John Deere 524K Loader Operation & Test Technical Manual TM10686 PDF

Description

John Deere 524K Loader Operation and Test Technical Manual TM10686 07OCT08 –  PDF DOWNLOAD

FILE DETAILS:

John Deere 524K Loader Operation and Test Technical Manual TM10686 07OCT08 –  PDF DOWNLOAD

Language : English
Pages : 1288
Downloadable : Yes
File Type : PDF

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TABLE OF CONTENTS:

John Deere 524K Loader Operation and Test Technical Manual TM10686 07OCT08 –  PDF DOWNLOAD

Contents 5
General Information 7
Safety Information 9
Recognize Safety Information 9
Follow Safety Instructions 9
Operate Only If Qualified 10
Wear Protective Equipment 10
Avoid Unauthorized Machine Modifications 10
Add Cab Guarding For Special Uses 11
Inspect Machine 11
Stay Clear of Moving Parts 11
Avoid High-Pressure Fluids 12
Avoid High-Pressure Oils 12
Beware of Exhaust Fumes 13
Prevent Fires 13
Clean Trash from Machine 14
Prevent Battery Explosions 14
Handle Chemical Products Safely 14
Dispose of Waste Properly 15
Prepare for Emergencies 15
Use Steps and Handholds Correctly 15
Start Only From Operator’s Seat 16
Use and Maintain Seat Belt 16
Prevent Unintended Machine Movement 17
Avoid Work Site Hazards 18
Use Special Care When Operating Loader 19
Keep Riders Off Machine 19
Avoid Backover Accidents 20
Avoid Machine Tip Over 21
Operating on Slopes 21
Operating or Traveling On Public Roads 22
Inspect and Maintain ROPS 22
Add and Operate Attachments Safely 22
Park And Prepare For Service Safely 23
Service Cooling System Safely 23
Service Tires Safely 24
Remove Paint Before Welding or Heating 25
Make Welding Repairs Safely 26
Drive Metal Pins Safely 26
Diagnostic Trouble Codes (DTC) 27
Engine Control Unit (ECU) Diagnostic Trouble Codes 39
Engine Control Unit (ECU) Diagnostic Trouble Codes 39
00010700 — Eng Air Filter Restricted 39
Engine Air Filter Restricted Diagnostic Procedure 40
40
40
40
41
41
00062701 — ECU Unswitched Power Short to Ground 41
ECU Unswitched Short to Ground Diagnostic Procedure 41
42
42
42
42
43
00067605 — Engine Heat Open or Short 43
Engine Heat Open or Short Diagnostic Procedure 43
43
43
44
44
44
44
00125313 — Injector Cal Required 45
Injector Calibration Required Diagnostic Procedure 45
45
45
45
00200309 — CAN Communication Lost for TCU 46
CAN Communication Lost For TCU Diagnostic Procedure 46
46
46
47
47
47
47
47
48
00203309 — CAN Communication Lost for FLC 48
CAN Communication Lost for FLC Diagnostic Procedure 48
48
49
49
49
50
50
50
50
50
Transmission Control Unit (TCU) Diagnostic Trouble Codes 51
Transmission Control Unit (TCU) Diagnostic Trouble Codes 51
00009109 — Timeout EEC2 Message 51
Timeout EEC2 Message Diagnostic Procedure 52
52
52
52
53
53
00051302 — Percent Torque Invalid 53
Percent Torque Invalid Diagnostic Procedure 53
53
54
54
54
54
00051309 — Timeout EEC1 Message 54
Timeout EEC1 Message Diagnostic Procedure 55
55
55
55
56
56
00051402 — Friction Invalid 56
Friction Invalid Diagnostic Procedure 56
56
57
57
57
57
00051409 — Timeout EEC3 Message 57
Timeout EEC3 Message Diagnostic Procedure 58
58
58
58
59
59
00054402 — Ref Torque Invalid 59
Ref Torque Invalid Diagnostic Procedure 59
59
60
60
60
60
00054409 — Timeout Engine Config Message 60
Timeout Engine Config Message Diagnostic Procedure 61
61
61
61
62
62
00077702 — TC Clutch Slippage 62
TC Clutch Slippage Diagnostic Procedure 62
62
63
63
63
63
64
64
00077703 — TC Lockup Sol Short to Power 64
TC Lockup Sol Short to Power Diagnostic Procedure 65
65
65
65
66
00077704 — TC Lockup Sol Short to Gnd 66
TC Lockup Sol Short to Gnd Diagnostic Procedure 66
66
67
67
67
00077705 — TC Lockup Sol Open Circuit 68
TC Lockup Sol Open Circuit Diagnostic Procedure 68
68
68
69
00092803 — Axle Disconnect Solenoid Short to Power 69
Axle Disconnect Solenoid Short to Power Diagnostic Procedure 69
69
70
70
70
00092805 — Axle Disconnect Solenoid Open Circuit 71
Axle Disconnect Solenoid Open Circuit Diagnostic Procedure 71
71
71
72
00092806 — Axle Disconnect Solenoid High Current 72
Axle Disconnect Solenoid High Current Diagnostic Procedure 72
72
73
73
73
00203309 — CAN Communication Lost for FLC 74
CAN Communication Lost for FLC Diagnostic Procedure 74
74
74
75
75
75
76
76
76
00214109 — CAN Communication Lost for SSM 76
CAN Communication Lost for SSM Diagnostic Procedure 76
77
77
77
77
78
78
78
52234400 — Torque Converter Output Temperature Too High 78
Torque Converter Output Temperature Too High Diagnostic Procedure 79
79
79
80
80
52235015 — Transmission Input Torque Overload 80
Transmission Input Torque Overload Diagnostic Procedure 80
81
81
81
52236407 — Transmission Clutch Calibration Failed 81
Transmission Clutch Calibration Failed Diagnostic Procedure 82
82
82
82
83
52236413 — Transmission Clutch Calibration Fault 83
Transmission Clutch Calibration Fault Diagnostic Procedure 83
83
84
52236513 — Limp Home Mode Requested 84
Limp Home Mode Requested Diagnostic Procedure 84
84
85
85
52236613 — Application Invalid 85
Application Invalid Diagnostic Procedure 85
86
86
86
52236713 — TCU Configuration Invalid 86
TCU Configuration Invalid Diagnostic Procedure 87
87
87
87
52236802 — TCU Memory Failure 88
TCU Memory Failure Diagnostic Procedure 88
88
88
88
52236903 — Remote Display Short to Power 89
Remote Display Short to Ground Diagnostic Procedure 89
89
89
90
90
52237002 — TCU Valve Power Supply 2 Short Circuit 90
TCU Valve Power Supply 2 Short Circuit Diagnostic Procedure 91
91
91
91
92
92
52237102 — TCU Valve Power Supply 1 Short Circuit 92
TCU Valve Power Supply 1 Short Circuit Diagnostic Procedure 93
93
93
94
52237303 — Power Supply High Voltage 94
Power Supply High Voltage Diagnostic Procedure 94
95
95
95
52237304 — Power Supply Low Voltage 95
Power Supply Low Voltage Diagnostic Procedure 96
96
96
96
97
52237403 — Sensor Supply Short to Power 97
Sensor Supply Short to Power Diagnostic Procedure 97
98
98
98
99
52237404 — Sensor Supply Short to Ground 99
Sensor Supply Short to Ground Diagnostic Procedure 99
100
100
100
101
52237500 — Transmission Oil Filter Restricted 101
Transmission Oil Filter Restricted Diagnostic Procedure 101
101
102
102
102
52237600 — Transmission Oil Temperature Over Maximum Value 103
Transmission Oil Temperature Over Maximum Value Diagnostic Procedure 103
103
104
104
104
52237903 — Park Brake Release Solenoid Short to Power 105
Park Brake Release Solenoid Short to Power Diagnostic Procedure 105
105
105
106
106
52237904 — Park Brake Release Solenoid Short to Ground 106
Park Brake Release Solenoid Short to Ground Diagnostic Procedure 107
107
107
107
108
52237905 — Park Brake Release Solenoid Open Circuit 108
Park Brake Release Solenoid Open Circuit Diagnostic Procedure 108
109
109
109
52238203 — Backup Alarm Short to Power 110
Backup Alarm Short to Power Diagnostic Procedure 110
110
110
111
111
52238204 — Backup Alarm Short to Ground 111
Backup Alarm Short to Ground Diagnostic Procedure 112
112
112
112
113
52238302 — Transmission Clutch KR Slippage 113
Transmission Clutch KR Slippage Diagnostic Procedure 113
114
114
114
114
114
115
115
52238303 — Clutch Reverse Solenoid Short to Power 115
Clutch Reverse Solenoid Short to Power Diagnostic Procedure 116
116
116
116
117
117
52238304 — Clutch Reverse Solenoid Short to Ground 117
Clutch Reverse Solenoid Short to Ground Diagnostic Procedure 118
118
118
118
119
119
52238305 — Clutch Reverse Solenoid Open Circuit 119
