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 Dozer 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 - John Deere 450J, 550J, 650J Crawler Dozer Technical Manual - Operation & Test.PDF
TM10721 - John Deere 450J, 550J, 650J Crawler Dozer Technical Manual - Operation & Test.epub

Total Pages: 1,130 pages
File Format: PDF/EPUB/MOBI/AZW (PC/Mac/Android/Kindle/iPhone/iPad; bookmarked, ToC, Searchable, Printable)
Language: English

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

tm10721 - 450J (SN 159987—216242), 550J, 650J (SN 159987— )Crawler Dozer

Table of Contents

Foreword

Technical Information Feedback Form

Section 9000: General Information

Group 01: Safety

Recognize Safety Information

Follow Safety Instructions

Operate Only If Qualified

Wear Protective Equipment

Avoid Unauthorized Machine Modifications

Inspect Machine

Stay Clear of Moving Parts

Avoid High-Pressure Fluids

Avoid High-Pressure Oils

Beware of Exhaust Fumes

Prevent Fires

Prevent Battery Explosions

Handle Chemical Products Safely

Dispose of Waste Properly

Prepare for Emergencies

Add Cab Guarding For Special Uses

Start Only From Operator's Seat

Prevent Unintended Machine Movement

Avoid Work Site Hazards

Keep Riders Off Machine

Avoid Backover Accidents

Avoid Machine Tip Over

Prevent Unintended Detonation of Explosive Devices

Park And Prepare For Service Safely

Service Cooling System Safely

Remove Paint Before Welding or Heating

Make Welding Repairs Safely

Drive Metal Pins Safely

Section 9001: Diagnostic Trouble Codes (DTC)

