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John Deere 450K, 550K & 650K Crawler Dozer Operation & Test Technical Manual TM14162X19 – PDF DOWNLOAD
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John Deere 450K 550K & 650K Crawler Dozer Operation & Test Technical Manual TM14162X19 – PDF DOWNLOAD
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Description
John Deere 450K, 550K & 650K Crawler Dozer Operation & Test Technical Manual TM14162X19 – PDF DOWNLOAD
FILE DETAILS:
John Deere 450K, 550K & 650K Crawler Dozer Operation & Test Technical Manual TM14162X19 – PDF DOWNLOAD
Language : English
Pages : 1117
Downloadable : Yes
File Type : PDF
IMAGES PREVIEW OF THE MANUAL:
DESCRIPTION:
John Deere 450K, 550K & 650K Crawler Dozer Operation & Test Technical Manual TM14162X19 – PDF DOWNLOAD
- This manual is written for an experienced technician. Essential tools required in performing certain service work are identified in this manual and are recommended for use.
- Live with safety: Read the safety messages in the introduction of this manual and the cautions presented throughout the text of the manual.
- Technical manuals are divided in two parts: repair and operation and tests. Repair sections tell how to repair the components. Operation and test sections help to quickly identify the majority of routine failures quickly.
- Information is organized in groups for the various components requiring service instruction. At the beginning of each group are summary listings of all applicable essential tools, service equipment and tools, other materials needed to do the job, service parts kits, specifications, wear tolerances, and torque values.
- Technical manuals are concise guides for specific machines. They are on-the-job guides containing only the vital information needed for diagnosis, analysis, testing, and repair.
- Fundamental service information is available from other sources covering basic theory of operation, fundamentals of troubleshooting, general maintenance, and basic type of failures and their causes.
TABLE OF CONTENTS:
John Deere 450K, 550K & 650K Crawler Dozer Operation & Test Technical Manual TM14162X19 – PDF DOWNLOAD
Contents.............................................................................................................. 7 General Information............................................................................................... 9 Safety........................................................................................................ 11 Information for European Union Directives and Eurasian Economic Union Technical Regulations Compliance.... 11 Recognize Safety Information.............................................................................. 12 Follow Safety Instructions................................................................................ 13 Operate Only If Qualified................................................................................. 13 Wear Protective Equipment................................................................................. 13 Avoid Unauthorized Machine Modifications.................................................................. 14 Inspect Machine........................................................................................... 14 Stay Clear of Moving Parts................................................................................ 14 Avoid High-Pressure Fluids................................................................................ 15 Avoid High-Pressure Oils.................................................................................. 15 Work In Ventilated Area................................................................................... 15 Avoid Static Electricity Risk When Refueling.............................................................. 16 High Debris Applications.................................................................................. 16 Prevent Fires............................................................................................. 17 In Case of Machine Fire................................................................................... 17 Prevent Battery Explosions................................................................................ 18 Handle Chemical Products Safely........................................................................... 18 Handle Starting Fluid Safely.............................................................................. 18 Decommissioning — Proper Recycling and Disposal of Fluids and Components.................................. 19 Exhaust Filter Ash Handling and Disposal.................................................................. 19 Prepare for Emergencies................................................................................... 19 Clean Debris from Machine................................................................................. 20 Add Cab Guarding for Special Uses......................................................................... 20 Use Steps and Handholds Correctly......................................................................... 20 Start Only From Operator's Seat........................................................................... 20 Use and Maintain Seat Belt................................................................................ 21 Prevent Unintended Machine Movement....................................................................... 21 Avoid Work Site Hazards................................................................................... 22 Keep Riders Off Machine................................................................................... 22 Avoid Backover Accidents.................................................................................. 23 Avoid Machine Tip Over and Machine Damage................................................................. 24 Use Special Care When Operating........................................................................... 24 Inspect and Maintain ROPS................................................................................. 25 Travel Safely............................................................................................. 25 Prevent Acid Burns........................................................................................ 26 Add and Operate Attachments Safely........................................................................ 26 Park and Prepare for Service Safely....................................................................... 27 Service Machines Safely................................................................................... 27 Service Cooling System Safely............................................................................. 27 Remove Paint Before Welding or Heating.................................................................... 28 Make Welding Repairs Safely............................................................................... 28 Drive Metal Pins Safely................................................................................... 28 Use Proper Lifting Equipment.............................................................................. 29 Clean Exhaust Filter Safely............................................................................... 30 Diagnostic Trouble Codes (DTCs)................................................................................... 37 Engine Control Unit (ECU) Diagnostic Trouble Codes............................................................ 39 Engine Control Unit (ECU) Diagnostic Trouble Codes........................................................ 39 000111.07 — Coolant Level................................................................................. 40 000237.02 — Vehicle ID.................................................................................... 41 000237.13 — Vehicle ID.................................................................................... 42 000237.31 — Vehicle ID.................................................................................... 43 000647.05 — Engine Fan Drive.............................................................................. 44 000647.06 — Engine Fan Drive.............................................................................. 46 001075.05 — Low Press Fuel Pump Circuit Fault............................................................. 48 001321.05 — Starter Relay................................................................................. 49 001321.06 — Starter Relay................................................................................. 50 001321.09 — Starter Relay................................................................................. 51 001321.16 — Starter Relay................................................................................. 52 001321.31 — Starter Relay................................................................................. 53 001761.01 — DEF Level Very Low............................................................................ 54 001761.18 — DEF Level Moderately Low...................................................................... 54 002003.09 — System Message................................................................................ 55 003031.12 — DEF Temperature Fault......................................................................... 55 003353.31 — Alternator Output............................................................................. 56 003516.01 — DEF Concentration Very Low.................................................................... 57 003516.07 — DEF Concentration Fault....................................................................... 57 003516.09 — DEF Concentration Communication Fault......................................................... 58 003516.12 — DEF Concentration Fault....................................................................... 58 003517.12 — DEF Level Fault............................................................................... 59 004211.03 — Hydraulic Fan Pressure........................................................................ 60 004211.04 — Hydraulic Fan Pressure........................................................................ 61 004366.05 — DEF Tank Heater Coolant Control Valve Circuit Has High Resistance............................. 62 Diagnostic Procedure.................................................................................. 62 004366.06 — DEF Tank Heater Coolant Control Valve Circuit Has Low Resistance.............................. 66 Diagnostic Procedure.................................................................................. 66 004366.16 — DEF Tank Temperature Moderately High.......................................................... 70 Diagnostic Procedure.................................................................................. 71 004366.18 — DEF Tank Insufficient Heating Fault........................................................... 73 Diagnostic Procedure.................................................................................. 74 005484.05 — Fan Reversing Valve........................................................................... 77 005484.06 — Fan Reversing Valve........................................................................... 78 524225.31 — Engine Start.................................................................................. 79 Standard Display Monitor (SDM) Diagnostic Trouble Codes....................................................... 81 Standard Display Monitor (SDM) Diagnostic Trouble Codes................................................... 81 000237.02 — Vehicle ID Fault.............................................................................. 