Clutch Reverse Solenoid Open Circuit Diagnostic Procedure 120
120
120
120
121
52238602 — Transmission Clutch KV Slippage 121
Transmission Clutch KV Slippage Diagnostic Procedure 121
122
122
122
122
122
123
123
52238603 — Clutch Forward Solenoid Short to Power 123
Clutch Forward Solenoid Short to Power Diagnostic Procedure 124
124
124
124
125
125
52238604 — Clutch Forward Solenoid Short to Ground 125
Clutch Forward Solenoid Short to Ground 126
126
126
126
127
127
52238605 — Clutch Forward Solenoid Open Circuit 127
Clutch Forward Solenoid Open Circuit Diagnostic Procedure 128
128
128
128
129
52238902 — Transmission Clutch K4 Slippage 129
Transmission Clutch K4 Slippage Diagnostic Procedure 129
130
130
130
130
131
131
131
52238903 — Clutch K4 Solenoid Short to Power 132
Clutch K4 Solenoid Short to Power Diagnostic Procedure 132
132
132
133
133
133
52238904 — Clutch K4 Solenoid Short to Ground 134
Clutch K4 Solenoid Short to Ground Diagnostic Procedure 134
134
134
135
135
135
52238905 — Clutch K4 Solenoid Open Circuit 136
Clutch K4 Solenoid Open Circuit Diagnostic Procedure 136
136
136
137
137
52239202 — Transmission Clutch K3 Slippage 137
Transmission Clutch K3 Slippage Diagnostic Procedure 138
138
138
138
138
139
139
139
52239203 — Clutch K3 Solenoid Short to Power 140
Clutch K3 Solenoid Short to Power Diagnostic Procedure 140
140
140
141
141
141
52239204 — Clutch K3 Solenoid Short to Ground 142
Clutch K3 Solenoid Short to Ground Diagnostic Procedure 142
142
142
143
143
143
52239205 — Clutch K3 Solenoid Open Circuit 144
Clutch K3 Solenoid Open Circuit Diagnostic Procedure 144
144
144
145
145
52239502 — Transmission Clutch K2 Slippage 145
Transmission Clutch K2 Slippage Diagnostic Procedure 146
146
146
146
146
147
147
147
52239503 — Clutch K2 Solenoid Short to Power 148
Clutch K2 Solenoid Short to Power Diagnostic Procedure 148
148
148
149
149
149
52239504 — Clutch K2 Solenoid Short to Ground 150
Clutch K2 Solenoid Short to Ground Diagnostic Procedure 150
150
150
151
151
151
52239505 — Clutch K2 Solenoid Open Circuit 152
Clutch K2 Solenoid Open Circuit Diagnostic Procedure 152
152
152
153
153
52239902 — Transmission Clutch K1 Slippage 153
Transmission Clutch K1 Slippage Diagnostic Procedure 154
154
154
154
154
155
155
155
52239903 — Clutch K1 Solenoid Short to Power 156
Clutch K1 Solenoid Short to Power Diagnostic Procedure 156
156
156
157
157
157
52239904 — Clutch K1 Solenoid Short to Ground 158
Clutch K1 Solenoid Short to Ground Diagnostic Procedure 158
158
158
159
159
159
52239905 — Clutch K1 Solenoid Open Circuit 160
Clutch K1 Solenoid Open Circuit Diagnostic Procedure 160
160
160
161
161
52240102 — Output Shaft Speed Sensor Fault 161
Output Shaft Speed Sensor Fault Diagnostic Procedure 162
162
162
162
52240103 — Output Shaft Speed Sensor Open or Short 163
Output Shaft Speed Sensor Open or Short Diagnostic Procedure 163
163
163
164
164
164
165
52240104 — Output Shaft Speed Sensor Short to Ground 165
Output Shaft Speed Sensor Short to Ground Diagnostic Procedure 165
166
166
166
167
52240112 — Output Shaft Speed Sensor Fault 167
Output Shaft Speed Sensor Fault Diagnostic Procedure 167
168
168
168
52240115 — Output Shaft Speed Sensor Overspeed 168
Output Shaft Speed Sensor Overspeed Diagnostic Procedure 169
169
169
169
52240203 — Clutch Speed Sensor Open or Short 170
Transmission Clutch Speed Sensor Open or Short Diagnostic Procedure 170
170
171
171
172
52240204 — Clutch Speed Sensor Short to Ground 172
Clutch Speed Sensor Short to Ground Diagnostic Procedure 172
173
173
173
174
52240212 — Clutch Speed Sensor Fault 174
Clutch Speed Sensor Fault Diagnostic Procedure 174
175
175
175
52240303 — Converter Output Speed Sensor Open or Short 175
Converter Output Speed Sensor Open or Short Diagnostic Procedure 176
176
176
177
177
177
52240304 — Converter Output Speed Sensor Short to Ground 178
Converter Output Speed Sensor Short to Ground Diagnostic Procedure 178
178
179
179
179
52240312 — Converter Output Speed Sensor Fault 180
Converter Output Speed Sensor Fault Diagnostic Procedure 180
180
180
181
52240403 — Converter Input Speed Sensor Open or Short 181
Converter Input Speed Sensor Open or Short Diagnostic Procedure 181
182
182
182
183
183
52240404 — Converter Input Speed Sensor Short to Ground 183
Converter Input Speed Sensor Short to Ground Diagnostic Procedure 184
184
184
185
185
52240412 — Converter Input Speed Sensor Fault 185
Converter Input Speed Sensor Fault Diagnostic Procedure 186
186
186
187
52240603 — Transmission Oil Temperature Sensor Open or Short 187
Transmission Oil Temperature Sensor Open or Short Diagnostic Procedure 187
188
188
188
189
189
189
52240604 — Transmission Oil Temperature Sensor Short to Ground 190
Transmission Oil Temperature Sensor Short to Ground Diagnostic Procedure 190
190
190
191
191
191
52240703 — Clutch Cut-off Sensor Short to Power 192
Clutch Cut-off Sensor Short to Power Diagnostic Procedure 192
192
192
193
193
52240704 — Clutch Cut-off Sensor Open or Short 193
Clutch Cut-off Sensor Open or Short Diagnostic Procedure 194
194
194
194
195
195
52240905 — 2nd FNR Open Circuit 195
2nd FNR Open Circuit Diagnostic Procedure (Pilot Control Joystick FNR) 196
196
196
196
197
2nd FNR Open Circuit Diagnostic Procedure (Joystick Steering FNR) 197
197
197
198
198
52240912 — 2nd FNR Multiple Inputs 199
2nd FNR Multiple Inputs Diagnostic Procedure (Pilot Control Joystick FNR) 199
199
200
200
201
2nd FNR Multiple Inputs Diagnostic Procedure (Joystick Steering FNR) 201
201
202
202
203
52241105 — 1st FNR Open Circuit 203
1st FNR Open Circuit Diagnostic Procedure (Steering Column FNR) 203
204
204
204
205
1st FNR Open Circuit Diagnostic Procedure (Pilot Control Joystick FNR) 205
205
205
206
206
52241112 — 1st FNR Multiple Inputs 207
1st FNR Multiple Inputs Diagnostic Procedure (Steering Column FNR) 207
207
208
208
209
1st FNR Multiple Inputs Diagnostic Procedure (Pilot Control Joystick FNR) 209
209
210
210
211
52241212 — Gear Selection Error 211
Gear Selection Error Diagnostic Procedure 211
212
212
212
213
52241902 — Clutch Cut-off Disabled 213
Clutch Cut-off Disabled Diagnostic Procedure 213
214
214
214
214
52242002 — Manual Downshift Disabled 215
Manual Downshift Disabled Diagnostic Procedure 215
215
215
215
52242102 — Auto to 1st Disabled 216
Auto to 1st Disabled Diagnostic Procedure 216
216
216
216
52404800 — Transmission Output Torque Exceeded 217
Transmission Output Torque Exceeded Diagnostic Procedure 217
217
217
52404900 — Transmission Input Torque Exceeded 218
Transmission Input Torque Exceeded Diagnostic Procedure 218
218
218
52428700 — Configure Machine Model 219
Configure Machine Model Diagnostic Procedure 219
219
219
Flex Load Controller (FLC) Diagnostic Trouble Codes 221
Flex Load Controller (FLC) Diagnostic Trouble Codes 221
00009604 — Fuel Level Short to Ground 221
Fuel Level Short to Ground Diagnostic Procedure 222
222
222
223
223
223
00009605 — Fuel Level Open or Short 224
Fuel Level Open or Short Diagnostic Procedure 224
224
224
225
225
226
226
00016716 — Alternator High Voltage 226
Alternator High Voltage Diagnostic Procedure 226
227
227
227
227
00016718 — Alternator Low Voltage 227
Alternator Low Voltage Diagnostic Procedure 228
228
228
228
228
00016816 — High Battery Voltage 229
High Battery Voltage Diagnostic Procedure 229
229
229
230
230
00023402 — Invalid TCU Software Rev 230
Invalid TCU Software Rev Diagnostic Procedure 230
