John Deere Tractors 5076E, 5076EL, 5082E, 5090E, 5090EL, 5090EH Diagnostic and Repair Service Manual (TM607519)
Catalog:
Model:
Complete All Inclusive Technical Manual with electrical wiring diagrams for John Deere Tractors 5076E, 5076EL, 5082E, 5090E, 5090EL, 5090EH (2WD / MFWD - PIN prefix P0) (April 2013), with all the shop information to maintain, diagnose, repair, and rebuild like professional mechanics (Diagnosis, Operation, Tests, Repair, Service, Troubleshooting).
John Deere Tractors 5090EL, 5090EH, 5090E, 5082E, 5076EL, 5076E workshop technical service manual includes:
* Numbered table of contents easy to use so that you can find the information you need fast.
* Detailed sub-steps expand on repair procedure information
* Numbered instructions guide you through every repair procedure step by step.
* Troubleshooting and electrical service procedures are combined with detailed wiring diagrams for ease of use.
* Notes, cautions and warnings throughout each chapter pinpoint critical information.
* Bold figure number help you quickly match illustrations with instructions.
* Detailed illustrations, drawings and photos guide you through every procedure.
* Enlarged inset helps you identify and examine parts in detail.
TM607519 English - John Deere 5076E, 5076EL, 5082E, 5090E, 5090EL and 5090EH Tractors, Diagnostics Technical Manual (March 2015) Technical Manual.pdf
tm607528 French - Manuel technique diagnostics pour tracteurs 5076E, 5076EL, 5082E, 5090E, 5090EL et 5090EH (mars 2015)
tm607554 Portuguese - Tratores 5076E, 5076EL, 5082E, 5090E, 5090EL e 5090EH, Manual Técnico de Diagnósticos (Março de 2015)
tm607559 Russian - Тракторы 5076E, 5076EL, 5082E, 5090E, 5090EL и 5090EH, Техническое
PRODUCT DETAILS:
Total Pages: 1,369 pages
File Format: PDF (PC/Mac/Android/Kindle/iPhone/iPad; bookmarked, ToC, Searchable, Printable)
Category: Diagnosis and Tests
MAIN SECTIONS
Foreword
General
Safety
General Specifications
General References
DIAGNOSTIC TROUBLE CODES
CCU Code Diagnostics
ICC Code Diagnostics
PTR Code Diagnostics
OBSERVABLE SYMPTOMS
Engines
Fuel and Air
Electrical
Control Units
Synchronized Transmissions
PowrReverser Transmissions
Drive Systems
Steering and Brakes
Hydraulics
Operator Cab
SYSTEM DIAGNOSIS
Starting, Charging and Start Aid
Synchronized Transmission
PowrReverser Transmission (If Equipped)
Differential Lock
MFWD
Rear PTO
Steering
Rear Brakes
SCV System Diagnosis
Rear Hitch System Diagnosis
ENGINES
General Information
Tests and Adjustments
Engine System Theory of Operation
FUEL, AIR, EXHAUST AND COOLING
General Information
Fuel, Air, Exhaust and Cooling Theory of Operation
ELECTRICAL
Diagnosis, Test and Adjust
Wiring Schematics
Wiring Harnesses
CONTROL UNITS
General References
Tests and Adjustments
CCU
ICC
PTR
SYNCHRONIZED TRANSMISSION
Tests and Adjustments
Theory of Operation
Schematics and Diagrams
PowrReverser™ TRANSMISSION
General Information
Preliminary and Operational Checks
Tests and Adjustments
Theory of Operation
Schematics and Diagrams
DRIVE SYSTEMS
Preliminary and Operational Checks
Tests and Adjustments
Theory of Operation
Schematics and Diagrams
STEERING AND BRAKES
General Information
Preliminary and Operational Checks
Test and Adjustments
Theory of Operation
HYDRAULICS
General Information
Preliminary and Operational Checks
Tests and Adjustments
Theory of Operation
Schematics and Diagrams
Operator's Cab
Operational Tests
Tests and Adjustments
Theory of Operation
SERVICE TOOLS
Dealer Fabricated Tools
Service Tools and Kits
TABLE OF CONTENTS
Section 210: General................28
Group 05: Safety................28
Recognize Safety Information................32
Understand Signal Words................33
Follow Safety Instructions................34
Prepare for Emergencies................35
Wear Protective Clothing................36
Protect Against Noise................37
Handle Fuel Safely—Avoid Fires................38
Handle Starting Fluid Safely................39
Keep ROPS Installed Properly................40
Use Foldable ROPS and Seat Belt Properly................41
Stay Clear of Rotating Drivelines................42
Use Steps and Handholds Correctly................44
Read Operator Manuals for ISOBUS Implements................45
Use Seat Belt Properly................46
Operating the Tractor Safely................47
Limited Use in Forestry Operation................49
Operating the Loader Tractor Safely................50
Keep Riders Off Machine................51
Instructional Seat................52
Use Safety Lights and Devices................53
Use a Safety Chain................54
Transport Towed Equipment at Safe Speeds................55
Use Caution On Slopes and Uneven Terrain................57
Freeing a Mired Machine................58
Avoid Contact with Agricultural Chemicals................59
Handle Agricultural Chemicals Safely................60
Handling Batteries Safely................62
Avoid Heating Near Pressurized Fluid Lines................64
Remove Paint Before Welding or Heating................65
Handle Electronic Components and Brackets Safely................66
Practice Safe Maintenance................67
Exhaust Filter Cleaning................68
Work In Ventilated Area................69
Support Machine Properly................70
Prevent Machine Runaway................71
Park Machine Safely................72
Transport Tractor Safely................73
Service Cooling System Safely................74
Service Accumulator Systems Safely................75
Service Tires Safely................76
Service Front-Wheel Drive Tractor Safely................77
Tightening Wheel Retaining Bolts/Nuts................78
Avoid High-Pressure Fluids................79
Do Not Open High-Pressure Fuel System................80
Store Attachments Safely................81
Dispose of Waste Properly................82
Group 10: General Specifications................1286
General Specifications................1286
Group 15: General References................29
Bolt and Cap Screw Torque Values................87
Glossary of Terms................89
JIC Hydraulic Symbols................93
Wiring Diagram and Schematic Information................416
Electrical Schematic Symbols................96
Reading Wiring Schematics and Diagrams................99
Visually Inspect Electrical System................103
Seven-Step Electrical Procedure................104
Using a Probe Light................107
Circuit Types................109
Circuit Malfunctions................111
