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John Deere 750K & 850K Crawler Dozer Operation & Test Technical Manual TM13280X19 – PDF DOWNLOAD
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John Deere 750K & 850K Crawler Dozer Operation & Test Technical Manual TM13280X19 – PDF DOWNLOAD
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Description
John Deere 750K & 850K Crawler Dozer Operation & Test Technical Manual TM13280X19 – PDF DOWNLOAD
FILE DETAILS:
John Deere 750K & 850K Crawler Dozer Operation & Test Technical Manual TM13280X19 – PDF DOWNLOAD
Language : English
Pages : 1346
Downloadable : Yes
File Type : PDF
IMAGES PREVIEW OF THE MANUAL:
DESCRIPTION:
John Deere 750K & 850K Crawler Dozer Operation & Test Technical Manual TM13280X19 – 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.
TABLE OF CONTENTS:
John Deere 750K & 850K Crawler Dozer Operation & Test Technical Manual TM13280X19 – PDF DOWNLOAD
Contents........................................................................................................................ 3 General Information......................................................................................................... 5 Safety.................................................................................................................. 7 Recognize Safety Information........................................................................................ 7 Follow Safety Instructions.......................................................................................... 7 Operate Only If Qualified........................................................................................... 7 Wear Protective Equipment........................................................................................... 8 Avoid Unauthorized Machine Modifications............................................................................ 8 Inspect Machine..................................................................................................... 8 Stay Clear of Moving Parts.......................................................................................... 8 Avoid High-Pressure Fluids.......................................................................................... 9 Avoid High-Pressure Oils............................................................................................ 9 Work In Ventilated Area............................................................................................. 9 Avoid Static Electricity Risk When Refueling........................................................................ 10 High Debris Applications............................................................................................ 10 Prevent Fires....................................................................................................... 11 Prevent Battery Explosions.......................................................................................... 11 In Case of Machine Fire............................................................................................. 12 Handle Chemical Products Safely..................................................................................... 12 Handle Starting Fluid Safely........................................................................................ 12 Decommissioning — Proper Recycling and Disposal of Fluids and Components............................................ 13 Exhaust Filter Ash Handling and Disposal............................................................................ 13 Prepare for Emergencies............................................................................................. 13 Clean Debris from Machine........................................................................................... 14 Add Cab Guarding for Special Uses................................................................................... 14 Use Steps and Handholds Correctly................................................................................... 14 Start Only From Operator's Seat..................................................................................... 14 Use and Maintain Seat Belt.......................................................................................... 15 Prevent Unintended Machine Movement................................................................................. 15 Avoid Work Site Hazards............................................................................................. 16 Keep Riders Off Machine............................................................................................. 16 Avoid Backover Accidents............................................................................................ 17 Avoid Machine Tip Over and Machine Damage........................................................................... 18 Use Special Care When Operating..................................................................................... 18 Inspect and Maintain ROPS........................................................................................... 19 Travel Safely....................................................................................................... 19 Prevent Acid Burns.................................................................................................. 20 Add and Operate Attachments Safely.................................................................................. 20 Park and Prepare for Service Safely................................................................................. 21 Service Machines Safely............................................................................................. 21 Service Cooling System Safely....................................................................................... 21 Remove Paint Before Welding or Heating.............................................................................. 22 Make Welding Repairs Safely......................................................................................... 22 Drive Metal Pins Safely............................................................................................. 22 Use Proper Lifting Equipment........................................................................................ 23 Clean Exhaust Filter Safely......................................................................................... 24 Diagnostics................................................................................................................. 32 Engine Control Unit (ECU) Diagnostic Trouble Codes...................................................................... 33 Engine Control Unit (ECU) Diagnostic Trouble Codes.................................................................. 33 000091.19 — Primary Analog Throttle Signal Erratic.................................................................. 33 000111.07 — Coolant Level Sensor Circuit Fault...................................................................... 34 000237.02 — Vehicle Identification Conflict......................................................................... 35 000237.13 — Vehicle Identification Fault............................................................................ 35 000237.31 — Communication Fault..................................................................................... 36 000647.05 — Engine Fan Drive Circuit Fault.......................................................................... 37 000647.06 — Engine Fan Drive Circuit Fault.......................................................................... 38 001321.05 — Starter Relay Open Circuit.............................................................................. 39 001321.06 — Starter Relay High Current.............................................................................. 40 001321.09 — Starter Signal Invalid.................................................................................. 41 001321.16 — Too Long to Start....................................................................................... 42 001321.31 — Starter Sol Open Circuit................................................................................ 43 001761.01 — Diesel Exhaust Fluid Extremely Low...................................................................... 44 001761.18 — Diesel Exhaust Fluid Very Low........................................................................... 45 002003.09 — Communication System Message Missing.................................................................... 45 003031.12 — Diesel Exhaust Fluid Temperature Sensor Fault........................................................... 46 003353.31 — Alternator Output Fault................................................................................. 47 003516.01 — Diesel Exhaust Fluid Concentration Extremely Low........................................................ 48 003516.07 — Diesel Exhaust Fluid Concentration Invalid.............................................................. 48 003516.09 — Diesel Exhaust Fluid Tank Header Communication Fault.................................................... 49 003516.12 — Diesel Exhaust Fluid Concentration Sensor Fault......................................................... 49 003517.12 — Diesel Exhaust Fluid Tank Level Sensor Fault............................................................ 50 004211.03 — Hydraulic Fan Pressure.................................................................................. 51 004211.04 — Hydraulic Fan Pressure.................................................................................. 52 005484.05 — Fan Reversing Solenoid.................................................................................. 53 005484.06 — Fan Reversing Solenoid.................................................................................. 54 524225.31 — Engine Speed Detected Without Start Signal.............................................................. 55 Display Menu Handler (DMH) Diagnostic Trouble Codes..................................................................... 57 Display Menu Handler (DMH) Diagnostic Trouble Codes................................................................. 57 000237.02 — Vehicle Identification Fault............................................................................ 57 000237.13 — Vehicle Identification Fault............................................................................ 58 000237.31 — Vehicle Identification Fault............................................................................ 58 002000.09 — Communication System Message Missing.................................................................... 59 002003.09 — Communication System Message Missing.................................................................... 59 002038.09 — Communication System Message Missing.................................................................... 60 002251.09 — Communication System Message Missing.................................................................... 60 Sealed Switch Module (SSM) Diagnostic Trouble Codes..................................................................... 61 Sealed Switch Module (SSM) Diagnostic Trouble Codes................................................................. 61 002033.09 — Communication System Message Missing.................................................................... 61 002634.04 — Ignition Relay Circuit Fault............................................................................ 62 002634.05 — Ignition Relay Circuit Fault............................................................................ 63 520752.04 — SSM Button Stuck........................................................................................ 64 520752.09 — Communication System Message Missing.................................................................... 64 520753.04 — SSM Button Stuck........................................................................................ 65 520753.09 — Communication System Message Missing.................................................................... 65 520754.04 — SSM Button Stuck........................................................................................ 66 520754.09 — Communication System Message Missing.................................................................... 66 520755.04 — SSM Button Stuck........................................................................................ 67 520755.09 — Communication System Message Missing.................................................................... 67 521274.09 — Communication System Message Missing.................................................................... 68 523335.04 — SSM Button Stuck........................................................................................ 68 523335.09 — Communication System Message Missing.................................................................... 69 523336.04 — SSM Button Stuck........................................................................................ 