230
00044405 — 12 Volt Center Tap Open or Short 231
12-Volt Center Tap Open or Short Diagnostic Procedure 231
231
231
232
232
232
00044418 — Battery Voltage Imbalance 232
Battery Voltage Imbalance Diagnostic Procedure 233
233
233
233
233
00052100 — Brake Pedal High Voltage 234
Brake Pedal High Voltage Diagnostic Procedure 234
234
234
234
00062812 — Controller Not Programmed 235
Controller Not Programmed Diagnostic Procedure 235
235
235
00062912 — FLC Watchdog Time Out 236
FLC Watchdog Time Out Diagnostic Procedure 236
236
236
00063912 — FLC CAN Failure 237
FLC CAN Failure Diagnostic Procedure 237
237
237
238
238
00063914 — FLC CAN Bus Off 238
FLC CAN Bus Off Diagnostic Procedure 238
238
239
239
239
00074605 — Differential Lock Solenoid Open or Short 239
Differential Lock Solenoid Open or Short Diagnostic Procedure 239
240
240
240
240
241
241
00074606 — Differential Lock Solenoid High Current 241
Differential Lock Solenoid High Current 241
242
242
242
242
243
00078505 — Pilot Solenoid Open or Short 243
Pilot Solenoid Open or Short Diagnostic Procedure 243
243
244
244
244
245
245
245
00078506 — Pilot Solenoid High Current 245
Pilot Solenoid High Current Diagnostic Procedure 246
246
246
246
247
247
247
00088005 — Brake Lights Open or Short 247
Brake Lights Open or Short Diagnostic Procedure 248
248
248
249
249
249
250
00088006 — Brake Lights High Current 250
Brake Lights High Current Diagnostic Procedure 250
250
251
251
251
251
00097705 — Reverse Fan Solenoid Open or Short 252
Reverse Fan Solenoid Open or Short Diagnostic Procedure 252
252
252
253
253
254
254
00097706 — Reverse Fan Solenoid High Current 254
Reverse Fan Solenoid High Current Diagnostic Procedure 254
255
255
255
256
256
00106902 — Tire Size Incorrect 256
Tire Size Incorrect Diagnostic Procedure 256
257
257
257
00107105 — Fan Speed Solenoid Open or Short 257
Fan Speed Solenoid Open or Short Diagnostic Procedure 258
258
258
259
259
260
260
00107106 — Fan Speed Solenoid High Current 260
Fan Speed Solenoid High Current Diagnostic Procedure 260
261
261
261
262
262
00150304 — Arm Rest Down Switch Short to Ground 262
Arm Rest Down Switch Short to Ground Diagnostic Procedure 262
263
263
263
264
264
264
00150311 — Arm Rest Position Undetermined 264
Arm Rest Position Undetermined Diagnostic Procedure 265
265
265
265
266
266
266
267
267
267
00155006 — AC Clutch High Current 267
AC Clutch High Current Diagnostic Procedure 268
268
268
268
00156504 — Arm Rest Up Switch Short to Ground 269
Arm Rest Up Switch Short to Ground Diagnostic Procedure 269
269
269
270
270
270
271
00163800 — Hydraulic Oil High Temperature 271
Hydraulic Oil High Temperature Diagnostic Procedure 271
271
272
00163804 — Hydraulic Oil Temperature Sensor Short to Ground 272
Hydraulic Oil Temperature Sensor Short to Ground Diagnostic Procedure 272
272
273
273
273
273
00171301 — Hydraulic Oil Filter Restricted 274
Hydraulic Oil Filter Restricted Diagnostic Procedure 274
274
274
275
275
275
00176203 — Hydraulic Pressure Sensor Short to Power 275
Hydraulic Pressure Sensor Short to Power Diagnostic Procedure 275
276
276
276
277
277
00176204 — Hydraulic Pressure Sensor Open or Short 277
Hydraulic Pressure Sensor Open or Short 277
278
278
278
279
279
279
00200009 — CAN Communication Lost for ECU 280
CAN Communication Lost For ECU Diagnostic Procedure 280
280
280
281
281
281
281
282
282
00200309 — CAN Communication Lost for TCU 282
CAN Communication Lost For TCU Diagnostic Procedure 282
282
283
283
283
283
283
284
284
00204009 — CAN Communication Lost for ADU 284
CAN Communication Lost For ADU Diagnostic Procedure 284
284
285
285
285
285
285
286
286
286
00205109 — CAN Communication Lost for TPMS 286
CAN Communication Lost for TPM Diagnostic Procedure 286
287
287
287
287
288
288
288
00205209 — CAN Communication Lost for JSC 288
CAN Communication Lost for JSC Diagnostic Procedure 288
289
289
289
289
290
290
290
00212909 — CAN Communication Lost for JSV 290
CAN Communication Lost for JSV Diagnostic Procedure 290
291
291
291
291
292
292
00213209 — CAN Communication Lost for ROD 292
CAN Communication Lost for ROD Diagnostic Procedure 292
292
293
293
293
294
294
00214109 — CAN Communication Lost for SSM 294
CAN Communication Lost For SSM Diagnostic Procedure 294
294
295
295
295
295
295
296
296
00216909 — CAN Communication Lost for RDR 296
CAN Communication Lost for RDR Diagnostic Procedure 296
296
297
297
297
298
298
00235005 — Drive Lamps Open or Short 298
Drive Lamps Open or Short Diagnostic Procedure 298
298
299
299
299
300
300
00235006 — Drive Lamps High Current 300
Drive Lamps High Current Diagnostic Procedure 300
301
301
301
301
302
00235505 — Front Work Lights Open or Short 302
Front Auxiliary Lights Open or Short Diagnostic Procedure 302
302
303
303
303
304
304
00235506 — Front Work Lights High Current 304
Front Work Lights High Current Diagnostic Procedure 304
305
305
305
305
306
00235605 — Front Work Lights Open or Short 306
Front Work Lights Open or Short Diagnostic Procedure 306
306
307
307
307
308
308
00235606 — Front Work Lights High Current 308
Front Work Lights High Current Diagnostic Procedure 308
309
309
309
309
310
00235905 — Machine Work Lights Open Circuit 310
00235906 — Machine Work Lights High Current 310
00236205 — Rear Work Lights Open or Short 310
Rear Work Lights Open or Short Diagnostic Procedure 311
311
311
312
312
312
312
00236206 — Rear Work Lights High Current 313
Rear Work Lights High Current Diagnostic Procedure 313
313
313
314
314
314
00236704 — Left Turn Switch Short to Ground 314
Left Turn Switch Short to Ground Diagnostic Procedure 315
315
315
315
316
316
00236805 — Left Turn Lights Open or Short 316
Left Turn Lights Open or Short Diagnostic Procedure 316
317
317
317
318
318
318
00236806 — Left Turn Lights High Current 319
Left Turn Lights High Current Diagnostic Procedure 319
319
319
320
320
320
00236904 — Right Turn Switch Short to Ground 321
Right Turn Switch Short to Ground Diagnostic Procedure 321
321
321
322
322
322
00237005 — Right Turn Lights Open or Short 322
Right Turn Lights Open or Short Diagnostic Procedure 323
323
323
324
324
325
325
00237006 — Right Turn Lights High Current 325
Right Turn Lights High Current Diagnostic Procedure 325
326
326
326
327
327
00237805 — Marker/Tail Lights Open or Short 327
Marker/Tail Lights Open or Short Diagnostic Procedure 327
328
328
329
330
330
330
00237806 — Marker/Tail Lights High Current 331
Marker/Tail Lights High Current Diagnostic Procedure 331
331
332
332
333
333
00238606 — Beacon Light High Current 333
Beacon Light High Current Diagnostic Procedure 333
334
334
334
334
335
00268005 — RTC/Float Detent Open or Short 335
RTC/Float Detent Open or Short Diagnostic Procedure 335
335
335
336
336
336
336
00268006 — RTC/Float Detent High Current 337
RTC/Float Detent High Current Diagnostic Procedure 337
337
337
338
338
338
00269702 — Timeout JSC Message 338
Timeout JSC Message Diagnostic Procedure 338
339
339
339
339
339
00271705 — RTD Detent Open or Short 340
RTD Detent Open or Short Diagnostic Procedure 340
340
340
341
341
341
341
00271706 — RTD Detent High Current 342
RTD Detent High Current Diagnostic Procedure 342
342
342
343
343
343
00275405 — BHKO Detent Open or Short 343
BHKO Detent Open or Short Diagnostic Procedure 344
344
344
344
345
345
345
00275406 — BHKO Detent High Current 345
BHKO Detent High Current Diagnostic Procedure 346
346
346
346
347
347
