John Deere 96 – CMU / A00 / E02: Fuel Level Signal Voltage Too High

Fault code 96 (also identified as 96.03) indicates that the signal voltage from the fuel level sensor is excessively high. Specifically, the voltage on the corresponding circuit (cc# 652) exceeds 1.96 VDC. This condition generally means the fuel level sensor circuit is open or shorted to a high power source, pointing to a fault in the sensor device itself or its associated wiring.

• CTS Combines (serial number 070231 and newer)
• 9780 CTS Combine
• 750J Crawler Dozer
• 850J Crawler Dozer
• 670D Grader
• 672D Grader
• 770D Grader
• 772D Grader
• 870D Grader
• 872D Grader
• 1010E Forwarder
• 1910E Forwarder
• Compact Track Loader
• Skid Steer Loader

1. 1

   Visually inspect the wiring harness from the fuel level sensor on the fuel tank to its connecting control module for pinched, chafed, or melted wires.

2. 2

   Inspect the electrical connectors at both the sensor and the controller for corrosion, moisture, or pushed-out pins.

3. 3

   Check the ground strap or wire for the fuel sending unit to ensure the connection to the machine's frame is clean, tight, and free of rust.

4. 4

   Disconnect the harness and use a multimeter to check the signal wire for an open circuit (no continuity).

5. 5

   With the key on and sensor disconnected, probe the signal wire in the harness for a short to power (no significant voltage should be present).

6. 6

   Check for a short to ground by measuring resistance between the signal wire and chassis ground (should read 'OL' or infinite resistance).

7. 7

   Test the fuel level sensor by measuring resistance across its signal and ground pins while slowly moving the float arm through its full range of motion (readings should change smoothly without erratic drops or 'OL').

1. 1

   Repair wiring and connectors

   If diagnostic checks reveal damage to the wiring harness or connectors, repair or replace the affected sections. Ensure any new connections are sealed against moisture using weatherproof connectors and heat shrink tubing. Clean any corroded terminals with electrical contact cleaner.

2. 2

   Restore ground connection

   If a faulty ground was identified, remove the ground connection, clean the contact points on the terminal and the chassis to bare metal, and re-secure it tightly.

3. 3

   Replace the fuel level sensor

   If the wiring and grounds are confirmed to be in good condition, the fuel level sensor is the likely point of failure. Replace the fuel level sensor by removing the sending unit assembly from the top of the fuel tank.