure Engine Oil Pressure Sensor (B23) Engine Oil Pressure Sensor (B23)
Circuit Voltage High Short-To-Power Short-To-Power (Check/Replace)
Wire N02 (Yellow) Harness (W6) Engine Harness (W6) - N02 (Yellow)
Short-To-Power Short-To-Power
Wire N02 (Yellow) Harness (W3) Load Center Harness (W3) - N02
Short-To-Power (Yellow) Short-To-Power
CCU (A2) CCU (A2) (Replace)
TM1637 (15JAN04)
Continued on next page
9015-20-38
TX17961,0000006 –19–12AUG02–2/9
644H and 644H MH Loader
011504
PN=428
Page 39
References
Symptom Problem
Solution
MDU (Reconfigure). See Monitor
Display Unit Reconfiguration Access
Service Menu, Machine Model (S
01), Tire Size (S 03), Enable Options
(S 06), and Delete Diagnostic
Trouble Codes in Group 9015—15.
F0499 Engine Oil Pressure Low Engine Oil Level Too High or Too Engine Oil Level (Check)
Low
Wrong Oil Type Engine Oil (Drain/Refill)
Engine Oil Filter Engine Oil Filter Restricted
(Check/Replace)
Oil Passages Restricted Engine Oil Passage (Check/Clean)
Engine Oil Pump Engine Oil Pump (Check/Replace)
Engine Oil Pressure Sensor (B23) Engine Oil Pressure Sensor (B23)
Open Open (Check/Replace)
Wire N02 (Yellow) Harness (W6) Engine Harness (W6) - N02 (Yellow)
Open Open (Check/Repair)
9015
20
39
Wire N02 (Yellow) Harness (W3) Load Center Harness (W3) - N02
Open (Yellow) Open
CCU (A2) CCU (A2) (Replace)
MDU (Reconfigure). See Monitor
Display Unit Reconfiguration Access
Service Menu, Machine Model (S
01), Tire Size (S 03), Enable Options
(S 06), and Delete Diagnostic
Trouble Codes in Group 9015—15.
F0500 Engine Coolant Engine Coolant Temperature Sensor Engine Coolant Temperature Sensor
Temperature High Long (CCU) (B16) Open (CCU) (B16) Open (Check/Replace)
Tell-Tale Code displayed in MDU
“Service” menu. See Monitor
Display Unit —Service Menu—
Tell-Tale Diagnostic Trouble
Codes (S 02) in Group 9015-15.
TM1637 (15JAN04)
Continued on next page
9015-20-39
TX17961,0000006 –19–12AUG02–3/9
644H and 644H MH Loader
011504
PN=429
Page 40
References
Symptom Problem
Solution
Wire X04 (Yellow) Harness (W3) Load Center Harness (W3) - X04
Open (Yellow) Open (Check/Repair)
Wire X04 (Yellow) Harness (W6) Engine Harness (W6) - X04 (Yellow)
Open Open (Check/Repair)
CCU (A2) CCU (Replace)
MDU (Reconfigure). See Monitor
Display Unit Reconfiguration Access
Service Menu, Machine Model (S
01), Tire Size (S 03), Enable Options
(S 06), and Delete Diagnostic
9015
20
F0515 Engine Air Filter Engine Air Filter Restriction Switch Engine Air Filter Restriction Switch
40
Trouble Codes in Group 9015—15.
Restriction Circuit (B19) Short-To-Ground (B19) Short-To-Ground
(Check/Repair)
Wire M06 (Purple) Harness (W6) Engine Harness (W6) - M06 (Purple)
Short-To-Ground Short-To-Ground (Check/Repair)
Wire M06 (Purple) Harness (W3) Load Center Harness (W3) - M06
Short-To-Ground (Purple) Short-To-Ground
(Check/Repair)
CCU (A2) CCU (Replace)
MDU (Reconfigure). See Monitor
Display Unit Reconfiguration Access
Service Menu, Machine Model (S
01), Tire Size (S 03), Enable Options
(S 06), and Delete Diagnostic
Trouble Codes in Group 9015—15.
F0516 Fuel Level Circuit Voltage Fuel Level Sender (B17) Fuel Level Sender (B17)
Low Short-To-Ground Short-To-Ground (Check/Replace)
Wire Y02 (Yellow) Harness (W5) Engine Frame Harness (W5) - Y02
Short-To-Ground (Yellow) Short-To-Ground
(Check/Repair)
Wire Y02 (Yellow) Harness (W3) Load Center Harness (W3) - Y02
Short-To-Ground (Yellow) Short-To-Ground
(Check/Repair)
TM1637 (15JAN04)
Continued on next page
9015-20-40
TX17961,0000006 –19–12AUG02–4/9
644H and 644H MH Loader
011504
PN=430
Page 41
References
Symptom Problem
Solution
CCU (A2) CCU (Replace)
MDU (Reconfigure). See Monitor
Display Unit Reconfiguration Access
Service Menu, Machine Model (S
01), Tire Size (S 03), Enable Options
(S 06), and Delete Diagnostic
Trouble Codes in Group 9015—15.
F0517 Engine Fuel Level Circuit Fuel Level Sender (B17) Open Fuel Level Sender (B17) Open
Open (Check/Replace)
Wire Y02 (Yellow) Harness (W5) Engine Frame Harness (W5) - Y02
Open (Yellow) Open (Check/Repair)
Wire Y02 (Yellow) Harness (W3) Load Center Harness (W3) - Y02
Open (Yellow) Open (Check/Repair)
CCU (A2) CCU (Replace)
MDU (Reconfigure). See Monitor
Display Unit Reconfiguration Access
Service Menu, Machine Model (S
01), Tire Size (S 03), Enable Options
(S 06), and Delete Diagnostic
Trouble Codes in Group 9015—15.
9015
20
41
F0575 Engine Coolant Level Engine Coolant Level Switch (B18) Engine Coolant Level Switch (B18)
Circuit (S.N. —574739) (S.N. —574739) Short-To-Ground Short-To-Ground (Check/Replace)
Wire Y01 (Yellow) Harness (W13) Rear Frame Harness (W13) - Y01
Short-To-Ground (Yellow) Short-To-Ground
(Check/Repair)
Wire Y01 (Yellow ) Harness (W5) Engine Frame Harness (W5) - Y01
Short-To-Ground (Yellow) Short-To-Ground
(Check/Repair)
Wire Y01 (Yellow) Harness (W3) Load Center Harness (W3) - Y01
Short-To-To Ground (Yellow) Short-To-Ground
(Check/Repair)
CCU (A2) CCU (Replace)
TM1637 (15JAN04)
Continued on next page
9015-20-41
TX17961,0000006 –19–12AUG02–5/9
644H and 644H MH Loader
011504
PN=431
Page 42
References
Symptom Problem
Solution
MDU (Reconfigure). See Monitor
Display Unit Reconfiguration Access
Service Menu, Machine Model (S
01), Tire Size (S 03), Enable Options
(S 06), and Delete Diagnostic
Trouble Codes in Group 9015—15.
F0576 Engine Coolant Engine Coolant Temperature Sensor Engine Coolant Temperature Sensor
Temperature Circuit Noisy (CCU) (B16) Noisy (CCU) (B16) Noisy (Check/Replace)
Wire X04 (Yellow) Harness (W3) Load Center Harness (W3) - X04
Noisy (Yellow) Noisy (Check/Repair)
9015
20
42
Wire X04 (Yellow) Harness (W6) Engine Harness (W6) - X04 (Yellow)
Noisy Noisy (Check/Repair)
CCU (A2) CCU (Replace)
MDU (Reconfigure). See Monitor
Display Unit Reconfiguration Access
Service Menu, Machine Model (S
01), Tire Size (S 03), Enable Options
(S 06), and Delete Diagnostic
Trouble Codes in Group 9015—15.
F0577 Engine Coolant Engine Coolant Temperature Sensor Engine Coolant Temperature Sensor
Temperature Circuit Short-To- (CCU) (B16) Short-To-Ground (CCU) (B16) Short-To-Ground
Ground (Check/Replace)
Wire X04 (Yellow) Harness (W3) Load Center Harness (W3) - X04
Short-To-Ground (Yellow) Short-To-Ground
(Check/Repair)
Wire X04 (Yellow) Harness (W6) Engine Harness (W6) - X04 (Yellow)
Short-To-Ground Short-To-Ground (Check/Repair)
CCU (A2) CCU (Replace)
MDU (Reconfigure). See Monitor
Display Unit Reconfiguration Access
Service Menu, Machine Model (S
01), Tire Size (S 03), Enable Options
(S 06), and Delete Diagnostic
Trouble Codes in Group 9015—15.
TM1637 (15JAN04)
Continued on next page
9015-20-42
TX17961,0000006 –19–12AUG02–6/9
644H and 644H MH Loader
011504
PN=432
Page 43
References
Symptom Problem
Solution
F0578 Engine Coolant Engine Coolant Temperature Sensor Engine Coolant Temperature Sensor
Temperature Circuit Open (CCU) (B16) Open (CCU) (B16) Open (Check/Replace)
Wire X04 (Yellow) Harness (W3) Engine Harness (W6) - X04 (Yellow)
Open Open (Check/Repair)
CCU (A2) CCU (Replace)
MDU (Reconfigure). See Monitor
Display Unit Reconfiguration Access
Service Menu, Machine Model (S
01), Tire Size (S 03), Enable Options
(S 06), and Delete Diagnostic
Trouble Codes in Group 9015—15.
F0580 Engine Air Filter Engine Air Filter Restriction Switch Engine Air Filter Restriction Switch
Restricted (B19) Short-To-Power (B19) Short-To-Power
(Check/Repair)
Wire M06 (Purple) Harness (W6) Engine Harness (W6) - M06 (Purple)
Short-To-Power Short-To-Power (Check/Repair)
Wire M06 (Purple) Harness (W3) Load Center Harness (W3) - M06
Short-To-Power (Purple) Short-To-Power
(Check/Repair)
9015
20
43
CCU (A2) CCU (Replace)
MDU (Reconfigure). See Monitor
Display Unit Reconfiguration Access
Service Menu, Machine Model (S
01), Tire Size (S 03), Enable Options
(S 06), and Delete Diagnostic
Trouble Codes in Group 9015—15.
F0588 Engine Coolant Level Low Engine Coolant Level Switch (B18) Engine Coolant Level Switch (B18)
(S.N. —574739) (S.N. —574739) Short-To-Power Short-To-Power (Check/Replace)
Wire Y01 (Yellow) Harness (W13) Rear Frame Harness (W13) - Y01
Short-To-Power (Yellow) Short-To-Power
(Check/Repair)
Wire Y01 (Yellow ) Harness (W5) Engine Frame Harness (W5) - Y01
Short-To-Power (Yellow) Short-To-Power
(Check/Repair)
TM1637 (15JAN04)
Continued on next page
9015-20-43
TX17961,0000006 –19–12AUG02–7/9
644H and 644H MH Loader
011504
PN=433
Page 44
References
Symptom Problem
Solution
Wire Y01 (Yellow) Harness (W3) Load Center Harness (W3) - Y01
Short-To-To Power (Yellow) Short-To-Power
(Check/Repair)
CCU (A2) CCU (Replace)
MDU (Reconfigure). See Monitor
Display Unit Reconfiguration Access
Service Menu, Machine Model (S
01), Tire Size (S 03), Enable Options
(S 06), and Delete Diagnostic
Trouble Codes in Group 9015—15.
F0599 Engine Coolant Radiator Coolant Level Too Low Radiator Coolant Level Too Low
9015
Temperature High (Check/Adjust)
20
44
Radiator Cap Leaking Radiator Cap Leaking
(Check/Replace)
Engine Fan Belt Worn or Loose Engine Fan Belt Worn or Loose
(Check/Adjust)
Engine Fan on Backwards Engine Fan on Backwards
(Check/Adjust)
Wire X04 (Yellow) Harness (W6) Engine Harness (W6) - X04 (Yellow)
Noisy Noisy (Check/Repair)
Engine Coolant Temperature Sensor Engine Coolant Temperature Sensor
(B16) Resistance Out of (CCU) (B16) Resistance Out of
Specification Specification (Check/Replace)
Wire X04 (Yellow) Harness (W3) Load Center Harness (W3) - X04
Noisy (Yellow) Noisy (Check/Repair)
Wire G01 (Black) Harness (W3) Load Center Harness (W3) - G01
Poor Connection (Black) Poor Connection
(Check/Repair)
Continued on next page
TX17961,0000006 –19–12AUG02–8/9
TM1637 (15JAN04)
9015-20-44
644H and 644H MH Loader
011504
PN=434
Page 45
References
Symptom Problem
CCU (A2) CCU (Replace)
Solution
MDU (Reconfigure). See Monitor
Display Unit Reconfiguration Access
Service Menu, Machine Model (S
01), Tire Size (S 03), Enable Options
(S 06), and Delete Diagnostic
Trouble Codes in Group 9015—15.