69 523336.09 — Communication System Message Missing.................................................................... 70 523338.04 — SSM Button Stuck........................................................................................ 70 523338.09 — Communication System Message Missing.................................................................... 71 523339.04 — SSM Button Stuck........................................................................................ 71 523339.09 — Communication System Message Missing.................................................................... 72 523340.04 — SSM Button Stuck........................................................................................ 72 523340.09 — Communication System Message Missing.................................................................... 73 523849.04 — SSM Button Stuck........................................................................................ 73 523849.09 — Communication System Message Missing.................................................................... 74 523850.04 — SSM Button Stuck........................................................................................ 74 523850.09 — Communication System Message Missing.................................................................... 75 523852.04 — SSM Button Stuck........................................................................................ 75 523852.09 — Communication System Message Missing.................................................................... 76 523854.04 — SSM Button Stuck........................................................................................ 76 523854.09 — Communication System Message Missing.................................................................... 77 523855.04 — SSM Button Stuck........................................................................................ 77 523855.09 — Communication System Message Missing.................................................................... 78 523856.04 — SSM Button Stuck........................................................................................ 78 523856.09 — Communication System Message Missing.................................................................... 79 523857.04 — SSM Button Stuck........................................................................................ 79 523857.09 — Communication System Message Missing.................................................................... 80 523858.04 — SSM Button Stuck........................................................................................ 80 523858.09 — Communication System Message Missing.................................................................... 81 523860.04 — SSM Button Stuck........................................................................................ 81 523860.09 — Communication System Message Missing.................................................................... 82 523861.04 — SSM Button Stuck........................................................................................ 82 523861.09 — Communication System Message Missing.................................................................... 83 523862.04 — SSM Button Stuck........................................................................................ 83 523862.09 — Communication System Message Missing.................................................................... 84 523863.04 — SSM Button Stuck........................................................................................ 84 523863.09 — Communication System Message Missing.................................................................... 85 523864.04 — SSM Button Stuck........................................................................................ 85 523864.09 — Communication System Message Missing.................................................................... 86 523865.04 — SSM Button Stuck........................................................................................ 86 523865.09 — Communication System Message Missing.................................................................... 87 523867.04 — SSM Button Stuck........................................................................................ 87 523867.09 — Communication System Message Missing.................................................................... 88 523868.04 — SSM Button Stuck........................................................................................ 88 523868.09 — Communication System Message Missing.................................................................... 89 Transmission Control Unit (TCU) Diagnostic Trouble Codes................................................................ 91 Transmission Control Unit (TCU) Diagnostic Trouble Codes............................................................ 91 000070.00 — Left Park Lock Lever Circuit Fault...................................................................... 92 000070.01 — Left Park Lock Lever Circuit Fault...................................................................... 93 000070.04 — Left Park Lock Lever Circuit Fault...................................................................... 94 000070.06 — Left Park Lock Lever Circuit Fault...................................................................... 95 000116.00 — Brake Pressure High..................................................................................... 96 000116.01 — Brake Pressure Low...................................................................................... 97 000116.03 — Brake Pressure Sensor Circuit Fault..................................................................... 98 000116.04 — Brake Pressure Sensor Circuit Fault..................................................................... 99 000158.03 — Switched Power Circuit Fault............................................................................ 100 000158.04 — Switched Power Circuit Fault............................................................................ 101 000168.04 — Unswitched Power Circuit Fault.......................................................................... 102 000177.00 — Transmission Oil Temperature High....................................................................... 103 000177.03 — Transmission Oil Temperature Circuit Fault.............................................................. 104 000177.04 — Transmission Oil Temperature Circuit Fault.............................................................. 105 000177.16 — Transmission Oil Temperature High....................................................................... 106 000237.02 — Vehicle Identification Fault............................................................................ 106 000237.13 — Vehicle Identification Fault............................................................................ 107 000237.31 — Vehicle Identification Fault............................................................................ 107 000521.00 — Decel Sensor Calibration Fault.......................................................................... 108 000521.01 — Decel Sensor Calibration Fault.......................................................................... 109 000521.03 — Decel Sensor Circuit Fault.............................................................................. 110 000521.04 — Decel Sensor Circuit Fault.............................................................................. 111 000521.05 — Decel Sensor Calibration Fault.......................................................................... 112 000521.06 — Decel Sensor Calibration Fault.......................................................................... 113 000521.13 — Decel Sensor Not Calibrated............................................................................. 113 000521.15 — Decel Sensor Calibration Fault.......................................................................... 114 000521.16 — Decel Sensor Calibration Fault.......................................................................... 115 000521.17 — Decel Sensor Calibration Fault.......................................................................... 116 000521.18 — Decel Sensor Calibration Fault.......................................................................... 117 000581.03 — Speed in Grip Switch Circuit Fault...................................................................... 118 000581.04 — Speed in Grip Switch Circuit Fault...................................................................... 119 000581.07 — Speed in Grip Button Stuck.............................................................................. 120 000604.03 — FNR Neutral Position Switch Circuit Fault............................................................... 121 000604.04 — FNR Neutral Position Switch Circuit Fault............................................................... 123 000604.15 — FNR Neutral Position Switch Calibration Fault........................................................... 124 000604.16 — FNR Neutral Position Switch Calibration Fault........................................................... 124 000604.17 — FNR Neutral Position Switch Calibration Fault........................................................... 125 000604.18 — FNR Neutral Position Switch Calibration Fault........................................................... 125 000619.05 — Brake Solenoid Circuit Fault............................................................................ 126 000619.06 — Brake Solenoid Circuit Fault............................................................................ 127 000629.12 — Control Unit Fault...................................................................................... 128 000743.05 — Engine Overspeed Solenoid Circuit Fault................................................................. 129 000743.06 — Engine Overspeed Solenoid Circuit Fault................................................................. 130 000907.00 — Left Motor Speed Sensor Circuit Fault................................................................... 131 000907.01 — Left Motor Speed Sensor Circuit Fault................................................................... 132 000907.03 — Left Motor Speed Sensor Circuit Fault................................................................... 133 000907.04 — Left Motor Speed Sensor Circuit Fault................................................................... 134 000907.07 — Left Motor Speed Sensor Fault........................................................................... 135 000907.12 — Left Motor Speed Sensor Circuit Fault................................................................... 136 000908.00 — Right Motor Speed Sensor Circuit Fault.................................................................. 137 000908.01 — Right Motor Speed Sensor Circuit Fault.................................................................. 138 000908.03 — Right Motor Speed Sensor Circuit Fault.................................................................. 139 000908.04 — Right Motor Speed Sensor Circuit Fault.................................................................. 140 000908.07 — Right Motor Speed Sensor Fault.......................................................................... 141 000908.12 — Right Motor Speed Sensor Circuit Fault.................................................................. 142 002000.09 — Communication System Message Missing.................................................................... 143 002030.09 — Communication System Message Missing.................................................................... 143 002660.00 — Steer Sensor Calibration Fault.......................................................................... 144 002660.01 — Steer Sensor Calibration Fault.......................................................................... 144 002660.03 — Steer Sensor Circuit Fault.............................................................................. 145 002660.04 — Steer Sensor Circuit Fault.............................................................................. 146 002660.07 — Steer Sensor Calibration Fault.......................................................................... 147 002660.13 — Steer Sensor Not Calibrated............................................................................. 147 002660.15 — Steer Sensor Calibration Fault.......................................................................... 148 002660.16 — Steer Sensor Calibration Fault.......................................................................... 148 002660.17 — Steer Sensor Calibration Fault.......................................................................... 149 002660.18 — Steer Sensor Calibration Fault.......................................................................... 149 002661.00 — FNR Sensor Calibration Fault............................................................................ 150 002661.01 — FNR Sensor Calibration Fault............................................................................ 