John Deere Crawler Dozer 450J, 550J, 650J Diagnostics Technical Manual (TM10721)
Catalog:
Model:
Complete Operation & Test manual with Electrical Wiring Diagrams for John Deere Crawler Dozer 450J, 550J, 650J (S.N. 159987-XXXXXX), with workshop information to maintain, diagnose, and rebuild like professional mechanics.
John Deere Crawler Dozers 450J, 550J, 650J workshop Diagnostics & Test 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.
TM10721 English - John Deere 450J (SN 159987-216242), 550J, 650J (SN 159987- ) Crawler Dozer Technical Manual - Operation & Test.PDF
tm10723 Spanish - 450J (159987—216242), 550J and 650J (159987— ) Bulldozer sobre orugas
tm10725 - 450J (159987—216242), 550J and 650J (159987— ) Bouteur chenillé
Total Pages: 1,130 pages
File Format: PDF (PC/Mac/Android/Kindle/iPhone/iPad; bookmarked, ToC, Searchable, Printable)
Language: English Spanish French
MAIN SECTIONS
Foreword
Technical Information Feedback Form
General Information
Safety
Diagnostic Trouble Codes (DTC)
Standard Display Monitor (SDM) Diagnostic Trouble Codes
Engine Control Unit (ECU) Diagnostic Trouble Codes
Transmission Control Unit (TCU) Diagnostic Trouble Codes
Electrohydraulic Controller (EHC) Diagnostic Trouble Codes
Blade Control Joystick (BCJ) Diagnostic Trouble Codes
Operational Checkout Procedure
System Operational Checks
Engine
Theory Of Operation
Diagnostic Information
Tests
Electrical System
System Information
System Diagrams
Sub-System Diagnostics
Monitor Operation
References
Hydraulic System
Theory of Operation
TABLE OF CONTENTS
Section 9000: General Information...16
Group 01: Safety...16
Recognize Safety Information...18
Follow Safety Instructions...19
Operate Only If Qualified...20
Wear Protective Equipment...21
Avoid Unauthorized Machine Modifications...22
Inspect Machine...23
Stay Clear of Moving Parts...24
Avoid High-Pressure Fluids...25
Avoid High-Pressure Oils...26
Beware of Exhaust Fumes...27
Prevent Fires...28
Prevent Battery Explosions...29
Handle Chemical Products Safely...30
Dispose of Waste Properly...31
Prepare for Emergencies...32
Add Cab Guarding For Special Uses...33
Start Only From Operator's Seat...34
Prevent Unintended Machine Movement...35
Avoid Work Site Hazards...36
Keep Riders Off Machine...38
Avoid Backover Accidents...39
Avoid Machine Tip Over...40
Prevent Unintended Detonation of Explosive Devices...42
Park And Prepare For Service Safely...43
Service Cooling System Safely...44
Remove Paint Before Welding or Heating...45
Make Welding Repairs Safely...46
Drive Metal Pins Safely...47
Section 9001: Diagnostic Trouble Codes (DTC)...48
Group 10: Standard Display Monitor (SDM) Diagnostic Trouble Codes...55
Standard Display Monitor (SDM) Diagnostic Trouble Codes...55
000096.03 - Fuel Level Sender Open or Short...48
000096.04 - Fuel Level Sender Short to Gnd...48
000107.03 - Eng Air Filter Short to Power...48
000107.04 - Eng Air Filter Restricted...48
000177.03 - Trans Oil Temp Open or Short to Power...48
000177.04 - Trans Oil Temp Short to Gnd...48
000177.16 - Transmission Oil Temperature High...48
000609.09 - CAN Comm No TCU Msg...48
001638.00 - Hydraulic Oil High Temp...48
001638.03 - Hydraulic Oil Temp Short to Power...48
001638.04 - Hydraulic Oil Temp Short to Gnd...48
001713.31 - Hydraulic Oil Filter Restricted...48
002000.09 - CAN Comm No ECU Config...48
003156.09 - CAN Blade Mode Missing From EHC...48