TX17961,0000006 –19–12AUG02–9/9
9015
20
45
TM1637 (15JAN04)
9015-20-45
644H and 644H MH Loader
011504
PN=435
Page 46
Engine Diagnostic Trouble Codes (DTCs) on
Level 3 ECU (S.N. —585560)
Fuel injection system will be Level 3 or Level 9 Electronic
fuel injection system. The term “level” is simply a means
to identify fuel systems. Level 3 system meters the fuel at
the injection pump. Level 9 system uses a High Pressure
Common Rail (HPCR) and meters fuel at the injectors.
See Distinguishing ECUs on 8.1 L Engines in CTM134.
• Level 3 ECU
– 2 ECU connectors (30 and 18-way connectors)
– Bosch In-Line Injection Pump
– Mechanically-controlled injection nozzles
• Level 9 ECU
9015
– 2 ECU connectors (Two 30-way connectors)
– Denso High Pressure Common Rail (HPCR) and
20
46
High Pressure Pump
– Electronically-controlled injection nozzles
Wire harness information (Group 9015-10):
• See System Functional Schematic
• See Loader Frame Harness (W2) Component Location
• See Load Center Harness (W3) Component Location
• See Front Console Harness (W4) Component Location
• See Engine Frame Harness (W5) Component Location
• See Engine Harness (W6) Component Location
• See Engine Air Heater Harness (W7) Component
Location
References
Symptom Problem
Solution
F0411 (000029.03) Analog Throttle (A) Input High See LEVEL 3 ECU - T3 - ANALOG
THROTTLE (A) INPUT HIGH
DIAGNOSTIC PROCEDURE in
Section 04, Group 160 of CTM134.
F0412 (000029.04) Analog Throttle (A) Input Low See LEVEL 3 ECU - T4 - ANALOG
THROTTLE (A) INPUT LOW
DIAGNOSTIC PROCEDURE in
Section 04, Group 160 of CTM134.
F0413 (000091.03) PWM Throttle Input High See LEVEL 3 ECU - T8 - PWM
THROTTLE INPUT HIGH
DIAGNOSTIC PROCEDURE in
Section 04, Group 160 of CTM134.
TM1637 (15JAN04)
Continued on next page
9015-20-46
RG40854,0000002 –19–08AUG02–1/9
644H and 644H MH Loader
011504
PN=436
Page 47
References
Symptom Problem
Solution
F0414 (000091.04) PWM Throttle Input Low See LEVEL 3 ECU - T9 - PWM
THROTTLE INPUT LOW
DIAGNOSTIC PROCEDURE in
Section 04, Group 160 of CTM134.
F0419 (000620.03) Sensor Supply Voltage High See LEVEL 3 ECU - DTC SPN 620
FMI 3 SENSOR SUPPLY VOLTAGE
HIGH DIAGNOSTIC PROCEDURE
in Section 04, Group 160 of
CTM134.
F0420 (000620.04) Sensor Supply Voltage Low See LEVEL 3 ECU - DTC SPN 620
FMI 4 SENSOR SUPPLY VOLTAGE
LOW DIAGNOSTIC PROCEDURE in
Section 04, Group 160 of CTM134.
F0423 (000171.03) Ambient Air Temperature Input See LEVEL 3 ECU - DTC SPN 171
Voltage High FMI 3 AMBIENT AIR
TEMPERATURE INPUT VOLTAGE
HIGH DIAGNOSTIC PROCEDURE
in Section 04, Group 160 of
CTM134.
9015
20
47
F0424 (000171.04) Ambient Air Temperature Input See LEVEL 3 ECU - DTC SPN 171
Voltage Low FMI 4 AMBIENT AIR
TEMPERATURE INPUT VOLTAGE
LOW DIAGNOSTIC PROCEDURE in
Section 04, Group 160 of CTM134.
F0425 (000110.03) Engine Coolant Temperature Input See LEVEL 3 ECU - DTC SPN 110
Voltage High FMI 3 ENGINE COOLANT
TEMPERATURE INPUT VOLTAGE
HIGH DIAGNOSTIC PROCEDURE
in Section 04, Group 160 of
CTM134.
F0426 (000110.04) Engine Coolant Temperature Input See LEVEL 3 ECU - DTC SPN 110
Voltage Low FMI 4 ENGINE COOLANT
TEMPERATURE INPUT VOLTAGE
LOW DIAGNOSTIC PROCEDURE in
Section 04, Group 160 of CTM134.
TM1637 (15JAN04)
Continued on next page
9015-20-47
RG40854,0000002 –19–08AUG02–2/9
644H and 644H MH Loader
011504
PN=437
Page 48
References
Symptom Problem
Solution
F0437 (000174.03) Fuel Temperature Input Voltage High See LEVEL 3 ECU - DTC SPN 174
FMI 3 FUEL TEMPERATURE
INPUT VOLTAGE HIGH
DIAGNOSTIC PROCEDURE in
Section 04, Group 160 of CTM134.
F0438 (000174.04) Fuel Temperature Input Voltage Low See LEVEL 3 ECU - DTC SPN 174
FMI 4 FUEL TEMPERATURE
INPUT VOLTAGE LOW
DIAGNOSTIC PROCEDURE in
Section 04, Group 160 of CTM134.
F0446 (000733.02) Rack Position Error with Engine OFF See LEVEL 3 ECU - DTC SPN 833
9015
20
48
FMI 2 RACK POSITION ERROR
WITH ENGINE OFF DIAGNOSTIC
PROCEDURE in Section 04, Group
160 of CTM134.
F0447 (000638.07) Rack Position Error See LEVEL 3 ECU - DTC SPN 834
FMI 07 RACK POSITION ERROR
DIAGNOSTIC PROCEDURE in
Section 04, Group 160 of CTM134.
F0448 (000733.03) Rack Position Voltage High See LEVEL 3 ECU - DTC SPN 833
FMI 3 RACK POSITION VOLTAGE
HIGH DIAGNOSTIC PROCEDURE
in Section 04, Group 160 of
CTM134.
F0449 (000733.04) Rack Position Voltage Low See LEVEL 3 ECU - DTC SPN 833
FMI 4 RACK POSITION VOLTAGE
LOW DIAGNOSTIC PROCEDURE in
Section 04, Group 160 of CTM134.
F0462 (000190.02) Engine Speed Input Noise See LEVEL 3 ECU - DTC SPN 190
FMI 2 ENGINE SPEED INPUT
NOISE DIAGNOSTIC PROCEDURE
in Section 04, Group 160 of
CTM134.
F0463 (001041.02) Start Signal Missing See LEVEL 3 ECU - DTC SPN 1041
FMI 2 START SIGNAL MISSING
DIAGNOSTIC PROCEDURE in
Section 04, Group 160 of CTM134.
TM1637 (15JAN04)
Continued on next page
9015-20-48
RG40854,0000002 –19–08AUG02–3/9
644H and 644H MH Loader
011504
PN=438
Page 49
References
Symptom Problem
Solution
F0464 (000190.00) Engine Overspeed Extreme See LEVEL 3 ECU - DTC SPN 190
FMI 0 ENGINE OVERSPEED
EXTREME in Section 04, Group 160
of CTM134.
F0465 (000191.02) (000723.02) Pump Speed Input Noise See LEVEL 3 ECU - DTC SPN 191
FMI 2 PUMP SPEED INPUT NOISE
DIAGNOSTIC PROCEDURE in
Section 04, Group 160 of CTM134.
F0466 (000190.14) Engine Speed/Pump Speed Out of See LEVEL 3 ECU - DTC SPN 190
Sync FMI 14 ENGINE SPEED/PUMP
SPEED OUT OF SYNC
DIAGNOSTIC PROCEDURE in
Section 04, Group 160 of CTM134.
F0467 (001041.03) Start Signal Always Active See LEVEL 3 ECU - DTC SPN 1041
FMI 3 START SIGNAL ALWAYS
ACTIVE DIAGNOSTIC
PROCEDURE in Section 04, Group
160 of CTM134.
F0468 (000632.11) Fuel Shut-off Circuit Fault See LEVEL 3 ECU - DTC SPN 632
FMI 11 FUEL SHUT-OFF CIRCUIT
FAULT DIAGNOSTIC PROCEDURE
in Section 04, Group 160 of
CTM134.
9015
20
49
000051.02 CAN Throttle Invalid See LEVEL 3 ECU - T7 - CAN
THROTTLE INVALID DIAGNOSTIC
PROCEDURE in Section 04, Group
160 of CTM134.
000091.08 PWM Abnormal Pulse Width See LEVEL 3 ECU - T10 - PWM
ABNORMAL PULSE WIDTH
DIAGNOSTIC PROCEDURE in
Section 04, Group 160 of CTM134.
000091.09 CAN Throttle Invalid See LEVEL 3 ECU - T7 - CAN
THROTTLE INVALID DIAGNOSTIC
PROCEDURE in Section 04, Group
160 of CTM134.
TM1637 (15JAN04)
Continued on next page
9015-20-49
RG40854,0000002 –19–08AUG02–4/9
644H and 644H MH Loader
011504
PN=439
Page 50
References
Symptom Problem
Solution
000100.01 Engine Oil Pressure Extremely Low See LEVEL 3 ECU - DTC SPN 100
FMI 1 ENGINE OIL PRESSURE
EXTREMELY LOW DIAGNOSTIC
PROCEDURE in Section 04, Group
160 of CTM134.
000100.03 Engine Oil Pressure Input Voltage See LEVEL 3 ECU - DTC SPN 100
Low FMI 3 ENGINE OIL PRESSURE
INPUT VOLTAGE HIGH
DIAGNOSTIC PROCEDURE in
Section 04, Group 160 of CTM134.
000100.04 Engine Oil Pressure Input Voltage See LEVEL 3 ECU - DTC SPN 100
9015
20
50
Low FMI 4 ENGINE OIL PRESSURE
INPUT VOLTAGE LOW
DIAGNOSTIC PROCEDURE in
Section 04, Group 160 of CTM134.
000100.18 Engine Oil Pressure Moderately Low See LEVEL 3 ECU - DTC SPN 100
FMI 18 ENGINE OIL PRESSURE
MODERATELY LOW DIAGNOSTIC
PROCEDURE in Section 04, Group
160 of CTM134.
000105.03 Manifold Air Temperature Input See LEVEL 3 ECU - DTC SPN 105
Voltage High FMI 3 MANIFOLD AIR
TEMPERATURE INPUT VOLTAGE
HIGH DIAGNOSTIC PROCEDURE
in Section 04, Group 160 of
CTM134.
000105.04 Manifold Air Temperature Input See LEVEL 3 ECU - DTC SPN 105
Voltage Low FMI 4 MANIFOLD AIR
TEMPERATURE INPUT VOLTAGE
LOW DIAGNOSTIC PROCEDURE in
Section 04, Group 160 of CTM134.
000105.16 Manifold Air Temperature Moderately See LEVEL 3 ECU - DTC SPN 105
High FMI 16 MANIFOLD AIR
TEMPERATURE MODERATELY
HIGH DIAGNOSTIC PROCEDURE
in Section 04, Group 160 of
CTM134.
TM1637 (15JAN04)
Continued on next page
9015-20-50
RG40854,0000002 –19–08AUG02–5/9
644H and 644H MH Loader
011504
PN=440
Page 51
References
Symptom Problem
Solution
000110.00 Engine Coolant Temperature High See LEVEL 3 ECU - DTC SPN 110
Extremely High FMI 0 ENGINE COOLANT
TEMPERATURE HIGH MOST
SEVERE DIAGNOSTIC
PROCEDURE in Section 04, Group
160 of CTM134.
000110.16 Engine Coolant Temperature See LEVEL 3 ECU - DTC SPN 110
Moderately High FMI 16 ENGINE COOLANT
TEMPERATURE HIGH
MODERATELY SEVERE
DIAGNOSTIC PROCEDURE in
Section 04, Group 160 of CTM134.
000158.02 Intermittent Loss of ECU Power See LEVEL 3 ECU - DTC SPN 158
Supply FMI 2 INTERMITTENT LOSS OF
ECU POWER SUPPLY in Section
04, Group 160 of CTM134.
000174.16 Fuel Temperature Moderately High See LEVEL 3 ECU - DTC SPN 174
FMI 16 FUEL TEMPERATURE
MODERATELY HIGH DIAGNOSTIC
PROCEDURE in Section 04, Group
160 of CTM134.
9015
20
51
000190.03 Engine Speed Input Voltage High See LEVEL 3 ECU - DTC SPN 190
FMI 3 ENGINE SPEED INPUT
VOLTAGE HIGH DIAGNOSTIC
PROCEDURE in Section 04, Group
160 of CTM134.
000190.04 Engine Speed Input Voltage Low See LEVEL 3 ECU - DTC SPN 190
FMI 4 ENGINE SPEED INPUT
VOLTAGE LOW DIAGNOSTIC
PROCEDURE in Section 04, Group
160 of CTM134.