Group 10: Standard Display Monitor (SDM) Diagnostic Trouble Codes

Standard Display Monitor (SDM) Diagnostic Trouble Codes

000096.03 - Fuel Level Sender Open or Short

000096.04 - Fuel Level Sender Short to Gnd

000107.03 - Eng Air Filter Short to Power

000107.04 - Eng Air Filter Restricted

000177.03 - Trans Oil Temp Open or Short to Power

000177.04 - Trans Oil Temp Short to Gnd

000177.16 - Transmission Oil Temperature High

000609.09 - CAN Comm No TCU Msg

001638.00 - Hydraulic Oil High Temp

001638.03 - Hydraulic Oil Temp Short to Power

001638.04 - Hydraulic Oil Temp Short to Gnd

001713.31 - Hydraulic Oil Filter Restricted

002000.09 - CAN Comm No ECU Config

003156.09 - CAN Blade Mode Missing From EHC

003359.31 - Trans Oil Filter Restricted

Group 20: Engine Control Unit (ECU) Diagnostic Trouble Codes

Engine Control Unit (ECU) Diagnostic Trouble Codes

000091.09 - CAN Throttle Missing from TCU

Group 30: Transmission Control Unit (TCU) Diagnostic Trouble Codes

Transmission Control Unit (TCU) Diagnostic Trouble Codes

000070.00 - Park Lock Lever Inputs Both On

000070.01 - Park Lock Lever Inputs Both Off

000091.00 - Throttle Sensor Input Greater Than Max Cal

000091.01 - Throttle Sensor Input Less Than Min Cal

000091.03 - Throttle Sensor Short to Power

000091.04 - Throttle Sensor Open or Short

000091.15 - Throttle Sensor Min Cal Too High

000091.16 - Throttle Sensor Max Cal Too High

000091.17 - Throttle Sensor Min Cal Too Low

000091.18 - Throttle Sensor Max Cal Too Low

000158.03 - TCU System Volts Too High

000158.04 - TCU System Volts Too Low

000177.00 - Transmission Overtemp

000190.09 - CAN Comm No Engine Speed

000521.00 - Decel Sensor Input Greater Than Max Cal

000521.01 - Decel Sensor Input Less Than Min Cal

000521.03 - Decel Sensor Short to Power

000521.04 - Decel Sensor Open or Short

000521.05 - Decel Sensor Brake Cal Too Low

000521.06 - Decel Sensor Brake Cal Too High

000521.15 - Decel Sensor Min Cal Too High

000521.16 - Decel Sensor Max Cal Too High

000521.17 - Decel Sensor Min Cal Too Low

000521.18 - Decel Sensor Max Cal Too Low

000581.00 - Speed Buttons Input Greater Than Max Cal

000581.01 - Speed Buttons Input Less Than Min Cal

000581.03 - Speed Buttons Short to Power

000581.04 - Speed Buttons Open or Short

000581.15 - Speed Buttons Min Cal Too High

000581.16 - Speed Buttons Max Cal Too High

000581.17 - Speed Buttons Min Cal Too Low

000581.18 - Speed Buttons Max Cal Too Low

000604.03 - TCL Neut Switch Open Circuit

000604.04 - TCL Neut Switch Short Circuit

000604.15 - TCL Neut Switch Min Cal Too High

000604.16 - TCL Neut Switch Max Cal Too High

000604.17 - TCL Neut Switch Min Cal Too Low

000604.18 - TCL Neut Switch Max Cal Too Low

000619.05 - Park Brake Solenoid No Response

000620.03 - Sensor Supply Short to Power

000620.04 - Sensor Supply Short to Gnd

000907.03 - Left Speed Sensor Short to Power

000907.04 - Left Speed Sensor Short

000907.07 - Left Speed Sensor No Response

000907.12 - Left Speed Sensor Open

000908.03 - Right Speed Sensor Short to Power

000908.04 - Right Speed Sensor Short

000908.07 - Right Speed Sensor No Response

000908.12 - Right Speed Sensor Open

002660.00 - Steer Sensor Input Greater Than Max Cal

002660.01 - Steer Sensor Input Less Than Min Cal

002660.03 - Steer Sensor Short to Power

002660.04 - Steer Sensor Open or Short

002660.15 - Steer Sensor Min Cal Too High

002660.16 - Steer Sensor Max Cal Too High

002660.17 - Steer Sensor Min Cal Too Low

002660.18 - Steer Sensor Max Cal Too Low

002661.00 - TCL Input Greater Than Max Cal

002661.01 - TCL Input Less Than Min Cal

002661.03 - TCL Sensor Short to Power

002661.04 - TCL Sensor Open or Short

002661.15 - TCL Sensor Min Cal Too High

002661.16 - TCL Sensor Max Cal Too High

002661.17 - TCL Sensor Min Cal Too Low

002661.18 - TCL Sensor Max Cal Too Low

522444.00 - Charge Pressure High

522444.01 - Charge Pressure Low

522444.03 - Charge Pressure Short to Power

522444.04 - Charge Pressure Open or Short

522447.05 - Right Fwd Pump Coil Open

522447.06 - Right Fwd Pump Coil Short

522447.15 - Right Fwd Pump Thresh Cal High

522447.16 - Right Fwd Pump Max Spd Cal High

522447.17 - Right Fwd Pump Thresh Cal Low

522447.18 - Right Fwd Pump Max Spd Cal Low

522448.05 - Right Rev Pump Coil Open

522448.06 - Right Rev Pump Coil Short

522448.15 - Right Rev Pump Thresh Cal High

522448.16 - Right Rev Pump Max Spd Cal High

522448.17 - Right Rev Pump Thresh Cal Low

522448.18 - Right Rev Pump Max Spd Cal Low

522449.05 - Left Rev Pump Coil Open

522449.06 - Left Rev Pump Coil Short

522449.15 - Left Rev Pump Thresh Cal High

522449.16 - Left Rev Pump Max Spd Cal High

522449.17 - Left Rev Pump Thresh Cal Low

522449.18 - Left Rev Pump Max Spd Cal Low

522450.05 - Left Fwd Pump Coil Open

522450.06 - Left Fwd Pump Coil Short

522450.15 - Left Fwd Pump Thresh Cal High

522450.16 - Left Fwd Pump Max Spd Cal High

522450.17 - Left Fwd Pump Thresh Cal Low