81 000237.13 — Vehicle ID Fault.............................................................................. 82 000237.31 — Vehicle ID Fault.............................................................................. 82 000628.12 — Control Unit Programming...................................................................... 83 002000.09 — Communication System Message Missing.......................................................... 83 002003.09 — Communication System Message Missing.......................................................... 84 002023.09 — Communication System Message Missing.......................................................... 84 002030.09 — Communication System Message Missing.......................................................... 85 002251.09 — Communication System Message Missing.......................................................... 85 Sealed Switch Module (SSM) Diagnostic Trouble Codes........................................................... 87 Sealed Switch Module (SSM) Diagnostic Trouble Codes....................................................... 87 002033.09 — Communication System Message Missing.......................................................... 87 002634.04 — Ignition Relay Circuit Fault.................................................................. 88 002634.05 — Ignition Relay Circuit Fault.................................................................. 89 520752.04 — SSM Button Stuck.............................................................................. 90 520752.09 — Communication System Message Missing.......................................................... 90 520753.04 — SSM Button Stuck.............................................................................. 91 520753.09 — Communication System Message Missing.......................................................... 91 520754.04 — SSM Button Stuck.............................................................................. 92 520754.09 — Communication System Message Missing.......................................................... 92 520755.04 — SSM Button Stuck.............................................................................. 93 520755.09 — Communication System Message Missing.......................................................... 93 521274.09 — Communication System Message Missing.......................................................... 94 523335.04 — SSM Button Stuck.............................................................................. 94 523335.09 — Communication System Message Missing.......................................................... 95 523336.04 — SSM Button Stuck.............................................................................. 95 523336.09 — Communication System Message Missing.......................................................... 96 523338.04 — SSM Button Stuck.............................................................................. 96 523338.09 — Communication System Message Missing.......................................................... 97 523339.04 — SSM Button Stuck.............................................................................. 97 523339.09 — Communication System Message Missing.......................................................... 98 523340.04 — SSM Button Stuck.............................................................................. 98 523340.09 — Communication System Message Missing.......................................................... 99 523849.04 — SSM Button Stuck.............................................................................. 99 523849.09 — Communication System Message Missing.......................................................... 100 523850.04 — SSM Button Stuck.............................................................................. 100 523850.09 — Communication System Message Missing.......................................................... 101 523852.04 — SSM Button Stuck.............................................................................. 101 523852.09 — Communication System Message Missing.......................................................... 102 523854.04 — SSM Button Stuck.............................................................................. 102 523854.09 — Communication System Message Missing.......................................................... 103 523855.04 — SSM Button Stuck.............................................................................. 103 523855.09 — Communication System Message Missing.......................................................... 104 523856.04 — SSM Button Stuck.............................................................................. 104 523856.09 — Communication System Message Missing.......................................................... 105 523857.04 — SSM Button Stuck.............................................................................. 105 523857.09 — Communication System Message Missing.......................................................... 106 523858.04 — SSM Button Stuck.............................................................................. 106 523858.09 — Communication System Message Missing.......................................................... 107 523860.04 — SSM Button Stuck.............................................................................. 107 523860.09 — Communication System Message Missing.......................................................... 108 523861.04 — SSM Button Stuck.............................................................................. 108 523861.09 — Communication System Message Missing.......................................................... 109 523862.04 — SSM Button Stuck.............................................................................. 109 523862.09 — Communication System Message Missing.......................................................... 110 523863.04 — SSM Button Stuck.............................................................................. 110 523863.09 — Communication System Message Missing.......................................................... 111 523864.04 — SSM Button Stuck.............................................................................. 111 523864.09 — Communication System Message Missing.......................................................... 112 523865.04 — SSM Button Stuck.............................................................................. 112 523865.09 — Communication System Message Missing.......................................................... 113 523867.04 — SSM Button Stuck.............................................................................. 113 523867.09 — Communication System Message Missing.......................................................... 114 523868.04 — SSM Button Stuck.............................................................................. 114 523868.09 — Communication System Message Missing.......................................................... 115 Transmission Control Unit (TCU) Diagnostic Trouble Codes...................................................... 117 Transmission Control Unit (TCU) Diagnostic Trouble Codes.................................................. 117 000070.00 — Park Lock Lever Circuit Fault................................................................. 118 000070.01 — Park Lock Lever Circuit Fault................................................................. 119 000070.04 — Park Lock Lever Circuit Fault................................................................. 120 000070.06 — Park Lock Lever Circuit Fault................................................................. 121 000116.00 — Brake Pressure High........................................................................... 122 000116.01 — Brake Pressure Low............................................................................ 123 000116.03 — Brake Pressure Circuit Fault.................................................................. 124 000116.04 — Brake Pressure Circuit Fault.................................................................. 125 000158.03 — Switched Power Circuit Fault.................................................................. 126 000158.04 — Switched Power Circuit Fault.................................................................. 127 000168.04 — Unswitched Power Circuit Fault................................................................ 128 000177.00 — Transmission Oil Temperature High............................................................. 129 000177.03 — Transmission Oil Temperature Circuit Fault.................................................... 130 000177.04 — Transmission Oil Temperature Circuit Fault.................................................... 131 000177.16 — Transmission Oil Temperature High............................................................. 132 000190.09 — Communication System Message Missing.......................................................... 132 000237.02 — Vehicle Identification Fault.................................................................. 133 000237.13 — Vehicle Identification Fault.................................................................. 133 000237.31 — Vehicle Identification Fault.................................................................. 134 000521.00 — Decel Sensor Calibration Fault................................................................ 134 000521.01 — Decel Sensor Calibration Fault................................................................ 135 000521.03 — Decel Sensor Circuit Fault.................................................................... 136 000521.04 — Decel Sensor Circuit Fault.................................................................... 137 000521.05 — Decel Sensor Calibration Fault................................................................ 138 000521.06 — Decel Sensor Calibration Fault................................................................ 138 000521.13 — Decel Sensor Not Calibrated................................................................... 139 000521.15 — Decel Sensor Calibration Fault................................................................ 139 000521.16 — Decel Sensor Calibration Fault................................................................ 140 000521.17 — Decel Sensor Calibration Fault................................................................ 140 000521.18 — Decel Sensor Calibration Fault................................................................ 141 000581.03 — Speed in Grip Circuit Fault................................................................... 142 000581.04 — Speed in Grip Circuit Fault................................................................... 143 000581.07 — Speed in Grip Button Stuck.................................................................... 144 000604.03 — Neutral Position Switch Circuit Fault......................................................... 145 000604.04 — Neutral Position Switch Circuit Fault......................................................... 147 000604.15 — Neutral Position Switch Calibration Fault..................................................... 148 000604.16 — Neutral Position Switch Calibration Fault..................................................... 148 000604.17 — Neutral Position Switch Calibration Fault..................................................... 149 000604.18 — Neutral Position Switch Calibration Fault..................................................... 149 000619.05 — Brake Solenoid Circuit Fault.................................................................. 150 000619.06 — Brake Solenoid Circuit Fault.................................................................. 