00287504 — Hazard Wakeup Short to Ground 347
Hazard Wakeup Short to Ground Diagnostic Procedure 347
347
348
348
348
348
349
00350904 — FLC Sensor 1 Voltage Low 349
FLC Sensor 1 Voltage Low Diagnostic Procedure 349
349
350
350
350
350
00351004 — FLC Sensor 2 Voltage Low 351
FLC Sensor 2 Voltage Low Diagnostic Procedure 351
351
351
352
352
352
00351104 — FLC Sensor 3 Voltage Low 352
FLC Sensor 3 Voltage Low Diagnostic Procedure 353
353
353
353
354
354
29926102 — Machine Configuration Invalid 354
Machine Configuration Invalid Diagnostic Procedure 354
355
355
52228001 — Brake Pressure Low 355
Brake Pressure Low Diagnostic Procedure 355
356
356
356
356
52234105 — Heated Mirror Open or Short 357
Heated Mirror Open or Short Diagnostic Procedure 357
357
357
358
358
358
359
52234106 — Heated Mirror Short to Ground 359
Heated Mirror Short to Ground Diagnostic Procedure 359
359
359
360
360
360
52242604 — Rear Wiper Park Short to Ground 360
Rear Wiper Park Short to Ground Diagnostic Procedure 361
361
361
361
362
362
52242704 — Front Wiper Park Short to Ground 362
Front Wiper Park Short to Ground Diagnostic Procedure 362
362
363
363
363
363
52243102 — Memory Test Failure 364
Memory Test Failure Diagnostic Procedure 364
364
364
52243205 — Rear Wiper High Speed Open or Short 365
Rear Wiper High Speed Open or Short Diagnostic Procedure 365
365
365
366
366
366
366
52243206 — Rear Wiper High Speed High Current 367
Rear Wiper High Speed High Current Diagnostic Procedure 367
367
367
368
368
368
52243305 — Rear Wiper Low Speed Open or Short 368
Rear Wiper Low Speed Open or Short Diagnostic Procedure 369
369
369
369
370
370
370
52243306 — Rear Wiper Low Speed High Current 370
Rear Wiper Low Speed High Current Diagnostic Procedure 371
371
371
371
372
372
52243405 — Front Wiper Low Speed Open or Short 372
Front Wiper Low Speed Open or Short Diagnostic Procedure 372
373
373
373
373
374
374
52243406 — Front Wiper Low Speed High Current 374
Front Wiper Low Speed High Current Diagnostic Procedure 374
375
375
375
375
376
52243505 — Front Wiper High Speed Open or Short 376
Front Wiper High Speed Open or Short Diagnostic Procedure 376
376
377
377
377
377
378
52243506 — Front Wiper High Speed High Current 378
Front Wiper High Speed High Current Diagnostic Procedure 378
378
379
379
379
379
52243603 — Bucket Position Short to Power 380
Bucket Position Short to Power Diagnostic Procedure 380
380
380
381
381
381
52243604 — Bucket Position Open or Short 382
Bucket Position Open or Short Diagnostic Procedure 382
382
382
383
383
384
384
52243704 — Return-to-Dig Switch Short to Ground 384
Return-to-Dig Switch Short to Ground Diagnostic Procedure 384
385
385
385
385
52243805 — Pin Disconnect Solenoid Open or Short 386
Pin Disconnect Solenoid Open or Short Diagnostic Procedure 386
386
386
387
387
387
387
52243806 — Pin Disconnect Solenoid High Current 388
Pin Disconnect Solenoid High Current Diagnostic Procedure 388
388
388
389
389
389
52254303 — Boom Cyl Rod Press Open or Short 389
Boom Cyl Rod Press Open or Short Diagnostic Procedure 389
390
390
390
391
391
391
52254304 — Boom Cyl Rod Press Short to Ground 392
Boom Cyl Rod Press Short to Ground Diagnostic Procedure 392
392
392
393
393
393
52254403 — Boom Cyl Head Press Open or Short 394
Boom Cyl Head Press Open or Short Diagnostic Procedure 394
394
394
395
395
396
396
52254404 — Boom Cyl Head Press Short to Ground 396
Boom Cyl Head Press Short to Ground Diagnostic Procedure 396
397
397
397
398
398
52262005 — Vehicle Horn Open or Short 398
Vehicle Horn Open or Short Diagnostic Procedure 398
399
399
399
400
400
400
52279605 — Rear Washer Pump Open or Short 401
Rear Washer Pump Open or Short Diagnostic Procedure 401
401
401
402
402
402
402
52279606 — Rear Washer Pump High Current 403
Rear Washer Pump High Current Diagnostic Procedure 403
403
403
404
404
404
52279705 — Front Washer Pump Open or Short 404
Front Washer Pump Open or Short Diagnostic Procedure 405
405
405
406
406
406
406
52279706 — Front Washer Pump High Current 407
Front Washer Pump High Current Diagnostic Procedure 407
407
407
408
408
408
52313701 — Steering Pressure Low 408
Steering Pressure Low Diagnostic Procedure 409
409
409
409
52313704 — Steering Pressure Switch Short to Ground 410
Steering Pressure Switch Short to Ground Diagnostic Procedure 410
410
410
411
411
411
52321904 — Switched Power Voltage Low 411
Switched Power Voltage Low Diagnostic Procedure 411
412
412
412
412
413
413
413
52344004 — Unswitched Power Voltage Low 413
Unswitched Power Voltage Low Diagnostic Procedure 413
414
414
414
414
415
415
52348905 — Engine Light Open Circuit 415
Engine Light Open Circuit Diagnostic Procedure 415
415
416
416
416
52357705 — Secondary Steering Pump Open or Short 416
Secondary Steering Pump Open or Short Diagnostic Procedure 417
417
417
417
418
418
52357706 — Secondary Steering Pump High Current 418
Secondary Steering Pump High Current Diagnostic Procedure 418
419
419
419
419
52368904 — Differential Lock Switch Short to Ground 420
Differential Lock Switch Short to Ground 420
420
420
421
421
421
421
52376710 — Joystick Steering Activation Switch Button Stuck 422
Joystick Steering Activation Switch Button Stuck Diagnostic Procedure 422
422
422
423
423
423
52376710 — Joystick Steering Activation Switch Button Stuck 423
Joystick Steering Activation Switch Button Stuck Diagnostic Procedure 423
424
424
424
424
425
52378603 — Boom Position Sensor Short to Power 425
Boom Position Sensor Short to Power Diagnostic Procedure 425
425
426
426
426
426
52379505 — JSV Power Open or Short 427
JSV Power Open or Short Diagnostic Procedure 427
427
427
427
428
52379506 — JSV Power High Current 428
JSV Power High Current Diagnostic Procedure 428
428
428
429
429
429
52383701 — Brake Pressure Low—Rear 429
Brake Pressure Low—Rear Diagnostic Procedure 429
430
430
430
430
52383703 — Rear Brake Pressure Sensor Short to Power 431
Rear Brake Pressure Sensor Short to Power Diagnostic Procedure 431
431
431
431
432
432
52383704 — Rear Brake Pressure Open or Short 432
Rear Brake Pressure Open or Short Diagnostic Procedure 432
432
433
433
433
433
434
52384001 — Brake Pressure Low—Front 434
Brake Pressure Low—Front Diagnostic Procedure 434
434
435
435
435
52384003 — Front Brake Pressure Short to Power 435
Front Brake Pressure Short to Power Diagnostic Procedure 436
436
436
436
437
437
52384004 — Front Brake Pressure Open or Short 437
Front Brake Pressure Open or Short Diagnostic Procedure 437
438
438
438
439
439
439
52386504 — Add Truck Switch Short to Ground 439
Add Truck Switch Short to Ground Diagnostic Procedure 439
440
440
440
440
441
52386704 — Counter Switch Short to Ground 441
Counter Switch Short to Ground Diagnostic Procedure 441
441
441
442
442
442
52386804 — Add Bucket Switch Short to Ground 442
Add Bucket Switch Short to Ground Diagnostic Procedure 442
443
443
443
443
444
52391105 — Hydraulic Power Management Solenoid Open or Short 444
Hydraulic Power Limiting Solenoid Open or Short Diagnostic Procedure 444
444
444
445
445
446
446
52391106 — Hydraulic Power Management Solenoid High Current 446
Hydraulic Power Management Solenoid High Current Diagnostic Procedure 446
447
447
447
448
448
52394805 — Ride Control Solenoid Open Circuit 448
Ride Control Solenoid Open Circuit Diagnostic Procedure 448
449
449
449
449
52394806 — Ride Control Solenoid High Current 450
Ride Control Solenoid High Current Diagnostic Procedure 450
450
450