522450.18 - Left Fwd Pump Max Spd Cal Low

523108.13 - TCU High Speed Not Calibrated

523108.14 - Sensor or Pump Speed Not Calibrated

523577.09 - Left Motor Sol No Response

523578.09 - Right Motor Sol No Response

Group 40: Electrohydraulic Controller (EHC) Diagnostic Trouble Codes

Electrohydraulic Controller (EHC) Diagnostic Trouble Codes

000158.03 - EHC System Volts Too High

000158.04 - EHC System Volts Too Low

000620.03 - Sensor Short to Power

000620.04 - Sensor Short to GND

001903.00 - Aux 1 PVE Open Circuit

001903.01 - Aux 1 PVE Low or Open Circuit

001903.03 - Aux 1 PVE Short to Power

001903.04 - Aux 1 PVE Short to GND

001903.31 - Aux 1 PVE Spool Pos Error

001915.00 - Aux 2 PVE Open Circuit

001915.01 - Aux 2 PVE Low or Open Circuit

001915.03 - Aux 2 PVE Short to Power

001915.04 - Aux 2 PVE Short to GND

001915.31 - Aux 2 PVE Spool Pos Error

002697.09 - CAN Joystick Pos Missing From BCJ

002712.00 - Hyd Enable Sw Inputs Both On

002712.01 - Hyd Enable Sw Inputs Both Off

003157.03 - Incr / Decr Buttons Short to Power

003157.04 - Incr / Decr Buttons Open or Short

003157.31 - Incr / Decr Buttons Invalid Output

522442.03 - Blade Buttons Short to Power

522442.04 - Blade Buttons Open or Short to Ground

522442.31 - Blade Buttons Invalid Output

523779.00 - Blade Rotate Current Above Max

523779.01 - Blade Rotate Current Below Min

523780.00 - Tilt PVE Open Circuit

523780.01 - Tilt PVE Low or Open Circuit

523780.03 - Tilt PVE Short to Power

523780.04 - Tilt PVE Short to GND

523780.31 - Tilt PVE Spool Pos Error

523781.00 - Height PVE Open Circuit

523781.01 - Height PVE Low or Open Circuit

523781.03 - Height PVE Short to Power

523781.04 - Height PVE Short to GND

523781.31 - Height PVE Spool Pos Error

524059.00 - Aux 2 Jstk Sensor 2 Volts High

524059.01 - Aux 2 Jstk Sensor 2 Volts Low

524059.03 - Aux 2 Jstk Sensor 2 Short to Power

524059.04 - Aux 2 Jstk Sensor 2 Short to GND

524059.31 - Aux 2 Jstk Sensor 2 Invalid Output

524062.00 - Aux 1 Jstk Sensor 2 Volts High

524062.01 - Aux 1 Jstk Sensor 2 Volts Low

524062.03 - Aux 1 Jstk Sensor 2 Short to Power

524062.04 - Aux 1 Jstk Sensor 2 Short to GND

524062.31 - Aux 1 Jstk Sensor 2 Invalid Output

524085.00 - Aux 2 Jstk Sensor 1 Volts High

524085.01 - Aux 2 Jstk Sensor 1 Volts Low

524085.03 - Aux 2 Jstk Sensor 1 Short to Power

524085.04 - Aux 2 Jstk Sensor 1 Short to GND

524085.14 - Aux 2 Jstk Sensor Mismatch

524085.31 - Aux 2 Jstk Sensor 1 Invalid Output

524086.00 - Aux 1 Jstk Sensor 1 Volts High

524086.01 - Aux 1 Jstk Sensor 1 Volts Low

524086.03 - Aux 1 Jstk Sensor 1 Short to Power

524086.04 - Aux 1 Jstk Sensor 1 Short to GND

524086.14 - Aux 1 Jstk Sensor Mismatch

524086.31 - Aux 1 Jstk Sensor 1 Invalid Output

Group 50: Blade Control Joystick (BCJ) Diagnostic Trouble Codes

Blade Control Joystick (BCJ) Diagnostic Trouble Codes

002697.03 - X-Axis Sensor Out of Range High

002697.04 - X-Axis Sensor Out of Range Low

002697.12 - X-Axis Joystick Internal Failure

002697.13 - X-Axis Joystick Setup Failure

002697.14 - X-Axis Joystick Sensor Failure

002698.03 - Y-Axis Sensor Out of Range High

002698.04 - Y-Axis Sensor Out of Range Low

002698.12 - Y-Axis Joystick Internal Failure

002698.13 - Y-Axis Joystick Setup Failure

002698.14 - Y-Axis Joystick Sensor Failure

Section 9005: Operational Checkout Procedure

Group 10: System Operational Checks

Operational Checkout

Section 9010: Engine

Group 05: Theory Of Operation

PowerTech E™ 4.5 L John Deere Engine

Cold Weather Starting Aid Operation

Group 15: Diagnostic Information

PowerTech E™ 4.5 L John Deere Engine

Engine Cooling System Component Location

Engine Fuel System Component Location

Engine Intake and Exhaust Component Location

Group 25: Tests

Fluid Sampling Procedure

Engine Speed Check

Fuel System Test

Intake Manifold Pressure Test—Turbocharger Boost

Section 9015: Electrical System

Group 05: System Information

Electrical Diagram Information

Group 10: System Diagrams

Fuse and Relay Specifications

System Functional Schematic, Wiring Diagram, and Component Location Legend

System Functional Schematic and Section Legend

Power and Ground Cables (W1) Component Location

Cab Roof Harness (W4) Component Location

Cab Roof Harness (W4) Wiring Diagram

Main Cab/Canopy Harness (W5) Component Location

Main Cab/Canopy Harness (W5) Wiring Diagram

Engine Harness (W6) Component Location

Engine Harness (W6) Wiring Diagram

Transmission Harness (W7) Component Location

Transmission Harness (W7) Wiring Diagram

A/C Harness (W8) Component Location

A/C Harness (W8) Wiring Diagram

Radio Harness (W9) Component Location

Radio Harness (W9) Wiring Diagram

Canopy Auxiliary Light Harness (W11) Component Location

Canopy Auxiliary Light Harness (W11) Wiring Diagram

Grill Harness (W13) Component Location

Grill Harness (W13) Wiring Diagram

Integrated Grade Control (IGC) Machine Harness (W21) Component Location—If Equipped