003359.31 - Trans Oil Filter Restricted...48
Group 20: Engine Control Unit (ECU) Diagnostic Trouble Codes...87
Engine Control Unit (ECU) Diagnostic Trouble Codes...87
000091.09 - CAN Throttle Missing from TCU...48
Group 30: Transmission Control Unit (TCU) Diagnostic Trouble Codes...92
Transmission Control Unit (TCU) Diagnostic Trouble Codes...92
000070.00 - Park Lock Lever Inputs Both On...48
000070.01 - Park Lock Lever Inputs Both Off...48
000091.00 - Throttle Sensor Input Greater Than Max Cal...48
000091.01 - Throttle Sensor Input Less Than Min Cal...48
000091.03 - Throttle Sensor Short to Power...48
000091.04 - Throttle Sensor Open or Short...48
000091.15 - Throttle Sensor Min Cal Too High...48
000091.16 - Throttle Sensor Max Cal Too High...48
000091.17 - Throttle Sensor Min Cal Too Low...48
000091.18 - Throttle Sensor Max Cal Too Low...49
000158.03 - TCU System Volts Too High...49
000158.04 - TCU System Volts Too Low...49
000177.00 - Transmission Overtemp...49
000190.09 - CAN Comm No Engine Speed...49
000521.00 - Decel Sensor Input Greater Than Max Cal...49
000521.01 - Decel Sensor Input Less Than Min Cal...49
000521.03 - Decel Sensor Short to Power...49
000521.04 - Decel Sensor Open or Short...49
000521.05 - Decel Sensor Brake Cal Too Low...49
000521.06 - Decel Sensor Brake Cal Too High...49
000521.15 - Decel Sensor Min Cal Too High...49
000521.16 - Decel Sensor Max Cal Too High...49
000521.17 - Decel Sensor Min Cal Too Low...49
000521.18 - Decel Sensor Max Cal Too Low...49
000581.00 - Speed Buttons Input Greater Than Max Cal...49
000581.01 - Speed Buttons Input Less Than Min Cal...49
000581.03 - Speed Buttons Short to Power...49
000581.04 - Speed Buttons Open or Short...49
000581.15 - Speed Buttons Min Cal Too High...49
000581.16 - Speed Buttons Max Cal Too High...49
000581.17 - Speed Buttons Min Cal Too Low...49
000581.18 - Speed Buttons Max Cal Too Low...49
000604.03 - TCL Neut Switch Open Circuit...49
000604.04 - TCL Neut Switch Short Circuit...49
000604.15 - TCL Neut Switch Min Cal Too High...49
000604.16 - TCL Neut Switch Max Cal Too High...49
000604.17 - TCL Neut Switch Min Cal Too Low...49
000604.18 - TCL Neut Switch Max Cal Too Low...49
000619.05 - Park Brake Solenoid No Response...49
000620.03 - Sensor Supply Short to Power...49
000620.04 - Sensor Supply Short to Gnd...49
000907.03 - Left Speed Sensor Short to Power...49
000907.04 - Left Speed Sensor Short...50
000907.07 - Left Speed Sensor No Response...50
000907.12 - Left Speed Sensor Open...50
000908.03 - Right Speed Sensor Short to Power...50
000908.04 - Right Speed Sensor Short...50
000908.07 - Right Speed Sensor No Response...50
000908.12 - Right Speed Sensor Open...50
002660.00 - Steer Sensor Input Greater Than Max Cal...50
002660.01 - Steer Sensor Input Less Than Min Cal...50
002660.03 - Steer Sensor Short to Power...50
002660.04 - Steer Sensor Open or Short...50
002660.15 - Steer Sensor Min Cal Too High...50
002660.16 - Steer Sensor Max Cal Too High...50
002660.17 - Steer Sensor Min Cal Too Low...50
002660.18 - Steer Sensor Max Cal Too Low...50
002661.00 - TCL Input Greater Than Max Cal...50
002661.01 - TCL Input Less Than Min Cal...50
002661.03 - TCL Sensor Short to Power...50
002661.04 - TCL Sensor Open or Short...50
002661.15 - TCL Sensor Min Cal Too High...50
002661.16 - TCL Sensor Max Cal Too High...50