151 000629.12 — Control Unit Fault............................................................................ 152 000907.00 — Left Motor Speed Sensor Circuit Fault......................................................... 153 000907.01 — Left Motor Speed Sensor Circuit Fault......................................................... 154 000907.03 — Left Motor Speed Sensor Circuit Fault......................................................... 155 000907.04 — Left Motor Speed Sensor Circuit Fault......................................................... 156 000907.07 — Left Motor Speed Sensor Fault................................................................. 157 000907.12 — Left Motor Speed Sensor Circuit Fault......................................................... 158 000908.00 — Right Motor Speed Sensor Circuit Fault........................................................ 159 000908.01 — Right Motor Speed Sensor Circuit Fault........................................................ 160 000908.03 — Right Motor Speed Sensor Circuit Fault........................................................ 161 000908.04 — Right Motor Speed Sensor Circuit Fault........................................................ 162 000908.07 — Right Motor Speed Sensor Fault................................................................ 163 000908.12 — Right Motor Speed Sensor Circuit Fault........................................................ 164 002000.09 — Communication System Message Missing.......................................................... 165 002030.09 — Communication System Message Missing.......................................................... 165 002141.09 — Communication System Message Missing.......................................................... 166 002660.00 — Steer Sensor Calibration Fault................................................................ 166 002660.01 — Steer Sensor Calibration Fault................................................................ 167 002660.03 — Steer Sensor Circuit Fault.................................................................... 168 002660.04 — Steer Sensor Circuit Fault.................................................................... 169 002660.07 — Steer Sensor Calibration Fault................................................................ 170 002660.13 — Steer Sensor Not Calibrated................................................................... 170 002660.14 — Steer Sensor Circuit Fault.................................................................... 171 002660.15 — Steer Sensor Calibration Fault................................................................ 171 002660.16 — Steer Sensor Calibration Fault................................................................ 172 002660.17 — Steer Sensor Calibration Fault................................................................ 172 002660.18 — Steer Sensor Calibration Fault................................................................ 173 002661.00 — FNR Sensor Calibration Fault.................................................................. 173 002661.01 — FNR Sensor Calibration Fault.................................................................. 174 002661.03 — FNR Sensor Circuit Fault...................................................................... 175 002661.04 — FNR Sensor Circuit Fault...................................................................... 176 002661.07 — FNR Sensor Calibration Fault.................................................................. 177 002661.13 — FNR Sensor Not Calibrated..................................................................... 177 002661.14 — FNR Sensor Circuit Fault...................................................................... 178 002661.15 — FNR Sensor Calibration Fault.................................................................. 178 002661.16 — FNR Sensor Calibration Fault.................................................................. 179 002661.17 — FNR Sensor Calibration Fault.................................................................. 179 002661.18 — FNR Sensor Calibration Fault.................................................................. 180 003359.31 — Transmission Oil Filter Restricted............................................................ 181 003509.03 — Sensor Supply 1 Circuit Fault................................................................. 182 003509.04 — Sensor Supply 1 Circuit Fault................................................................. 183 003510.03 — Sensor Supply 2 Circuit Fault................................................................. 184 003510.04 — Sensor Supply 2 Circuit Fault................................................................. 186 003511.03 — Sensor Supply 3 Circuit Fault................................................................. 188 003511.04 — Sensor Supply 3 Circuit Fault................................................................. 190 003512.03 — Sensor Supply 4 Circuit Fault................................................................. 192 003512.04 — Sensor Supply 4 Circuit Fault................................................................. 194 521549.03 — Steer Sensor Circuit Fault.................................................................... 195 521549.04 — Steer Sensor Circuit Fault.................................................................... 196 521549.07 — Steer Sensor Calibration Fault................................................................ 197 521551.03 — FNR Sensor Circuit Fault...................................................................... 198 521551.04 — FNR Sensor Circuit Fault...................................................................... 199 521551.07 — FNR Sensor Calibration Fault.................................................................. 200 521999.00 — Park Lock Lever Circuit Fault................................................................. 201 521999.01 — Park Lock Lever Circuit Fault................................................................. 202 521999.04 — Park Lock Lever Circuit Fault................................................................. 203 521999.06 — Park Lock Lever Circuit Fault................................................................. 204 522444.00 — Charge Pressure High.......................................................................... 205 522444.01 — Charge Pressure Low........................................................................... 205 522444.03 — Charge Pressure Sensor Circuit Fault.......................................................... 206 522444.04 — Charge Pressure Sensor Circuit Fault.......................................................... 207 522447.05 — Right Forward Pump Coil Circuit Fault......................................................... 208 522447.06 — Right Forward Pump Coil Circuit Fault......................................................... 209 522447.15 — Right Forward Pump Coil Calibration Fault..................................................... 210 522447.16 — Right Forward Pump Coil Calibration Fault..................................................... 210 522447.17 — Right Forward Pump Coil Calibration Fault..................................................... 211 522447.18 — Right Forward Pump Coil Calibration Fault..................................................... 211 522448.05 — Right Reverse Pump Coil Circuit Fault......................................................... 212 522448.06 — Right Reverse Pump Coil Circuit Fault......................................................... 213 522448.15 — Right Reverse Pump Coil Calibration Fault..................................................... 214 522448.16 — Right Reverse Pump Coil Calibration Fault..................................................... 214 522448.17 — Right Reverse Pump Coil Calibration Fault..................................................... 215 522448.18 — Right Reverse Pump Coil Calibration Fault..................................................... 215 522449.05 — Left Reverse Pump Coil Circuit Fault.......................................................... 216 522449.06 — Left Reverse Pump Coil Circuit Fault.......................................................... 217 522449.15 — Left Reverse Pump Coil Calibration Fault...................................................... 218 522449.16 — Left Reverse Pump Coil Calibration Fault...................................................... 218 522449.17 — Left Reverse Pump Coil Calibration Fault...................................................... 219 522449.18 — Left Reverse Pump Coil Calibration Fault...................................................... 219 522450.05 — Left Forward Pump Coil Circuit Fault.......................................................... 220 522450.06 — Left Forward Pump Coil Circuit Fault.......................................................... 221 522450.15 — Left Forward Pump Coil Calibration Fault...................................................... 222 522450.16 — Left Forward Pump Coil Calibration Fault...................................................... 222 522450.17 — Left Forward Pump Coil Calibration Fault...................................................... 223 522450.18 — Left Forward Pump Coil Calibration Fault...................................................... 223 523108.13 — Transmission Pumps/Motors Not Calibrated...................................................... 224 523108.14 — Transmission Not Calibrated................................................................... 224 523577.05 — Left Motor Solenoid Circuit Fault............................................................. 225 523577.06 — Left Motor Solenoid Circuit Fault............................................................. 226 523577.13 — Transmission Motors Not Calibrated............................................................ 227 523577.16 — Left Motor Solenoid Calibration Fault......................................................... 227 523577.18 — Left Motor Solenoid Calibration Fault......................................................... 228 523578.05 — Right Motor Solenoid Circuit Fault............................................................ 229 523578.06 — Right Motor Solenoid Circuit Fault............................................................ 230 523578.16 — Right Motor Solenoid Calibration Fault........................................................ 231 523578.18 — Right Motor Solenoid Calibration Fault........................................................ 231 523579.05 — Left Motor Solenoid Circuit Fault............................................................. 232 523579.06 — Left Motor Solenoid Circuit Fault............................................................. 233 523580.05 — Right Motor Solenoid Circuit Fault............................................................ 234 523580.06 — Right Motor Solenoid Circuit Fault............................................................ 235 524089.00 — Left System Pressure High..................................................................... 236 524089.01 — Left System Pressure Low...................................................................... 236 524089.03 — Left System Pressure Circuit Fault............................................................ 237 524089.04 — Left System Pressure Circuit Fault............................................................ 238 524090.00 — Right System Pressure High.................................................................... 239 524090.01 — Right System Pressure Low..................................................................... 239 524090.03 — Right System Pressure Circuit Fault........................................................... 