451
451
451
52404401 — Axle Oil Filter Restricted 451
52404403 — Axle Oil Filter Short to Power 452
52425031 — Inspect Park Brake 452
Inspect Park Brake Diagnostic Procedure 452
452
453
52426519 — Check Sum Error 453
Check Sum Error Diagnostic Procedure 453
453
453
Sealed Switch Module (SSM) Diagnostic Trouble Codes 455
Sealed Switch Module (SSM) Diagnostic Trouble Codes 455
00062912 — SSM Watchdog Time Out 455
SSM Watchdog Time Out Diagnostic Procedure 456
456
456
456
00203309 — SSM Lost Communications 457
SSM Lost Communications Diagnostic Procedure 457
457
457
457
458
458
458
458
458
00263404 — SSM Ignition Relay Signal Short to Ground 459
Sealed Switch Module (SSM) Ignition Relay Signal Short to Ground Diagnostic Procedure 459
459
459
460
460
00263405 — SSM Ignition Relay Signal Open Circuit 460
Sealed Switch Module (SSM) Ignition Relay Signal Open Circuit Diagnostic Procedure 460
461
461
461
461
52075204 — Button 17 Keypad Stuck 462
Button 17 Keypad Stuck Diagnostic Procedure 462
462
462
463
463
463
52075209 — Button 17 LED Message 463
Button 17 LED Message Diagnostic Procedure 463
464
464
464
464
465
465
465
52075304 — Front Washer Keypad Stuck 465
Front Washer Keypad Stuck Diagnostic Procedure 466
466
466
466
466
467
52075404 — Front Wiper Keypad Stuck 467
Front Wiper Keypad Stuck Diagnostic Procedure 467
467
468
468
468
468
52075409 — Lost Front Wiper LED Message 468
Lost Front Wiper LED Message Diagnostic Procedure 469
469
469
469
470
470
470
470
52075504 — Drive Lights Keypad Stuck 471
Drive Lights Keypad Stuck Diagnostic Procedure 471
471
471
472
472
472
52075509 — Lost Drive Lights LED Message 472
Lost Drive Lights LED Message Diagnostic Procedure 472
473
473
473
473
474
474
474
52333504 — Work Lights Keypad Stuck 474
Work Lights Keypad Stuck Diagnostic Procedure 475
475
475
475
475
476
52333509 — Lost Work Lights LED Message 476
Lost Work Lights LED Message Diagnostic Procedure 476
476
477
477
477
477
477
478
52333604 — Rear Wiper Keypad Stuck 478
Rear Wiper Keypad Stuck Diagnostic Procedure 478
478
479
479
479
479
52333609 — Lost Rear Wiper LED Message 479
Lost Rear Wiper LED Message Diagnostic Procedure 480
480
480
480
481
481
481
481
52333804 — Rear Washer Keypad Stuck 482
Rear Washer Keypad Stuck Diagnostic Procedure 482
482
482
483
483
483
52333904 — Axle Disconnect Keypad Stuck 483
Axle Disconnect Keypad Stuck Diagnostic Procedure 483
484
484
484
484
484
52333909 — Lost Axle Disconnect LED Message 485
Lost Axle Disconnect LED Message Diagnostic Procedure 485
485
485
486
486
486
486
486
52334004 — Button 21 Keypad Stuck 487
Button 21 Keypad Stuck Diagnostic Procedure 487
487
487
488
488
488
52334009 — Button 21 LED Message 488
Button 21 LED Message Diagnostic Procedure 488
489
489
489
489
490
490
490
52384904 — A/C Keypad Stuck 490
A/C Keypad Stuck Diagnostic Procedure 491
491
491
491
491
492
52334909 — Lost A/C LED Message 492
Lost A/C LED Message Diagnostic Procedure 492
492
493
493
493
493
493
494
52385004 — Pin Disconnect Keypad Stuck 494
Pin Disconnect Keypad Stuck Diagnostic Procedure 494
494
495
495
495
495
52385009 — Lost Pin Disconnect LED Message 495
Lost A/C LED Message Diagnostic Procedure 496
496
496
496
497
497
497
497
52385204 — Spin Control Keypad Stuck 498
Spin Control Keypad Stuck Diagnostic Procedure 498
498
498
499
499
499
52385209 — Lost Spin Control LED Message 499
Lost Spin Control LED Message Diagnostic Procedure 499
500
500
500
500
501
501
501
52385404 — Diff Lock Keypad Stuck 501
Differential Lock Keypad Stuck Diagnostic Procedure 502
502
502
502
502
503
52385409 — Lost Diff Lock LED Message 503
Lost Differential Lock LED Message Diagnostic Procedure 503
503
504
504
504
504
504
505
52385504 — RTCarry Keypad Stuck 505
Return-to-Carry Keypad Stuck Diagnostic Procedure 505
505
506
506
506
506
52385509 — Lost RTC LED Message 506
Lost Return-to-Carry LED Message Diagnostic Procedure 507
507
507
507
508
508
508
508
52385604 — BHKO Keypad Stuck 509
Boom Height Kickout Keypad Stuck Diagnostic Procedure 509
509
509
510
510
510
52385609 — Lost BHKO LED Message 510
Lost Boom Height Kickout LED Message Diagnostic Procedure 510
511
511
511
511
512
512
512
52385704 — Clutch Cut-off Keypad Stuck 512
Clutch Cut-Off Keypad Stuck Diagnostic Procedure 513
513
513
513
513
514
52385709 — Lost Clutch Cut-off LED Message 514
Lost Clutch Cut-off LED Message Diagnostic Procedure 514
514
515
515
515
515
515
516
52385804 — Ride Control Keypad Stuck 516
Ride Control Keypad Stuck Diagnostic Procedure 516
516
517
517
517
517
52385809 — Lost Ride Control LED Message 517
Lost Ride Control LED Message Diagnostic Procedure 518
518
518
518
519
519
519
519
52386004 — Auto Transmission Keypad Stuck 520
Auto Transmission Keypad Stuck Diagnostic Procedure 520
520
520
521
521
521
52386009 — Lost Auto Trans LED Message 521
Lost Auto Transmission LED Message Diagnostic Procedure 521
522
522
522
522
523
523
523
52386104 — Return to Dig Keypad Stuck 523
Return-to-Dig Keypad Stuck Diagnostic Procedure 524
524
524
524
524
525
52386109 — Lost RTD LED Message 525
Lost RTD LED Message Diagnostic Procedure 525
525
526
526
526
526
526
527
52386204 — Park Brake Keypad Stuck 527
Park Brake Keypad Stuck Diagnostic Procedure 527
527
528
528
528
528
52386209 — Lost Park Brake LED Message 528
Lost Park Brake LED Message Diagnostic Procedure 529
529
529
529
530
530
530
530
52386304 — Pilot Enable Keypad Stuck 531
Pilot Enable Keypad Stuck Diagnostic Procedure 531
531
531
532
532
532
52386309 — Lost Pilot Enable LED Message 532
Lost Pilot Enable LED Message Diagnostic Procedure 532
533
533
533
533
534
534
534
52386404 — Hazards Keypad Stuck 534
Hazards Keypad Stuck Diagnostic Procedure 535
535
535
535
535
536
52386409 — Lost Hazard LED Message 536
Lost Hazard LED Message Diagnostic Procedure 536
536
537
537
537
537
537
538
52386504 — Beacon Light Keypad Stuck 538
Beacon Light Keypad Stuck Diagnostic Procedure 538
538
539
539
539
539
52386509 — Lost Beacon LED Message 539
Lost Beacon LED Message Diagnostic Procedure 540
540
540
540
541
541
541
541
52386704 — Ignition Off Keypad Stuck 542
Ignition Off Keypad Stuck Diagnostic Procedure 542
542
542
543
543
543
52386804 — Ignition On Keypad Stuck 543
Ignition On Keypad Stuck Stuck Diagnostic Procedure 543
544
544
544
544
544
52386809 — Lost Ign On LED Message 545
Lost Ignition On LED Message Diagnostic Procedure 545
545
545
546
546
546
546
546
Advanced Display Unit (ADU) Diagnostic Trouble Codes 547
Advanced Display Unit (ADU) Diagnostic Trouble Codes 547
00015803 — Switched Power Voltage High 547
Switched Power Voltage High Diagnostic Procedure 548
548
548
548
548
549
00015804 — Switched Power Voltage Low 549
Switched Power Voltage Low Diagnostic Procedure 549
549
550
550
550
550
551
551
00016803 — High Battery Voltage 551
High Battery Voltage Diagnostic Procedure 551
552
552
552
552
552
00016804 — Low Battery Voltage 553
Low Battery Voltage Diagnostic Procedure 553
553
553
554
554
554
554
555
00044200 — Display Temp High 555
Display Temp High Diagnostic Procedure 555
555
556
00044201 — Display Temp Low 556
Display Temp Low Diagnostic Procedure 556
556
557
00149111 — LCD Backlight Failure 557
LCD Backlight Failure Diagnostic Procedure 557
557
558
00359702 — 5 Volt Power Supply Invalid 558
5 Volt Power Supply Invalid Diagnostic Procedure 558
558
559
00359802 — 15 Volt Power Supply Invalid 559
15 Volt Power Supply Invalid Diagnostic Procedure 559