000190.05 Engine Speed Circuit Open See LEVEL 3 ECU - DTC SPN 190
FMI 5 ENGINE SPEED CIRCUIT
OPEN DIAGNOSTIC PROCEDURE
in Section 04, Group 160 of
CTM134.
TM1637 (15JAN04)
Continued on next page
9015-20-51
RG40854,0000002 –19–08AUG02–6/9
644H and 644H MH Loader
011504
PN=441
Page 52
References
Symptom Problem
Solution
000190.16 Engine Overspeed Moderate See LEVEL 3 ECU - DTC SPN 190
FMI 16 ENGINE OVERSPEED
MODERATE in Section 04, Group
160 of CTM134.
000191.14 Engine Speed/Pump Speed Out of See LEVEL 3 ECU - DTC SPN 190
Sync FMI 14 ENGINE SPEED/PUMP
SPEED OUT OF SYNC
DIAGNOSTIC PROCEDURE in
Section 04, Group 160 of CTM134.
000191.16 Engine Overspeed Extreme See LEVEL 3 ECU - DTC SPN 190
FMI 0 ENGINE OVERSPEED
9015
20
52
EXTREME in Section 04, Group 160
of CTM134.
000629.13 ECU Error See LEVEL 3 ECU - DTC SPN 629
FMI 13 ECU ERROR DIAGNOSTIC
PROCEDURE in Section 04, Group
160 of CTM134.
000638.02 Rack Instability See LEVEL 3 ECU - DTC SPN 834
FMI 02 RACK INSTABILITY
DIAGNOSTIC PROCEDURE in
Section 04, Group 160 of CTM134.
000639.02 CAN Error See LEVEL 3 ECU - DTC SPN 639
FMI 13 CAN ERROR DIAGNOSTIC
PROCEDURE in Section 04, Group
160 of CTM134.
000639.13 CAN Error See LEVEL 3 ECU - DTC SPN 639
FMI 13 CAN ERROR DIAGNOSTIC
PROCEDURE in Section 04, Group
160 of CTM134.
000833.02 Rack Position Error with Engine OFF See LEVEL 3 ECU - DTC SPN 833
FMI 2 RACK POSITION ERROR
WITH ENGINE OFF DIAGNOSTIC
PROCEDURE in Section 04, Group
160 of CTM134.
TM1637 (15JAN04)
Continued on next page
9015-20-52
RG40854,0000002 –19–08AUG02–7/9
644H and 644H MH Loader
011504
PN=442
Page 53
References
Symptom Problem
Solution
000833.03 Rack Position Voltage High See LEVEL 3 ECU - DTC SPN 833
FMI 3 RACK POSITION VOLTAGE
HIGH DIAGNOSTIC PROCEDURE
in Section 04, Group 160 of
CTM134.
000833.04 Rack Position Voltage Low See LEVEL 3 ECU - DTC SPN 833
FMI 4 RACK POSITION VOLTAGE
LOW DIAGNOSTIC PROCEDURE in
Section 04, Group 160 of CTM134.
000834.02 Rack Instability See LEVEL 3 ECU - DTC SPN 834
FMI 2 RACK INSTABILITY
DIAGNOSTIC PROCEDURE in
Section 04, Group 160 of CTM134.
000834.03 Rack Actuator Circuit Shorted to See LEVEL 3 ECU - DTC SPN 834
Power FMI 3 RACK ACTUATOR CIRCUIT
SHORTED TO POWER
DIAGNOSTIC PROCEDURE in
Section 04, Group 160 of CTM134.
000834.05 Rack Actuator Circuit Open See LEVEL 3 ECU - DTC SPN 834
FMI 5 RACK ACTUATOR CIRCUIT
OPEN DIAGNOSTIC PROCEDURE
in Section 04, Group 160 of
CTM134.
9015
20
53
000834.06 Rack Actuator Circuit Grounded See LEVEL 3 ECU - DTC SPN 834
FMI 6 RACK ACTUATOR CIRCUIT
GROUNDED DIAGNOSTIC
PROCEDURE in Section 04, Group
160 of CTM134.
000834.07 Rack Position Error See LEVEL 3 ECU - DTC SPN 834
FMI 7 RACK POSITION ERROR
DIAGNOSTIC PROCEDURE in
Section 04, Group 160 of CTM134.
001041.03 Start Signal Always Active See LEVEL 3 ECU - DTC SPN 1041
FMI 3 START SIGNAL ALWAYS
ACTIVE DIAGNOSTIC
PROCEDURE in Section 04, Group
160 of CTM134.
TM1637 (15JAN04)
Continued on next page
9015-20-53
RG40854,0000002 –19–08AUG02–8/9
644H and 644H MH Loader
011504
PN=443
Page 54
References
Symptom Problem
Solution
001569.31 Fuel Derate See LEVEL 3 ECU - DTC SPN 1569
FMI 31 FUEL DERATE in Section
04, Group 160 of CTM134.
002000.13 Security Violation See LEVEL 3 ECU - DTC SPN 2000
FMI 13 SECURITY VIOLATION in
Section 04, Group 160 of CTM134.
RG40854,0000002 –19–08AUG02–9/9
9015
20
54
TM1637 (15JAN04)
9015-20-54
644H and 644H MH Loader
011504
PN=444
Page 55
References
Engine Diagnostic Trouble Codes (DTCs) on
Level 9 ECU (S.N. 585561—)
Fuel injection system will be Level 3 or Level 9 Electronic
fuel injection system. The term level is simply a means to
identify fuel systems. Level 3 system meters the fuel at
the injection pump. Level 9 system uses a High Pressure
Common Rail (HPCR) and meters fuel at the injectors.
See Distinguishing ECUs on 8.1 L Engines in CTM134.
• Level 3 ECU
– 2 ECU connectors (30 and 18-way connectors)
– Bosch In-Line Injection Pump
– Mechanically-controlled injection nozzles
• Level 9 ECU
– 2 ECU connectors (Two 30-way connectors)
– Denso High Pressure Common Rail (HPCR) and
High Pressure Pump
– Electronically-controlled injection nozzles
Wire harness information (Group 9015-10):
• See System Functional Schematic
• See Loader Frame Harness (W2) Component Location
• See Load Center Harness (W3) Component Location
• See Front Console Harness (W4) Component Location
• See Engine Frame Harness (W5) Component Location
• See Engine Harness (W6) Component Location
• See Engine Air Heater Harness (W7) Component
Location
9015
20
55
Symptom Problem
Solution
F0423 (000105.03) Manifold Air Temperature Input See LEVEL 9 ECU - DTC SPN 105
Voltage High FMI 3 MANIFOLD AIR
TEMPERATURE INPUT VOLTAGE
HIGH DIAGNOSTIC PROCEDURE
in Section 04, Group 160 of
CTM255.
F0424 (000105.04) Manifold Air Temperature Input See LEVEL 9 ECU - DTC SPN 105
Voltage Low FMI 4 MANIFOLD AIR
TEMPERATURE INPUT VOLTAGE
LOW DIAGNOSTIC PROCEDURE in
Section 04, Group 160 of CTM255.
TM1637 (15JAN04)
Continued on next page
9015-20-55
RG40854,0000003 –19–08AUG02–1/10
644H and 644H MH Loader
011504
PN=445
Page 56
References
Symptom Problem
Solution
F0425 (000110.03) Engine Coolant Temperature Input See LEVEL 9 ECU - DTC SPN 110
Voltage High FMI 3 ENGINE COOLANT
TEMPERATURE INPUT VOLTAGE
HIGH DIAGNOSTIC PROCEDURE
in Section 04, Group 160 of
CTM255.
F0426 (000110.04) Engine Coolant Temperature Input See LEVEL 9 ECU - DTC SPN 110
Voltage Low FMI 4 ENGINE COOLANT
TEMPERATURE INPUT VOLTAGE
LOW DIAGNOSTIC PROCEDURE in
Section 04, Group 160 of CTM255.
F0431 (000651.05) Cylinder #1 EI Circuit Open See LEVEL 9 ECU - DTC SPN 651
9015
20
56
FMI 5 CYLINDER #1 EI CIRCUIT
OPEN DIAGNOSTIC PROCEDURE
in Section 04, Group 160 of
CTM255.
F0431 (000651.06) Cylinder #1 EI Circuit Shorted See LEVEL 9 ECU - DTC SPN 651
FMI 6 CYLINDER #1 EI CIRCUIT
SHORTED DIAGNOSTIC
PROCEDURE in Section 04, Group
160 of CTM255.
F0432 (000652.05) Cylinder #2 EI Circuit Open See LEVEL 9 ECU - DTC SPN 652
FMI 5 CYLINDER #2 EI CIRCUIT
OPEN DIAGNOSTIC PROCEDURE
in Section 04, Group 160 of
CTM255.
F0432 (000652.06) Cylinder #2 EI Circuit Shorted See LEVEL 9 ECU - DTC SPN 652
FMI 6 CYLINDER #2 EI CIRCUIT
SHORTED DIAGNOSTIC
PROCEDURE in Section 04, Group
160 of CTM255.
F0433 (000653.05) Cylinder #3 EI Circuit Open See LEVEL 9 ECU - DTC SPN 653
FMI 5 CYLINDER #3 EI CIRCUIT
OPEN DIAGNOSTIC PROCEDURE
in Section 04, Group 160 of
CTM255.
TM1637 (15JAN04)
Continued on next page
9015-20-56
RG40854,0000003 –19–08AUG02–2/10
644H and 644H MH Loader
011504
PN=446
Page 57
References
Symptom Problem
Solution
F0433 (000653.06) Cylinder #3 EI Circuit Shorted See LEVEL 9 ECU - DTC SPN 653
FMI 6 CYLINDER #3 EI CIRCUIT
SHORTED DIAGNOSTIC
PROCEDURE in Section 04, Group
160 of CTM255.
F0434 (000654.05) Cylinder #4 EI Circuit Open See LEVEL 9 ECU - DTC SPN 654
FMI 5 CYLINDER #4 EI CIRCUIT
OPEN DIAGNOSTIC PROCEDURE
in Section 04, Group 160 of
CTM255.
F0434 (000654.06) Cylinder #4 EI Circuit Shorted See LEVEL 9 ECU - DTC SPN 654
FMI 6 CYLINDER #4 EI CIRCUIT
SHORTED DIAGNOSTIC
PROCEDURE in Section 04, Group
160 of CTM255.
F0435 (000655.05) Cylinder #5 EI Circuit Open See LEVEL 9 ECU - DTC SPN 655
FMI 5 CYLINDER #5 EI CIRCUIT
OPEN DIAGNOSTIC PROCEDURE
in Section 04, Group 160 of
CTM255.
9015
20
57
F0435 (000655.06) Cylinder #5 EI Circuit Shorted See LEVEL 9 ECU - DTC SPN 655
FMI 6 CYLINDER #5 EI CIRCUIT
SHORTED DIAGNOSTIC
PROCEDURE in Section 04, Group
160 of CTM255.
F0436 (000656.05) Cylinder #6 EI Circuit Open See LEVEL 9 ECU - DTC SPN 656
FMI 5 CYLINDER #6 EI CIRCUIT
OPEN DIAGNOSTIC PROCEDURE
in Section 04, Group 160 of
CTM255.
F0436 (000656.06) Cylinder #6 EI Circuit Shorted See LEVEL 9 ECU - DTC SPN 656
FMI 6 CYLINDER #6 EI CIRCUIT
SHORTED DIAGNOSTIC
PROCEDURE in Section 04, Group
160 of CTM255.
TM1637 (15JAN04)
Continued on next page
9015-20-57
RG40854,0000003 –19–08AUG02–3/10
644H and 644H MH Loader
011504
PN=447
Page 58
References
Symptom Problem
Solution
F0437 (000174.03) Fuel Temperature Input Voltage High See LEVEL 9 ECU - DTC SPN 174
FMI 3 FUEL TEMPERATURE
INPUT VOLTAGE HIGH
DIAGNOSTIC PROCEDURE in
Section 04, Group 160 of CTM255.
F0438 (000174.04) Fuel Temperature Input Voltage Low See LEVEL 9 ECU - DTC SPN 174
FMI 4 FUEL TEMPERATURE
INPUT VOLTAGE LOW
DIAGNOSTIC PROCEDURE in
Section 04, Group 160 of CTM255.
F0439 (001347.05) Pump Control Valve #1 Error See LEVEL 9 ECU - DTC SPN 1347
9015
20
58
FMI 5 PUMP CONTROL VALVE #1
ERROR DIAGNOSTIC
PROCEDURE in Section 04, Group
160 of CTM255.
F0440 (001348.05) Pump Control Valve #2 Error See LEVEL 9 ECU - DTC SPN 1348
FMI 05 PUMP CONTROL VALVE #2
ERROR DIAGNOSTIC
PROCEDURE in Section 04, Group
160 of CTM255.