Troubleshooting Circuit Malfunctions................114
Understanding Electrical vs. Electronic Circuits................119
Intermittent Electronic Problems................122
Relay Circuit Types................126
Using a Digital Multimeter................139
Troubleshooting Unresolved Problems................141
Section 211: DIAGNOSTIC TROUBLE CODES................142
Group CCU: CCU Code Diagnostics................142
CCU - Non-Tractor CCU Codes................142
CCU 000096.03 - Fuel Level Sensor Circuit Voltage High................142
CCU 000096.04 - Fuel Level Sensor Circuit Voltage Low................142
CCU 000237.02 - VIN Security Data Conflict................142
CCU 000237.31 - VIN Security Messages Missing................142
CCU 000569.05 - Rear Differential Lock Solenoid Circuit Fault................142
CCU 000628.02 - CCU EOL Data Fault................142
CCU 000630.14 - Rear PTO Configuration Invalid................142
CCU 001638.00 - Hydraulic Oil Temperature Very Hot................142
CCU 001638.03 - Hydraulic Oil Temperature Sensor Circuit Voltage High................142
CCU 001638.04 - Hydraulic Oil Temperature Sensor Circuit Voltage Low................142
CCU 001638.16 - Hydraulic Oil Temperature High................142
CCU 001883.00 - Rear PTO Overspeed................142
CCU 001883.01 - Rear PTO Underspeed................142
CCU 002818.31 - Operator Presence Switch Not Activated................142
CCU 003509.03 - Sensor Supply Voltage Out of Range High................142
CCU 003509.04 - Sensor Supply Voltage Out of Range Low................142
CCU 523316.04 - CCU Switched Supply Voltage Low................142
CCU 523839.02 - Secondary Brake Switch Conflict................142
CCU 523844.12 - Differential Lock Braking Disabled................142
CCU 523907.02 - PTO Remote Enable Switch Conflict................142
CCU 523908.02 - Rear PTO External Switch Conflict................142
CCU 524037.02 - MFWD Switch Circuit Fault................142
CCU 524223.03 - Differential Lock Circuit Voltage High................142
CCU 524224.14 - PTO Switch Voltage Mismatch................142
CCU 524235.05 - MFWD Solenoid Circuit Fault................142
CCU 524252.05 - Rear PTO Solenoid Circuit Fault................142
CCU 524255.31 - Rear Remote PTO Enabled................142
CCU 600006.31 - Default DTC................142
Group ICC: ICC Code Diagnostics................142
ICC - Non-Tractor ICC Codes................142
ICC 000237.02 - ICC VIN Security Mismatch................143
ICC 000237.31 - ICC VIN Security Missing................143
ICC 000628.12 - ICC Programming Fault................143
ICC 000630.02 - ICC Calibration Memory Fault................143
ICC 002818.31 - Operator Presence Switch Not Activated................143
Group PTR: PTR Code Diagnostics................143
PTR 000084.07 - Excessive Wheel Speed Detected During Calibration................143
PTR 000158.01 - System Switched Voltage Low................143
PTR 000162.02 - High/Low Switch Circuit Conflict................143
PTR 000162.31 - High, Low Switch Stuck On................143
PTR 000190.18 - Engine Speed Missing During Shift................143
PTR 000191.00 - Excessive Top Shaft Speed During Calibration................143
PTR 000191.17 - Top Shaft Speed Too Low................143
PTR 000598.02 - Clutch Switch Open With Pedal Up................143
PTR 000598.04 - Clutch Switch Signal Failed Low................143
PTR 000628.02 - EOL Check Sum Error................143
PTR 000630.14 - Tractor Model Out Of Range/Transmission Calibration Value High................143
PTR 000752.03 - Power Shuttle Potentiometer Input Voltage High................143
PTR 000752.04 - Power Shuttle Potentiometer Input Voltage Low................143
PTR 001504.10 - Seat Switch Closed Too Long................143
PTR 002820.31 - Operator Not Present During Shift................143
PTR 002825.07 - Not Valid Neutral Park Command................143
PTR 003509.03 - PTR Sensor Supply Voltage High................143
PTR 003509.04 - PTR Sensor Supply Voltage Low................143
PTR 521233.05 - High Valve Driver Fault................143
PTR 521234.05 - Low Valve Driver Fault................143
PTR 521235.05 - Reverse Valve Driver Fault................143
PTR 522456.07 - Speed Control Lever Park and Neutral Switch Conflict................143
PTR 522456.31 - Speed Control Lever Transition Without Using Clutch Pedal................143
PTR 523953.02 - Speed Control Lever Sensor Circuit Conflict................143
PTR 523959.31 - No Wheel Speed While in Gear................143
PTR 523966.31 - Come Home Detected................143
PTR 524020.31 - Reverser in Gear at Power-Up................143
PTR 524021.31 - Directional Reverser Lever Switch Circuit Fault................144
PTR 524160.02 - Not Valid Neutral/Not Neutral Switch................144
PTR 524173.02 - Clutch Pedal Compare Error................144
PTR 524173.14 - Sync Lever Shift Without Clutch Pedal Engaged................144
PTR 524173.15 - Clutch Pedal Voltage High................144
PTR 524173.16 - Both Clutch Pedals Voltage High................144
PTR 524173.17 - Clutch Pedal Voltage Low................144
PTR 524173.18 - Both Clutch Pedals Voltage Low................144
PTR 524230.05 - Enable Valve Driver Fault................144
PTR 524230.07 - Enable Valve Stuck................144
PTR 524234.03 - Pressure Sensor Voltage High................144
PTR 524234.04 - Pressure Sensor Voltage Low................144
PTR 524254.03 - Transmission Enable Valve Power High................144
PTR 524254.04 - Transmission Enable Valve Power Low................144
PTR 524267.15 - High Speed Shuttle Shift................144
Section 212: OBSERVABLE SYMPTOMS................260
Group 20: Engines................260
Engine Problems................260
Group 30: Fuel and Air................260
Fuel, Air, Exhaust and Cooling Problems................260
Group 40: Electrical................260
Electrical Problems................260
Group 45: Control Units................260
Electronic Problems................260
Group 51: Synchronized Transmissions................260
Synchronized Transmission Problems................260
Group 55: PowrReverser Transmissions................260
PowrReverser POWRREVERSER is a trademark of Deere & Company Transmission Problems................260
Group 56: Drive Systems................260
Drive System Problems................260
Group 60: Steering and Brakes................260