559
560
00359902 — 33 Volt Power Supply Invalid 560
33 Volt Power Supply Invalid Diagnostic Procedure 560
560
561
52343614 — ADU Watchdog Time Out 561
ADU Watchdog Time Out Diagnostic Procedure 561
561
562
52343831 — Memory Error 562
Memory Error Diagnostic Procedure 562
562
562
52365102 — Memory Stack Overflow 563
Memory Stack Overflow Diagnostic Procedure 563
563
563
52377303 — CAN HIGH Voltage High 564
CAN HIGH Voltage High Diagnostic Procedure 564
564
564
564
565
52377304 — CAN HIGH Voltage Low 565
CAN HIGH Voltage Low Diagnostic Procedure 565
565
566
566
52377403 — CAN LOW Voltage High 566
CAN LOW Voltage High Diagnostic Procedure 566
567
567
567
52377404 — CAN LOW Voltage Low 567
CAN LOW Voltage Low Diagnostic Procedure 567
568
568
568
52407610 — Information Button Stuck 568
Information Button Stuck Diagnostic Procedure 569
569
569
569
570
52407710 — Back Key Button Stuck 570
Back Key Button Stuck Diagnostic Procedure 570
570
571
571
571
52407810 — Menu Select Button Stuck 571
Menu Select Button Stuck Diagnostic Procedure 572
572
572
572
573
52408010 — Down Arrow Button Stuck 573
Down Arrow Button Stuck Diagnostic Procedure 573
573
574
574
574
52408210 — Up Arrow Button Stuck 574
Up Arrow Button Stuck Diagnostic Procedure 575
575
575
575
576
Rear Object Detection (ROD) Diagnostic Trouble Codes 577
Rear Object Detection (ROD) Diagnostic Trouble Codes 577
00089612 — ROD Sensor Failure 577
ROD Sensor Failure Diagnostic Procedure 577
578
Ground Speed Radar (RDR) Diagnostic Trouble Codes 579
Ground Speed Radar (RDR) Diagnostic Trouble Codes 579
00062812 — Controller Not Programmed 579
Controller Not Programmed Diagnostic Procedure 579
580
52345618 — Degraded Mode 580
Degraded Mode Diagnostic Procedure 580
580
580
Operational Checkout Procedure 581
Operational Checkout Procedure 583
Operational Checkout 583
Diagnostic Trouble Code Check 583
583
Operational Checks—Ignition OFF, Engine OFF Checks 584
584
584
Operational Checks—Ignition ON, Engine OFF Checks 585
586
587
588
589
589
590
Operational Checks—Ignition ON, Engine ON Checks 591
591
591
592
592
593
593
594
594
595
596
597
598
598
599
599
599
600
600
601
601
602
602
603
603
604
605
605
606
607
607
Engine 609
Theory of Operation 611
PowerTech E™ 68 L John Deere Engine 611
Diagnostic Information 613
PowerTech E™ 68 L John Deere Engine 613
Engine Cooling System Component Location 614
Engine Fuel System Component Location 616
Engine Intake and Exhaust Component Location 618
Tests 621
PowerTech E™ 68 L John Deere Engine 621
Fluid Sampling Procedure—If Equipped 622
Engine Idle Speeds and Auto Shutdown Check 628
Engine Slow Idle Speed Adjustment 629
Intake Manifold Pressure Test—Turbocharger Boost 629
Electrical System 633
System Information 636
Electrical Diagram Information 636
Electrical Schematic Symbols 640
System Diagrams 644
Fuse and Relay Specifications 644
System Functional Schematic, Wiring Diagram, and Component Location Master Legend 646
System Functional Schematic and Section Legend 654
Power and Ground Cables (W1) Component Location 672
Loader Frame Harness (W2) Component Location 674
Loader Frame Harness (W2) Wiring Diagram 676
Load Center Harness (W3) Component Location 678
Load Center Harness (W3) Wiring Diagram 680
Front Console Harness (W4) Component Location 692
Front Console Harness (W4) Wiring Diagram 694
Engine Frame Harness (W5) Component Location 696
Engine Frame Harness (W5) Wiring Diagram 698
Engine Harness (W6) Component Location 702
Engine Harness (W6) Wiring Diagram 704
Transmission Harness (W10) Component Location 708
Transmission Harness (W10) Wiring Diagram 710
Rear Frame Harness (W13) Component Location 712
Rear Frame Harness (W13) Wiring Diagram 714
Secondary Steering Harness (W17) Component Location—If Equipped 716
Secondary Steering Harness (W17) Wiring Diagram—If Equipped 717
Cab Roof Harness (W19) Component Location 718
Cab Roof Harness (W19) Wiring Diagram 719
Heater and Air Conditioner Harness (W20) Component Location 721
Heater and Air Conditioner Harness (W20) Wiring Diagram 722
Rear Object Detection Harness (W21) Component Location—If Equipped 724
Rear Object Detection Harness (W21) Wiring Diagram—If Equipped 725
Radio Harness (W23) Component Location 727
Radio Harness (W23) Wiring Diagram 728
JDLink™ System Harnesses (W29 and W30) Component Location—If Equipped 729
GlobalTRACS® Terminal (GTT) Harness (W29) Wiring Diagram—If Equipped 732
Machine Information Gateway (MIG) Harness (W30) Wiring Diagram—If Equipped 734
Sub-System Diagnostics 737
Start and Charge Circuits Theory of Operation 737
Controller Area Network (CAN) Theory of Operation 742
Engine Control Unit (ECU) Circuit Theory of Operation 745
Flex Load Controller (FLC) Circuit Theory of Operation 755
Transmission Control Unit (TCU) Circuit Theory of Operation 782
Park Brake Circuit Theory of Operation 795
Advanced Display Unit (ADU) Circuit Theory of Operation 799
Rear Object Detection (ROD) Circuit Theory of Operation—If Equipped 802
Auto-Differential Lock Circuit Theory of Operation—If Equipped 805
Embedded Payload Scale (EPS) Circuit Theory of Operation—If Equipped 808
Monitor Operation 813
Advanced Display Unit (ADU)—Service Mode 813
Advanced Display Unit (ADU)—Clear Codes 814
Advanced Display Unit (ADU)—Auto Idle 815
Advanced Display Unit (ADU)—Auto Shutdown 816
Advanced Display Unit (ADU)—Enable Options 817
Advanced Display Unit (ADU)—Tire Size 818
Advanced Display Unit (ADU)—Fan Speed 819
Advanced Display Unit (ADU)—Maximum High Gear 820
Advanced Display Unit (ADU)—Transmission Clutch Calibration 821
Advanced Display Unit (ADU)—Slow Idle Adjust 822
Advanced Display Unit (ADU)—Hide/Unhide Main Menu 823
References 825
Electrical Component Specifications 825
Service ADVISOR™ Diagnostic Application 830
Service ADVISOR™ Connection Procedure 831
Reading Diagnostic Trouble Codes with Service ADVISOR™ Diagnostic Application 832
Diagnostic Trouble Codes—After Machine Repair 836
JDLink™ Connection Procedure—If Equipped 837
CAN Circuit Test 838
Controller Area Network (CAN) Diagnostics 838
839
839
839
840
841
841
842
842
Alternator Test 843
Transmission Control Valve Solenoid Check 845
Clutch Cut-Off Sensor Check and Adjustment 846
Boom Height Kickout (BHKO) Adjustment 847
Return-to-Carry (RTC) Adjustment 848
Return-to-Dig Adjustment—Z-Bar Linkage 849
Boom Height Kickout/Return-to-Carry (BHKO/RTC) Position Sensor Remove and Install 850
Boom Height Kickout/Return-to-Carry (BHKO/RTC) Position Sensor Disassemble and Assemble 852
Boom Height Kickout/Return-to-Carry (BHKO/RTC) Position Sensor Calibration 854
Embedded Payload Scale (EPS) Diagnostics—If Equipped 855
EPS Diagnostics 855
855
856
856
856
856
857
857
Change Backup Alarm Volume 858
Pressure Switches and Sensors Remove and Install 858
Intermittent Diagnostic Trouble Code (DTC) Diagnostics 859
Connector Terminal Test 860
Connector Terminal Test Diagnostic Procedure 860
861
861
861
Replace Metri-Pack® (Push Type) Connectors 862
Replace Metri-Pack® Connectors 863
Replace DEUTSCH® Circular Connectors 864
Replace DEUTSCH® Rectangular or Triangular Connectors 865
Install DEUTSCH® Contact 866
Replace WEATHER PACK® Connector 868
Install WEATHER PACK® Contact 869
Replace CINCH™ Connectors 870
Install CINCH™ Contact 872
Repair 32 and 48 Way CINCH™ Connectors 873
Remove Connector Body from Blade Terminals 876
Engine Control Unit (ECU) Remove and Install 877