F0441 (000637.08) Crank Position Input Missing See LEVEL 9 ECU - DTC SPN 637
FMI 08 CRANK POSITION INPUT
MISSING DIAGNOSTIC
PROCEDURE in Section 04, Group
160 of CTM255.
F0442 (000637.02) Crank Position Input Noise See LEVEL 9 ECU - DTC SPN 636
FMI 02 CRANK POSITION INPUT
NOISE DIAGNOSTIC PROCEDURE
in Section 04, Group 160 of
CTM255.
F0442 (000637.10) Crank Position Input Pattern Error See LEVEL 9 ECU - DTC SPN 637
FMI 10 CRANK POSITION INPUT
PATTERN ERROR DIAGNOSTIC
PROCEDURE in Section 04, Group
160 of CTM255.
TM1637 (15JAN04)
Continued on next page
9015-20-58
RG40854,0000003 –19–08AUG02–4/10
644H and 644H MH Loader
011504
PN=448
Page 59
References
Symptom Problem
Solution
F0443 (000636.08) Pump Position Sensor Input Missing See LEVEL 9 ECU - DTC SPN 636
FMI 08 PUMP POSITION SENSOR
INPUT MISSING DIAGNOSTIC
PROCEDURE in Section 04, Group
160 of CTM255.
F0444 (000636.02) Pump Position Sensor Input Noise See LEVEL 9 ECU - DTC SPN 636
FMI 02 PUMP POSITION SENSOR
INPUT NOISE DIAGNOSTIC
PROCEDURE in Section 04, Group
160 of CTM255.
F0444 (000636.10) Pump Position Sensor Input Pattern See LEVEL 9 ECU - DTC SPN 636
Error FMI 10 PUMP POSITION SENSOR
INPUT PATTERN ERROR
DIAGNOSTIC PROCEDURE in
Section 04, Group 160 of CTM255.
F0445 (000637.07) Crank Position/Pump Position Timing See LEVEL 9 ECU - DTC SPN 637
Moderately Out of Sync FMI 7 CRANK POSITION/PUMP
POSITION TIMING MODERATELY
OUT OF SYNC DIAGNOSTIC
PROCEDURE in Section 04, Group
160 of CTM255.
9015
20
59
F0450 (000094.03) Fuel Rail Pressure Input Voltage See LEVEL 9 ECU - DTC SPN 94
High FMI 3 FUEL RAIL PRESSURE
INPUT VOLTAGE HIGH
DIAGNOSTIC PROCEDUREin
Section 04, Group 160 of CTM255.
F0451 (000094.04) Fuel Rail Pressure Input Voltage See LEVEL 9 ECU - DTC SPN 94
Low FMI 3 FUEL RAIL PRESSURE
INPUT VOLTAGE LOW
DIAGNOSTIC PROCEDURE in
Section 04, Group 160 of CTM255.
F0453 (000097.03) Water in Fuel Signal Voltage High See LEVEL 9 ECU - DTC SPN 97
FMI 3 WATER IN FUEL SIGNAL
VOLTAGE HIGH DIAGNOSTIC
PROCEDURE in Section 04, Group
160 of CTM255.
TM1637 (15JAN04)
Continued on next page
9015-20-59
RG40854,0000003 –19–08AUG02–5/10
644H and 644H MH Loader
011504
PN=449
Page 60
References
Symptom Problem
Solution
F0454 (000097.04) Water in Fuel Signal Voltage Low See LEVEL 9 ECU - DTC SPN 97
FMI 4 WATER IN FUEL SIGNAL
VOLTAGE LOW DIAGNOSTIC
PROCEDURE in Section 04, Group
160 of CTM255.
F0455 (000105.16) Manifold Air Temperature Moderately See LEVEL 9 ECU - DTC SPN 105
High FMI 16 MANIFOLD AIR
TEMPERATURE MODERATELY
HIGH DIAGNOSTIC PROCEDURE
in Section 04, Group 160 of
CTM255.
F0456 (001348.10) Pump Control Valve #2 Fuel Flow See LEVEL 9 ECU - DTC SPN 1348
9015
20
60
Not Detected FMI 10 PUMP CONTROL VALVE #2
FUEL FLOW NOT DETECTED
DIAGNOSTIC PROCEDURE in
Section 04, Group 160 of CTM255.
F0469 (001347.10) Pump Control Valve #1 Fuel Flow See LEVEL 9 ECU - DTC SPN 1347
Not Detected FMI 10 PUMP CONTROL VALVE #1
FUEL FLOW NOT DETECTED
DIAGNOSTIC PROCEDURE in
Section 04, Group 160 of CTM255.
F0470 (001347.07) Fuel Rail Pressure Control Error See LEVEL 9 ECU - DTC SPN 1347
FMI 7 FUEL RAIL PRESSURE
CONTROL ERROR DIAGNOSTIC
PROCEDURE in Section 04, Group
160 of CTM255.
F0471 (001080.04) Fuel Rail Pressure Sensor Supply See LEVEL 9 ECU - DTC SPN 1080
Voltage Low FMI 4 FUEL RAIL PRESSURE
SENSOR SUPPLY VOLTAGE LOW
DIAGNOSTIC PROCEDURE in
Section 04, Group 160 of CTM255.
F0485 (000097.16) Water in Fuel Detected See LEVEL 9 ECU - DTC SPN 97
FMI 16 WATER IN FUEL
DETECTED DIAGNOSTIC
PROCEDURE in Section 04, Group
160 of CTM255.
TM1637 (15JAN04)
Continued on next page
9015-20-60
RG40854,0000003 –19–08AUG02–6/10
644H and 644H MH Loader
011504
PN=450
Page 61
References
Symptom Problem
Solution
000091.09 CAN Throttle Invalid See LEVEL 9 ECU - T7 - CAN
THROTTLE INVALID DIAGNOSTIC
PROCEDURE in Section 04, Group
160 of CTM255.
000094.10 Fuel Rail Pressure Loss Detected See LEVEL 9 ECU - DTC SPN 94
FMI 10 FUEL RAIL PRESSURE
LOSS DETECTED DIAGNOSTIC
PROCEDURE in Section 04, Group
160 of CTM255.
000094.13 Fuel Rail Pressure Higher Than See LEVEL 9 ECU - DTC SPN 94
Expected FMI 13 FUEL RAIL PRESSURE
HIGHER THAN EXPECTED
DIAGNOSTIC PROCEDURE in
Section 04, Group 160 of CTM255.
000094.17 Fuel Rail Pressure Not Developed See LEVEL 9 ECU - DTC SPN 94
FMI 17 FUEL RAIL PRESSURE
NOT DEVELOPED DIAGNOSTIC
PROCEDURE in Section 04, Group
160 of CTM255.
9015
20
61
000110.00 Engine Coolant Temperature High See LEVEL 9 ECU - DTC SPN 110
Extremely High FMI 0 ENGINE COOLANT
TEMPERATURE HIGH MOST
SEVERE DIAGNOSTIC
PROCEDURE in Section 04, Group
160 of CTM255.
000110.16 Engine Coolant Temperature See LEVEL 9 ECU - DTC SPN 110
Moderately High FMI 16 ENGINE COOLANT
TEMPERATURE HIGH
MODERATELY SEVERE
DIAGNOSTIC PROCEDURE in
Section 04, Group 160 of CTM255.
000158.17 ECU Power Down Error See LEVEL 9 ECU - DTC SPN 158
FMI 17 ECU POWER DOWN
ERROR DIAGNOSTIC
PROCEDURE in Section 04, Group
160 of CTM255.
TM1637 (15JAN04)
Continued on next page
9015-20-61
RG40854,0000003 –19–08AUG02–7/10
644H and 644H MH Loader
011504
PN=451
Page 62
References
Symptom Problem
Solution
000174.16 Fuel Temperature High Moderately See LEVEL 9 ECU - DTC SPN 174
Severe FMI 16 FUEL TEMPERATURE
HIGH MODERATELY SEVERE
DIAGNOSTIC PROCEDURE in
Section 04, Group 160 of CTM255.
000611.03 Electronic Injector Wiring Shorted To See LEVEL 9 ECU - DTC SPN 611
Power Source FMI 3 ELECTRONIC INJECTOR
WIRING SHORTED TO POWER
SOURCE DIAGNOSTIC
PROCEDURE in Section 04, Group
160 of CTM255.
000611.04 Electronic Injector Wiring Shorted To See LEVEL 9 ECU - DTC SPN 611
9015
20
62
Ground FMI 4 ELECTRONIC INJECTOR
WIRING SHORTED TO GROUND
DIAGNOSTIC PROCEDURE in
Section 04, Group 160 of CTM255.
000620.03 Sensor Supply 1 Voltage High See LEVEL 9 ECU - DTC SPN 620
FMI 3 SENSOR SUPPLY 1
VOLTAGE HIGH DIAGNOSTIC
PROCEDURE in Section 04, Group
160 of CTM255.
000620.04 Sensor Supply 1 Voltage Low See LEVEL 9 ECU - DTC SPN 620
FMI 4 SENSOR SUPPLY 1
VOLTAGE LOW DIAGNOSTIC
PROCEDURE in Section 04, Group
160 of CTM255.
000627.01 Electronic Injector Supply Voltage See LEVEL 9 ECU - DTC SPN 627
Problem FMI 1 ELECTRONIC INJECTOR
SUPPLY VOLTAGE PROBLEM
DIAGNOSTIC PROCEDURE in
Section 04, Group 160 of CTM255.
000629.13 ECU Error See LEVEL 9 ECU - DTC SPN 629
FMI 13 ECU ERROR in Section 04,
Group 160 of CTM255.
000639.13 CAN Bus Error See LEVEL 9 ECU - DTC SPN 639
FMI 13 CAN BUS ERROR
DIAGNOSTIC PROCEDURE in
Section 04, Group 160 of CTM255.
TM1637 (15JAN04)
Continued on next page
9015-20-62
RG40854,0000003 –19–08AUG02–8/10
644H and 644H MH Loader
011504
PN=452
Page 63
References
Symptom Problem
Solution
000651.07 Cylinder #1 EI Fuel Delivery Failure See LEVEL 9 ECU - DTC SPN 651
FMI 7 CYLINDER #1 EI FUEL
DELIVERY FAILURE DIAGNOSTIC
PROCEDURE in Section 04, Group
160 of CTM255.
000652.07 Cylinder #2 EI Fuel Delivery Failure See LEVEL 9 ECU - DTC SPN 652
FMI 7 CYLINDER #2 EI FUEL
DELIVERY FAILURE DIAGNOSTIC
PROCEDURE in Section 04, Group
160 of CTM255.
000653.07 Cylinder #3 EI Fuel Delivery Failure See LEVEL 9 ECU - DTC SPN 653
FMI 7 CYLINDER #3 EI FUEL
DELIVERY FAILURE DIAGNOSTIC
PROCEDURE in Section 04, Group
160 of CTM255.
000654.07 Cylinder #4 EI Fuel Delivery Failure See LEVEL 9 ECU - DTC SPN 654
FMI 7 CYLINDER #4 EI FUEL
DELIVERY FAILURE DIAGNOSTIC
PROCEDURE in Section 04, Group
160 of CTM255.
9015
20
63
000655.07 Cylinder #5 EI Fuel Delivery Failure See LEVEL 9 ECU - DTC SPN 655
FMI 7 CYLINDER #5 EI FUEL
DELIVERY FAILURE DIAGNOSTIC
PROCEDURE in Section 04, Group
160 of CTM255.
000656.07 Cylinder #6 EI Fuel Delivery Failure See LEVEL 9 ECU - DTC SPN 656
FMI 7 CYLINDER #6 EI FUEL
DELIVERY FAILURE DIAGNOSTIC
PROCEDURE in Section 04, Group
160 of CTM255.
001080.03 Fuel Rail Pressure Sensor Supply See LEVEL 9 ECU - DTC SPN 1080
Voltage High FMI 3 FUEL RAIL PRESSURE
SENSOR SUPPLY VOLTAGE HIGH
DIAGNOSTIC PROCEDURE in
Section 04, Group 160 of CTM255.
TM1637 (15JAN04)
Continued on next page
9015-20-63
RG40854,0000003 –19–08AUG02–9/10
644H and 644H MH Loader
011504
PN=453
Page 64
References
Symptom Problem
Solution
001568.02 Torque Curve Selection Invalid See LEVEL 9 ECU - DTC SPN 1568
FMI 2 TORQUE CURVE
SELECTION INVALID in Section 04,
Group 160 of CTM255.
001569.31 Fuel Derate See LEVEL 9 ECU - DTC SPN 1569
FMI 31 FUEL DERATE in Section
04, Group 160 of CTM255.