240 524090.04 — Right System Pressure Circuit Fault........................................................... 241 524233.07 — Hydrostatic Drive System Not Responding....................................................... 242 Vehicle Control Unit (VCU) Diagnostic Trouble Codes........................................................... 243 Vehicle Control Unit (VCU) Diagnostic Trouble Codes....................................................... 243 000237.02 — Vehicle Identification Fault.................................................................. 243 000237.13 — Vehicle Identification Fault.................................................................. 244 000237.31 — Vehicle Identification Fault.................................................................. 244 000628.12 — Control Unit Programming...................................................................... 245 000924.03 — Auxiliary Power Circuit Fault................................................................. 246 000924.06 — Auxiliary Power Circuit Fault................................................................. 247 001638.00 — Hydraulic Oil Temperature High................................................................ 248 001638.04 — Hydraulic Oil Temperature Circuit Fault....................................................... 249 001713.01 — Hydraulic Oil Filter Restricted............................................................... 250 002000.09 — Communication System Message Missing.......................................................... 251 002141.09 — Communication System Message Missing.......................................................... 251 002347.03 — Front Drive Light Circuit Fault............................................................... 252 002347.05 — Front Drive Light Circuit Fault............................................................... 253 002347.06 — Front Drive Light Circuit Fault............................................................... 254 002361.03 — Rear Drive Work Light Circuit Fault........................................................... 255 002361.05 — Rear Drive Work Light Circuit Fault........................................................... 256 002361.06 — Rear Drive Work Light Circuit Fault........................................................... 257 004089.03 — Hyd Sys Press Circuit Fault .................................................................. 258 520688.03 — Hyd Enable Sol Circuit Fault.................................................................. 259 520688.05 — Hyd Enable Sol Circuit Fault.................................................................. 260 520688.06 — Hyd Enable Sol Circuit Fault.................................................................. 261 521997.03 — Left Door Wiper Circuit Fault................................................................. 262 521997.06 — Left Door Wiper Circuit Fault................................................................. 264 521998.03 — Right Door Wiper Circuit Fault................................................................ 266 521998.06 — Right Door Wiper Circuit Fault................................................................ 268 522433.03 — Rear Wiper Circuit Fault...................................................................... 270 522433.06 — Rear Wiper Circuit Fault...................................................................... 272 522434.03 — Front Wiper Circuit Fault..................................................................... 274 522434.06 — Front Wiper Circuit Fault..................................................................... 276 522796.03 — Door Washer Circuit Fault..................................................................... 277 522796.05 — Door Washer Circuit Fault..................................................................... 278 522796.06 — Door Washer Circuit Fault..................................................................... 279 522797.03 — Front/Rear Washer Circuit Fault............................................................... 280 522797.05 — Front/Rear Washer Circuit Fault............................................................... 281 522797.06 — Front/Rear Washer Circuit Fault............................................................... 282 Hydraulic Valve Controller (HVC) Diagnostic Trouble Codes..................................................... 283 Hydraulic Valve Controller (HVC) Diagnostic Trouble Codes................................................. 283 000237.02 — Vehicle Identification Fault.................................................................. 283 000237.13 — Vehicle Identification Fault.................................................................. 284 000237.31 — Vehicle Identification Fault.................................................................. 284 000628.12 — Control Unit Programming...................................................................... 285 001899.03 — Blade Lower Sol Circuit Fault................................................................. 286 001899.04 — Blade Lower Sol Circuit Fault................................................................. 287 001899.05 — Blade Lower Sol Circuit Fault................................................................. 288 001899.06 — Blade Lower Sol Circuit Fault................................................................. 289 001899.15 — Warming Current Fault......................................................................... 290 001899.17 — Warming Current Fault......................................................................... 291 001900.03 — Blade Raise Sol Circuit Fault................................................................. 292 001900.04 — Blade Raise Sol Circuit Fault................................................................. 293 001900.05 — Blade Raise Sol Circuit Fault................................................................. 294 001900.06 — Blade Raise Sol Circuit Fault................................................................. 295 001900.15 — Warming Current Fault......................................................................... 296 001900.17 — Warming Current Fault......................................................................... 297 001911.03 — Blade Tilt Left Sol Circuit Fault............................................................. 298 001911.04 — Blade Tilt Left Sol Circuit Fault............................................................. 299 001911.05 — Blade Tilt Left Sol Circuit Fault............................................................. 300 001911.06 — Blade Tilt Left Sol Circuit Fault............................................................. 301 001911.15 — Warming Current Fault......................................................................... 302 001911.17 — Warming Current Fault......................................................................... 303 001912.03 — Blade Tilt Right Sol Circuit Fault............................................................ 304 001912.04 — Blade Tilt Right Sol Circuit Fault............................................................ 305 001912.05 — Blade Tilt Right Sol Circuit Fault............................................................ 306 001912.06 — Blade Tilt Right Sol Circuit Fault............................................................ 307 001912.15 — Warming Current Fault......................................................................... 308 001912.17 — Warming Current Fault......................................................................... 309 001923.03 — Blade Angle Right Sol Circuit Fault........................................................... 310 001923.04 — Blade Angle Right Sol Circuit Fault........................................................... 311 001923.05 — Blade Angle Right Sol Circuit Fault........................................................... 312 001923.06 — Blade Angle Right Sol Circuit Fault........................................................... 313 001923.15 — Warming Current Fault......................................................................... 314 001923.17 — Warming Current Fault......................................................................... 315 001924.03 — Blade Angle Left Sol Circuit Fault............................................................ 316 001924.04 — Blade Angle Left Sol Circuit Fault............................................................ 317 001924.05 — Blade Angle Left Sol Circuit Fault............................................................ 318 001924.06 — Blade Angle Left Sol Circuit Fault............................................................ 319 001924.15 — Warming Current Fault......................................................................... 320 001924.17 — Warming Current Fault......................................................................... 321 001935.03 — Rear Aux 1 Sol Circuit Fault.................................................................. 322 001935.04 — Rear Aux 1 Sol Circuit Fault.................................................................. 323 001935.05 — Rear Aux 1 Sol Circuit Fault.................................................................. 324 001935.06 — Rear Aux 1 Sol Circuit Fault.................................................................. 325 001935.15 — Warming Current Fault......................................................................... 326 001935.17 — Warming Current Fault......................................................................... 327 001936.03 — Rear Aux 1 Sol Circuit Fault.................................................................. 328 001936.04 — Rear Aux 1 Sol Circuit Fault.................................................................. 329 001936.05 — Rear Aux 1 Sol Circuit Fault.................................................................. 330 001936.06 — Rear Aux 1 Sol Circuit Fault.................................................................. 331 001936.15 — Warming Current Fault......................................................................... 332 001936.17 — Warming Current Fault......................................................................... 333 002030.09 — Communication System Message Missing.......................................................... 334 002051.09 — Communication System Message Missing.......................................................... 336 002141.09 — Communication System Message Missing.......................................................... 337 002722.03 — Right Hand Joystick Lower Button Circuit Fault................................................ 338 002722.07 — Right Hand Joystick Lower Button Stuck........................................................ 340 002723.03 — Right Hand Joystick Lower Rocker Circuit Fault................................................ 342 002723.04 — Right Hand Joystick Lower Rocker Circuit Fault................................................ 344 002723.07 — Right Hand Joystick Lower Rocker Button Stuck................................................. 346 002724.03 — Right Hand Joystick Upper Button Circuit Fault................................................ 348 002724.07 — Right Hand Joystick Upper Button Stuck........................................................ 350 002725.03 — Right Hand Joystick Upper Rocker Circuit Fault................................................ 352 002725.04 — Right Hand Joystick Upper Rocker Circuit Fault................................................ 354 002725.07 — Right Hand Joystick Upper Rocker Button Stuck................................................. 