Steering and Brake System Problems................260
Group 70: Hydraulics................260
Hitch Problems................260
Selective Control Valve Problems................260
Group 90: Operator Cab................260
Air Conditioning Problems................260
Section 213: SYSTEM DIAGNOSIS................286
Group 40: Starting, Charging and Start Aid................286
Starting, Charging and Start Aid System Diagnosis................290
Group 51: Synchronized Transmission................286
Synchronized Transmission Diagnosis................294
Group 55: PowrReverser Transmission (If Equipped)................286
System Diagnosis - Transmission................296
Group 56A: Differential Lock................286
Differential Lock System Diagnosis................299
Group 56B: MFWD................286
System Diagnosis - Mechanical Front Wheel Drive (MFWD)................302
MFWD System Diagnosis................303
Group 56C: Rear PTO................286
System Diagnosis - Power Take Off (PTO)................306
Rear Mechanical PTO System Diagnosis................307
Group 60A: Steering................286
Steering System Diagnosis................312
Group 60B: Rear Brakes................286
Rear Brake System Diagnosis................318
Group 70A: SCV System Diagnosis................286
Single and Dual Rear SCV System Diagnosis................324
Dual Mid-Mount SCV System Diagnosis................327
Group 70C: Rear Hitch System Diagnosis................286
Rear Mechanical Hitch System Diagnosis................335
Section 220: ENGINES................340
Group 05: General Information................340
John Deere Engine Repair—Use Component Technical Manual................342
General Engine Specifications................1286
List of All Tractor-Specific Engine Information................344
Group 15: Tests and Adjustments................340
Throttle Lever Adjustment - OOS................346
Group 20: Engine System Theory of Operation................340
Overview of 5076E, 5076EL, 5082E, 5090E, 5090EL and 5090EH Tractor Engines................348
Section 230: FUEL, AIR, EXHAUST AND COOLING................349
Group 05: General Information................349
John Deere Engine Fuel Systems Repair—Use Component Technical Manual................351
Group 20: Fuel, Air, Exhaust and Cooling Theory of Operation................349
Fuel System Operation—OOS Tractors................354
Fuel System Operation— Cab Tractors................356
Air Intake System Operation—Without Turbocharger................358
Air Intake System Operation—With Turbocharger................360
Cooling System Theory of Operation................362
Exhaust System Theory of Operation................363
Section 240: ELECTRICAL................364
Group 15: Diagnosis, Test and Adjust................364
Wire Color Chart................369
Battery Voltage and Specific Gravity Tests................371
Charge Battery................373
Battery Load Test................375
Starter Amp Draw/RPM Test................377
Starter No-Load Amp Draw/RPM Test................379
Alternator/Regulator Test................381
Starter Solenoid Test................383
Starter Relay Test................384
Key Switch Test................386
Plug-In Relay Test................388
Diode Pack Test................390
Fuse Test................392
Neutral Start Switch Test................393
PTO Switch Test................394
PTO Seat Switch Test................396
Light Switch Test................398
Flasher Module Test—Cab Tractors................400
Turn Signal Switch Test— OOS Tractors................401
Fuel Shut-Off Solenoid Test................403
Blower Switch Test................404
Start Resistor Test................406
Blower Motor Resistors................407
A/C Temperature Control Switch Test................408
Front Wiper/Washer Switch Test................409
Door Switch Test................411
Dome Light Switch Test................412
Group 20: Wiring Schematics................364
Functional Schematics Listing................415
Schematic Information................416
Component Identification Table................417
SE1- Starting Motor, Charging Circuit, Starting Aid And Fuel Preheater, SE2A- Neutral Start Mech Engines PR And Mech Transmission, SE2B- EH PTO, Neutral Start, Fuel (12/12 PR)................419
SE3- Accessory Power, SE4- Horn................420
SE5A- 4 Position Light Switch, SE5B- 5 Position Light Switch, SE6- Headlamps................421
SE7A- Turn Signal Switch And Hazard Warning Lights/ SAE, SE7B- Turn Signal Switch And Hazard Warning Lights/ EEC................422
SE8- Tail/ Brake/ Clearance/ License Plate/ Warning/ Turn Lights................423
SE9A- Cab Work Light and Beacon Light Switch, SE9B- OOS Work Lighting................424
SE10 - Power Source, SE11A - SAE Trailer Interfaces, SE11B - EEC Trailer Interfaces................425
SE12 - Power Outlet And Lighter, SE13 - Heater, SE14 - Air Conditioning................426
SE15 - Windshield Wiper, SE16 - Dome Light/ Door Switch/ Radio................427
SE17A - Instrument Cluster (TSS)................428
SE17B - Instrument Cluster (PR)................429
SE18 - Seat Switch, Backup Alarm And Wheel Speed Sensor, SE19 - ELX Relay And Fuses(PR Only), SE20 - EH MFWD (PR Only), SE21 - Brake Switch................430
SE22 - EH Transmission................431
SE23 - CAN Terminators, SE24 - AMS................432
Group 25: Wiring Harnesses................365
Wiring Harnesses Schematic Listing................434
Positive Battery Cable (Cab and OOS)................435
Negative Battery Cable (Cab and OOS)................436
Power Cable (Cab and OOS)................437
Hood Harness (Headlights)................438
OOS Lights Harness (Clearance, Warning and License Plate Lights)................439
Cab Roof Harness................441
PR Front Console Cab Harness................444
PR Transmission Harness................447
Cab Harness (PR)................449
Cab Harness (TSS)................452
TSS Front Console Cab Harness................454
EEC Light Relay Harness................457
SAE Light Relay Harness................459
OOS Harness (PR)................461
OOS Harness (TSS)................466
Universal Auto Track Console Harness (Cab)................470
Cab Roof To Starfire Receiver Harness................472
Global Positioning System (GPS) Harness................473
7-Pin Trailer Harness (EEC)................366