RG40854,0000003 –19–08AUG02–10/10
9015
20
64
TM1637 (15JAN04)
9015-20-64
644H and 644H MH Loader
011504
PN=454
Page 65
Steering and Brake Diagnostic Trouble
Codes
References
Symptom Problem
Solution
F0998 Steering Pressure Circuit Steering System Pressure Switch Steering System Pressure Switch
(B25) Short-To-Ground (B25) Short-To-Ground
(Check/Repair)
Wire N08 (Yellow) Harness (W17) Secondary Steering Switch Harness
Short-To-Ground (W17) - N08 (Yellow)
Short-To-Ground (Check/Repair)
Wire N08 (Yellow) Harness (W3) Load Center Harness (W3) - N08
Short-To-Ground (Yellow) Short-To-Ground
(Check/Repair)
Monitor Configuration Wrong MDU (Reconfigure). See Monitor
Display Unit Reconfiguration Access
Service Menu, Machine Model (S
01), Tire Size (S 03), Enable Options
(S 06), and Delete Diagnostic
Trouble Codes in Group 9015—15.
F0999 Steering Pressure Low Power for Pressure Switches Fuse Power for Pressure Switches Fuse
(F10) (F10) (Check/Replace)
Monitor Configuration Wrong MDU (Reconfigure). See Monitor
Display Unit Reconfiguration Access
Service Menu, Machine Model (S
01), Tire Size (S 03), Enable Options
(S 06), and Delete Diagnostic
Trouble Codes in Group 9015—15.
9015
20
65
Steering System Pressure Switch Steering System Pressure Switch
(B25) Open (B25) Open (Check/Repair)
Wire N08 (Yellow) Harness (W17) Secondary Steering Switch Harness
Short-To-Power (W17) - N08 (Yellow)
Short-To-Power (Check/Repair)
Wire N08 (Yellow) Harness (W3) Load Center Harness (W3) - N08
Open (Yellow) Open (Check/Repair)
F1097 Service Brake Pressure Service Brake System Pressure Service Brake Pressure Switch (B27)
Circuit Switch (B27) Short-To-Power Short-To-Power (Check/Repair)
TX17961,0000003 –19–12AUG02–1/2
644H and 644H MH Loader
TM1637 (15JAN04)
Continued on next page
9015-20-65
011504
PN=455
Page 66
References
Symptom Problem
Solution
Wire N07 (Yellow) Harness (W3) Load Center Harness (W3) - N07
Short-To-Power (Yellow) Short-To-Power
(Check/Repair)
F1099 Service Brake Pressure Service Brake System Pressure Service Brake Pressure Switch (B27)
Low Switch (B27) Open Open (Check/Repair)
Load Center Harness (W3) - T20 Load Center Harness (W3) - T20
(Blue) Open (Blue) Open (Check/Repair)
Wire N07 (Yellow) Harness (W3) Load Center Harness (W3) - N07
Open (Yellow) Open (Check/Repair)
9015
20
66
TX17961,0000003 –19–12AUG02–2/2
TM1637 (15JAN04)
9015-20-66
644H and 644H MH Loader
011504
PN=456
Page 67
References
Electrical System Diagnostic Trouble Codes
Symptom Problem
Solution
F1620 Spare Relay 1 Driver Short CCU (A2) CCU (Replace)
MDU (Reconfigure). See Monitor
Display Unit Reconfiguration Access
Service Menu, Machine Model (S
01), Tire Size (S 03), Enable Options
(S 06), and Delete Diagnostic
Trouble Codes in Group 9015—15.
F1621 Spare Relay 3 Driver Short CCU (A2) CCU (Replace)
MDU (Reconfigure). See Monitor
Display Unit Reconfiguration Access
Service Menu, Machine Model (S
01), Tire Size (S 03), Enable Options
(S 06), and Delete Diagnostic
Trouble Codes in Group 9015—15.
F1622 Spare Relay 4 Driver Short CCU (A2) CCU (Replace)
MDU (Reconfigure). See Monitor
Display Unit Reconfiguration Access
Service Menu, Machine Model (S
01), Tire Size (S 03), Enable Options
(S 06), and Delete Diagnostic
Trouble Codes in Group 9015—15.
9015
20
67
F1623 Spare Relay 5 Driver Short CCU (A2) CCU (Replace)
MDU (Reconfigure). See Monitor
Display Unit Reconfiguration Access
Service Menu, Machine Model (S
01), Tire Size (S 03), Enable Options
(S 06), and Delete Diagnostic
Trouble Codes in Group 9015—15.
Continued on next page
TX17961,0000004 –19–12AUG02–1/16
TM1637 (15JAN04)
9015-20-67
644H and 644H MH Loader
011504
PN=457
Page 68
References
Symptom Problem
Solution
F1624 Air Preheat Driver Engine Air Heater Coil Relay (K34) Engine Air Heater Relay (K34)
Short-To- Ground Short-To-Ground Short-To-Ground (Check/Replace)
Wire E13 (White) Harness (W3) Load Center Harness (W3) - E13
Short-To-Ground (White) Short-To-Ground
(Check/Repair)
CCU (A2) CCU (Replace)
MDU (Reconfigure). See Monitor
Display Unit Reconfiguration Access
Service Menu, Machine Model (S
01), Tire Size (S 03), Enable Options
9015
20
68
(S 06), and Delete Diagnostic
Trouble Codes in Group 9015—15.
F1625 Detent Enable Driver Monitor Configuration Wrong MDU (Reconfigure). See Monitor
Short-To-Ground Display Unit Reconfiguration Access
Service Menu, Machine Model (S
01), Tire Size (S 03), Enable Options
(S 06), and Delete Diagnostic
Trouble Codes in Group 9015—15.
Detent Enable and Pilot Enable Detent Enable Relay (K32)
Relay (K32) Short-To-Ground Short-To-Ground (Check/Replace)
Wire H25 (Green) Harness (W3) Load Center Harness (W3) - H25
Short-To-Ground (Green) Short-To-Ground
(Check/Repair)
CCU (A2) CCU (Replace)
MDU (Reconfigure). See Monitor
Display Unit Reconfiguration Access
Service Menu, Machine Model (S
01), Tire Size (S 03), Enable Options
(S 06), and Delete Diagnostic
Trouble Codes in Group 9015—15.
Continued on next page
TX17961,0000004 –19–12AUG02–2/16
TM1637 (15JAN04)
9015-20-68
644H and 644H MH Loader
011504
PN=458
Page 69
References
Symptom Problem
Solution
F1626 Ride Control Boom Driver Monitor Configuration Wrong MDU (Reconfigure). See Monitor
Short-To- Ground Display Unit Reconfiguration Access
Service Menu, Machine Model (S
01), Tire Size (S 03), Enable Options
(S 06), and Delete Diagnostic
Trouble Codes in Group 9015—15.
Ride Control Boom Relay (K30) Ride Control Boom Relay (K30)
Short-To-Ground Short-To-Ground (Check/Repair)
Wire J04 (Tan) Harness (W3) Load Center Harness (W3) -J04
Short-To-Ground (Tan) Short-To-Ground
(Check/Repair)
CCU (A2) CCU (Replace)
MDU (Reconfigure). See Monitor
Display Unit Reconfiguration Access
Service Menu, Machine Model (S
01), Tire Size (S 03), Enable Options
(S 06), and Delete Diagnostic
Trouble Codes in Group 9015—15.
9015
20
69
F1628 Ride Control On Driver Monitor Configuration Wrong MDU (Reconfigure). See Monitor
Short-To- Ground Display Unit Reconfiguration Access
Service Menu, Machine Model (S
01), Tire Size (S 03), Enable Options
(S 06), and Delete Diagnostic
Trouble Codes in Group 9015—15.
Ride Control On/Off Relay (K31) Ride Control On/Off Relay (K31)
Short-To-Ground Short-To-Ground (Check/Replace)
Wire J06 (Tan) Harness (W3) Load Center Harness (W3) - J06
Short-To-Ground (Tan) Short-To-Ground
(Check/Repair)
CCU (A2) CCU (Replace)
MDU (Reconfigure). See Monitor
Display Unit Reconfiguration Access
Service Menu, Machine Model (S
01), Tire Size (S 03), Enable Options
(S 06), and Delete Diagnostic
Trouble Codes in Group 9015—15.
TM1637 (15JAN04)
Continued on next page
9015-20-69
TX17961,0000004 –19–12AUG02–3/16
644H and 644H MH Loader
011504
PN=459
Page 70
References
Symptom Problem
Solution
F1629 Left Turn Driver Left Flasher Relay (K23) Left Flasher Relay (K23)
Short-To-Ground Short-To-Ground Short-To-Ground (Check/Replace)
Wire L08 (Brown) Harness (W3) Load Center Harness (W3) - L08
Short-To-Ground (Brown) Short-To-Ground
(Check/Repair)
CCU (A2) CCU (Replace)
MDU (Reconfigure). See Monitor
Display Unit Reconfiguration Access
Service Menu, Machine Model (S
01), Tire Size (S 03), Enable Options
9015
20
70
(S 06), and Delete Diagnostic
Trouble Codes in Group 9015—15.
F1630 Right Turn Driver Right Flasher Relay (K24) Right Flasher Relay (K24)
Short-To- Ground Short-To-Ground Short-To-Ground (Check/Replace)
Wire L11 (Brown) Harness (W3) Load Center Harness (W3) - L11
Short-To-Ground (Brown) Short-To-Ground
(Check/Repair)
CCU (A2) CCU (Replace)
MDU (Reconfigure). See Monitor
Display Unit Reconfiguration Access
Service Menu, Machine Model (S
01), Tire Size (S 03), Enable Options
(S 06), and Delete Diagnostic
Trouble Codes in Group 9015—15.
Continued on next page
TX17961,0000004 –19–12AUG02–4/16
TM1637 (15JAN04)
9015-20-70
644H and 644H MH Loader
011504
PN=460
Page 71
References
Symptom Problem
Solution
F1633 Secondary Steering Driver Monitor Configuration Wrong MDU (Reconfigure). See Monitor
Short-To- Ground Display Unit Reconfiguration Access
Service Menu, Machine Model (S
01), Tire Size (S 03), Enable Options
(S 06), and Delete Diagnostic
Trouble Codes in Group 9015—15.
Secondary Steering Relay (K21) Secondary Steering Relay (K21)
Short-To-Ground Short-To-Ground (Check/Replace)
Wire H14 (Green) Harness (W3) Load Center Harness (W3) - H14
Short-To-Ground (Green) Short-To-Ground
(Check/Repair)
CCU (A2) CCU (Replace)
MDU (Reconfigure). See Monitor
Display Unit Reconfiguration Access
Service Menu, Machine Model (S
01), Tire Size (S 03), Enable Options
(S 06), and Delete Diagnostic
Trouble Codes in Group 9015—15.
9015
20
71
F1634 Rear Wiper Driver Rear Intermittent Wiper Relay (K18) Rear Intermittent Wiper Driver Relay
Short-To-Ground Short-To-Ground (K18) Short-To-Ground
(Check/Replace)
Wire A29 (Orange) Harness (W3) Load Center Harness (W3) - A29
Short-To-Ground (Orange) Short-To-Ground
(Check/Repair)
CCU (A2) CCU (Replace)
MDU (Reconfigure). See Monitor
Display Unit Reconfiguration Access
Service Menu, Machine Model (S
01), Tire Size (S 03), Enable Options
(S 06), and Delete Diagnostic
Trouble Codes in Group 9015—15.
Continued on next page
TX17961,0000004 –19–12AUG02–5/16
TM1637 (15JAN04)
9015-20-71
644H and 644H MH Loader
011504
PN=461
Page 72
References
Symptom Problem
Solution
F1635 Front Wiper Driver Front Intermittent Wiper Relay (K16) Front Intermittent Wiper Relay (K16)
Short-To-Ground Short-To-Ground Short-To-Ground (Check/Replace)
Wire A27 (Orange) Harness (W3) Load Center Harness (W3) - A27
Short-To-Ground (Orange) Short-To-Ground
(Check/Repair)
CCU (A2) CCU (Replace)
MDU (Reconfigure). See Monitor
Display Unit Reconfiguration Access
Service Menu, Machine Model (S
01), Tire Size (S 03), Enable Options
9015
20
72
(S 06), and Delete Diagnostic
Trouble Codes in Group 9015—15.
F1636 CCU Relay Driver CCU (A2) CCU (Replace)
Overtemp
MDU (Reconfigure). See Monitor
Display Unit Reconfiguration Access
Service Menu, Machine Model (S
01), Tire Size (S 03), Enable Options
(S 06), and Delete Diagnostic
Trouble Codes in Group 9015—15.
F1637 CCU Timer Reset CCU (A2) CCU (Replace)
MDU (Reconfigure). See Monitor
Display Unit Reconfiguration Access
Service Menu, Machine Model (S
01), Tire Size (S 03), Enable Options
(S 06), and Delete Diagnostic
Trouble Codes in Group 9015—15.