356 002734.03 — Rear Auxiliary 1 Joystick Circuit Fault....................................................... 358 002734.04 — Rear Auxiliary 1 Joystick Circuit Fault....................................................... 359 002734.14 — Rear Auxiliary 1 Joystick Circuit Fault....................................................... 360 002735.03 — Rear Auxiliary 2 Joystick Circuit Fault....................................................... 361 002735.04 — Rear Auxiliary 2 Joystick Circuit Fault....................................................... 363 002735.14 — Rear Auxiliary 2 Joystick Circuit Fault....................................................... 365 Blade Control Joystick (BCJ) Diagnostic Trouble Codes......................................................... 367 Blade Control Joystick (BCJ) Diagnostic Trouble Codes..................................................... 367 000444.01 — Switched Power Circuit Fault.................................................................. 368 002697.02 — Control Unit Fault............................................................................ 369 002697.03 — Right Hand Joystick X-Axis Position Circuit Fault............................................. 369 002697.04 — Right Hand Joystick X-Axis Position Circuit Fault............................................. 370 002697.13 — Right Hand Joystick X-Axis Calibration Error.................................................. 370 002697.14 — Right Hand Joystick X-Axis Position Circuit Fault............................................. 371 002698.02 — Control Unit Fault............................................................................ 371 002698.03 — Right Hand Joystick Y-Axis Position Circuit Fault............................................. 372 002698.04 — Right Hand Joystick Y-Axis Position Circuit Fault............................................. 372 002698.13 — Right Hand Joystick Y-Axis Calibration Error.................................................. 373 002698.14 — Right Hand Joystick Y-Axis Position Circuit Fault............................................. 373 003509.02 — Sensor Supply 1 Circuit Fault................................................................. 374 003510.02 — Sensor Supply 2 Circuit Fault................................................................. 374 522431.12 — Control Unit Fault............................................................................ 375 522507.13 — Control Unit Fault............................................................................ 375 523438.12 — Control Unit Fault............................................................................ 376 523455.12 — Control Unit Fault............................................................................ 376 524152.12 — Control Unit Fault............................................................................ 377 524259.00 — Control Unit Fault............................................................................ 377 524259.01 — Control Unit Fault............................................................................ 378 524259.09 — Control Unit Fault............................................................................ 378 524259.12 — Control Unit Fault............................................................................ 379 524259.14 — Control Unit Fault............................................................................ 379 Vehicle Control Unit 2 (VC2) Diagnostic Trouble Codes......................................................... 381 Vehicle Control Unit 2 (VC2) Diagnostic Trouble Codes..................................................... 381 000096.03 — Fuel Level Sensor Circuit Fault............................................................... 381 000096.04 — Fuel Level Sensor Circuit Fault............................................................... 382 000158.03 — Switched Power Circuit Fault.................................................................. 383 000158.04 — Switched Power Circuit Fault.................................................................. 384 000168.04 — Unswitched Power Circuit Fault................................................................ 385 000628.12 — Control Unit Programming...................................................................... 386 521537.03 — Front Work Light Circuit Fault................................................................ 387 521537.05 — Front Work Light Circuit Fault................................................................ 388 521537.06 — Front Work Light Circuit Fault................................................................ 389 521555.03 — Front Work Light Circuit Fault................................................................ 390 521555.05 — Front Work Light Circuit Fault................................................................ 391 521555.06 — Front Work Light Circuit Fault................................................................ 392 523440.04 — Unswitched Power Circuit Fault................................................................ 393 Operational Checkout Procedure.................................................................................... 395 Operational Checkout Procedure................................................................................ 397 Operational Checkout...................................................................................... 397 Diagnostic Trouble Code (DTC) Check................................................................... 397 Operational Checks—Switched Power OFF, Engine OFF Checks.............................................. 397 Operational Checks—Switched Power ON, Engine OFF...................................................... 404 Operational Checks—Switched Power ON, Engine ON....................................................... 416 Engine............................................................................................................ 439 Theory of Operation........................................................................................... 441 John Deere Engine......................................................................................... 441 Cold Start Aid System Theory of Operation—If Equipped..................................................... 441 System Diagrams............................................................................................... 443 John Deere Engine......................................................................................... 443 Engine Cooling System Component Location.................................................................. 445 Engine Fuel System Component Location..................................................................... 449 Engine Intake and Exhaust Component Location.............................................................. 453 Diagnostic Information........................................................................................ 457 John Deere Engine......................................................................................... 457 Adjustments................................................................................................... 459 John Deere Engine......................................................................................... 459 Service Filter Cleaning................................................................................... 459 Tests......................................................................................................... 461 John Deere Engine......................................................................................... 461 Low-Pressure Fuel Pump Pressure Test...................................................................... 461 Fluid Sampling Procedure—If Equipped...................................................................... 462 Engine Idle Speeds and Auto-Shutdown Check................................................................ 466 Exhaust Emissions Test Point.............................................................................. 467 Electrical System................................................................................................. 471 Theory of Operation........................................................................................... 473 Start and Charge Circuits Theory of Operation............................................................. 473 Park Brake Circuit Theory of Operation.................................................................... 479 Controller Area Network (CAN) Circuit Theory of Operation................................................. 483 Engine Control Unit (ECU) Circuit Theory of Operation..................................................... 493 Standard Display Monitor (SDM) Circuit Theory of Operation................................................ 509 Vehicle Control Unit (VCU) Circuit Theory of Operation.................................................... 514 Transmission Control Unit (TCU) Circuit Theory of Operation............................................... 524 Air Conditioner and Heater Circuits Theory of Operation................................................... 537 Seat Heater and Air Seat Motor Circuits Theory of Operation............................................... 542 Radio Circuit Theory of Operation......................................................................... 545 Integrated Grade Control (IGC) Circuit Theory of Operation—If Equipped.................................... 549 JDLink™ Circuit Theory of Operation—If Equipped........................................................... 555 Exhaust Aftertreatment Circuit Theory of Operation........................................................ 563 System Diagrams............................................................................................... 569 Electrical Diagram Information............................................................................ 569 Electrical Schematic Symbols.............................................................................. 575 Fuse and Relay Specifications............................................................................. 578 System Functional Schematic, Wiring Diagram, and Component Location Legend................................ 580 System Functional Schematic and Section Legend............................................................ 586 Power and Ground Cables Component Location................................................................ 589 Aftertreatment Harness (W8) Component Location............................................................ 590 Aftertreatment Harness (W8) Wiring Diagram................................................................ 591 Engine Auxiliary Harness (W9) Component Location.......................................................... 593 Engine Auxiliary Harness (W9) Wiring Diagram.............................................................. 595 Cooling Package Harness (W10) Component Location.......................................................... 598 Cooling Package Harness (W10) Wiring Diagram.............................................................. 599 Cooling Package (IGC Controls) Harness (W11) Component Location........................................... 600 Cooling Package (IGC Controls) Harness (W11) Wiring Diagram............................................... 601 Standard Fan Harness (W12) Component Location............................................................. 603 Standard Fan Harness (W12) Wiring Diagram................................................................. 604 Reversing Fan Harness (W13) Component Location—If Equipped................................................ 605 Reversing Fan Harness (W13) Wiring Diagram—If Equipped.................................................... 