7-Pin Trailer Harness (SAE)................366
Beacon Light Harness (OOS)................477
Beacon Light Harness (Cab)................478
Engine Harness (Stage 3A)................479
Engine Harness................481
Section 245: CONTROL UNITS................483
Group 05: General References................483
Electro-Hydraulic Controller General Information................493
Access Control Unit Addresses................518
Recall, Record, and Clear Codes................501
Performance Monitor General Operation................506
Address 200-251 — General Control Unit Data................510
Diagnostic Trouble Code Listing................512
CCU Code List................513
ICC Code List................515
PTR Code List................516
Control Unit Addresses................518
CCU Address List................519
ICC Address List................522
PTR Address List................524
Programming Control Units................527
CAN Network Voltage Checks................534
CAN Communication System Theory of Operation................537
CAN System Diagnosis................483
VIN Security Fault Diagnosis................542
Group 15: Tests and Adjustments................483
Electro-Hydraulic Controller Switched Supply Voltage and Ground Test................545
Electro-Hydraulic Controller Unswitched Supply Voltage and Ground Test................547
A/C Compressor Clutch Coil Test Points................549
Blower Motor Test Points................551
Group CCU: CCU................483
Chassis Control Unit (CCU) Configuration................562
Chassis Control Unit (CCU) Configuration and Calibration................568
CCU 000 — Initial Address................569
CCU 001 — Recall Diagnostic Codes................570
CCU 002 — System Beep Address With Speed Sensors................571
CCU 003 — System Beep Address Without Speed Sensors................574
CCU 004 — Switched Supply Voltage................576
CCU 005 — Rear PTO Speed Signal Status................577
CCU 006 — Primary Wheel Speed Signal Status................578
CCU 007 — Rear PTO Switch Status................579
CCU 008 — Engine Speed Signal Status................580
CCU 010 — Hydraulic Oil Temperature Sensor Voltage................581
CCU 012 — Rear PTO Remote Enable/Remote Fender Switch Status................582
CCU 013 — Primary Fuel Level Sensor Voltage................583
CCU 015 — Sensor Reference Voltage Status................584
CCU 024 — Secondary Hand Brake/Brake Pedal Switch Status................585
CCU 025 — MFWD Switch Status................586
CCU 050 — CCU Unswitched Supply Voltage................587
CCU 051 — Sensor Reference Voltage................588
CCU 052 — Hydraulic Oil Temperature................589
CCU 054 — Fuel Level Sensor Voltage................590
CCU 055 — Primary Wheel Speed................591
CCU 058 — Rear PTO Speed................592
CCU 059 — Engine Speed................593
CCU 060 — Front PTO Speed................594
CCU 063 — Differential Drive Shaft Speed................595
CCU 064 — Engine Oil Pressure Switch Status................596
CCU 065 — Engine Coolant Temperature................597
CCU 066 — Engine Coolant Temperature Sensor Voltage................598
CCU 103 — MFWD Configuration................599
CCU 104 — Rear PTO Configuration 1................600
CCU 105 — Rear PTO Configuration 2................601
CCU 106 — Rear PTO Speed Configuration................602
CCU 107 — Rear PTO Pulses Per Revolution................603
CCU 108 — Front PTO Pulses per Revolution................604
CCU 109 — Front PTO Installed................605
CCU 111 — Rear Tire Rolling Circumference................606
CCU 115 — Differential Lock Configuration................608
CCU 116 — Differential Lock Switch................609
CCU 117 — Differential Lock Disengage Wheel Speed Configuration................610
CCU 120 — Rear PTO Valve Current................611
CCU 129 — Enable Debug Messages Configuration................612
CCU 130 — Secondary Handbrake Configuration................613
CCU 134 — Engine Hours Display/Input................614
CCU 135 — Engine Function Configuration................615
CCU 136 — Engine Elevated Idle Speed................616
CCU 137 — Engine Low Idle Speed................617
CCU 138 — Engine Fast Idle Speed................618
CCU 139 — Rated Engine Speed................619
CCU 140 — Max Reasonable Engine Speed................620
CCU 180 — Not Used................621
CCU 200-251 — General Control Unit Data................622
CCU—Beep Mode Test With Speed Sensors................623
CCU—Beep Mode Test Without Speed Sensors................626
CCU—Fuel Level Sensor Circuit Test (PR Transmission)................627
CCU—Differential Lock Solenoid Circuit Test (PR Transmission)................629
CCU—Hydraulic Oil Temperature Sensor Circuit Test................631
CCU—Seat Switch Circuit Test................848
CCU—Sensor Excitation Circuit Test (PR Transmission)................638
CCU—Secondary Brake Switch Circuit Test (PR Transmission)................641
CCU—Differential Lock Switch Circuit Test (PR Transmission)................643
CCU—Remote PTO Enable Switch Circuit Test (PR Transmission)................646
MFWD Switch Circuit Test................648
MFWD Solenoid Circuit Test................653
Brake Switch Assembly Circuit Test................656
Rear EH PTO Switch Circuit Test................661
Rear EH PTO Solenoid Circuit Test................666
Rear EH PTO Speed Sensor Circuit Test................669
CCU Controller Theory of Operation................673
Hydraulic Oil Temperature Sensor Theory of Operation................677
Engine Speed Sensor Theory of Operation................678
Wheel Speed Sensor Theory of Operation................679
EH MFWD Switch Theory of Operation................680
MFWD Solenoid Theory of Operation................681
Brake Switch Assembly Theory of Operation................682
Rear EH PTO Solenoid Theory of Operation................683
Rear EH PTO Speed Sensor Theory of Operation................684
Hydraulic Oil Temperature Sensor Diagnostic Wiring Diagram................685
Engine Speed Sensor Diagnostic Wiring Diagram (OOS)................686
Engine Speed Sensor Diagnostic Wiring Diagram (Cab)................687
Wheel Speed Sensor Diagnostic Wiring Diagram (OOS)................688
Wheel Speed Sensor Diagnostic Wiring Diagram (Cab)................689
MFWD Diagnostic Wiring Diagram (OOS)................690
MFWD Diagnostic Wiring Diagram (Cab)................691