150 002661.03 — FNR Sensor Circuit Fault................................................................................ 151 002661.04 — FNR Sensor Circuit Fault................................................................................ 152 002661.07 — FNR Sensor Calibration Fault............................................................................ 153 002661.13 — FNR Sensor Not Calibrated............................................................................... 153 002661.15 — FNR Sensor Calibration Fault............................................................................ 154 002661.16 — FNR Sensor Calibration Fault............................................................................ 154 002661.17 — FNR Sensor Calibration Fault............................................................................ 155 002661.18 — FNR Sensor Calibration Fault............................................................................ 155 003359.31 — Transmission Oil Filter Restricted...................................................................... 156 003509.03 — Sensor Supply 1 Circuit Fault........................................................................... 157 003509.04 — Sensor Supply 1 Circuit Fault........................................................................... 158 003510.03 — Sensor Supply 2 Circuit Fault........................................................................... 159 003510.04 — Sensor Supply 2 Circuit Fault........................................................................... 161 003511.03 — Sensor Supply 3 Circuit Fault........................................................................... 163 003511.04 — Sensor Supply 3 Circuit Fault........................................................................... 165 003512.03 — Sensor Supply 4 Circuit Fault........................................................................... 167 003512.04 — Sensor Supply 4 Circuit Fault........................................................................... 169 520570.05 — Transmission Cold Start Solenoid Circuit Fault.......................................................... 171 520570.06 — Transmission Cold Start Solenoid Circuit Fault.......................................................... 172 521999.00 — Right Park Lock Lever Circuit Fault..................................................................... 173 521999.01 — Right Park Lock Lever Circuit Fault..................................................................... 174 521999.04 — Right Park Lock Lever Circuit Fault..................................................................... 175 521999.06 — Right Park Lock Lever Circuit Fault..................................................................... 176 522439.05 — Tank Bypass Solenoid Circuit Fault...................................................................... 177 522439.06 — Tank Bypass Solenoid Circuit Fault...................................................................... 178 522444.00 — Charge Pressure High.................................................................................... 179 522444.01 — Charge Pressure Low..................................................................................... 179 522444.03 — Charge Pressure Circuit Fault........................................................................... 180 522444.04 — Charge Pressure Circuit Fault........................................................................... 181 522447.05 — Right Forward Pump Coil Circuit Fault................................................................... 182 522447.06 — Right Forward Pump Coil Circuit Fault................................................................... 183 522447.15 — Right Forward Pump Coil Calibration Fault............................................................... 184 522447.16 — Right Forward Pump Coil Calibration Fault............................................................... 184 522447.17 — Right Forward Pump Coil Calibration Fault............................................................... 185 522447.18 — Right Forward Pump Coil Calibration Fault............................................................... 185 522448.05 — Right Reverse Pump Coil Circuit Fault................................................................... 186 522448.06 — Right Reverse Pump Coil Circuit Fault................................................................... 187 522448.15 — Right Reverse Pump Coil Calibration Fault............................................................... 188 522448.16 — Right Reverse Pump Coil Calibration Fault............................................................... 188 522448.17 — Right Reverse Pump Coil Calibration Fault............................................................... 189 522448.18 — Right Reverse Pump Coil Calibration Fault............................................................... 189 522449.05 — Left Reverse Pump Coil Circuit Fault.................................................................... 190 522449.06 — Left Reverse Pump Coil Circuit Fault.................................................................... 191 522449.15 — Left Reverse Pump Coil Calibration Fault................................................................ 192 522449.16 — Left Reverse Pump Coil Calibration Fault................................................................ 192 522449.17 — Left Reverse Pump Coil Calibration Fault................................................................ 193 522449.18 — Left Reverse Pump Coil Calibration Fault................................................................ 193 522450.05 — Left Forward Pump Coil Circuit Fault.................................................................... 194 522450.06 — Left Forward Pump Coil Circuit Fault.................................................................... 195 522450.15 — Left Forward Pump Coil Calibration Fault................................................................ 196 522450.16 — Left Forward Pump Coil Calibration Fault................................................................ 196 522450.17 — Left Forward Pump Coil Calibration Fault................................................................ 197 522450.18 — Left Forward Pump Coil Calibration Fault................................................................ 197 522451.05 — Cooler Bypass Solenoid Circuit Fault.................................................................... 198 522451.06 — Cooler Bypass Solenoid Circuit Fault.................................................................... 199 523108.13 — Transmission Pumps/Motors Not Calibrated................................................................ 200 523108.14 — Transmission Not Calibrated............................................................................. 200 523577.05 — Left Motor Solenoid Circuit Fault....................................................................... 201 523577.06 — Left Motor Solenoid Circuit Fault....................................................................... 202 523577.13 — Transmission Motors Not Calibrated...................................................................... 203 523577.16 — Left Motor Solenoid Calibration Fault................................................................... 203 523577.18 — Left Motor Solenoid Calibration Fault................................................................... 204 523578.05 — Right Motor Solenoid Circuit Fault...................................................................... 205 523578.06 — Right Motor Solenoid Circuit Fault...................................................................... 206 523578.16 — Right Motor Solenoid Calibration Fault.................................................................. 207 523578.18 — Right Motor Solenoid Calibration Fault.................................................................. 207 524089.00 — Left System Pressure High............................................................................... 208 524089.01 — Left System Pressure Low................................................................................ 208 524089.03 — Left System Pressure Sensor Circuit Fault............................................................... 209 524089.04 — Left System Pressure Sensor Circuit Fault............................................................... 210 524090.00 — Right System Pressure High.............................................................................. 211 524090.01 — Right System Pressure Low............................................................................... 211 524090.03 — Right System Pressure Sensor Circuit Fault.............................................................. 212 524090.04 — Right System Pressure Sensor Circuit Fault.............................................................. 213 524233.07 — Hydrostatic Drive System Not Responding................................................................. 214 Vehicle Control Unit (VCU) Diagnostic Trouble Codes..................................................................... 215 Vehicle Control Unit (VCU) Diagnostic Trouble Codes................................................................. 215 000237.02 — Vehicle Identification Fault............................................................................ 215 000237.13 — Vehicle Identification Fault............................................................................ 216 000237.31 — Vehicle Identification Fault............................................................................ 216 000924.03 — Auxiliary Power Circuit Fault........................................................................... 217 000924.06 — Auxiliary Power Circuit Fault........................................................................... 218 001638.00 — Hydraulic Oil Temperature High.......................................................................... 219 001638.03 — Hydraulic Oil Temperature Sensor Circuit Fault.......................................................... 220 001713.01 — Hydraulic Oil Filter Restricted......................................................................... 221 001713.03 — Hydraulic Oil Filter Restriction Switch Circuit Fault................................................... 222 002000.09 — Communication System Message Missing.................................................................... 223 002141.09 — Communication System Message Missing.................................................................... 223 002347.03 — Front Drive Light Circuit Fault......................................................................... 224 002347.05 — Front Drive Light Circuit Fault......................................................................... 225 002347.06 — Front Drive Light Circuit Fault......................................................................... 226 002361.03 — Rear Drive Work Light Circuit Fault..................................................................... 227 002361.05 — Rear Drive Work Light Circuit Fault..................................................................... 228 002361.06 — Rear Drive Work Light Circuit Fault..................................................................... 229 004088.03 — Hydraulic Load Sense Pressure Sensor Circuit Fault...................................................... 230 004088.04 — Hydraulic Load Sense Pressure Sensor Circuit Fault...................................................... 231 004089.03 — Hydraulic System Pressure Sensor Circuit Fault.......................................................... 232 004089.04 — Hydraulic System Pressure Sensor Circuit Fault.......................................................... 233 520688.03 — Hydraulic Enable Solenoid Circuit Fault................................................................. 234 520688.05 — Hydraulic Enable Solenoid Circuit Fault................................................................. 235 520688.06 — Hydraulic Enable Solenoid Circuit Fault................................................................. 236 521996.05 — Rear Washer Motor Circuit Fault......................................................................... 237 521996.06 — Rear Washer Motor Circuit Fault......................................................................... 238 521997.05 — Left Door Wiper Circuit Fault........................................................................... 239 521997.06 — Left Door Wiper Circuit Fault........................................................................... 241 521998.05 — Right Door Wiper Circuit Fault.......................................................................... 243 521998.06 — Right Door Wiper Circuit Fault.......................................................................... 245 522312.05 — Front Washer Motor Circuit Fault........................................................................ 246 522312.06 — Front Washer Motor Circuit Fault........................................................................ 247 522433.05 — Rear Wiper Circuit Fault................................................................................ 