606 Control Valve (SmartGrade™ and IGC Controls) Harness (W14) Component Location............................. 608 Control Valve (SmartGrade™ and IGC Controls) Harness (W14) Wiring Diagram................................. 609 Vehicle Harness (W16) Component Location.................................................................. 613 Vehicle Harness (W16) Wiring Diagram...................................................................... 617 Vehicle (SmartGrade™ and IGC Controls) Harness (W17) Component Location................................... 625 Vehicle (SmartGrade™ and IGC Controls) Harness (W17) Wiring Diagram....................................... 629 Load Center Harness (W18) Component Location.............................................................. 636 Load Center Harness (W18) Wiring Diagram.................................................................. 639 Load Center (SmartGrade™ and IGC Controls) Harness (W19) Component Location............................... 661 Load Center (SmartGrade™ and IGC Controls) Harness (W19) Wiring Diagram................................... 662 Operator’s Station Harness (W20) Component Location....................................................... 675 Operator’s Station Harness (W20) Wiring Diagram........................................................... 678 Operator’s Station (SmartGrade™ and IGC Controls) Harness (W21) Component Location........................ 687 Operator’s Station (SmartGrade™ and IGC Controls) Harness (W21) Wiring Diagram............................ 691 Front Dash Harness (W22) Component Location............................................................... 701 Front Dash Harness (W22) Wiring Diagram................................................................... 703 Left Console Harness (W23) Component Location............................................................. 705 Left Console Harness (W23) Wiring Diagram................................................................. 707 Cab Roof Harness (W24) Component Location................................................................. 711 Cab Roof Harness (W24) Wiring Diagram..................................................................... 715 Canopy Roof Harness (W25) Component Location.............................................................. 717 Canopy Roof Harness (W25) Wiring Diagram.................................................................. 719 Heater and Air Conditioner Harness (W27) Component Location............................................... 722 Heater and Air Conditioner Harness (W27) Wiring Diagram................................................... 724 Condenser Harness (W28) Component Location................................................................ 725 Condenser Harness (W28) Wiring Diagram.................................................................... 725 Under Seat Heater Harness (W29) Component Location........................................................ 726 Under Seat Heater Harness (W29) Wiring Diagram............................................................ 727 Dome Light Harness (W30) Component Location............................................................... 727 Dome Light Harness (W30) Wiring Diagram................................................................... 728 Power Outlet Harness (W31) Component Location............................................................. 728 Power Outlet Harness (W31) Wiring Diagram................................................................. 729 Engine Harness (W32) Component Location................................................................... 731 Engine Harness (W32) Wiring Diagram....................................................................... 735 Fuel Injector Harness (W33) Component Location............................................................ 741 Fuel Injector Harness (W33) Wiring Diagram................................................................ 743 Glow Plug Harnesses (W34, W35, and W36) Component Location................................................ 745 Glow Plug Harnesses (W34, W35, and W36) Wiring Diagrams................................................... 747 Front Lights Harness (W37) Component Location............................................................. 749 Front Lights Harness (W37) Wiring Diagram................................................................. 751 Fuel Filter Interface Harness (W44) Component Location.................................................... 757 Fuel Filter Interface Harness (W44) Wiring Diagram........................................................ 757 Hydraulic Oil Filter Harness (W45) Component Location..................................................... 757 Hydraulic Oil Filter Harness (W45) Wiring Diagram......................................................... 758 Auxiliary Radio Input Harness (W46) Component Location—If Equipped........................................ 758 Auxiliary Radio Input Harness (W46) Wiring Diagram—If Equipped............................................ 758 Satellite Radio Harness (W47) Component Location—If Equipped.............................................. 758 Satellite Radio Harness (W47) Wiring Diagram—If Equipped.................................................. 759 Multiband Antenna Harness (W49) Component Location........................................................ 759 Multiband Antenna Harness (W49) Wiring Diagram............................................................ 759 JDLink™ Harnesses (W6002 and W6003) Component Location.................................................... 761 Modular Telematics Gateway (MTG) Harness (W6002) Wiring Diagram........................................... 764 Satellite (SAT) Harness (W6003) Wiring Diagram............................................................ 767 Diagnostic Information........................................................................................ 769 Service ADVISOR™ Diagnostic Application................................................................... 769 Service ADVISOR™ Connection Procedure..................................................................... 769 Using Service ADVISOR™ Remote............................................................................. 771 Reading Diagnostic Trouble Codes with Service ADVISOR™ Diagnostic Application............................. 774 Intermittent Diagnostic Trouble Code (DTC) Diagnostics.................................................... 776 Diagnostic Trouble Codes—After Machine Repair............................................................. 776 Electrical Component Specifications....................................................................... 777 Monitor Operation............................................................................................. 785 Accessing Service Mode, SDM............................................................................... 785 Diagnostics—Clear Stored Diagnostic Trouble Codes, SDM.................................................... 785 Operation—Exhaust Filter, SDM............................................................................. 786 Diagnostics—Machine Information, SDM...................................................................... 787 Diagnostics—TCU Diagnostics, SDM.......................................................................... 789 Operation—Software Delivery, SDM.......................................................................... 790 Setup—Machine Setup, SDM.................................................................................. 791 Diagnostic Test Box........................................................................................... 793 Setup and Functional Test................................................................................. 793 Two Wire Sensor Circuit Check—Out of Range High........................................................... 798 Two Wire Sensor Circuit Check—Out of Range Low............................................................ 800 Three Wire Sensor Circuit Check—Out of Range High......................................................... 801 Three Wire Sensor Circuit Check—Out of Range Low.......................................................... 803 Topcon® Integrated Grade Control (IGC) Operation (Factory Installation)....................................... 805 Topcon® Integrated Grade Control (IGC) Circuit Schematic (Factory Installation)........................... 805 Topcon® Integrated Grade Control (IGC) Circuit Theory of Operation (Factory Installation)................. 808 IGC Controller-Receiver Harnesses (W40 and W41) Component Location........................................ 810 IGC Controller-Receiver Harness 1 (W40) Wiring Diagram.................................................... 811 IGC Controller-Receiver Harness 2 (W41) Wiring Diagram.................................................... 812 IGC Display Unit Harness (W42) Component Location......................................................... 813 IGC Display Unit Harness (W42) Wiring Diagram............................................................. 814 IGC Grille Harness (W43) Component Location............................................................... 815 IGC Grille Harness (W43) Wiring Diagram................................................................... 817 SmartGrade™ Operation......................................................................................... 821 SmartGrade™ Control Unit Harness 1 and 2 (W50 and W51) Component Location................................. 821 SmartGrade™ Control Unit Harness 1 (W50) Wiring Diagram................................................... 821 SmartGrade™ Control Unit Harness 2 (W51) Wiring Diagram................................................... 822 SmartGrade™ Chassis Inertial Measurement Unit (IMU) Harness (W52) Component Location...................... 822 SmartGrade™ Chassis Inertial Measurement Unit (IMU) Harness (W52) Wiring Diagram.......................... 822 SmartGrade™ Front Frame Harness (W53) Component Location.................................................. 823 SmartGrade™ Front Frame Harness (W53) Wiring Diagram...................................................... 823 SmartGrade™ Grille Harness (W54) Component Location....................................................... 823 SmartGrade™ Grille Harness (W54) Wiring Diagram........................................................... 824 SmartGrade™ Blade Inertial Measurement Unit (IMU) Harness (W55) Component Location........................ 824 SmartGrade™ Blade Inertial Measurement Unit (IMU) Harness (W55) Wiring Diagram............................ 824 SmartGrade™ Display Unit Harness (W56) Component Location................................................. 825 SmartGrade™ Display Unit Harness (W56) Wiring Diagram..................................................... 826 Adjustments................................................................................................... 827 Transmission Control Unit (TCU) Calibration............................................................... 827 Hydraulic Valve Controller (HVC) Calibration.............................................................. 828 Decelerator/Brake Pedal Adjustment........................................................................ 829 Transmission Control Lever (TCL) Adjustment............................................................... 830 Tests......................................................................................................... 833 Controller Area Network (CAN) Circuit Test................................................................ 833 Controller Area Network (CAN) Diagnostics ............................................................ 