Brake Switch Assembly Diagnostic Wiring Diagram (OOS)................692
Brake Switch Assembly Diagnostic Wiring Diagram (Cab)................693
Rear EH PTO Switch Diagnostic Wiring Diagram................694
Rear EH PTO Solenoid Diagnostic Wiring Diagram................695
Rear EH PTO Speed Sensor Diagnostic Wiring Diagram................696
Group ICC: ICC................486
Instrument Cluster Control Unit (ICC) Configuration and Calibration................699
ICC 000 — Initial Address................701
ICC 001 — Recall Diagnostic Codes................702
ICC 002 — ICU System Beep Address................703
ICC 005 — Switch Status................705
ICC 006 — Indicator Status................706
ICC 010 — Fuel Level Sender Voltage................708
ICC 020 — Units Selection................709
ICC 021 — Auto Clear DTC Hours................710
ICC 022 — Backlight Dimming Percentage................712
ICC 022 — Backlight Dimming Percentage................712
ICC 023 — Activate Backlight................713
ICC 024 — Enable Air Filter Restriction HW Input................714
ICC 025 — Enable Battery Charge HW Input................715
ICC 026 — Enable PTO Speed Display................716
ICC 027 — Enable HI/LO Transmission Gear Display................717
ICC 031 — Revert to Hours Status................718
ICC 032 — ICC Flash Rate 1................719
ICC 033 — ICC Flash Rate 2................720
ICC 036 — Engine Coolant Warning Level................721
ICC 037 — Engine Coolant Stop Level................722
ICC 040 — Fuel Gauge Configuration................723
ICC 041 — Resistance Verses Fuel Level Gauge Constant 1................724
ICC 042 — Resistance Verses Fuel Level Gauge Constant 2................725
ICC 043 — Resistance Verses Fuel Level Gauge Constant 3................726
ICC 044 — Resistance Verses Fuel Level Gauge Constant 4................727
ICC 045 — Resistance Verses Fuel Level Gauge Constant 5................728
ICC 046 — Resistance Verses Fuel Level Gauge Constant 6................729
ICC 047 — Resistance Verses Fuel Level Gauge Constant 7................730
ICC 048 — Resistance Verses Fuel Level Gauge Constant 8................731
ICC 049 — Resistance Verses Fuel Level Gauge Constant 9................732
ICC 200-251 — General Control Unit Data................733
ICC—Instrument Cluster Control Unit Test................734
Group PTR: PTR................487
Power Train Reverser (PTR) Control Unit Configuration and Calibration................739
PTR 000 — Initial Address................740
PTR 001 — Recall Diagnostic Codes................741
PTR 002 — PTR System Beep Mode................742
PTR 003 — PTR System Beep Mode With Speed Sensors................744
PTR 004 — Engine and Countershaft Speed Sensor Status................746
PTR 005 — Come Home, Trans Enable, Clutch Pedal Switch, and Seat Switch Status................748
PTR 006 — Forward, Neutral, Not Neutral, and Reverse Switch Status................750
PTR 007 — Speed Lever Neutral, High, Low, and Park Switch Status................751
PTR 008 — Trans Enable Relay, High, Low, and Reverse Driver Command................752
PTR 009 — High, Low, and Reverse Driver Status................754
PTR 010 — Trans Enable Solenoid Current................755
PTR 011 — Power Shuttle Input Voltage................756
PTR 012 — Trans Enable Pressure Sensor Voltage................757
PTR 013 — Clutch Pedal Potentiometer Channel A Voltage................759
PTR 014 — Clutch Pedal Potentiometer Channel B Voltage................760
PTR 015 — Creeper Lever Position Sensor Voltage................761
PTR 022 — Clutch Pack Overfill Protection Status................762
PTR 032 — Clutch Pedal Position................763
PTR 033 — Clutch Pedal Pressure Command................764
PTR 034 — Trans Enable Actual Pressure................765
PTR 036 — Countershaft Speed................767
PTR 050 — PTR Switched Supply Voltage................768
PTR 051 — PTR Sensor Supply Voltage................769
PTR 052 — Hydraulic Oil Temperature................770
PTR 060 — Transmission Type................771
PTR 061 — Hydraulic Oil Type Selection................772
PTR 062 — Temperature Offset For Alternate Hydraulic Oil................773
PTR 063 — Transmission Calibration................774
PTR 064 — Transmission Fill Pressure and Fill Time Calibration Values................781
PTR 065 — Forward Valve High Fill Pressure Adjustment................783
PTR 066 — Forward Valve High Fill Time Adjustment................784
PTR 067 — Forward Valve Low Fill Pressure Adjustment................785
PTR 068 — Forward Valve Low Fill Time Adjustment................786
PTR 069 — Reverse Valve Fill Pressure Adjustment................787
PTR 070 — Reverse Valve Fill Time Adjustment................788
PTR 072 — Has Calibration been Completed................789
PTR 075 — PTR PowerShuttle Setup Status................790
PTR 076 — PowerShuttle Minimum Wheel Speed Fill Pressure................791
PTR 077 — PowerShuttle Minimum Wheel Speed................792
PTR 078 — PowerShuttle Pressure Offset................793
PTR 079 — High Speed Shuttle Shift Limit................794
PTR 084 — Engine Brake Torque................795
PTR 086 — Hi/Lo Switch Setup................796
PTR 087 — Park Switch Polarity................797
PTR 088 — Seat Switch Polarity................798
PTR 100 — Come Home Mode Enable................799
PTR 101 — Come Home Mode Relay Block Polarity................800
PTR 200-251 — General Control Unit Data................801
PTR Control Unit Beep Mode Test With Speed Sensors................802
PTR Control Unit Beep Mode Test Without Speed Sensors................806
PTR—Power Shuttle Control Circuit Test................807
PTR—Clutch Pedal Position Circuit Test................810
PTR—Clutch Pedal Switch Circuit Test................813
PTR—Park Switch Circuit Test................815
PTR—Top Shaft Speed Sensor Circuit Test................819
PTR—Speed Lever Neutral Switch Circuit Test................821
PTR—Forward Neutral Reverse (FNR) Switch Circuit Test................823
PTR—High/Low Shifter Switch Circuit Test................825
Directional Reverser Switch Circuit Test................827
Clutch Disengaged Switch Circuit Test................831
Optional Hi/Lo Switch Circuit Test................835
Optional Infinitely Variable Shuttle Control Circuit Test................840
Charging System Circuit Test................845