Continued on next page
TX17961,0000004 –19–12AUG02–6/16
TM1637 (15JAN04)
9015-20-72
644H and 644H MH Loader
011504
PN=462
Page 73
References
Symptom Problem
Solution
F1638 Proportional Fan Drive Y37 Variable Speed Fan Motor Check solenoid for short to ground,
Circuit Error Relief Solenoid circuit overload, or open circuit. See
System Functional Schematic,
CCU output for proportional fan section SE18. See Engine Frame
drive has short to ground, circuit Harness (W5) Component Location.
overload, or open circuit Go to Group 9015-10.
H35 Green Wire Check wire for short to ground,
circuit overload, or open circuit. See
System Functional Schematic,
section SE18. See Engine Frame
Harness (W5) Component Location.
Go to Group 9015-10.
Normal operation: Supplies 0-12 V to
Y37.
R23 Black Wire Check wire for short to ground,
circuit overload, or open circuit. See
System Functional Schematic,
section SE18. See Engine Frame
Harness (W5) Component Location.
Go to Group 9015-10.
9015
20
73
TM1637 (15JAN04)
Continued on next page
9015-20-73
TX17961,0000004 –19–12AUG02–7/16
644H and 644H MH Loader
011504
PN=463
Page 74
References
Symptom Problem
Solution
F1639 Reverse Fan Circuit Error Y38 Reverse Fan Solenoid Check solenoid for short to ground,
circuit overload, or open circuit. See
CCU output for reverse fan drive System Functional Schematic,
has short to ground, circuit section SE18. See Engine Frame
overload, or open circuit Harness (W5) Component Location.
Go to Group 9015-10.
H26 Green Wire Check wire for short to ground,
circuit overload, or open circuit. See
System Functional Schematic,
section SE18. See Engine Frame
Harness (W5) Component Location.
Go to Group 9015-10.
9015
20
74
Normal operation: Supplies 24 V to
Y38.
R23 Black Wire Check wire for short to ground,
circuit overload, or open circuit. See
System Functional Schematic,
section SE18. See Engine Frame
Harness (W5) Component Location.
Go to Group 9015-10.
F1641 Drive Light Switch Circuit Drive and Tail/Marker Light Switch Drive and Tail/Marker Switch (S26)
Open (S26) Open Open (Check/Replace)
Wire L17 (Brown) Harness (W3) Load Center Harness (W3) - L17
Open (Brown) Open (Check/Repair)
CCU (A2) CCU (Replace)
MDU (Reconfigure). See Monitor
Display Unit Reconfiguration Access
Service Menu, Machine Model (S
01), Tire Size (S 03), Enable Options
(S 06), and Delete Diagnostic
Trouble Codes in Group 9015—15.
Continued on next page
TX17961,0000004 –19–12AUG02–8/16
TM1637 (15JAN04)
9015-20-74
644H and 644H MH Loader
011504
PN=464
Page 75
References
Symptom Problem
Solution
F1644 MDU Memory Bad MDU (H2) MDU (Replace)
MDU (Reconfigure). See Monitor
Display Unit Reconfiguration Access
Service Menu, Machine Model (S
01), Tire Size (S 03), Enable Options
(S 06), and Delete Diagnostic
Trouble Codes in Group 9015—15.
F1645 CCU Memory Bad CCU (A2) CCU (Replace)
MDU (Reconfigure). See Monitor
Display Unit Reconfiguration Access
Service Menu, Machine Model (S
01), Tire Size (S 03), Enable Options
(S 06), and Delete Diagnostic
Trouble Codes in Group 9015—15.
F1647 Machine Odometer Bad MDU (H2) MDU (Replace)
Tell-Tale Code displayed in MDU
“Service” menu. See Monitor
Display Unit —Service Menu—
Tell-Tale Diagnostic Trouble
Codes (S 02) in Group 9015-15.
9015
20
75
Continued on next page
MDU (Reconfigure). See Monitor
Display Unit Reconfiguration Access
Service Menu, Machine Model (S
01), Tire Size (S 03), Enable Options
(S 06), and Delete Diagnostic
Trouble Codes in Group 9015—15.
TX17961,0000004 –19–12AUG02–9/16
TM1637 (15JAN04)
9015-20-75
644H and 644H MH Loader
011504
PN=465
Page 76
References
Symptom Problem
Solution
F1648 Machine Hourmeter Bad MDU (H2) MDU (Replace)
Tell-Tale Code displayed in MDU
“Service” menu. See Monitor
Display Unit —Service Menu—
Tell-Tale Diagnostic Trouble
Codes (S 02) in Group 9015-15.
MDU (Reconfigure). See Monitor
Display Unit Reconfiguration Access
Service Menu, Machine Model (S
01), Tire Size (S 03), Enable Options
(S 06), and Delete Diagnostic
9015
20
F1649 CCU Hourmeter Bad CCU (A2) CCU (Replace)
76
Trouble Codes in Group 9015—15.
Tell-Tale Code displayed in MDU
“Service” menu. See Monitor
Display Unit —Service Menu—
Tell-Tale Diagnostic Trouble
Codes (S 02) in Group 9015-15.
MDU (Reconfigure). See Monitor
Display Unit Reconfiguration Access
Service Menu, Machine Model (S
01), Tire Size (S 03), Enable Options
(S 06), and Delete Diagnostic
Trouble Codes in Group 9015—15.
F1651 No ECU Transmit Wire M12 (Purple) Harness (W3) Load Center Harness (W3)—M12
Open (Purple) Open (Check/Repair.)
Wire M13 (Purple) Harness (W3) Load Center Harness (W3)—M13
Open (Purple) Open (Check/Repair.)
ECU ECU (Replace)
MDU (Reconfigure). See Monitor
Display Unit Reconfiguration Access
Service Menu, Machine Model (S
01), Tire Size (S 03), Enable Options
(S 06), and Delete Diagnostic
Trouble Codes in Group 9015—15.
TM1637 (15JAN04)
Continued on next page
9015-20-76
TX17961,0000004 –19–12AUG02–10/16
644H and 644H MH Loader
011504
PN=466
Page 77
References
Symptom Problem
Solution
F1653 No CCU Transmit Wire M12 (Purple) Harness (W3) Load Center Harness (W3)—M12
Open (Purple) Open (Check/Repair.)
Wire M13 (Purple) Harness (W3) Load Center Harness (W3)—M13
Open (Purple) Open (Check/Repair.)
CCU (A2) CCU (Replace)
MDU (Reconfigure). See Monitor
Display Unit Reconfiguration Access
Service Menu, Machine Model (S
01), Tire Size (S 03), Enable Options
(S 06), and Delete Diagnostic
Trouble Codes in Group 9015—15.
F1655 No TCU CAN Transmit Engine Controller Switched 15A Engine Controller Switched 15A
Fuse Bad Fuse Check/Replace
Wire M12 (Purple) Harness (W3) Load Center Harness (W3) M12
Open (Purple) Open (Check/Repair.)
Wire M13 (Purple) Harness (W3) Load Center Harness (W3) M13
Open (Purple) Open (Check/Repair.)
9015
20
77
Wire R02 (Black) Harness (W3) Load Center Harness (W3) R02
Open (Black) Open (Check/Repair.)
TCU (A3) TCU (Replace)
MDU (Reconfigure). See Monitor
Display Unit Reconfiguration Access
Service Menu, Machine Model (S
01), Tire Size (S 03), Enable Options
(S 06), and Delete Diagnostic
Trouble Codes in Group 9015—15.
F1658 Battery Voltage Balance CCU 12V Battery Unswitched Fuse CCU 12V Battery Unswitched Fuse
(F9) Open (F9) Open (Check/Replace)
Wire P31 (Red) Harness (W3) Open Load Center Harness (W3) - P31
(Red) Open (Check/Repair)
TM1637 (15JAN04)
Continued on next page
9015-20-77
TX17961,0000004 –19–12AUG02–11/16
644H and 644H MH Loader
011504
PN=467
Page 78
References
Symptom Problem
Solution
F1660 Alternator Voltage High Alternator (G4) Output Voltage Too Alternator (G4) Output Voltage Too
High High (Check/Repair)
CCU (A2) CCU (Replace)
MDU (Reconfigure). See Monitor
Display Unit Reconfiguration Access
Service Menu, Machine Model (S
01), Tire Size (S 03), Enable Options
(S 06), and Delete Diagnostic
Trouble Codes in Group 9015—15.
F1661 Alternator Voltage Low Alternator Output Voltage Too Low Alternator (G4) Output Voltage Too
9015
20
78
Wire B10 (Red) Harness (W3) Open Load Center Harness (W3) - B10
Low (Check/Repair)
(Red) Open (Check/Repair)
CCU 28V Battery Switched Fuse CCU 28V Battery Unswitched Fuse
(F11) Open (F11) Open (Check/Replace)
CCU (A2) CCU (Replace)
MDU (Reconfigure). See Monitor
Display Unit Reconfiguration Access
Service Menu, Machine Model (S
01), Tire Size (S 03), Enable Options
(S 06), and Delete Diagnostic
Trouble Codes in Group 9015—15.
F1662 Power Voltage High Alternator (G4) Output Voltage Too Alternator G4 Output Voltage Too
High High (Check/Repair)
CCU (A2) CCU (Replace)
MDU (Reconfigure). See Monitor
Display Unit Reconfiguration Access
Service Menu, Machine Model (S
01), Tire Size (S 03), Enable Options
(S 06), and Delete Diagnostic
Trouble Codes in Group 9015—15.
TM1637 (15JAN04)
Continued on next page
9015-20-78
TX17961,0000004 –19–12AUG02–12/16
644H and 644H MH Loader
011504
PN=468
Page 79
References
Symptom Problem
Solution
F1663 Power Voltage Low CCU 28V Battery Switched Fuse CCU 28V Battery Switched Fuse
(F11) Open (F11) Open (Check/Replace)
Wire B10 (Red) Harness (W3) Open Load Center Harness (W3) - B10
(Red) Open (Check/Repair)
F1664 Brake Light Pressure Brake Light Pressure Switch (B40) Brake Light Pressure Switch (B40)
Circuit Short-To-Ground Short-To-Ground (Check/Replace.)
Wire L03 (Brown) Harness (W3) Load Center Harness (W3) - L03
Short-To-Ground (Brown) Short-To-Ground
(Check/Repair)
CCU (A2) CCU (Replace)
MDU (Reconfigure). See Monitor
Display Unit Reconfiguration Access
Service Menu, Machine Model (S
01), Tire Size (S 03), Enable Options
(S 06), and Delete Diagnostic
Trouble Codes in Group 9015—15.
F1665 Drive Light Switch Circuit Drive and Tail/Marker Light Switch Drive and Tail/Marker Switch (S26)
(S26) Open Open (Check/Replace)
9015
20
79
Wire L06 (Brown) Harness (W3) Load Center Harness (W3) - L06
Open (Brown) Open (Check/Repair)
CCU (A2) CCU (Replace)
MDU (Reconfigure). See Monitor
Display Unit Reconfiguration Access
Service Menu, Machine Model (S
01), Tire Size (S 03), Enable Options
(S 06), and Delete Diagnostic
Trouble Codes in Group 9015—15.
Continued on next page
TX17961,0000004 –19–12AUG02–13/16
TM1637 (15JAN04)
9015-20-79
644H and 644H MH Loader
011504
PN=469
Page 80
References
Symptom Problem
Solution
F1667 Turn Switch Circuit Short Turn Switch (S25) Short-To-Ground Turn Switch (S25) Short-To-Ground
(Check/Repair)
Wire L07 (Brown) Harness (W4) Front Console Harness (W4) - L07
Short-To-Ground (Brown) Short-To-Ground
(Check/Repair)
Wire L10 (Brown) Harness (W4) Front Console Harness (W4) - L10
Short-To-Ground (Brown) Short-To-Ground
(Check/Repair)
MDU (H2) MDU (Replace)
9015
20
80
MDU (Reconfigure). See Monitor
Display Unit Reconfiguration Access
Service Menu, Machine Model (S
01), Tire Size (S 03), Enable Options
(S 06), and Delete Diagnostic
Trouble Codes in Group 9015—15.
F1668 Hazard Switch Circuit 4-Way Flasher Switch (S24) 4-Way Flasher Switch (S24)
Short-To-Ground Short-To-Ground (Check/Replace)
Wire L20 (Brown) Harness (W3) Load Center Harness (W3) - L20
Short-To-Ground (Brown) Short-To-Ground
(Check/Repair)
CCU (A2) CCU (Replace)
MDU (Reconfigure). See Monitor
Display Unit Reconfiguration Access
Service Menu, Machine Model (S
01), Tire Size (S 03), Enable Options
(S 06), and Delete Diagnostic
Trouble Codes in Group 9015—15.