002661.17 - TCL Sensor Min Cal Too Low...50
002661.18 - TCL Sensor Max Cal Too Low...50
522444.00 - Charge Pressure High...50
522444.01 - Charge Pressure Low...50
522444.03 - Charge Pressure Short to Power...50
522444.04 - Charge Pressure Open or Short...50
522447.05 - Right Fwd Pump Coil Open...50
522447.06 - Right Fwd Pump Coil Short...50
522447.15 - Right Fwd Pump Thresh Cal High...50
522447.16 - Right Fwd Pump Max Spd Cal High...50
522447.17 - Right Fwd Pump Thresh Cal Low...50
522447.18 - Right Fwd Pump Max Spd Cal Low...50
522448.05 - Right Rev Pump Coil Open...51
522448.06 - Right Rev Pump Coil Short...51
522448.15 - Right Rev Pump Thresh Cal High...51
522448.16 - Right Rev Pump Max Spd Cal High...51
522448.17 - Right Rev Pump Thresh Cal Low...51
522448.18 - Right Rev Pump Max Spd Cal Low...51
522449.05 - Left Rev Pump Coil Open...51
522449.06 - Left Rev Pump Coil Short...51
522449.15 - Left Rev Pump Thresh Cal High...51
522449.16 - Left Rev Pump Max Spd Cal High...51
522449.17 - Left Rev Pump Thresh Cal Low...51
522449.18 - Left Rev Pump Max Spd Cal Low...51
522450.05 - Left Fwd Pump Coil Open...51
522450.06 - Left Fwd Pump Coil Short...51
522450.15 - Left Fwd Pump Thresh Cal High...51
522450.16 - Left Fwd Pump Max Spd Cal High...51
522450.17 - Left Fwd Pump Thresh Cal Low...51
522450.18 - Left Fwd Pump Max Spd Cal Low...51
523108.13 - TCU High Speed Not Calibrated...51
523108.14 - Sensor or Pump Speed Not Calibrated...51
523577.09 - Left Motor Sol No Response...51
523578.09 - Right Motor Sol No Response...51
Group 40: Electrohydraulic Controller (EHC) Diagnostic Trouble Codes...293
Electrohydraulic Controller (EHC) Diagnostic Trouble Codes...293
000158.03 - EHC System Volts Too High...51
000158.04 - EHC System Volts Too Low...51
000620.03 - Sensor Short to Power...51
000620.04 - Sensor Short to GND...51
001903.00 - Aux 1 PVE Open Circuit...51
001903.01 - Aux 1 PVE Low or Open Circuit...51
001903.03 - Aux 1 PVE Short to Power...51
001903.04 - Aux 1 PVE Short to GND...51
001903.31 - Aux 1 PVE Spool Pos Error...51
001915.00 - Aux 2 PVE Open Circuit...52
001915.01 - Aux 2 PVE Low or Open Circuit...52
001915.03 - Aux 2 PVE Short to Power...52
001915.04 - Aux 2 PVE Short to GND...52
001915.31 - Aux 2 PVE Spool Pos Error...52
002697.09 - CAN Joystick Pos Missing From BCJ...52
002712.00 - Hyd Enable Sw Inputs Both On...52
002712.01 - Hyd Enable Sw Inputs Both Off...52
003157.03 - Incr / Decr Buttons Short to Power...52
003157.04 - Incr / Decr Buttons Open or Short...52
003157.31 - Incr / Decr Buttons Invalid Output...52
522442.03 - Blade Buttons Short to Power...52
522442.04 - Blade Buttons Open or Short to Ground...52
522442.31 - Blade Buttons Invalid Output...52
523779.00 - Blade Rotate Current Above Max...52
523779.01 - Blade Rotate Current Below Min...52
523780.00 - Tilt PVE Open Circuit...52
523780.01 - Tilt PVE Low or Open Circuit...52
523780.03 - Tilt PVE Short to Power...52
523780.04 - Tilt PVE Short to GND...52
523780.31 - Tilt PVE Spool Pos Error...52
523781.00 - Height PVE Open Circuit...52
523781.01 - Height PVE Low or Open Circuit...52
523781.03 - Height PVE Short to Power...52
523781.04 - Height PVE Short to GND...52
523781.31 - Height PVE Spool Pos Error...52
524059.00 - Aux 2 Jstk Sensor 2 Volts High...52
524059.01 - Aux 2 Jstk Sensor 2 Volts Low...52
524059.03 - Aux 2 Jstk Sensor 2 Short to Power...52