Seat Switch Circuit Test................848
Forward Solenoid Circuit Test................853
PTR - Forward Solenoid Circuit Test (With Forward High)................856
PTR - Forward Solenoid Circuit Test (With Forward Low)................859
Reverse Solenoid Circuit Test................862
Clutch Enable Proportional Valve Circuit Test................865
Optional Hi/Lo Solenoid Circuit Test................868
Clutch Pedal Position Sensor Circuit Test................871
Enable Pressure Sensor Circuit Test................876
Countershaft Speed Sensor Circuit Test................881
PTR Control Unit Theory of Operation................886
Come-Home Mode Theory of Operation................890
Directional Reverser Switch Theory of Operation................891
Clutch Disengaged Switch Theory of Operation................892
Optional Hi/Lo Switch Theory of Operation................893
Optional Infinitely Variable Shuttle Control Theory of Operation................894
Park Switch Theory of Operation................895
Seat Switch Theory of Operation................896
Forward Solenoid Theory of Operation................898
Reverse Solenoid Theory of Operation................899
Clutch Enable Proportional Valve Theory of Operation................900
Optional Hi/Lo Solenoid Theory of Operation................901
Clutch Pedal Position Sensor Theory of Operation................902
Enable Pressure Sensor Theory of Operation................903
Countershaft Speed Sensor Theory of Operation................904
Directional Reverser Switch Circuit Diagnostic Wiring Diagram (Cab)................905
Directional Reverser Switch Circuit Diagnostic Wiring Diagram (OOS)................906
Clutch Disengaged Switch Diagnostic Wiring Diagram (Cab)................907
Clutch Disengaged Switch Diagnostic Wiring Diagram (OOS)................908
Hi/ Lo Switch and Solenoid Diagnostic Wiring Diagram................909
Optional Infinitely Variable Shuttle Control Diagnostic Wiring Diagram (Cab)................910
Optional Infinitely Variable Shuttle Control Diagnostic Wiring Diagram (OOS)................911
Park Switch Diagnostic Wiring Diagram (Cab)................912
Park Switch Diagnostic Wiring Diagram (OOS)................913
Seat Switch Diagnostic Wiring Diagram (Cab)................914
Seat Switch Diagnostic Wiring Diagram (OOS)................915
Forward Solenoid Diagnostic Wiring Diagram (Cab)................916
Forward Solenoid Diagnostic Wiring Diagram (OOS)................917
Reverse Solenoid Diagnostic Wiring Diagram (Cab)................918
Reverse Solenoid Diagnostic Wiring Diagram (OOS)................919
Clutch Enable Proportional Valve Diagnostic Wiring Diagram................920
Clutch Pedal Position Sensor Diagnostic Wiring Diagram (Cab)................921
Clutch Pedal Position Sensor Diagnostic Wiring Diagram (OOS)................922
Enable Pressure Sensor Diagnostic Wiring Diagram................923
Countershaft Speed Sensor Diagnostic Wiring Diagram (Cab)................924
Countershaft Speed Sensor Diagnostic Wiring Diagram (OOS)................925
Section 251: SYNCHRONIZED TRANSMISSION................926
Group 15: Tests and Adjustments................926
Check and Adjust Clutch Pedal Free Play................930
Tests and Adjustments - Transmission................933
Group 20: Theory of Operation................926
Transmission Theory of Operation Reference Listing................935
Theory of Operation - Transmission................1014
Clutch Operation—Synchronized Transmissions (PY10960, PY10962, PY10963)................937
Transmission Lubrication System................945
Synchronized Transmission—Gear Shift Power Flow................947
Synchronized Transmission Synchronizer Operation—Reverse and 2nd Gear (Disk-and-Plate Type Synchronizer)................949
Synchronized Transmission Synchronizer Operation—1st and 3rd Gear (Cone-Type Synchronizer)................951
Synchronized Transmission—Range Shift Power Flow................1047
Group 25: Schematics and Diagrams................926
Transmission Component Location Listing................956
Schematics and Diagrams - Transmission................1057
Power Train Components—Synchronized Transmissions (PY10960, PY10962, PY10963)................958
Clutch Components—Synchronized Transmission (PY10960, PY10962, PY10963)................959
Transmission Components................961
Section 255: PowrReverser™ TRANSMISSION................963
Group 05: General Information................963
Transmission General Information, Reference Listing................966
General Information - Transmission................967
Install Test Equipment - Transmission (Without EH Hi/Lo)................968
Install Test Equipment - Transmission (With EH Hi/Lo)................976
Group 10: Preliminary and Operational Checks................963
Transmission Preliminary and Operational Checks, Reference Listing................985
Preliminary and Operational Checks - Transmission................986
Transmission Preliminary Checks................1069
Transmission Operational Checks................989
Group 15: Tests and Adjustments................963
Transmission Tests and Adjustments................995
Test and Adjustments - Transmission................996
Forward Clutch Leak Test (Without EH Hi/Lo)................997
Forward Clutch Leak Test With Forward High................1000
Forward Clutch Leak Test With Forward Low................1003
Pump Flow Test................1006
Clutch Enable Pressure Test................1008
Main Pressure Relief Valve Adjustment................1010
Group 20: Theory of Operation................963
PowrReverser Transmission Theory of Operation Information Reference Listing................1013
Theory of Operation - Transmission................1014
Mechanical PTO Clutch Operation—Clutch Disengaged................1015
Mechanical PTO Clutch Operation—Clutch Engaged................1017
PR General Information................1019
PR Clutch Operation in Forward (Without EH Hi/Lo)................1020
PR Clutch Operation in Forward High................1022
PR Clutch Operation in Forward Low................1024
PR Clutch Operation in Reverse (Without EH Hi/Lo)................1026
PR Clutch Operation in Reverse (With EH Hi/Lo)................1028
PR Control Valve Operation—ElectroHydraulic Directional Reverser in Neutral (Without EH Hi/Lo)................1030
PR Control Valve Operation—ElectroHydraulic Directional Reverser in Neutral (With EH Hi/Lo)................1032