248 522433.06 — Rear Wiper Circuit Fault................................................................................ 250 522434.05 — Front Wiper Circuit Fault............................................................................... 252 522434.06 — Front Wiper Circuit Fault............................................................................... 254 522440.05 — Blade Angle Left Solenoid Circuit Fault................................................................. 255 522440.06 — Blade Angle Left Solenoid Circuit Fault................................................................. 256 522441.05 — Blade Angle Right Solenoid Circuit Fault................................................................ 257 522441.06 — Blade Angle Right Solenoid Circuit Fault................................................................ 258 522442.03 — Blade Angle Buttons Circuit Fault....................................................................... 259 522442.04 — Blade Angle Buttons Circuit Fault....................................................................... 260 522442.07 — Blade Angle Buttons Stuck Button........................................................................ 261 Hydraulic Valve Controller (HVC) Diagnostic Trouble Codes............................................................... 263 Hydraulic Valve Controller (HVC) Diagnostic Trouble Codes........................................................... 263 000237.02 — Vehicle Identification Fault............................................................................ 263 000237.13 — Vehicle Identification Fault............................................................................ 263 000237.31 — Vehicle Identification Fault............................................................................ 264 001899.03 — Blade Lower Valve Circuit Fault......................................................................... 265 001899.04 — Blade Lower Valve Circuit Fault......................................................................... 266 001899.05 — Blade Lower Valve Circuit Fault......................................................................... 267 001899.06 — Blade Lower Valve Circuit Fault......................................................................... 268 001900.03 — Blade Raise Valve Circuit Fault......................................................................... 269 001900.04 — Blade Raise Valve Circuit Fault......................................................................... 270 001900.05 — Blade Raise Valve Circuit Fault......................................................................... 271 001900.06 — Blade Raise Valve Circuit Fault......................................................................... 272 001908.03 — Quick-Drop Solenoid Circuit Fault....................................................................... 273 001908.05 — Quick-Drop Solenoid Circuit Fault....................................................................... 274 001908.06 — Quick-Drop Solenoid Circuit Fault....................................................................... 275 001911.03 — Blade Tilt Left Valve Circuit Fault..................................................................... 276 001911.04 — Blade Tilt Left Valve Circuit Fault..................................................................... 277 001911.05 — Blade Tilt Left Valve Circuit Fault..................................................................... 278 001911.06 — Blade Tilt Left Valve Circuit Fault..................................................................... 279 001912.03 — Blade Tilt Right Valve Circuit Fault.................................................................... 280 001912.04 — Blade Tilt Right Valve Circuit Fault.................................................................... 281 001912.05 — Blade Tilt Right Valve Circuit Fault.................................................................... 282 001912.06 — Blade Tilt Right Valve Circuit Fault.................................................................... 283 001923.03 — Blade Angle Right Valve Circuit Fault................................................................... 284 001923.04 — Blade Angle Right Valve Circuit Fault................................................................... 285 001923.05 — Blade Angle Right Valve Circuit Fault................................................................... 286 001923.06 — Blade Angle Right Valve Circuit Fault................................................................... 287 001924.03 — Blade Angle Left Valve Circuit Fault.................................................................... 288 001924.04 — Blade Angle Left Valve Circuit Fault.................................................................... 289 001924.05 — Blade Angle Left Valve Circuit Fault.................................................................... 290 001924.06 — Blade Angle Left Valve Circuit Fault.................................................................... 291 001935.03 — Rear Auxiliary 1 Valve Circuit Fault.................................................................... 292 001935.04 — Rear Auxiliary 1 Valve Circuit Fault.................................................................... 293 001935.05 — Rear Auxiliary 1 Valve Circuit Fault.................................................................... 294 001935.06 — Rear Auxiliary 1 Valve Circuit Fault.................................................................... 295 001936.03 — Rear Auxiliary 1 Valve Circuit Fault.................................................................... 296 001936.04 — Rear Auxiliary 1 Valve Circuit Fault.................................................................... 297 001936.05 — Rear Auxiliary 1 Valve Circuit Fault.................................................................... 298 001936.06 — Rear Auxiliary 1 Valve Circuit Fault.................................................................... 299 001947.03 — Rear Auxiliary 2 Valve Circuit Fault.................................................................... 300 001947.04 — Rear Auxiliary 2 Valve Circuit Fault.................................................................... 301 001947.05 — Rear Auxiliary 2 Valve Circuit Fault.................................................................... 302 001947.06 — Rear Auxiliary 2 Valve Circuit Fault.................................................................... 303 001948.03 — Rear Auxiliary 2 Valve Circuit Fault.................................................................... 304 001948.04 — Rear Auxiliary 2 Valve Circuit Fault.................................................................... 305 001948.05 — Rear Auxiliary 2 Valve Circuit Fault.................................................................... 306 001948.06 — Rear Auxiliary 2 Valve Circuit Fault.................................................................... 307 001979.03 — Power Pitch Enable Solenoid Circuit Fault............................................................... 308 001979.06 — Power Pitch Enable Solenoid Circuit Fault............................................................... 309 002030.09 — Communication System Message Missing.................................................................... 310 002051.09 — Communication System Message Missing.................................................................... 310 002141.09 — Communication System Message Missing.................................................................... 311 002722.03 — Right Hand Joystick Lower Button Circuit Fault.......................................................... 312 002722.07 — Right Hand Joystick Lower Button Stuck.................................................................. 314 002723.03 — Right Hand Joystick Lower Rocker Circuit Fault.......................................................... 316 002723.04 — Right Hand Joystick Lower Rocker Circuit Fault.......................................................... 318 002723.07 — Right Hand Joystick Lower Rocker Button Stuck........................................................... 320 002724.03 — Right Hand Joystick Upper Button Circuit Fault.......................................................... 322 002724.07 — Right Hand Joystick Upper Button Stuck.................................................................. 324 002725.03 — Right Hand Joystick Upper Rocker Circuit Fault.......................................................... 326 002725.04 — Right Hand Joystick Upper Rocker Circuit Fault.......................................................... 328 002725.07 — Right Hand Joystick Upper Rocker Button Stuck........................................................... 330 002734.03 — Rear Auxiliary 1 Joystick Circuit Fault................................................................. 332 002734.04 — Rear Auxiliary 1 Joystick Circuit Fault................................................................. 333 002734.14 — Rear Auxiliary 1 Joystick Circuit Fault................................................................. 334 002735.03 — Rear Auxiliary 2 Joystick Circuit Fault................................................................. 335 002735.04 — Rear Auxiliary 2 Joystick Circuit Fault................................................................. 336 002735.14 — Rear Auxiliary 2 Joystick Circuit Fault................................................................. 337 516647.03 — Blade Pitch Position Sensor Circuit Fault............................................................... 338 516647.04 — Blade Pitch Position Sensor Circuit Fault............................................................... 339 516647.08 — Blade Pitch Position Sensor Circuit Fault............................................................... 340 516647.09 — Blade Pitch Position Sensor Circuit Fault............................................................... 341 Blade Control Joystick (BCJ) Diagnostic Trouble Codes................................................................... 343 Blade Control Joystick (BCJ) Diagnostic Trouble Codes............................................................... 343 000444.01 — Switched Power Circuit Fault............................................................................ 343 002697.02 — Control Unit Fault...................................................................................... 344 002697.03 — Right Hand Joystick X-Axis Position Circuit Fault....................................................... 344 002697.04 — Right Hand Joystick X-Axis Position Circuit Fault....................................................... 345 002697.13 — Right Hand Joystick X-Axis Calibration Error............................................................ 345 002697.14 — Right Hand Joystick X-Axis Position Circuit Fault....................................................... 346 002698.02 — Control Unit Fault...................................................................................... 346 002698.03 — Right Hand Joystick Y-Axis Position Circuit Fault....................................................... 347 002698.04 — Right Hand Joystick Y-Axis Position Circuit Fault....................................................... 347 002698.14 — Right Hand Joystick Y-Axis Position Circuit Fault....................................................... 348 003509.02 — Sensor Supply 1 Circuit Fault........................................................................... 348 003510.02 — Sensor Supply 2 Circuit Fault........................................................................... 349 522431.12 — Control Unit Failure.................................................................................... 349 522507.13 — Control Unit Failure.................................................................................... 350 523438.12 — Control Unit Failure.................................................................................... 350 523455.12 — Control Unit Failure.................................................................................... 351 524152.12 — Control Unit Failure.................................................................................... 351 524259.00 — Control Unit Failure.................................................................................... 352 523455.01 — Control Unit Failure.................................................................................... 352 523455.09 — Control Unit Failure.................................................................................... 353 523455.12 — Control Unit Failure.................................................................................... 353 523455.14 — Control Unit Failure.................................................................................... 354 Vehicle Control Unit 2 (VC2) Diagnostic Trouble Codes................................................................... 355 Vehicle Control Unit 2 (VC2) Diagnostic Trouble Codes............................................................... 355 000096.03 — Fuel Level Sensor Circuit Fault......................................................................... 