Continued on next page
TX17961,0000004 –19–12AUG02–14/16
TM1637 (15JAN04)
9015-20-80
644H and 644H MH Loader
011504
PN=470
Page 81
References
Symptom Problem
Solution
F1671 Return to Carry Detent Return to Carry (RTC)/Float Detent Check solenoid for short to ground,
Solenoid Circuit Error Solenoid Coil in A4 Pilot Controller circuit overload, or open circuit. See
System Functional Schematic,
CCU output for Return to Carry section SE27 and SE18. Go to
Detent Solenoid has short to Group 9015-10.
ground, circuit overload, or open
circuit
H34 Green Wire Check wire for short to ground,
circuit overload, or open circuit. See
System Functional Schematic,
section SE27 and SE18. Go to
Group 9015-10.
Normal operation: Supplies 24 V to
Return to Carry detent solenoid coil
in A4 Pilot Controller.
R23 Black Wire Check wire for short to ground,
circuit overload, or open circuit. See
System Functional Schematic,
section SE27 and SE18. Go to
Group 9015-10.
9015
20
81
TM1637 (15JAN04)
Continued on next page
9015-20-81
TX17961,0000004 –19–12AUG02–15/16
644H and 644H MH Loader
011504
PN=471
Page 82
References
Symptom Problem
Solution
F1672 Boom Height Kickout Boom Height Kickout Detent Check solenoid for short to ground,
Detent Solenoid Circuit Error Solenoid Coil in A4 Pilot Controller circuit overload, or open circuit. See
System Functional Schematic,
CCU output for Boom Height section SE27 and SE18. Go to
Kickout Detent Solenoid has Group 9015-10.
short to ground, circuit overload,
or open circuit
H33 Green Wire Check wire for short to ground,
circuit overload, or open circuit. See
System Functional Schematic,
section SE27 and SE18. Go to
Group 9015-10.
9015
20
82
Normal operation: Supplies 24 V to
Boom Height Kickout Detent
Solenoid in A4 Pilot Controller.
R23 Black Wire Check wire for short to ground,
circuit overload, or open circuit. See
System Functional Schematic,
section SE27 and SE18. Go to
Group 9015-10.
F1699 Configuration Error Controllers Not All Configured For MDU (Reconfigure). See Monitor
624H (Reconfigure) Display Unit Reconfiguration Access
Service Menu, Machine Model (S
01), Tire Size (S 03), Enable Options
(S 06), and Delete Diagnostic
Trouble Codes in Group 9015—15.
TX17961,0000004 –19–12AUG02–16/16
TM1637 (15JAN04)
9015-20-82
644H and 644H MH Loader
011504
PN=472
Page 83
References
Hydraulic System Diagnostic Trouble Codes
Symptom Problem
Solution
F2100 Hydraulic Oil Temperature Hydraulic Oil Temperature Sensor Hydraulic Oil Temperature Sensor
High Long (B15) Short-To-Ground (B15) Short-To-Ground
(Check/Replace)
Tell-Tale Code displayed in MDU
“Service” menu. See Monitor
Display Unit —Service Menu—
Tell-Tale Diagnostic Trouble
Codes (S 02) in Group 9015-15.
Wire X01 (Yellow) Harness (W5) Engine Frame Harness (W5) (X35)
Short-To-Ground (Yellow) Short-To-Ground
(Check/Repair)
Wire X01 (Yellow) Harness (W3) Load Center Harness (W3) - X01
Short-To-Ground (Yellow) Short-To-Ground
(Check/Repair)
CCU (A2) CCU (Replace)
MDU (Reconfigure). See Monitor
Display Unit Reconfiguration Access
Service Menu, Machine Model (S
01), Tire Size (S 03), Enable Options
(S 06), and Delete Diagnostic
Trouble Codes in Group 9015—15.
9015
20
83
TM1637 (15JAN04)
Continued on next page
9015-20-83
TX17961,0000005 –19–12AUG02–1/9
644H and 644H MH Loader
011504
PN=473
Page 84
References
Symptom Problem
Solution
F3115 Hydraulic Oil Filter Hydraulic Oil Filter Restriction Switch Hydraulic Oil Filter Restriction Switch
Restriction Short-To-Ground (B21) Short-To-Ground (B21) Short-To-Ground
(Check/Replace)
Wire N01 (Yellow) Harness (W3) Load Center Harness (W3) - N01
Short-To-Ground (Yellow) Short-To-Ground
(Check/Repair)
Wire N01 (Yellow) Harness (W5) Engine Frame Harness (W5) - N01
Short-To-Ground (Yellow) Short-To-Ground
(Check/Repair)
CCU (A2) CCU (Replace)
9015
20
84
MDU (Reconfigure). See Monitor
Display Unit Reconfiguration Access
Service Menu, Machine Model (S
01), Tire Size (S 03), Enable Options
(S 06), and Delete Diagnostic
Trouble Codes in Group 9015—15.
F3150 Hydraulic Oil Filter Hydraulic Oil Filter Restriction Switch Hydraulic Oil Filter Restriction Switch
Restriction Circuit (B21) Short-To-Power (B21) Short-To-Power
Short-To-Power (Check/Replace)
Wire N01 (Yellow) Harness (W3) Load Center Harness (W3) - N01
Short-To-Power (Yellow) Short-To-Power
Wire N01 (Yellow) Harness (W5) Engine Frame Harness (W5) - N01
Short-To-Power (Yellow) Short-To-Power
(Check/Repair)
CCU (A2) CCU (Replace)
MDU (Reconfigure). See Monitor
Display Unit Reconfiguration Access
Service Menu, Machine Model (S
01), Tire Size (S 03), Enable Options
(S 06), and Delete Diagnostic
Trouble Codes in Group 9015—15.
TM1637 (15JAN04)
Continued on next page
9015-20-84
TX17961,0000005 –19–12AUG02–2/9
644H and 644H MH Loader
011504
PN=474
Page 85
References
Symptom Problem
Solution
F3160 Ride Control Circuit Monitor Configuration Wrong Monitor Configuration Wrong
Short-to-Power (Reconfigure). See Monitor Display
Unit Reconfiguration Access Service
Menu, Machine Model (S 01), Tire
Size (S 03), Enable Options (S 06),
and Delete Diagnostic Trouble
Codes in Group 9015—15.
Ride Control Switch (S31) Ride Control Switch (S31)
Short-To-Power Short-To-Power (Check/Repair)
Wire J05 (Tan) Harness (W3) Load Center Harness (W3) - J05
Short-To-Power (Tan) Short-To-Power
(Check/Repair)
Wire J02 (Tan) Harness (W3) Load Center Harness (W3) - J02
Short-To-Power (Tan) Short-To-Power
(Check/Repair)
CCU (A2) CCU (Replace)
MDU (Reconfigure). See Monitor
Display Unit Reconfiguration Access
Service Menu, Machine Model (S
01), Tire Size (S 03), Enable Options
(S 06), and Delete Diagnostic
Trouble Codes in Group 9015—15.
9015
20
85
TM1637 (15JAN04)
Continued on next page
9015-20-85
TX17961,0000005 –19–12AUG02–3/9
644H and 644H MH Loader
011504
PN=475
Page 86
References
Symptom Problem
Solution
F3161 Ride Control Auto Circuit Monitor Configuration Wrong MDU (Reconfigure). See Monitor
Short-To- Ground Display Unit Reconfiguration Access
Service Menu, Machine Model (S
01), Tire Size (S 03), Enable Options
(S 06), and Delete Diagnostic
Trouble Codes in Group 9015—15.
Ride Control Switch (S31) Ride Control Switch (S31)
Short-To-Ground Short-To-Ground (Check/Repair)
Wire J05 (Tan) Harness (W3) Load Center Harness (W3) - J05
Short-To-Ground (Tan) Short-To-Ground
(Check/Repair)
9015
20
86
CCU (A2) CCU (Replace)
MDU (Reconfigure). See Monitor
Display Unit Reconfiguration Access
Service Menu, Machine Model (S
01), Tire Size (S 03), Enable Options
(S 06), and Delete Diagnostic
Trouble Codes in Group 9015—15.
F3162 Ride Control On Circuit Monitor Configuration Wrong MDU (Reconfigure). See Monitor
Short-To- Ground Display Unit Reconfiguration Access
Service Menu, Machine Model (S
01), Tire Size (S 03), Enable Options
(S 06), and Delete Diagnostic
Trouble Codes in Group 9015—15.
Ride Control Switch (S31) Ride Control Switch (S31)
Short-To-Ground Short-To-Ground (Check/Repair)
Wire J02 (Tan) Harness (W3) Load Center Harness (W3) - J02
Short-To-Ground (Tan) Short-To-Ground
(Check/Repair)
CCU (A2) CCU (Replace)
MDU (Reconfigure). See Monitor
Display Unit Reconfiguration Access
Service Menu, Machine Model (S
01), Tire Size (S 03), Enable Options
(S 06), and Delete Diagnostic
Trouble Codes in Group 9015—15.
TM1637 (15JAN04)
Continued on next page
9015-20-86
TX17961,0000005 –19–12AUG02–4/9
644H and 644H MH Loader
011504
PN=476
Page 87
References
Symptom Problem
Solution
F3163 Boom Position Sensor B9 Boom Position Sensor Check sensor for short to ground or
Voltage Low open circuit. See System Functional
Schematic, section SE18. Go to
CCU input voltage for the Boom Group 9015-10.
Position Sensor is less than 0.2
V.
H28 Green Wire Check wire for short to ground or
open circuit. See System Functional
Schematic, section SE18. Go to
Group 9015-10.
Normal operation: Input voltage to
CCU from B9 Boom Position Sensor.
P51 Red Wire Check wire for short to ground or
open circuit. See System Functional
Schematic, section SE18. Go to
Group 9015-10.
Normal operation: Supplies5Vto
B9 Boom Position Sensor.
9015
20
87
R13 Black Wire Check wire for short to ground. See
System Functional Schematic,
section SE18. Go to Group 9015-10.
Normal operation: Return circuit to
CCU from B9 Boom Position Sensor.
Continued on next page
TX17961,0000005 –19–12AUG02–5/9
TM1637 (15JAN04)
9015-20-87
644H and 644H MH Loader
011504
PN=477
Page 88
References
Symptom Problem
Solution
F3164 Boom Position Sensor H28 Green Wire Check wire for short to power or
Voltage High open circuit. See System Functional
Schematic, section SE18. Go to
CCU input voltage for the Boom Group 9015-10.
Position Sensor is greater than
4.8 V. Normal operation: Input voltage to
CCU from B9 Boom Position Sensor.
P51 Red Wire Check wire for short to power. See
System Functional Schematic,
section SE18. Go to Group 9015-10.
Normal operation: Supplies5Vto
9015
20
88
R13 Black Wire Check wire for open circuit. See
B9 Boom Position Sensor.
System Functional Schematic,
section SE18. Go to Group 9015-10.
Normal operation: Return circuit to
CCU from B9 Boom Position Sensor.
F3165 Reverse Fan Switch Short S41 Reverse Fan Switch Check switch.See System Functional
Schematic, section SE16. Go to
Group 9015-10
H36 Green Check wire. See System Functional
Schematic, section SE16. Go to
Group 9015-10
F3171 Hydraulic Oil Pressure Hydraulic System Pressure Sensor Hydraulic System Pressure Sensor
Circuit Voltage Low (B8) (B8) Short To Battery
(Check/Replace)
Short to Battery
Wire N05 (Yellow) Harness (W3) Load Center Harness (W3) - N05
Short to Battery (Yellow) Short To Battery
(Check/Repair)
Wire N05 (Yellow) Harness (W5) Engine Frame Harness (W5) - N05
Short to Battery (Yellow) Short to Battery
(Check/Repair)
CCU (A2) CCU (Replace)
TM1637 (15JAN04)
Continued on next page
9015-20-88
TX17961,0000005 –19–12AUG02–6/9
644H and 644H MH Loader
011504
PN=478
Page 89
References
Symptom Problem
Solution
F3172 Hydraulic Oil Pressure Hydraulic System Pressure Sensor Hydraulic System Pressure Sensor
Circuit Voltage High (B8) Short to Ground (B8) Short To Ground
(Check/Replace)
Wire N05 (Yellow) Harness (W3) Load Center Harness (W3) - N05
Short to Ground (Yellow) Short To Ground
(Check/Repair)
Wire N05 (Yellow) Harness (W5) Engine Frame Harness (W5) - N05
Short to Ground (Yellow) Short To Ground
(Check/Repair)
CCU (A2) CCU (Replace)
F3173 LPM Mode Circuit LPM Switch (Off/On) (S5) Shorted to LPM Switch (Off/On) (S5) Short To
Battery Battery (Check/Replace)
Wire H10 (Green) Harness (W14) LPM Mode Harness (W14)— H10
Short to Battery (Green) Short To Battery
(Check/Repair)
Wire H10 (Green) Harness (W3) Load Center Harness (W3)—H10
Short to Battery (Green) Short to Battery
9015
20
89
CCU (A2) CCU (Replace)
F3174 LPM Enable Circuit LPM Switch (Off/On) (S5) LPM Switch (Off/On) (S5) Short-To-
Short-To-Ground Short-To-Ground Ground (Check/Replace)
Wire H10 (Green) Harness (W14) LPM Mode Harness (W14)
Short-To-Ground (Check/Repair)
Wire H10 (Green) Harness (W3) Load Center Harness (W3)
Short-To-Ground (Check/Repair)
CCU (A2) CCU (Replace)
Continued on next page
TX17961,0000005 –19–12AUG02–7/9
TM1637 (15JAN04)
9015-20-89
644H and 644H MH Loader
011504
PN=479
Page 90
References
Symptom Problem
Solution
F3175 Hydraulic Oil Temperature Hydraulic Oil Temperature Sensor Hydraulic Oil Temperature Sensor
Circuit Short-To-Ground (B15) Short-To-Ground (B15) Short-To-Ground
(Check/Replace)
Wire X01 (Yellow) Harness (W5) Engine Frame Harness (W5) - X01
Short-To-Ground (Yellow) Short-To-Ground
(Check/Repair)
Wire X01 (Yellow) Harness (W3) Load Center Harness (W3) - X01
Short-To-Ground (Yellow) Short-To-Ground
(Check/Repair)
CCU (A2) CCU (Replace)
9015
20
90
MDU (Reconfigure). See Monitor
Display Unit Reconfiguration Access
Service Menu, Machine Model (S
01), Tire Size (S 03), Enable Options
(S 06), and Delete Diagnostic
Trouble Codes in Group 9015—15.