PR Control Valve Operation—ElectroHydraulic Directional Reverser in Forward (Without EH Hi/Lo)................1034
PR Control Valve Operation—ElectroHydraulic Directional Reverser in Forward High................1036
PR Control Valve Operation—ElectroHydraulic Directional Reverser in Forward Low................1038
PR Control Valve Operation—ElectroHydraulic Directional Reverser in Reverse (Without EH Hi/Lo)................1040
PR Control Valve Operation—ElectroHydraulic Directional Reverser in Reverse (With EH Hi/Lo)................1042
Transmission—Gearshift Power Flow................1044
Transmission—Range Shift Power Flow................1047
Gearshift Synchronizer Operation................1050
Transmission Lubrication System (Without EH Hi/Lo)................1051
Transmission Lubrication System (With EH Hi/Lo)................1053
Group 25: Schematics and Diagrams................964
PowrReverser™ Transmission Component Location Listing................1056
Schematics and Diagrams - Transmission................1057
Trans-Axle Hydraulic Schematic (Without EH Hi/Lo)................1058
Trans-Axle Hydraulic Schematic (With EH Hi/Lo)................1060
Power Train Components—OOS................1062
Power Train Components—Cab................1063
Mechanical PTO Clutch Components................1064
Section 256: DRIVE SYSTEMS................1065
Group 10: Preliminary and Operational Checks................1065
Drive Systems Preliminary and Operational Checks, Reference Listing................1068
Preliminary Checks................1069
Rear Differential Lock Operational Check................1071
PTO Operational Checks................1072
MFWD Operational Checks................1074
Group 15: Tests and Adjustments................1065
Adjust PTO Clutch Lever Linkage — OOS................1077
Adjust PTO Clutch Lever Linkage — Cab................1079
Adjust 540E PTO Lever Linkage—With Throttle Limiter (Synchronized Transmission Only) — If Equipped................1081
Adjust 540E PTO Lever Linkage—Without Throttle Limiter (Synchronized Transmission Only) — If Equipped................1083
Park Brake Band Adjustment (If equipped)................1085
Park Brake Linkage Adjustment (If equipped)................1087
Group 20: Theory of Operation................1065
Drive Systems Theory of Operation Reference Listing................1090
Theory of Operation - Drive Systems................1091
Differential Power Flow................1092
Hi-Crop Axle Differential Power Flow................1094
Hi-Crop Axle Differential Power Flow (April 2013)................1096
Differential Lock Operation................1097
Final Drive Operation................1099
Mechanical Front Wheel Drive (MFWD) Drop Gearbox Operation................1100
Rear PTO Operation................1102
Rear 540/540E PTO Operation................1104
Park Brake Operation (Synchronized Transmission)................1106
Park Pawl Operation (PowrReverser Transmission)................1108
Group 25: Schematics and Diagrams................1065
Drive Systems Component Location Listing................1110
Schematics and Diagrams - Drive Systems................1111
Final Drive Components................1112
Hi-Crop Final Drive Components................1113
Hi-Crop Final Drive Components (April 2013)................1114
Rear PTO Components................1115
Rear 540/540E PTO Components................1116
Park Brake Components (Synchronized Transmission)................1117
Park Pawl Components (PowrReverser Transmission................1119
Section 260: STEERING AND BRAKES................1120
Group 05: General Information................1120
Install Test Equipment................1167
Group 10: Preliminary and Operational Checks................1120
Steering Preliminary Check................1126
Steering Operational Check................1127
Rear Brakes Preliminary Check................1128
Rear Brake Operational Test................1129
Group 15: Test and Adjustments................1120
Steering Pump Flow Test................1132
Steering Valve Relief Test................1133
Steering Leak Test................1134
Checking Toe-In—Adjustable Front Axle................1136
Adjusting Toe-In—Adjustable Front Axle................1137
Adjusting Toe-In—Adjustable Front Axle (Hi-Crop Tractors)................1139
Checking Toe-In—MFWD Axle................1141
Adjusting Toe-In—MFWD Axle................1142
Set MFWD Steering Stops Turning Radius................1143
Bleed Rear Brakes................1144
Rear Brake Valve Leak Test................1145
Brake Pedal Adjustment................1146
Adjust Brake Retractors................1148
Group 20: Theory of Operation................1120
Steering Valve Operation—Neutral and Manual Turning................1151
Steering Valve Operation—Power Turning................1153
Brake System Operation................1155
Brake Valve Operation................1157
Section 270: HYDRAULICS................1161
Group 05: General Information................1161
Install Test Equipment................1167
Hydraulic Oil Warm-Up Procedure................1171
Group 10: Preliminary and Operational Checks................1161
Hydraulic System Preliminary Checks................1174
Group 15: Tests and Adjustments................1161
Pump Flow Test (Tractors Without SCV)................1178
Pump Flow Test (Tractors With SCV)................1180
Main Relief Valve Test (Tractors Without SCV)................1182
Main Relief Valve Test (Tractors With SCV)................1184
Rockshaft Load Sense Relief Valve Test................1186
SCV Leakage Test................1188
Rockshaft Leakage Test................1190
Rockshaft Lift Cycle Test................1192
Mid-Mount Control Valve Cable Adjustment................1194
Rockshaft Draft-Sensing and Position Control Cable Adjustment................1196
Rockshaft Lever Friction Adjustment................1197
Rockshaft Position-Sensing Feedback Linkage Adjustment................1198
Rockshaft Draft-Sensing Feedback Linkage Adjustment................1202
Group 20: Theory of Operation................1161
Hydraulic System Theory of Operation Information Reference Listing................1205
Hydraulic System Operation................1206
Hydraulic Filter Operation................1209
Hydraulic Pump Operation................1210
Rockshaft Control Valve Operation—Two Flow Regulator Valves................1212
Rockshaft Control Valve Operation—Neutral Position................1214