841 Alternator Test........................................................................................... 847 Wire Harness Test......................................................................................... 849 Relay Test................................................................................................ 850 Hydraulic System.................................................................................................. 852 Theory of Operation........................................................................................... 853 Hydraulic System Operation................................................................................ 853 Hydraulic Pump Operation.................................................................................. 853 Hydraulic Control Valve Operation......................................................................... 855 Hydraulic Control Valve Operation—IGC..................................................................... 861 Hydraulic System Relief Valve Operation................................................................... 867 Hydraulic Oil Filter and Reservoir Operation.............................................................. 868 Hydraulic Fan Drive Operation............................................................................. 871 Ripper Operation.......................................................................................... 873 Winch Operation........................................................................................... 875 System Diagrams............................................................................................... 879 Hydraulic System Schematic................................................................................ 879 Hydraulic System Schematic—IGC............................................................................ 885 Hydraulic System Line Identification...................................................................... 897 Hydraulic System Line Identification—IGC.................................................................. 901 Hydraulic Fan Component Location.......................................................................... 905 Hydraulic System Component Location....................................................................... 913 Hydraulic System Component Location—IGC................................................................... 917 Ripper Hydraulic Component Location....................................................................... 920 Winch Hydraulic Component Location........................................................................ 922 Diagnostic Information........................................................................................ 923 Hydraulic System Diagnose Malfunctions.................................................................... 923 No Hydraulic Functions Diagnostic Procedure........................................................... 923 Hydraulic Functions Slow Diagnostic Procedure......................................................... 923 Hydraulic Pump Noisy Diagnostic Procedure............................................................. 925 Blade Float Does Not Work Diagnostic Procedure........................................................ 926 One Hydraulic Function Does Not Work Diagnostic Procedure............................................. 927 Function Drifts Down Diagnostic Procedure............................................................. 928 Oil Overheats Diagnostic Procedure.................................................................... 928 Hydraulic System Diagnose Malfunctions—Integrated Grade Control (IGC)..................................... 931 No Hydraulic Functions Diagnostic Procedure—Integrated Grade Control (IGC)............................ 931 Hydraulic Functions Slow Diagnostic Procedure—IGC..................................................... 932 Blade Float Does Not Work Diagnostic Procedure—IGC.................................................... 934 One Hydraulic Function Does Not Work Diagnostic Procedure—IGC......................................... 934 Hydraulic Power Low Diagnostic Procedure—IGC.......................................................... 935 Function Drifts Down Diagnostic Procedure—IGC......................................................... 936 Oil Overheats Diagnostic Procedure—IGC................................................................ 937 Blade Response Not Smooth Diagnostic Procedure—IGC.................................................... 938 Hydraulic Fan Does Not Reach Full Speed—If Equipped....................................................... 939 Hydraulic Fan Does Not Reach Full Speed Diagnostic Procedure.......................................... 939 Hydraulic Fan Runs at Full Speed Only—If Equipped......................................................... 940 Hydraulic Fan Runs at Full Speed Only Diagnostic Procedure............................................ 940 Hydraulic Fan Does Not Spin—If Equipped................................................................... 941 Hydraulic Fan Does Not Spin Diagnostic Procedure...................................................... 941 Hydraulic Fan Will Not Reverse Direction—If Equipped...................................................... 942 Hydraulic Fan Will Not Reverse Direction Diagnostic Procedure......................................... 942 Adjustments................................................................................................... 943 Blade Control Lever Linkage Adjustment.................................................................... 943 Auxiliary Hydraulic Control Lever Linkage Adjustment...................................................... 944 Blade Pitch Linkage Adjustment............................................................................ 945 Tests......................................................................................................... 947 JT02156A Digital Pressure and Temperature Analyzer Kit Installation....................................... 947 Ultra Clean® Hand Launcher................................................................................ 947 Hydrostatic Oil Sampling Procedure—If Equipped............................................................ 947 Hydraulic Oil Warm-Up Procedure........................................................................... 947 Hydraulic Accumulator Discharge Procedure—IGC............................................................. 948 Hydraulic Accumulator Precharge Test—IGC.................................................................. 949 Hydraulic System Relief Valve Test........................................................................ 950 Circuit Relief Valve Test—With Remote Pump................................................................ 952 Lift Cylinder Drift Test.................................................................................. 954 Cylinder Leakage Test..................................................................................... 955 Pressure Reducing Valve Pressure Test and Adjustment—IGC.................................................. 956 Hydraulic Pump Flow Test.................................................................................. 958 Fan Motor Speed Test—If Equipped.......................................................................... 960 Fan Motor Case Drain Test—If Equipped..................................................................... 961 Fan Pump Flow Test—If Equipped............................................................................ 963 Hydrostatic System................................................................................................ 965 Theory of Operation........................................................................................... 967 Hydrostatic System Operation.............................................................................. 967 Transmission Control Circuit Operation (Flow Chart)....................................................... 968 Hydrostatic Pump Operation................................................................................ 970 Pump Pressure Control Pilot (PCP) Operation............................................................... 971 Pump Displacement Control Valve (PDCV) Operation.......................................................... 973 Multi-Function Valve Operation............................................................................ 974 Charge Pump Operation..................................................................................... 976 Neutral Charge Relief Valve Operation..................................................................... 977 Hydrostatic Charge Oil Filter Operation................................................................... 978 Park Brake Valve Operation................................................................................ 980 Hydrostatic Motor Operation............................................................................... 981 Flushing Valve and Operating Charge Relief Valve Operation................................................ 985 Hydrostatic Thermal Bypass Valve Operation................................................................ 986 System Diagrams............................................................................................... 987 Hydrostatic System Schematic.............................................................................. 987 Hydrostatic System Component Location..................................................................... 991 Hydrostatic System Line Identification.................................................................... 995 Hydrostatic System Diagram—Neutral (Park Brake On)........................................................ 999 Hydrostatic System Diagram—Reverse (Slow Speed)...........................................................1003 Hydrostatic System Diagram—Forward (Fast Speed)...........................................................1007 Diagnostic Information........................................................................................1011 Overheating Malfunctions..................................................................................1011 Overheating Diagnostic Procedure......................................................................1011 High/Low Charge Pressure Malfunctions.....................................................................1013 High/Low Charge Pressure Malfunctions Diagnostic Procedure............................................1013 Mistrack/Index Malfunctions...............................................................................1015 Mistrack or Index Diagnostic Procedure................................................................1015 Machine Full Speed Malfunctions...........................................................................1018 Machine Will Not Reach Full Speed Diagnostic..........................................................1018 Low Power Malfunctions....................................................................................1021 Low Power Diagnostic Procedure........................................................................1021 Track Malfunctions........................................................................................1024 Engine Starts But One or Both Tracks Will Not Move Diagnostic Procedure...............................1024 TCU Calibration Malfunctions..............................................................................1026 TCU Calibration Malfunctions Diagnostic