524059.04 - Aux 2 Jstk Sensor 2 Short to GND...52
524059.31 - Aux 2 Jstk Sensor 2 Invalid Output...52
524062.00 - Aux 1 Jstk Sensor 2 Volts High...52
524062.01 - Aux 1 Jstk Sensor 2 Volts Low...52
524062.03 - Aux 1 Jstk Sensor 2 Short to Power...53
524062.04 - Aux 1 Jstk Sensor 2 Short to GND...53
524062.31 - Aux 1 Jstk Sensor 2 Invalid Output...53
524085.00 - Aux 2 Jstk Sensor 1 Volts High...53
524085.01 - Aux 2 Jstk Sensor 1 Volts Low...53
524085.03 - Aux 2 Jstk Sensor 1 Short to Power...53
524085.04 - Aux 2 Jstk Sensor 1 Short to GND...53
524085.14 - Aux 2 Jstk Sensor Mismatch...53
524085.31 - Aux 2 Jstk Sensor 1 Invalid Output...53
524086.00 - Aux 1 Jstk Sensor 1 Volts High...53
524086.01 - Aux 1 Jstk Sensor 1 Volts Low...53
524086.03 - Aux 1 Jstk Sensor 1 Short to Power...53
524086.04 - Aux 1 Jstk Sensor 1 Short to GND...53
524086.14 - Aux 1 Jstk Sensor Mismatch...53
524086.31 - Aux 1 Jstk Sensor 1 Invalid Output...53
Group 50: Blade Control Joystick (BCJ) Diagnostic Trouble Codes...412
Blade Control Joystick (BCJ) Diagnostic Trouble Codes...412
002697.03 - X-Axis Sensor Out of Range High...53
002697.04 - X-Axis Sensor Out of Range Low...53
002697.12 - X-Axis Joystick Internal Failure...53
002697.13 - X-Axis Joystick Setup Failure...53
002697.14 - X-Axis Joystick Sensor Failure...53
002698.03 - Y-Axis Sensor Out of Range High...53
002698.04 - Y-Axis Sensor Out of Range Low...53
002698.12 - Y-Axis Joystick Internal Failure...53
002698.13 - Y-Axis Joystick Setup Failure...53
002698.14 - Y-Axis Joystick Sensor Failure...53
Section 9005: Operational Checkout Procedure...423
Group 10: System Operational Checks...423
Operational Checkout...441
Section 9010: Engine...458
Group 05: Theory Of Operation...458
PowerTech E™ 4.5 L John Deere Engine...463
Cold Weather Starting Aid Operation...461
Group 15: Diagnostic Information...458
PowerTech E™ 4.5 L John Deere Engine...463
Engine Cooling System Component Location...464
Engine Fuel System Component Location...465
Engine Intake and Exhaust Component Location...467
Group 25: Tests...458
Fluid Sampling Procedure...473
Engine Speed Check...478
Fuel System Test...479
Intake Manifold Pressure Test—Turbocharger Boost...482
Section 9015: Electrical System...486
Group 05: System Information...486
Electrical Diagram Information...493
Group 10: System Diagrams...486
Fuse and Relay Specifications...504
System Functional Schematic, Wiring Diagram, and Component Location Legend...511
System Functional Schematic and Section Legend...518
Power and Ground Cables (W1) Component Location...529
Cab Roof Harness (W4) Component Location...530
Cab Roof Harness (W4) Wiring Diagram...533
Main Cab/Canopy Harness (W5) Component Location...540
Main Cab/Canopy Harness (W5) Wiring Diagram...543
Engine Harness (W6) Component Location...557
Engine Harness (W6) Wiring Diagram...560
Transmission Harness (W7) Component Location...564
Transmission Harness (W7) Wiring Diagram...568
A/C Harness (W8) Component Location...571
A/C Harness (W8) Wiring Diagram...573
Radio Harness (W9) Component Location...574
Radio Harness (W9) Wiring Diagram...575
Canopy Auxiliary Light Harness (W11) Component Location...576
Canopy Auxiliary Light Harness (W11) Wiring Diagram...577
Grill Harness (W13) Component Location...578
Grill Harness (W13) Wiring Diagram...579
Integrated Grade Control (IGC) Machine Harness (W21) Component Location—If Equipped...580