F3176 Hydraulic Oil Temperature Hydraulic Oil Temperature Sensor Hydraulic Oil Temperature Sensor
Circuit Open (B15) Open (B15) Open (Check/Repair)
Wire X01 (Yellow) Harness (W5) Engine Frame Harness (W5) - X01
Open (Yellow) Open (Check/Repair)
Wire X01 (Yellow) Harness (W3) Load Center Harness (W3) - X01
Open (Yellow) Open (Check/Repair)
Continued on next page
TX17961,0000005 –19–12AUG02–8/9
TM1637 (15JAN04)
9015-20-90
644H and 644H MH Loader
011504
PN=480
Page 91
References
Symptom Problem
Solution
F3177 Hydraulic Oil Temperature Hydraulic Oil Temperature Sensor Hydraulic Oil Temperature Sensor
Circuit Noisy (B15) Noisy (B15) Noisy (Check/Replace)
Wire X01 (Yellow) Harness (W5) Engine Frame Harness (W5) - X01
Noisy (Yellow) Noisy (Check/Repair)
Wire X01 (Yellow) Harness (W3) Load Center Harness (W3) - X01
Noisy (Yellow) Noisy (Check/Repair)
CCU (A2) CCU (Replace)
MDU (Reconfigure). See Monitor
Display Unit Reconfiguration Access
Service Menu, Machine Model (S
01), Tire Size (S 03), Enable Options
(S 06), and Delete Diagnostic
Trouble Codes in Group 9015—15.
F3199 Hydraulic Oil Temperature Hydraulic Oil Temperature Sensor Hydraulic Oil Temperature Sensor
High (B15) Open (B15) Open (Check/Replace)
Wire X01 (Yellow) Harness (W3) Load Center Harness (W3) - X01
Open (Yellow) Open (Check/Repair)
9015
20
91
Wire X01 (Yellow) Harness (W5) Engine Frame Harness (W5)—X01
Open (Yellow) Open (Check/Repair)
CCU (A2) CCU (Replace)
MDU (Reconfigure). See Monitor
Display Unit Reconfiguration Access
Service Menu, Machine Model (S
01), Tire Size (S 03), Enable Options
(S 06), and Delete Diagnostic
Trouble Codes in Group 9015—15.
TX17961,0000005 –19–12AUG02–9/9
TM1637 (15JAN04)
9015-20-91
644H and 644H MH Loader
011504
PN=481
Page 92
Battery Specifications
References
Standard Battery—Volts 12.........................................................................
Standard Battery—Cold Cranking
Power 625 amps at —18°C(0°F)................................................................
Standard Battery—Reserve
Capacity 160 minutes at 25 amps...............................................................
Standard Battery—BCI Group
Size 30H.......................................................................................................
Standard Battery—Fully Charged
Electrolyte Specific Gravity 1.265—1.280....................................................
Heavy Duty Battery—Volts 12.....................................................................
Heavy Duty Battery—Cold
Cranking Power 950 amps at —18°C(0°F)................................................
Heavy Duty Battery—Reserve
Capacity 190 minutes at 25 amps...............................................................
9015
Heavy Duty Battery—BCI Group
20
Size 31.........................................................................................................
92
Heavy Duty Battery—Fully
Charged Electrolyte Specific
Gravity 1.265—1.280...................................................................................
Specification
Specification
TX,20,111126 –19–04SEP96–1/1
TM1637 (15JAN04)
9015-20-92
644H and 644H MH Loader
011504
PN=482
Page 93
References
Check Controller
• Review diagnostic procedures closely before replacing
the controller.
• Recheck connectors, wire crimps, 5 volt and 24 volt
power terminals, and ground terminals.
If a failed connection or wire is suspected to be the cause
of the intermittent problem: clear diagnostic trouble codes,
then check the connection or wire by wiggling it while
watching for new diagnostic trouble codes.
To check the connection between the harness and a
sensor or the harness and the controller, use JT07328,
Connector Adapter Test Kit.
Insert the male end of the appropriate test adapter into
the female end of the controller or sensor connector
terminal. There should be moderate resistance when the
test adapter is inserted into the terminal. If the connection
is loose, replace the female terminal.
If all other components related to the system failure have
checked OK, it is reasonable to assume the controller is
malfunctioning.
Connector Adapter Test Kit ..............JT07328
Used with JT07306 Digital Multimeter to make voltage and
resistance measurements in control system wiring harness
connectors. Can also be used to test terminals for proper
fit.
9015
20
93
CED,TX17961,83 –19–27MAR00–1/2
TM1637 (15JAN04)
9015-20-93
RG8803 –UN–26NOV97
CED,TX17961,83 –19–27MAR00–2/2
644H and 644H MH Loader
011504
PN=483
Page 94
Diagnose Battery Malfunctions
References
Symptom Problem
Solution
Battery Using Too Much Water Shorted battery cell Check battery state of charge. (See
Procedure for Testing Batteries.)
High ambient temperature Add distilled water.
Cracked battery case Check battery hold down clamps.
Replace battery.
Regulator Do Alternator Output Check. See
Monitor Basic Display, Alternator
Output Check And Seat Belt
9015
20
Cracked Battery Case Battery hold down clamp too tight, Install new battery. Install hold down
94
Indicator Check. (Group 9005-10)
too loose or missing clamps correctly.
Frozen battery Keep electrolyte at correct level and
battery fully charged during cold
weather.
Low Battery Output Low water level See Battery Using Too Much Water
and Cracked Battery Case
symptoms.
Dirty or wet battery top, causing Clean battery top. Recharge battery.
discharge
Corroded or loose battery cable Clean and tighten cable end clamps.
ends Recharge battery.
Broken or loose battery posts Wiggle posts by hand. If posts are
loose or will turn, replace battery.
Loose fan/alternator belt or worn Inspect belt or pulley. Adjust or
pulleys replace as necessary.
TX,20,111117 –19–04SEP96–1/1
TM1637 (15JAN04)
9015-20-94
644H and 644H MH Loader
011504
PN=484
Page 95
Check Battery Electrolyte Level And
Terminals
1. Remove hold-down clamps.
2. Remove battery covers.
References
Continued on next page
TX,20,111118 –19–04SEP96–1/3
9015
20
95
TM1637 (15JAN04)
9015-20-95
644H and 644H MH Loader
011504
PN=485
Page 96
9015
20
96
References
A—Battery Post
B—Fill Tube
C—Electrolyte Level Range
Single Level Fill Tube Application
TS203 –UN–23AUG88
T6996DB –UN–09SEP03
TM1637 (15JAN04)
Continued on next page
9015-20-96
Dual Level Fill Tube Application
TX,20,111118 –19–04SEP96–2/3
644H and 644H MH Loader
T6996DA –UN–09SEP03
011504
PN=486
Page 97
References
CAUTION: Battery gas can explode. Keep
sparks and flames away from batteries. Use a
flashlight to check battery electrolyte level.
Never check battery charge by placing a metal
object across the posts. Use a voltmeter or
hydrometer.
Always remove grounded (-) battery clamp first
and replace it last.
Sulfuric acid in battery electrolyte is poisonous.
It is strong enough to burn skin, eat holes in
clothing, and cause blindness if splashed into
eyes.
Avoid the hazard by:
1. Filling batteries in a well-ventilated area.
2. Wearing eye protection and rubber gloves.
3. Avoiding breathing fumes when electrolyte is
added.
4. Avoiding spilling or dripping electrolyte.
5. Use proper jump start procedure.
9015
20
97
If you spill acid on yourself:
1. Flush your skin with water.
2. Apply baking soda or lime to help neutralize
the acid.
3. Flush your eyes with water for 10—15
minutes. Get medical attention immediately.
Flush Eyes With Water—Time 10-15 minutes............................................
Specification
If acid is swallowed:
1. Drink large amounts of water or milk.
2. Then drink milk of magnesia, beaten eggs, or
vegetable oil.
3. Get medical attention immediately.
IMPORTANT: During freezing weather, batteries must
be charged after water is added to
prevent battery freezing. Charge battery
using a battery charger or by running
the engine.
3. Fill each cell to within specified range with distilled
water. DO NOT overfill.
TM1637 (15JAN04)
9015-20-97
TX,20,111118 –19–04SEP96–3/3
644H and 644H MH Loader
011504
PN=487
Page 98
References
Procedure For Testing Batteries
Visual Check
1. Check for damage such as cracked or broken case
and electrolyte leakage.
If damage is seen, replace battery.
2. Check electrolyte level. (See procedure in this group)
If low, add distilled water to specified level and charge
battery.
3. Check terminals for corrosion.
9015
20
98
If corroded, clean using a wire brush or battery post
cleaner such as JT05838 Battery Post/Clamp Cleaner.
4. Check posts for looseness.
If posts are loose, replace battery.
Hydrometer Test
1. Check specific gravity with a hydrometer or battery
tester such as JT05460 Coolant/Battery Tester.
2. Record specific gravity reading for each cell.
If high and low readings vary LESS than 0.050 and
average specific gravity is between 1.225 and 1.280,
battery is fully charged, go to LOAD TEST.
If high and low readings vary LESS than 0.050 and
average specific gravity is LESS than 1.225, charge
battery and repeat test. If average specific gravity is
still LESS than 1.225, replace both batteries.
If high and low readings vary MORE than 0.050,
charge battery and repeat test. If high and low
readings still vary MORE than 0.050, replace both
batteries.
TM1637 (15JAN04)
Continued on next page
9015-20-98
TX,20,111119 –19–01AUG96–1/2
644H and 644H MH Loader
011504
PN=488
Page 99
Load Test
1. Check battery capacity with a load tester such as
JT05832 Battery Load Tester. Follow tester
manufacturer’s instructions for proper load test
procedures.
2. If one battery fails load test, replace both batteries.
Alternator Check
1. Perform Monitor Basic Display, Alternator Output
Check And Seat Belt Indicator Check using SERVICE
ADVISOR system Battery Power template (See
SERVICE ADVISOR system Computer Connection
(S.N. —573732) or (S.N. 573733—)inPDMkit
instructions)
References
TX,20,111119 –19–01AUG96–2/2
9015
20
99
Or use monitor display. (Go to 9005-10).
If battery voltage is not within specification, check
alternator using the follow checks:
2. Measure voltage at B+ terminal (A) using multimeter
with engine off. Battery voltage should be present.
3. Measure voltage at D+ terminal (B) with engine
running. Battery voltage should be within specification.
Alternator—Specification
Output at D+ terminal—Engine
running—Voltage 18—28 Volts...................................................................
If alternator is within specification and SERVICE
ADVISOR system Power 24VDC template or monitor
display battery voltage out does not match alternator
output, check harnesses.
See Charging Circuit Theory of Operation for more
information on the entire charging circuit. (Go to 9015-15.)
T133161B –UN–11AUG00
A—B+ terminal
B—D+ terminal
SERVICE ADVISOR is a trademark of Deere & Company
TM1637 (15JAN04)
9015-20-99
CED,TX17994,366 –19–22AUG00–1/1
644H and 644H MH Loader
011504
PN=489
Page 100
Transmission Control Valve Solenoid Check
9015
20
,100
References
TM1637 (15JAN04)
Continued on next page
9015-20-100
TX,15,111260 –19–13FEB97–1/2
644H and 644H MH Loader
011504
PN=490
T110956 –19–27AUG97
Loading...