Procedure.....................................................1026 Tests.........................................................................................................1035 Ultra Clean® Hand Launcher................................................................................1035 Transmission Oil Warm-Up Procedure........................................................................1036 Hydrostatic Oil Sampling Procedure—If Equipped............................................................1037 Releasing Park Brake to Tow the Machine...................................................................1038 Hydrostatic Pump and Motor Initial Start-Up Procedure.....................................................1040 Hydrostatic Pump Flushing Procedure.......................................................................1041 Hydraulic Oil Cleanup Procedure...........................................................................1041 Pressure Control Pilot (PCP) Manual Override Test.........................................................1042 Pressure Control Pilot (PCP) Test.........................................................................1043 Pressure Control Pilot (PCP) Internal Adjustment..........................................................1045 Multi-Function Relief Valve Test..........................................................................1047 Transmission Efficiency Test..............................................................................1050 Neutral Charge Relief and Operating Charge Relief Pressure Test...........................................1053 Pump Displacement Control Valve (PDCV) Neutral (Null) Adjustment..........................................1055 Pump Servo Pressure Test..................................................................................1057 Charge Pump Flow Test.....................................................................................1059 Charge Pressure Sensor Test...............................................................................1061 Motor Shift Solenoid Valve Adjustment.....................................................................1062 Hydrostatic Motor Min./Max. Angle Servo Piston Pressure Test..............................................1064 Hydrostatic Thermal Bypass Valve Test.....................................................................1066 Park Brake Test...........................................................................................1068 Heating and Air Conditioning......................................................................................1071 Theory of Operation...........................................................................................1073 Air Conditioning System Cycle of Operation................................................................1073 System Diagrams...............................................................................................1075 Heating and Air Conditioning System Component Location....................................................1075 Diagnostic Information........................................................................................1079 Air Conditioning System Does Not Operate..................................................................1079 Air Conditioning System Does Not Operate Diagnostic Procedure.........................................1079 Air Conditioning System Does Not Cool Interior of Cab.....................................................1082 Air Conditioning System Does Not Cool Interior of Cab Diagnostic Procedure............................1082 Air Conditioning System Runs Constantly, Too Cold.........................................................1083 Air Conditioning System Runs Constantly, Too Cold Diagnostic Procedure................................1083 Heating System Does Not Operate...........................................................................1085 Heating System Does Not Operate Diagnostic Procedure..................................................1085 Heating System Does Not Warm Interior of Cab..............................................................1087 Heating System Does Not Warm Interior of Cab Diagnostic Procedure.....................................1087 Interior Windows Continue to Fog..........................................................................1088 Interior Windows Continue to Fog Diagnostic Procedure.................................................1088 Tests.........................................................................................................1091 R134a Refrigerant Cautions and Proper Handling............................................................1091 R134a Oil Charge Capacity.................................................................................1091 R134a Refrigerant Charge Capacity.........................................................................1091 Heater and Air Conditioner Operational Checks.............................................................1092 Visual Inspection of Components.......................................................................1092 Air Conditioner Compressor Clutch Test....................................................................1093 R134a Refrigerant Leak Test...............................................................................1094 R134a Refrigerant Hoses and Tubing Inspection.............................................................1094 Air Conditioner High/Low-Pressure Switch Test.............................................................1095 Air Conditioner Freeze Control Switch Test................................................................1096 Air Conditioning System Test..............................................................................1097 Operating Pressure Diagnostic Chart.......................................................................1098 Dealer Fabricated Tools...........................................................................................1099 Dealer Fabricated Tools.......................................................................................1101 DFT1369 Pump Control Pilot (PCP) Test Harness.............................................................1101 Page Number........................................................................................................... 7 Section 9000...................................................................................................... 9 Group 01...................................................................................................... 11 Section 9001...................................................................................................... 37 Group 10...................................................................................................... 39 Group 20...................................................................................................... 81 Group 30...................................................................................................... 87 Group 40...................................................................................................... 117 Group 50...................................................................................................... 243 Group 60...................................................................................................... 283 Group 70...................................................................................................... 367 Group 80...................................................................................................... 381 Section 9005...................................................................................................... 395 Group 10...................................................................................................... 397 Section 9010...................................................................................................... 439 Group 05...................................................................................................... 441 Group 10...................................................................................................... 443 Group 15...................................................................................................... 457 Group 20...................................................................................................... 459 Group 25...................................................................................................... 461 Section 9015...................................................................................................... 471 Group 05...................................................................................................... 473 Group 10...................................................................................................... 569 Group 15...................................................................................................... 769 Group 16...................................................................................................... 785 Group 17...................................................................................................... 793 Group 18...................................................................................................... 805 Group 19...................................................................................................... 821 Group 20...................................................................................................... 827 Group 25...................................................................................................... 833 Section 9025...................................................................................................... 852 Group 05...................................................................................................... 853 Group 10...................................................................................................... 879 Group 15...................................................................................................... 923 Group 20...................................................................................................... 943 Group 25...................................................................................................... 947 Section 9026...................................................................................................... 965 Group 05...................................................................................................... 967 Group 10...................................................................................................... 987 Group 15......................................................................................................1011 Group 25......................................................................................................1035 Section 9031......................................................................................................1071 Group 05......................................................................................................1073 Group 10......................................................................................................1075 Group 15......................................................................................................1079 Group 25......................................................................................................1091 Section 9900......................................................................................................1099 Group 99......................................................................................................1101
S.S 24/02/2025