Integrated Grade Control (IGC) Machine Harness (W21) Wiring Diagram—If Equipped...582
Integrated Grade Control (IGC) Cab Harness (W22) Component Location—If Equipped...583
Integrated Grade Control (IGC) Cab Harness (W22) Wiring Diagram—If Equipped...585
Charge Pressure Sensor Harness (W25) Wiring Diagram (S.N. 173345— )...587
JDLink™ System Harnesses Component Location—MIG/GTT...588
JDLink™ System Harnesses Component Location—MTG/SAT...589
JDLink™ System Wiring Diagrams—MIG/GTT...591
JDLink™ Ground Harness (W32) Wiring Diagram—If Equipped...594
JDLink™ System Wiring Diagrams—MTG/SAT...595
Group 15: Sub-System Diagnostics...487
Starting and Charging Circuit Theory of Operation...601
Controller Area Network (CAN) Circuit Theory of Operation...603
Engine Control Unit (ECU) Circuit Theory of Operation...605
Standard Display Monitor (SDM) Circuit Theory of Operation...611
Transmission Control Unit (TCU) Circuit Theory of Operation...614
Integrated Grade Control (IGC) Circuit Theory of Operation—If Equipped...619
JDLink™ Circuit Theory of Operation—If Equipped...624
Group 16: Monitor Operation...487
Standard Display Monitor (SDM) Menu Structure—Service Mode...633
Standard Display Monitor (SDM)—Change Units...639
Standard Display Monitor (SDM)—Hide/Unhide Main Menu...640
Standard Display Monitor (SDM)—Setting Hour Meter...642
Group 20: References...487
Service ADVISOR™ Diagnostic Application...645
Service ADVISOR™ Connection Procedure...646
Reading Diagnostic Trouble Codes with Service ADVISOR™ Diagnostic Application...649
JDLink™ System Identification...652
JDLink™ Connection Procedure—If Equipped...655
Alternator Test...657
CAN Circuit Test...659
Electrical Component Specifications...664
Transmission Control Unit (TCU) Calibration...667
Integrated Grade Control (IGC) Checks—If Equipped...487
Integrated Grade Control (IGC) Diagnose Malfunctions—If Equipped...487
Decelerator/Brake Pedal Adjustment...703
Engine Speed Control Remove and Install...705
Rotary Sensor Remove and Install...707
Transmission Control Lever (TCL) Adjustment...709
Replace Weather Pack™ Connector...713
Install Weather Pack™ Contact...715
Replace DEUTSCH® Connectors...717
Replace Rectangular or Triangular Connectors...719
Install DEUTSCH® Contact...721
Repair 32 and 48 Way CINCH™ Connectors...723
Replace (Pull Type) Metri-Pack™ Connectors...727
Replace (Push Type) Metri-Pack™ Connectors...729
Section 9025: Hydraulic System...730
Group 05: Theory of Operation...730
Hydraulic System Operation...733
Hydraulic Pump Operation...734
Hydraulic Pump and Reservoir Operation...735
Hydraulic Filter Operation...737
Hydraulic Control Valve Operation...741
Hydraulic System Relief Valve Operation...742
Inlet Valve Operation...744
Auxiliary Valve Operation...745
Blade Lift Valve Operation...747
Blade Angle Valve Operation...749
Blade Tilt Valve Operation...751
Outlet Valve Cover Operation...753
Hydraulic Control Valve Operation—IGC...754
Hydraulic Cylinder Operation...758
Group 15: Diagnostic Information...730
Hydraulic System Schematic...761
Hydraulic System Schematic—IGC...763
Hydraulic Component Location...765
Hydraulic Component Location—IGC...770
Ripper Hydraulic Component Location...773
Hydraulic System Diagnose Malfunctions...730
Hydraulic System Diagnose Malfunctions—IGC...730
Group 20: Adjustments...730
Hydraulic Control Lever Linkage Adjustment...810