Flex Load Controller (FLC) Remove and Install 877
Transmission Control Unit (TCU) Remove and Install 880
Sealed Switch Module (SSM) Remove and Install 881
Advanced Display Unit (ADU) Remove and Install 881
Power Train 883
Theory of Operation 885
TeamMate™ Axles 885
Power Train Operation 885
Torque Converter Operation 886
Transmission Operation 888
Transmission Operation—First Gear Forward 890
Transmission Clutch Pack Engagement and Solenoids Activated 893
Transmission Filter Bypass Valve Operation 894
Transmission Control Valve Component Operation 895
Transmission Clutch Modulation Operation 898
Thermal Bypass Valve Operation 900
Standard Differential Operation 902
Differential Lock Operation 903
Rear Axle Disconnect Operation—If Equipped 905
Axle Circulation Dual Pump Operation—If Equipped 906
Park Brake Operation 908
Diagnostic Information 912
Transmission System Schematic—First Forward 912
Transmission Control System 914
Power Train Component Location 916
Transmission Clutch Slippage 917
Transmission Clutch Slippage Diagnostic Procedure 917
Machine Will Not Move in Either Direction 919
Machine Will Not Move in Either Direction Diagnostic Procedure 919
920
920
920
920
920
921
921
921
921
921
922
922
922
922
923
923
923
923
924
Machine Will Not Shift Correctly 924
Machine Will Not Shift Correctly Diagnostic Procedure 924
924
924
925
925
925
925
926
926
926
926
926
927
Transmission System Pressure Is Low in Neutral 927
Transmission System Pressure Is Low in Neutral Diagnostic Procedure 927
927
927
928
928
928
Transmission Pressure Is Low (One or Two Gear Ranges) 928
Transmission Pressure Is Low (One or Two Gear Ranges) Diagnostic Procedure 928
929
929
929
929
930
930
Transmission Shifts Too Slow 930
Transmission Shifts Too Slow Diagnostic Procedure 930
930
931
931
931
931
932
932
932
932
932
Transmission Shifts Too Fast 933
Transmission Shifts Too Fast Diagnostic Procedure 933
933
933
933
934
934
Machine Creeps in Neutral 934
Machine Creeps in Neutral Diagnostic Procedure 934
934
935
935
935
935
935
936
Transmission Hydraulic System Overheats 936
Transmission Hydraulic System Overheats Diagnostic Procedure 936
936
936
936
937
937
937
937
937
938
938
Transmission Excessive Noise 938
Transmission Excessive Noise Diagnostic Procedure 938
Rear Axle Disconnect Does Not Disengage (2WD state) 940
Rear Axle Disconnect Does Not Disengage (2WD state) Diagnostic Procedure 940
Rear Axle Disconnect Does Not Engage (4WD state) 942
Rear Axle Disconnect Does Not Engage (4WD state) Diagnostic Procedure 942
942
943
943
943
943
943
943
943
944
944
944
Oil Aerated 944
Oil Aerated Diagnostic Procedure 944
944
945
945
Oil Ejected from Filler Tube 945
Oil Ejected from Filler Tube Diagnostic Procedure 945
945
945
Machine Vibrates 946
Machine Vibrates Diagnostic Procedure 946
946
946
946
947
947
Machine Power and Acceleration Low 947
Machine Power and Acceleration Low Diagnostic Procedure 947
947
947
948
948
948
948
Torque Converter Stall RPM 948
Torque Converter Stall RPM Diagnostic Procedure 948
948
949
949
949
949
949
Differential Lock Will Not Engage 950
Differential Lock Will Not Engage Diagnostic Procedure 950
950
950
950
950
951
Differential Lock Slips and Chatters 951
Differential Lock Slips and Chatters Diagnostic Procedure 951
951
951
952
952
Differential Lock Will Not Disengage 952
Differential Lock Will Not Disengage Diagnostic Procedure 952
952
952
953
953
953
Differential Oil Level Rises 953
Differential Oil Level Rises Diagnostic Procedure 953
953
953
954
954
Differential Oil Level Low 954
Differential Oil Level Low Diagnostic Procedure 954
954
Differential and Axle Noise Excessive 954
Differential and Axle Noise Excessive Diagnostic Procedure 954
955
955
955
955
956
956
956
Axle Wheel Hub Face Seal Leaking 956
Axle Wheel Hub Face Seal Leaking Diagnostic Procedure 956
956
956
957
Axle Overheats 957
Axle Overheats Diagnostic Procedure 957
957
957
958
958
Service Brakes Poor or Do Not Apply 958
Service Brakes Poor or Do Not Apply Diagnostic Procedure 958
958
958
959
959
959
959
959
Service Brakes Aggressive 960
Service Brakes Aggressive Diagnostic Procedure 960
960
960
960
960
961
Service Brakes Dragging 961
Service Brakes Dragging Diagnostic Procedure 961
961
961
962
962
Service Brakes Lock Up 962
Service Brakes Lock Up Diagnostic Procedure 962
962
962
963
963
963
963
Service Brakes Chatter 963
Service Brakes Chatter Diagnostic Procedure 963
964
964
964
964
964
965
Service Brake Warning Light On 965
Service Brake Warning Light On Diagnostic Procedure 965
965
965
965
966
966
966
Driveline Excessive Vibration or Noise 966
Driveline Excessive Vibration or Noise Diagnostic Procedure 966
Park Brake Will Not Hold 968
Park Brake Will Not Hold Diagnostic Procedure 968
Park Brake Overheats 969
Park Brake Overheats Diagnostic Procedure 970
970
970
970
970
970
Park Brake Light Flashes When Shifting From Forward to Reverse 971
Park Brake Light Flashes When Shifting From Forward to Reverse Diagnostic Procedure 971
971
971
971
Park Brake Light Flashes During Each Shift 971
Park Brake Light Flashes During Each Shift Diagnostic Procedure 972
972
972
972
972
972
Park Brake Light Does Not Come On 973
Park Brake Light Does Not Come On Diagnostic Procedure 973
973
973
973
974
Park Brake Will Not Apply 974
Park Brake Will Not Apply Diagnostic Procedure 974
975
975
975
975
975
975
Adjustments 977
Service Brake Bleeding Procedure 977
External Service Brake Inspection 978
Transmission Control Unit (TCU)—Electronic Clutch Calibration 981
Tests 983
Transmission Oil Sampling Procedure 983
Transmission Oil Warmup Procedure 983
Park Brake Pressure Test 984
Park Brake Drag Test 986
Transmission Pump Flow Test 988
Transmission System Pressure Test 990
Transmission Clutch Pressure Test 992
Transmission Element Leakage Test 995
Transmission Lube Pressure Test 998
Differential Lock Pressure Test1000
Torque Converter—In Pressure Test1003
Torque Converter—Out Pressure Test1005
Torque Converter Relief Pressure Test1008
Torque Converter—Out Flow Test1010
Torque Converter Stall Speed Test1013
Transmission Oil Cooler Thermal Bypass Valve Temperature Test1014
Transmission Oil Cooler Thermal Bypass Valve Pressure Test1017
Transmission Oil Cooler Restriction Test1019
Axle Circulation Pump Flow Test1021
Axle Breather Test1023
Hydraulic System1025
Theory of Operation1029
Loader Hydraulic System Operation1029
Main Hydraulic Pump Operation1032
Hydraulic Pump Manifold Operation1034
Hydraulic Fan Operation1036
Hydraulic Reversing Fan Operation—If Equipped1038
Orbital Steering System Component Operation1041
Orbital Steering Valve Operation1042
Secondary Steering System Operation—If Equipped1043
Secondary Steering Valve Operation—If Equipped1044
Pilot Pressure Reducing Valve Operation1046
Service Brake Hydraulic System Operation1047
Service Brake Accumulator Operation1048
Service Brake Valve Operation1050
Pin Disconnect Operation—If Equipped1052
Pilot Control Lever Operation1054
Control Valve Pilot Orifice Check Valve Operation1056
Loader Control Valve Operation1057
Boom Section Operation—Boom Down and Steering1058
Bucket Section Operation—Boom Raise and Bucket Dump1060
Bucket Section Operation—Boom Raise and Bucket Dump (High-Lift Option)1062
Auxiliary Section—Operating and Boom Raise1064
Auxiliary Section—Spool Stroke Adjuster Operation1066
Loader Control Valve—Outlet Section Operation1067
Load Sense Circuit Operation—Neutral1069