355 000096.04 — Fuel Level Sensor Circuit Fault......................................................................... 356 000158.03 — Switched Power Circuit Fault............................................................................ 357 000158.04 — Switched Power Circuit Fault............................................................................ 358 000168.04 — Unswitched Power Circuit Fault.......................................................................... 359 521537.03 — Front Left Work Light Circuit Fault..................................................................... 360 521537.05 — Front Left Work Light Circuit Fault..................................................................... 361 521537.06 — Front Left Work Light Circuit Fault..................................................................... 362 521555.03 — Front Right Work Light Circuit Fault.................................................................... 363 521555.05 — Front Right Work Light Circuit Fault.................................................................... 364 521555.06 — Front Right Work Light Circuit Fault.................................................................... 365 523440.04 — Unswitched Power Circuit Fault.......................................................................... 366 523489.03 — Engine Compartment Work Light Circuit Fault............................................................. 367 523489.05 — Engine Compartment Work Light Circuit Fault............................................................. 368 523489.06 — Engine Compartment Work Light Circuit Fault............................................................. 369 Operational Checkout Procedure.............................................................................................. 371 Operational Checkout Procedure.......................................................................................... 373 Operational Checkout................................................................................................ 373 Diagnostic Trouble Code (DTC) Check............................................................................. 373 Operational Checks—Switched Power OFF, Engine OFF Checks........................................................ 373 Operational Checks—Switched Power ON, Engine OFF................................................................ 384 Operational Checks—Switched Power ON, Engine ON................................................................. 398 Engine...................................................................................................................... 431 Theory of Operation..................................................................................................... 433 John Deere Engine................................................................................................... 433 Cold Start Aid System Theory of Operation—If Equipped............................................................... 433 Fast Fill Fuel System Theory of Operation—If Equipped............................................................... 434 System Diagrams......................................................................................................... 435 Engine Cooling System Component Location............................................................................ 435 Engine Fuel System Component Location............................................................................... 439 Engine Intake and Exhaust Component Location........................................................................ 443 Diagnostic Information.................................................................................................. 447 John Deere Diesel Engine............................................................................................ 447 Fast Fill Fuel System Underfill—If Equipped......................................................................... 447 Fast Fill Fuel System Underfill Diagnostic Procedure............................................................ 447 Fast Fill Fuel System Overfill—If Equipped.......................................................................... 448 Fast Fill Fuel System Overfill Diagnostic Procedure............................................................. 448 Fast Fill Fuel System Nozzle Leaks at Receiver—If Equipped.......................................................... 448 Fast Fill Fuel System Nozzle Leaks at Receiver Diagnostic Procedure............................................. 448 Adjustments............................................................................................................. 449 John Deere Engine................................................................................................... 449 Service Filter Cleaning............................................................................................. 449 Tests................................................................................................................... 451 John Deere Engine................................................................................................... 451 Low-Pressure Fuel Pump Pressure Test................................................................................ 451 Fluid Sampling Procedure—If Equipped................................................................................ 452 Engine Idle Speeds and Auto-Shutdown Check.......................................................................... 456 Exhaust Emissions Test Point........................................................................................ 457 Electrical System........................................................................................................... 461 Theory of Operation..................................................................................................... 463 Start and Charge Circuits Theory of Operation....................................................................... 463 Park Brake Circuit Theory of Operation.............................................................................. 469 Controller Area Network (CAN) Theory of Operation................................................................... 473 Engine Control Unit (ECU) Circuit Theory of Operation............................................................... 485 Vehicle Control Unit (VCU) Circuit Theory of Operation.............................................................. 502 Transmission Control Unit (TCU) Circuit Theory of Operation......................................................... 513 Standard Display Monitor (SDM) Circuit Theory of Operation.......................................................... 531 Primary Display Unit (PDU) Circuit Theory of Operation.............................................................. 535 Integrated Grade Control (IGC) Circuit Theory of Operation—If Equipped.............................................. 539 Exhaust Aftertreatment Circuit Theory of Operation.................................................................. 544 System Diagrams......................................................................................................... 557 Electrical Diagram Information...................................................................................... 557 Electrical Schematic Symbols........................................................................................ 563 Fuse and Relay Specifications....................................................................................... 566 System Functional Schematic, Component Location, and Wiring Diagram Master Legend................................... 568 System Functional Schematic......................................................................................... 572 System Functional Schematic, Component Location, and Wiring Diagram Master Legend—Integrated Grade Control (IGC).... 576 System Functional Schematic—Integrated Grade Control (IGC).......................................................... 582 Aftertreatment Harness (W10) Component Location..................................................................... 586 Aftertreatment Harness (W10) Wiring Diagram......................................................................... 591 Engine Auxiliary Harness (W11) Component Location................................................................... 598 Engine Auxiliary Harness (W11) Wiring Diagram....................................................................... 605 Cooling Package Harness (W12) Component Location.................................................................... 612 Cooling Package Harness (W12) Wiring Diagram........................................................................ 613 Cooling Package (IGC Controls) Harness (W13) Component Location..................................................... 615 Cooling Package (IGC Controls) Harness (W13) Wiring Diagram......................................................... 617 Fan Harness (W14) Component Location................................................................................ 621 Fan Harness (W14) Wiring Diagram.................................................................................... 624 Vehicle Harness (W15) Component Location............................................................................ 627 Vehicle Harness (W15) Wiring Diagram................................................................................ 639 Vehicle (SmartGrade™ and IGC Controls) Harness (W16) Component Location............................................. 670 Vehicle (SmartGrade™ and IGC Controls) Harness (W16) Wiring Diagram................................................. 685 Control Valve (PAT, 4-Spool) Harness (W17) Component Location....................................................... 726 Control Valve (PAT, 4-Spool) Harness (W17) Wiring Diagram........................................................... 727 Control Valve (PAT, 5-Spool) Harness (W18) Wiring Diagram........................................................... 731 Control Valve (OSD) Harness (W19) Component Location................................................................ 733 Control Valve (OSD) Harness (W19) Wiring Diagram.................................................................... 735 Engine Compartment Light Switch Harness (W20) Component Location.................................................... 737 Engine Compartment Light Switch Harness (W20) Wiring Diagram........................................................ 738 Fuel Tank Harness (W21) Component Location.......................................................................... 739 Fuel Tank Harness (W21) Wiring Diagram.............................................................................. 741 Operator's Station Harness (W22) Component Location................................................................. 743 Operator's Station Harness (W22) Wiring Diagram..................................................................... 746 Operator's Station (SmartGrade™ and IGC Controls) Harness (W23) Component Location.................................. 750 Operator's Station (SmartGrade™ and IGC Controls) Harness (W23) Wiring Diagram...................................... 753 Front Dash (PDU) Harness (W24) Component Location................................................................... 761 Front Dash (PDU) Harness (W24) Wiring Diagram....................................................................... 763 Front Dash (SDM) Harness (W25) Component Location................................................................... 765 Front Dash (SDM) Harness (W25) Wiring Diagram....................................................................... 767 Left Console Harness (W26) Component Location....................................................................... 769 Left Console Harness (W26) Wiring Diagram........................................................................... 770 Cab Roof Harness (W27) Component Location........................................................................... 772 Cab Roof Harness (W27) Wiring Diagram............................................................................... 774 Canopy Roof Harness (W28) Component Location........................................................................ 778 Canopy Roof Harness (W28) Wiring Diagram............................................................................ 779 Radio Auxiliary Harness (W29) Component Location.................................................................... 781 Heater and Air Conditioner Harness (W30) Component Location......................................................... 781 Heater and Air Conditioner Harness (W30) Wiring Diagram............................................................. 782 Condenser Harness (W31) Component Location.......................................................................... 783 Condenser Harness (W31) Wiring Diagram.............................................................................. 