Rockshaft Control Valve Operation—Raise Position................1216
Rockshaft Control Valve Operation—Lower Position................1218
Surge Relief Valve Operation................1220
Rate-of-Drop Valve Operation—Full Open................1222
Rate-of-Drop Valve Operation—Full Closed................1224
Rockshaft Draft-Sensing Operation................1226
SCV Operation (Neutral Position)................1228
Selective Control Valve Operation—Extend and Retract Positions................1230
Selective Control Valve Operation—Boom Spool Float Position................1232
Dual Mid-Mount Control Valve Operation—Neutral Position................1234
Dual Mid-Mount Control Valve Operation—Extend and Retract Positions................1236
Dual Mid-Mount Control Valve Operation—Float Position................1238
Dual Mid-Mount Control Valve Operation—Regenerative Position................1240
Double-Acting Sleeve Coupler Operation................1242
Selective Control Valve Operation—Bucket Spool Regenerative Position................1244
Group 25: Schematics and Diagrams................1162
Hydraulic System Schematic Listing................1247
Legend for Hydraulic Schematic—Without Selective Control Valves................1248
Legend for Hydraulic Schematic—With Selective Control Valves................1250
Power Beyond Hydraulic Schematic................1252
Hydraulic System Schematic—POWRREVERSER POWRREVERSER is a trademark of Deere & Company Transmission (Sheet 1 of 2)................1162
Hydraulic System Schematic—POWRREVERSER POWRREVERSER is a trademark of Deere & Company Transmission with Electro-Hydraulic Hi/Lo (Sheet 1 of 2) (Not Applicable)................1162
Hydraulic System Schematic—POWRREVERSER POWRREVERSER is a trademark of Deere & Company Transmission with Mechanical Hitch (Sheet 2 of 2)................1162
Hydraulic System Schematic—Straddle Mount Tractors With Mid-Mount Valve................1259
Section 290: Operator's Cab................1261
Group 10: Operational Tests................1261
Air-Conditioning System, Heater and Operator's Seat——Summary of References................1264
Air-Conditioning System and Heater—Test Sequence................1265
Air Comfort Seat—Test Sequence................1270
Group 15: Tests and Adjustments................1261
Air-Conditioning System, Heater and Operator's Seat, Test and Adjustments—Summary of References................1273
Safety at Work................1274
Handling Refrigerant................1275
Safety Equipment................1276
In an Emergency................1277
Storage of Refrigerant Containers................1278
R134a Refrigerant................1320
Important................1280
A/C ON/OFF Switch and Temperature Control Knob................1281
Heater Temperature Control Knob................1282
Essential Tools................1283
Service Equipment and Tools................1284
Other Material................1285
Specifications................1286
Explanation of Checks................1287
Adjust Heater Temperature Control Cable................1311
Adjust A/C Temperature Control Switch................1313
Pressure Deviations................1315
Group 20: Theory of Operation................1261
Air-Conditioning, Heating and Ventilation Systems, Operation—Summary of References................1318
Principle of Heat Exchange................1319
R134a Refrigerant................1320
Refrigerant Circuit Layout................1321
Functional Description of Components—Refrigerant Circuit................1323
Functional Description of Components — Compressor................1325
Functional Description of Components — Condenser................1326
Functional Description of Components—Receiver-Drier................1327
Functional Description of Components—Expansion Valve................1328
Functional Description of Components—Thermostat Switch................1330
Functional Description of Components—Evaporator................1331
Functional Description of Components—High/Low Pressure Switch................1332
Functional Description of Components—Control Knobs for Heating and Cooling................1333
Heating and Ventilation................1334
Section 299: SERVICE TOOLS................1336
Group 05: Dealer Fabricated Tools................1336
DFRW26—Test Lead for Automotive-Style Fuses................1339
DFRW51—Electronic Circuit Load Tester................1340
DFRW83—Nozzle Assembly................1341
DFRW126—Modified Tap Out Harness................1343
DFRW133—Tap Out Harness................1344
Group 10: Service Tools and Kits................1336
AR94522—ISO SCV Coupler................1346
JDG774—Solenoid Test Harness................1347
JDG10466................1348
JT02051—Manifold with Gauges................1349
JT02081—Halogen Leak Detector................1350
JT02153—Current Clamp-On Probe................1351
JT03043—Adapter 1/2 M NPT x 1-1/16 M 37°................1352
JT03044—Adapter 3/4 M NPT x 1-1/16 M 37°................1353
JT03051—Adapter 1-1/16 F 37° x 1-1/16 F 37°................1354
JT03059—90° Elbow, 1 1/16-12 M 37° x 1 1/16-12 F 37° Sw................1355
JT03110—Adapter................1356
JT03262—Adapter................1357
JT03345—Gauge................1358
JT03364—Hose with Coupler................1359
JT03367—Connector................1360
JT03459—Adapter 1-3/16 F ORFS x 7/16 37°................1361
JT03481—Kit................1362
JT03481-1—Adapter Male Quick Coupler Plug x 1/4 M NPT................1363
JT03481-3—Straight Fitting 3/4-14 F NPT x M20 x 1.5 ORB................1364
JT03481-4—Straight Fitting 1/8 M BSPT X 1/8 F NPT................1365
JT03520—Special Adapter................1366
JT05473—Gauge w/Quick Coupler, 0-35,000 kPa (0-5000 psi)................1367
JT05494—7/16-20 M 37° x 3/4-16 M ORB................1368
JT05498—Hose 508 mm (20 in.)................1369
JT05634—Pressure Gauge................1370
JT05685—Battery Load Tester................1371
JT05690—1 1/16-12 M 37° x 1 3/16-12 F ORFS................1372
JT05791—Digital Multimeter................1373
JT05843—Hydrometer................1374
JT07032—Gauge 400 kPa (60 psi)................1375
JT07041—Gauge 2800 kPa (400 psi)................1376
JT07148—Digital Hydraulic Tester................1377
LVB24862—Wiring Harness................1378
RE200690—Performance Monitor................1379
John Deere Tractors 5076E, 5076EL, 5082E, 5090E, 5090EL, 5090EH Diagnostic and Repair Service Manual (TM607519)