Load Sense Circuit Operation—Steering1071
Load Sense Circuit Operation—Steering and Boom Down1073
Load Sense Circuit Operation—Boom Raise and Bucket Dump1075
Main Relief Valve Operation1077
Load Sense Relief Valve Operation1079
Circuit Relief With Anticavitation Valve Operation1080
Anticavitation Valve Operation1084
Hydraulic Return Filter Operation1085
Ride Control Operation—If Equipped1087
Diagnostic Information1092
Hydraulic System Schematic1092
Hydraulic System Component Location1094
No Hydraulic Functions1101
No Hydraulic Functions Diagnostic Procedure1101
Hydraulic Functions Slow1102
Hydraulic Functions Slow Diagnostic Procedure1102

Main Hydraulic Pump Noisy1105
Main Hydraulic Pump Noisy Diagnostic Procedure1105
No Orbital Steering Function1107
No Orbital Steering Function Diagnostic Procedure1107
1108
1108
1108
1108
1108
1109
1109
Boom Float Function Not Working1109
Boom Float Function Not Working Diagnostic Procedure1109
1109
1109
1109
1110
1110
One Hydraulic Function Not Working1110
One Hydraulic Function Not Working Diagnostic Procedure1110
1110
1110
1110
1111
1111
1111
Hydraulic Function Drifts Down1111
Hydraulic Function Drifts Down Diagnostic Procedure1111
1111
1112
1112
1112
1112
1112
Boom Down Does Not Work (Engine Off)1112
Boom Down Does Not Work (Engine Off) Diagnostic Procedure1112
1112
1113
1113
1113
Ride Control Not Working1113
Ride Control Not Working Procedure1113
1113
1113
1114
1114
1114
Oil Overheats1114
Oil Overheats Diagnostic Procedure1114
Hydraulic Oil Foams1116
Hydraulic Oil Foams Diagnostic Procedure1116
1116
1117
1117
Pin Disconnect Cylinders Will Not Retract—If Equipped1117
Pin Disconnect Cylinders Will Not Retract Diagnostic Procedure1117
1117
1117
1118
1118
Constant Steering Required to Maintain Straight Travel1118
Constant Steering Required to Maintain Straight Travel Diagnostic Procedure1118
1118
1118
1119
1119
Slow Steering Wheel Movement Will Not Cause Frame Movement1119
Slow Steering Wheel Movement Will Not Cause Frame Movement Diagnostic Procedure1119
1119
1120
Steering Wheel Turns Without Resistance and Causes No Frame Movement1120
Steering Wheel Turns Without Resistance and Causes No Frame Movement Diagnostic Procedure1120
1120
1120
1120
1121
Steering Erratic1121
Steering Erratic Diagnostic Procedure1121
1121
1121
1122
1122
Steering Wheel Free Play1122
Steering Wheel Free Play Diagnostic Procedure1122
1122
1123
Orbital Steering Valve Binds or Locks Up1123
Orbital Steering Valve Binds or Locks Up Diagnostic Procedure1123
1123
1123
1123
1124
Steering Wheel Turns by Itself1124
Steering Wheel Turns by Itself Diagnostic Procedure1124
1124
1124
Machine Turns in Opposite Direction as Steering Wheel1124
Machine Turns in Opposite Direction as Steering Wheel Diagnostic Procedure1125
1125
Steering Wheel Kickback1125
Steering Wheel Kickback Diagnostic Procedure1125
1125
Orbital Steering Jerky1125
Orbital Steering Jerky Diagnostic Procedure1125
1126
1126
Secondary Steering Motor Will Not Operate—If Equipped1126
Secondary Steering Motor Will Not Operate Diagnostic Procedure1126
1126
1126
Secondary Steering Pump Runs But Will Not Steer Machine—If Equipped1127
Secondary Steering Pump Runs But Will Not Steer Machine Diagnostic Procedure1127
1127
Hydraulic Fan Does Not Reach Full Speed1127
Hydraulic Fan Does Not Reach Full Speed Diagnostic Procedure1127
Hydraulic Fan Runs at Full Speed Only1129
Hydraulic Fan Runs at Full Speed Only Diagnostic Procedure1129
1129
1129
1129
Hydraulic Fan Does Not Spin1129
Hydraulic Fan Does Not Spin Diagnostic Procedure1129
1130
1130
1130
1130
1130
1130
Hydraulic Fan Will Not Reverse Direction—If Equipped1131
Hydraulic Fan Will Not Reverse Direction Diagnostic Procedure1131
1131
1131
1131
Adjustments1133
Hydraulic Oil Cleanup Procedure Using Portable Filter Caddy1133
Pilot Control Lever Adjustment1133
Auxiliary Pilot Control Lever Adjustment1134
Ride Control Accumulator Gas Charge Procedure—If Equipped1135
Auxiliary Valve Section—Stroke Adjustment1138
Test1141
Hydraulic Oil Sampling Procedure1141
Hydraulic Oil Warmup Procedure1141
Hydraulic System Pressure and Accumulators Discharge1142
Digital Pressure and Temperature Analyzer Installation1144
Main Hydraulic Pump Control Valve Test and Adjustment1145
Load Sense Relief Valve Pressure Test and Adjustment1150
Main Hydraulic Pump Flow Test1154
Main Hydraulic Pump Case Drain Test1158
Main Relief Valve Pressure Test1162
Circuit Relief With Anticavitation Valve Pressure Test1167
Loader Cylinder Drift Test1170
Boom, Bucket, and Steering Cylinder Leakage Test1172
Hydraulic Oil Cooler Restriction Test1175
Orbital Steering Valve Leakage Test1179
Steering Cylinder Drift Test1182
Secondary Steering Pump Pressure Relief Valve Test—If Equipped1186
Secondary Steering Valve—Hydraulic System Isolation Check Valve Leakage Test—If Equipped1189
Secondary Steering Valve—Secondary Steering Pump Isolation Check Valve Leakage Test—If Equipped1194
Pilot Control Valve Pressure Test1198
Auxiliary Pilot Control Valve Pressure Test1204
Pilot Pressure Reducing Valve Pressure Test1210
Pilot Accumulator Gas Precharge Test1214
Cycle Time Test1217
Service Brake Accumulator Gas Precharge and Low Brake Pressure Warning Test1218
Service Brake Valve Pressure Test1223
Service Brake Valve Leakage Test1227
Service Brake Accumulator Inlet Check Valve Leakage Test1231
Pin Disconnect Pressure Test—If Equipped1232
Hydraulic Fan Pump Pressure Test1237
Hydraulic Fan Motor Speed Test1240
Hydraulic Fan Pump Flow Test1243
Hydraulic Fan Motor Case Drain Test1247
Hydraulic Reversing Fan Test—If Equipped1250
Hydraulic Oil Filter Inspection Procedure1252
Heating and Air Conditioning1253
Theory of Operation1255
Air Conditioning System Cycle of Operation1255
Diagnostic Information1257
Air Conditioning System Does Not Operate1257
Air Conditioning System Does Not Operate Diagnostic Procedure1257
Air Conditioner Does Not Cool Interior of Cab1260
Air Conditioner Does Not Cool Interior of Cab Diagnostic Procedure1260
Air Conditioner Runs Constantly, Too Cold1262
Air Conditioner Runs Constantly, Too Cold Diagnostic Procedure1262
1262
1262
Heater System Does Not Operate1262
Heater System Does Not Operate Diagnostic Procedure1262
1263
1263
1263
1264
Heater Does Not Warm Interior of Cab1264
Heater Does Not Warm Interior of Cab Diagnostic Procedure1264
1264
1264
1264
1265
1265
1265
Interior Windows Continue to Fog1265
Interior Windows Continue to Fog Diagnostic Procedure1265
1265
Tests1267
Refrigerant Cautions and Proper Handling1267
R134a Refrigerant Cautions1268
R134a Oil Charge Capacity1268
R134a Refrigerant Charge Capacity1269
Refrigerant Hoses and Tubing Inspection1269
R134a Air Conditioning System Test1270
Operating Pressure Diagnostic Chart1272
Air Conditioning High/Low Pressure Switch Test1274
Freeze Control Switch Test1276
Refrigerant Leak Testing1276

DESCRIPTION:

John Deere 524K Loader Operation and Test Technical Manual TM10686 07OCT08 –  PDF DOWNLOAD

• Foreword:
• 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.
• This is the safety-alert symbol. When you see this symbol on the machine or in this manual, be alert to the potential for personal injury. Technical manuals are divided in two parts: repair and operation and tests. Repair sections tell how to repair the components. Operation and tests sections help you 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.

G.B 06/01/25