783 Under Seat Heater Harness (W32) Component Location.................................................................. 784 Under Seat Heater Harness (W32) Wiring Diagram...................................................................... 785 Dome Light Harness (W33) Component Location......................................................................... 785 Dome Light Harness (W33) Wiring Diagram............................................................................. 786 Power Outlet Harness (W34) Component Location....................................................................... 786 Power Outlet Harness (W34) Wiring Diagram........................................................................... 787 Blade Pitch Harnesses (W35, W36, and W37) Component Location........................................................ 788 Blade Pitch Frame Harness (W35) Wiring Diagram...................................................................... 790 Blade Pitch Harness (W36) Component Location........................................................................ 791 Blade Pitch Harness (W36) Wiring Diagram............................................................................ 792 Pitch Cylinder Harness (W37) Component Location..................................................................... 793 Pitch Cylinder Harness (W37) Wiring Diagram......................................................................... 793 Engine Harness (W38) Component Location............................................................................. 795 Engine Harness (W38) Wiring Diagram................................................................................. 803 Fuel Injector Harness (W39) Component Location...................................................................... 814 Fuel Injector Harness (W39) Wiring Diagram.......................................................................... 815 Glow Plug Harnesses (W40, W41, and W42) Component Location.......................................................... 817 Glow Plug Harnesses (W40, W41, and W42) Wiring Diagrams............................................................. 819 750K Motor Speed Sensor Harnesses (W43 and W44) Component Location.................................................. 821 750K Motor Speed Sensor Harnesses (W43 and W44) Wiring Diagrams..................................................... 821 Satellite Radio Harness (W47) Component Location—If Equipped........................................................ 822 Satellite Radio Harness (W47) Wiring Diagram—If Equipped............................................................ 823 JDLink™ Harnesses (W6002 and W6003) Component Location.............................................................. 825 Modular Telematics Gateway (MTG) Harness (W6002) Wiring Diagram..................................................... 828 Satellite (SAT) Harness (W6003) Wiring Diagram...................................................................... 829 Diagnostic Information.................................................................................................. 831 Service ADVISOR™ Diagnostic Application............................................................................. 831 Service ADVISOR™ Connection Procedure............................................................................... 831 Using Service ADVISOR™ Remote....................................................................................... 833 Reading Diagnostic Trouble Codes with Service ADVISOR™ Diagnostic Application....................................... 836 Intermittent Diagnostic Trouble Code (DTC) Diagnostics.............................................................. 838 Diagnostic Trouble Codes—After Machine Repair....................................................................... 839 Electrical Component Specifications................................................................................. 840 Display Unit Operation.................................................................................................. 847 Accessing Service Mode, SDM......................................................................................... 847 Diagnostics—Clear Stored Diagnostic Trouble Codes, SDM.............................................................. 847 Operation—Exhaust Filter, SDM....................................................................................... 848 Diagnostics—Machine Information, SDM................................................................................ 849 Diagnostics—TCU Diagnostics, SDM.................................................................................... 851 Operation—Software Delivery, SDM.................................................................................... 852 Setup—Machine Setup, SDM............................................................................................ 853 Accessing Service Mode, PDU......................................................................................... 854 Diagnostics—Clear Stored Diagnostic Trouble Codes, PDU.............................................................. 854 Operation—Exhaust Filter, PDU....................................................................................... 855 Diagnostics—Machine Information, PDU................................................................................ 856 Operation—Software Delivery, PDU.................................................................................... 857 Diagnostics—Transmission Test Modes, PDU............................................................................ 858 Setup—Machine Setup, PDU............................................................................................ 859 Diagnostic Test Box..................................................................................................... 861 Setup and Functional Test........................................................................................... 861 Two Wire Sensor Circuit Check—Out of Range High..................................................................... 866 Two Wire Sensor Circuit Check—Out of Range Low...................................................................... 868 Three Wire Sensor Circuit Check—Out of Range High................................................................... 869 Three Wire Sensor Circuit Check—Out of Range Low.................................................................... 871 Topcon® Integrated Grade Control (IGC) Operation (Factory Installation)................................................. 873 Topcon® Integrated Grade Control (IGC) Circuit Schematic (Factory Installation)..................................... 873 Topcon® Integrated Grade Control (IGC) Circuit Theory of Operation (Factory Installation)........................... 876 IGC Controller/Receiver Harnesses (W45 and W46) Component Location.................................................. 878 IGC Controller/Receiver Harness 1 (W45) Wiring Diagram.............................................................. 879 IGC Controller/Receiver Harness 2 (W46) Wiring Diagram.............................................................. 880 IGC Display Unit Harness (W47) Component Location................................................................... 881 IGC Display Unit Harness (W47) Wiring Diagram....................................................................... 882 IGC Grille Harness (W48) Component Location......................................................................... 883 IGC Grille Harness (W48) Wiring Diagram............................................................................. 884 SmartGrade Operation.................................................................................................... 885 SmartGrade™ Control Unit Harness 1 and 2 (W50 and W51) Component Location........................................... 885 SmartGrade™ Control Unit Harness 1 (W50) Wiring Diagram............................................................. 885 SmartGrade™ Control Unit Harness 2 (W51) Wiring Diagram............................................................. 886 SmartGrade™ Chassis Inertial Measurement Unit (IMU) Harness (W52) Component Location................................ 886 SmartGrade™ Chassis Inertial Measurement Unit (IMU) Harness (W52) Wiring Diagram.................................... 886 SmartGrade™ Front Frame Harness (W53) Component Location............................................................ 887 SmartGrade™ Front Frame Harness (W53) Wiring Diagram................................................................ 887 SmartGrade™ Grille Harness (W54) Component Location................................................................. 887 SmartGrade™ Grille Harness (W54) Wiring Diagram..................................................................... 888 SmartGrade™ Blade Inertial Measurement Unit (IMU) Harness (W55) Component Location.................................. 888 SmartGrade™ Blade Inertial Measurement Unit (IMU) Harness (W55) Wiring Diagram...................................... 888 SmartGrade™ Display Unit Harness (W56) Component Location........................................................... 889 SmartGrade™ Display Unit Harness (W56) Wiring Diagram............................................................... 890 Adjustments............................................................................................................. 891 Transmission Control Unit (TCU) Calibration......................................................................... 891 Hydraulic Valve Controller (HVC) Calibration........................................................................ 892 Decelerator/Brake Pedal Adjustment.................................................................................. 893 Transmission Control Lever (TCL) Adjustment......................................................................... 894 Tests................................................................................................................... 897 Controller Area Network (CAN) Circuit Test.......................................................................... 897 Controller Area Network (CAN) Diagnostics ...................................................................... 907 Alternator Test..................................................................................................... 912 Wire Harness Test................................................................................................... 914 Relay Test.......................................................................................................... 915 Hydraulic System............................................................................................................ 918 Theory of Operation..................................................................................................... 919 Hydraulic System Operation.......................................................................................... 919 Hydraulic Pump Operation............................................................................................ 921 Pressure Reducing Valve Operation................................................................................... 931 Pilot Control Valve Operation....................................................................................... 933 Hydraulic Control Valve Operation................................................................................... 935 Hydraulic Control Valve Operation—IGC............................................................................... 941 Load Sense Circuit Operation........................................................................................ 949 Load Sense Circuit Operation—IGC.................................................................................... 951 Engine Overspeed Protection Valve Operation......................................................................... 952 Hydraulic System Relief Valve Operation............................................................................. 954 Circuit Relief Valve with Anticavitation Operation.................................................................. 955 Hydraulic Oil Filter Manifold Operation............................................................................. 956 Blade Angle Operation............................................................................................... 957 Power Pitch Operation—IGC........................................................................................... 962 Ripper Operation.................................................................................................... 963 Ripper Operation—IGC................................................................................................ 964 Hydraulic Cylinder Operation........................................................................................ 965 Quick-Drop Valve Operation.......................................................................................... 