Auxiliary Lever Linkage Adjustment...812
Blade Pitch Linkage Adjustment...814
Group 25: Tests...730
Hydraulic Oil Warm-Up Procedure...816
Hydraulic Oil Sampling Procedure—If Equipped...817
Hydraulic Pump Flow Test...818
Hydraulic System Relief Valve Test...821
Hydraulic System Relief Valve Test—IGC...824
Circuit Relief Valve Test—With Remote Pump...826
Hydraulic Pump Cycle Time Test...829
Lift Cylinder Drift Test...830
Cylinder Leakage Test...832
Oil Clean-up Procedure...834
Section 9026: Hydrostatic System...845
Group 05: Theory of Operation...842
Hydrostatic System...845
Transmission Control Circuit Operation (Flow Chart)...846
Charge Pump Operation...848
Hydrostatic Filter Operation...849
Neutral Charge Relief Valve Operation...852
Park Brake Operation...854
Multi-Function Valve Operation...857
Oil Cooler Bypass Valve Operation...859
Pump Pressure Control Pilot (PCP) Operation...861
Pump Displacement Control Valve (PDCV) Operation...863
Hydrostatic Pump Operation...865
Flushing Valve and Operating Charge Relief Valve Operation...867
Hydrostatic Motor Operation...869
Group 15: Diagnostic Information...842
Hydrostatic Schematic—Neutral (Park Brake ON)...872
Hydrostatic System Component Location...873
Hydrostatic System Diagram—Park Brake On (Neutral)...875
Hydrostatic System Diagram—Forward (Slow Speed)...877
Hydrostatic System Diagram—Reverse (Fast Speed)...879
Overheating Malfunctions...842
High/Low Charge Pressure Malfunctions...842
Mistrack/Index Malfunctions...842
Machine Full Speed Malfunctions...842
Low Power Malfunctions...842
Track Malfunctions...842
TCU Calibration Malfunctions...842
Group 25: Test...842
JT05800 Digital Thermometer Installation...928
Digital Pressure And Temperature Analyzer Installation...929
Hydraulic Oil Cleanup Procedure...930
Ultra Clean® Hand Launcher...931
Transmission Oil Warmup Procedure...932
Hydrostatic Oil Sampling Procedure—If Equipped...934
Releasing Park Brake to Tow the Machine...935
Hydrostatic Pump and Motor Initial Start-Up Procedure...939
Hydrostatic Pump Flushing Procedure...942
Pressure Control Pilot (PCP) Manual Override Test...944
Pressure Control Pilot (PCP) Test...946
Pressure Control Pilot (PCP) Internal Adjustment...950
Multi-Function Relief Valve Test...953
Transmission Efficiency Test...958
Neutral Charge Relief and Operating Charge Relief Pressure Test...963
Pump Displacement Control Valve (PDCV) Neutral (Null) Adjustment...966
Pump Servo Pressure Test...970
Hydrostatic Motor Min./Max. Angle Servo Piston Pressure Test...973
Hydrostatic Motor Min. Angle Stop Adjustment...975
Charge Pump Flow Test...979
Cooler Bypass Valve Test...982
Section 9031: Heating and Air Conditioning...985
Group 05: Theory of Operation...985
Air Conditioning System Cycle Of Operation...988
Group 15: Diagnostic Information...985
Air Conditioning System Diagnose Malfunctions...985
Heater System Diagnose Malfunctions...985
Group 25: Test...985
Proper Refrigerant Handling...1019
R134a Refrigerant Cautions...1020
R134a Oil Charge Capacity...1021
R134a Refrigerant Charge Capacity...1022
Refrigerant Hoses And Tubing Inspection...1023
Operating Pressure Diagnostic Chart...1024
Air Conditioner High/Low Pressure (Binary) Switch Test...1029
Freeze Control Switch Test...1031
Leak Testing...1032
John Deere Crawler Dozer 450J, 550J, 650J Diagnostics Technical Manual (TM10721)