966 Mechanical Angle Blade Operation.................................................................................... 967 Hydraulic Reversing Fan Drive Operation............................................................................. 970 System Diagrams......................................................................................................... 973 Hydraulic System Schematic.......................................................................................... 973 Hydraulic System Schematic—IGC......................................................................................1001 Hydraulic System Line Identification................................................................................1033 Hydraulic System Line Identification—IGC............................................................................1041 Main Hydraulic Component Location...................................................................................1049 Main Hydraulic Component Location—IGC...............................................................................1057 Ripper Hydraulic Component Location.................................................................................1065 Ripper Hydraulic Component Location—IGC.............................................................................1069 Winch Ready Hydraulic Component Location............................................................................1076 Winch Ready Hydraulic Component Location—IGC........................................................................1077 Diagnostic Information..................................................................................................1079 Hydraulic System Diagnose Malfunctions..............................................................................1079 No Hydraulic Functions Diagnostic Procedure.....................................................................1079 One Hydraulic Function Does Not Work Diagnostic Procedure.......................................................1080 Slow Hydraulic Functions Diagnostic Procedure...................................................................1081 Low Hydraulic Power Diagnostic Procedure........................................................................1083 Function Drifts Down Diagnostic Procedure.......................................................................1084 Hydraulic Oil Overheating Diagnostic Procedure..................................................................1085 Hydraulic Pump/System Noise Diagnostic Procedure................................................................1087 Blade Float Does Not Work Diagnostic Procedure..................................................................1088 Hydraulic System Diagnose Malfunctions—IGC..........................................................................1088 No Hydraulic Functions Diagnostic Procedure.....................................................................1088 One Hydraulic Function Does Not Work Diagnostic Procedure.......................................................1090 Slow Hydraulic Functions Diagnostic Procedure...................................................................1091 Low Hydraulic Power Diagnostic Procedure........................................................................1093 Function Drifts Down Diagnostic Procedure.......................................................................1094 Hydraulic Oil Overheating Diagnostic Procedure..................................................................1095 Hydraulic Pump/System Noise Diagnostic Procedure................................................................1097 Blade Float Does Not Work Diagnostic Procedure..................................................................1098 Blade Response Not Smooth Diagnostic Procedure..................................................................1099 Hydraulic Fan Does Not Reach Full Speed.............................................................................1100 Hydraulic Fan Does Not Reach Full Speed Diagnostic Procedure....................................................1100 Hydraulic Fan Runs at Full Speed Only...............................................................................1101 Hydraulic Fan Runs at Full Speed Only Diagnostic Procedure......................................................1101 Hydraulic Fan Does Not Spin.........................................................................................1101 Hydraulic Fan Does Not Spin Diagnostic Procedure................................................................1102 Hydraulic Fan Will Not Reverse Direction............................................................................1102 Hydraulic Fan Will Not Reverse Direction Diagnostic Procedure...................................................1102 Tests...................................................................................................................1105 JT02156A Digital Pressure and Temperature Analyzer Kit Installation.................................................1105 Ultra Clean® Hand Launcher..........................................................................................1105 Hydraulic Oil Cleanup Procedure.....................................................................................1105 Hydraulic Accumulator Discharge Procedure...........................................................................1106 Hydraulic Accumulator Precharge Test................................................................................1108 Pump Load Sense Differential and System Pressure (Load Sense Relief) Test and Adjustment............................1110 Pump Load Sense Differential and System Pressure (Load Sense Relief) Test and Adjustment—IGC........................1113 Pump Cut-Off Pressure Test and Adjustment...........................................................................1116 Pump Cut-Off Pressure Test and Adjustment—IGC.......................................................................1120 Hydraulic System Relief Valve Test..................................................................................1124 Hydraulic System Relief Valve Test—IGC..............................................................................1127 Circuit Relief Valve Test...........................................................................................1129 Cylinder Function Drift Test........................................................................................1132 Cylinder Leakage Test...............................................................................................1134 Pressure Reducing Valve Pressure Test and Adjustment................................................................1136 Hydraulic Pump Flow Test............................................................................................1138 Hydraulic Pump Case Drain Test......................................................................................1140 Fan Pump Flow Test..................................................................................................1141 Fan Motor Speed Test................................................................................................1142 Fan Motor Case Drain Test...........................................................................................1143 Hydrostatic System..........................................................................................................1146 Theory of Operation.....................................................................................................1147 Hydrostatic System Operation........................................................................................1147 Transmission Control Circuit Operation (Flow Chart).................................................................1148 Hydrostatic Pump Operation..........................................................................................1150 Pump Pressure Control Pilot (PCP) Operation.........................................................................1151 Pump Displacement Control Valve (PDCV) Operation....................................................................1153 Multi-Function Valve Operation......................................................................................1154 Charge Pump Operation...............................................................................................1156 Hydraulic Integrated Circuit (HIC) Valve Operation..................................................................1157 Neutral Charge Relief Valve Operation...............................................................................1159 Hydrostatic Charge Oil Filter Operation.............................................................................1160 Park Brake Valve Operation..........................................................................................1161 Oil Cooler and Reservoir Bypass Operation...........................................................................1163 Hydrostatic Motor Operation.........................................................................................1164 Flushing Valve and Operating Charge Relief Valve Operation..........................................................1171 Hydrostatic Cold Start Valve Operation..............................................................................1172 System Diagrams.........................................................................................................1173 Hydrostatic System Schematic—Neutral (Park Brake On)................................................................1173 Hydrostatic System Component Location...............................................................................1189 Hydrostatic System Line Identification..............................................................................1197 Park Brake System Component Location................................................................................1204 Hydrostatic System Diagram—Neutral (Park Brake On)..................................................................1207 Hydrostatic System Diagram—Reverse (Slow Speed).....................................................................1215 Hydrostatic System Diagram—Forward (Fast Speed).....................................................................1223 Diagnostic Information..................................................................................................1231 Overheating Malfunctions............................................................................................1231 Overheating Diagnostic Procedure................................................................................1231 Low Charge Pressure Malfunctions....................................................................................1233 Low Charge Pressure Diagnostic Procedure........................................................................1233 Mistrack/Index Malfunctions.........................................................................................1236 Mistrack or Index Diagnostic Procedure..........................................................................1236 Machine Full Speed Malfunctions.....................................................................................1238 Machine Will Not Reach Full Speed Diagnostic Procedure..........................................................1238 Low Power Malfunctions..............................................................................................1240 Low Power Diagnostic Procedure..................................................................................1240 Track Malfunctions..................................................................................................1242 Engine Starts But One or Both Tracks Will Not Move Diagnostic Procedure.........................................1242 TCU Calibration Malfunctions........................................................................................1244 TCU Calibration Malfunctions Diagnostic Procedure...............................................................1244 Tests...................................................................................................................1251 Ultra Clean® Hand Launcher..........................................................................................1251 Machine Supporting Procedure........................................................................................1252 Transmission Oil Warm-Up Procedure..................................................................................1254 Releasing Park Brake to Tow the Machine.............................................................................1255 Hydrostatic Pump and Motor Initial Start-Up Procedure...............................................................1257 Hydrostatic Pump Flushing Procedure.................................................................................1259 Hydraulic Oil Cleanup Procedure.....................................................................................1259 Pressure Control Pilot (PCP) Manual Override Test...................................................................1260 Pressure Control Pilot (PCP) Test...................................................................................1261 Pressure Control Pilot (PCP) Internal Adjustment....................................................................1263 Multi-Function Relief Valve Test....................................................................................1265 Transmission Efficiency Test........................................................................................1268 Neutral Charge Relief and Operating Charge Relief Pressure Test.....................................................1271 Pump Displacement Control Valve (PDCV) Neutral (Null) Adjustment....................................................1273 Pump Servo Pressure Test............................................................................................1275 Motor Shift Solenoid Valve Adjustment...............................................................................1277 Hydrostatic Motor Min./Max. Angle Servo Piston Pressure Test........................................................1279 Charge Pump Flow Test...............................................................................................1281 Charge Pressure Sensor Test.........................................................................................1283 Hydrostatic Cold Start Valve Test...................................................................................1284 Hydrostatic Oil Cooler Bypass Test..................................................................................1286 Hydrostatic Oil Reservoir Bypass Test...............................................................................1288 Park Brake Test.....................................................................................................1290 Park Brake Relief Valve Test........................................................................................1292 Ball Shuttle Valve Test.............................................................................................1293 Cab Tilt Relief Valve Test..........................................................................................1294 Hand Pump Bleed Procedure...........................................................................................1294 Heating and Air Conditioning................................................................................................1295 Theory of Operation.....................................................................................................1297 Air Conditioning System Cycle of Operation..........................................................................1297 System Diagrams.........................................................................................................1299 Heating and Air Conditioning System Component Location..............................................................1299 Under Seat Heater System Component Location.........................................................................1302 Diagnostic Information..................................................................................................1303 Air Conditioning System Does Not Operate............................................................................1303 Air Conditioning System Does Not Operate Diagnostic Procedure...................................................1303 Air Conditioning System Does Not Cool Interior of Cab...............................................................1306 Air Conditioning System Does Not Cool Interior of Cab Diagnostic Procedure......................................1306 Air Conditioning System Runs Constantly, Too Cold...................................................................1308 Air Conditioning System Runs Constantly, Too Cold Diagnostic Procedure..........................................1308 Heating System Does Not Operate.....................................................................................1310 Heating System Does Not Operate Diagnostic Procedure............................................................1310 Heating System Does Not Warm Interior of Cab........................................................................1312 Heating System Does Not Warm Interior of Cab Diagnostic Procedure...............................................1312 Interior Windows Continue to Fog....................................................................................1313 Interior Windows Continue to Fog Diagnostic Procedure...........................................................1313 Tests...................................................................................................................1315 R134a Refrigerant Cautions and Proper Handling......................................................................1315 R134a Oil Charge Capacity...........................................................................................1315 R134a Refrigerant Charge Capacity...................................................................................1316 Heater and Air Conditioner Operational Checks.......................................................................1316 Visual Inspection of Components.................................................................................1316 Air Conditioner Compressor Clutch Test..............................................................................1317 R134a Refrigerant Leak Test.........................................................................................1318 R134a Refrigerant Hoses and Tubing Inspection.......................................................................1318 Air Conditioner High/Low-Pressure Switch Test.......................................................................1319 Air Conditioner Freeze Control Switch Test..........................................................................1320 Air Conditioning System Test........................................................................................1321 Operating Pressure Diagnostic Chart.................................................................................1323 Reference Material..........................................................................................................1325 Tool Information........................................................................................................1327 Support Kit Spacer Bar Installation.................................................................................1327 Dealer Fabricated Tools.....................................................................................................1329 Dealer Fabricated Tools.................................................................................................1331 DFT1369 Pump Control Pilot (PCP) Test Harness.......................................................................1331 DFT1379 Pump Control Pilot (PCP) Test Harness.......................................................................1332 Page Number..................................................................................................................... 3 Section 9000................................................................................................................ 5 Group 01................................................................................................................ 7 Section 9001................................................................................................................ 32 Group 10................................................................................................................ 33 Group 20................................................................................................................ 57 Group 30................................................................................................................ 61 Group 40................................................................................................................ 91 Group 50................................................................................................................ 215 Group 60................................................................................................................ 263 Group 70................................................................................................................ 343 Group 80................................................................................................................ 355 Section 9005................................................................................................................ 371 Group 10................................................................................................................ 373 Section 9010................................................................................................................ 431 Group 05................................................................................................................ 433 Group 10................................................................................................................ 435 Group 15................................................................................................................ 447 Group 20................................................................................................................ 449 Group 25................................................................................................................ 451 Section 9015................................................................................................................ 461 Group 05................................................................................................................ 463 Group 10................................................................................................................ 557 Group 15................................................................................................................ 831 Group 16................................................................................................................ 847 Group 17................................................................................................................ 861 Group 18................................................................................................................ 873 Group 19................................................................................................................ 885 Group 20................................................................................................................ 891 Group 25................................................................................................................ 897 Section 9025................................................................................................................ 918 Group 05................................................................................................................ 919 Group 10................................................................................................................ 973 Group 15................................................................................................................1079 Group 25................................................................................................................1105 Section 9026................................................................................................................1146 Group 05................................................................................................................1147 Group 10................................................................................................................1173 Group 15................................................................................................................1231 Group 25................................................................................................................1251 Section 9031................................................................................................................1295 Group 05................................................................................................................1297 Group 10................................................................................................................1299 Group 15................................................................................................................1303 Group 25................................................................................................................1315 Section 9050................................................................................................................1325 Group 10................................................................................................................1327 Section 9900................................................................................................................1329 Group 99................................................................................................................1331
S.S 22/02/2025