Integrated Grade Control (IGC) Machine Harness (W21) Wiring Diagram—If Equipped

Integrated Grade Control (IGC) Cab Harness (W22) Component Location—If Equipped

Integrated Grade Control (IGC) Cab Harness (W22) Wiring Diagram—If Equipped

Charge Pressure Sensor Harness (W25) Wiring Diagram (S.N. 173345— )

JDLink™ System Harnesses Component Location—MIG/GTT

JDLink™ System Harnesses Component Location—MTG/SAT

JDLink™ System Wiring Diagrams—MIG/GTT

JDLink™ Ground Harness (W32) Wiring Diagram—If Equipped

JDLink™ System Wiring Diagrams—MTG/SAT

Group 15: Sub-System Diagnostics

Starting and Charging Circuit Theory of Operation

Controller Area Network (CAN) Circuit Theory of Operation

Engine Control Unit (ECU) Circuit Theory of Operation

Standard Display Monitor (SDM) Circuit Theory of Operation

Transmission Control Unit (TCU) Circuit Theory of Operation

Integrated Grade Control (IGC) Circuit Theory of Operation—If Equipped

JDLink™ Circuit Theory of Operation—If Equipped

Group 16: Monitor Operation

Standard Display Monitor (SDM) Menu Structure—Service Mode

Standard Display Monitor (SDM)—Change Units

Standard Display Monitor (SDM)—Hide/Unhide Main Menu

Standard Display Monitor (SDM)—Setting Hour Meter

Group 20: References

Service ADVISOR™ Diagnostic Application

Service ADVISOR™ Connection Procedure

Reading Diagnostic Trouble Codes with Service ADVISOR™ Diagnostic Application

JDLink™ System Identification

JDLink™ Connection Procedure—If Equipped

Alternator Test

CAN Circuit Test

Electrical Component Specifications

Transmission Control Unit (TCU) Calibration

Integrated Grade Control (IGC) Checks—If Equipped

Integrated Grade Control (IGC) Diagnose Malfunctions—If Equipped

Decelerator/Brake Pedal Adjustment

Engine Speed Control Remove and Install

Rotary Sensor Remove and Install

Transmission Control Lever (TCL) Adjustment

Replace Weather Pack™ Connector

Install Weather Pack™ Contact

Replace DEUTSCH® Connectors

Replace Rectangular or Triangular Connectors

Install DEUTSCH® Contact

Repair 32 and 48 Way CINCH™ Connectors

Replace (Pull Type) Metri-Pack™ Connectors

Replace (Push Type) Metri-Pack™ Connectors

Section 9025: Hydraulic System

Group 05: Theory of Operation

Hydraulic System Operation

Hydraulic Pump Operation

Hydraulic Pump and Reservoir Operation

Hydraulic Filter Operation

Hydraulic Control Valve Operation

Hydraulic System Relief Valve Operation

Inlet Valve Operation

Auxiliary Valve Operation

Blade Lift Valve Operation

Blade Angle Valve Operation

Blade Tilt Valve Operation

Outlet Valve Cover Operation

Hydraulic Control Valve Operation—IGC

Hydraulic Cylinder Operation

Group 15: Diagnostic Information

Hydraulic System Schematic

Hydraulic System Schematic—IGC

Hydraulic Component Location

Hydraulic Component Location—IGC

Ripper Hydraulic Component Location

Hydraulic System Diagnose Malfunctions

Hydraulic System Diagnose Malfunctions—IGC

Group 20: Adjustments

Hydraulic Control Lever Linkage Adjustment

Auxiliary Lever Linkage Adjustment

Blade Pitch Linkage Adjustment

Group 25: Tests

Hydraulic Oil Warm-Up Procedure

Hydraulic Oil Sampling Procedure—If Equipped

Hydraulic Pump Flow Test

Hydraulic System Relief Valve Test

Hydraulic System Relief Valve Test—IGC

Circuit Relief Valve Test—With Remote Pump

Hydraulic Pump Cycle Time Test

Lift Cylinder Drift Test

Cylinder Leakage Test

Oil Clean-up Procedure

Section 9026: Hydrostatic System

Group 05: Theory of Operation

Hydrostatic System

Transmission Control Circuit Operation (Flow Chart)

Charge Pump Operation

Hydrostatic Filter Operation

Neutral Charge Relief Valve Operation

Park Brake Operation

Multi-Function Valve Operation

Oil Cooler Bypass Valve Operation

Pump Pressure Control Pilot (PCP) Operation

Pump Displacement Control Valve (PDCV) Operation

Hydrostatic Pump Operation

Flushing Valve and Operating Charge Relief Valve Operation

Hydrostatic Motor Operation

Group 15: Diagnostic Information

Hydrostatic Schematic—Neutral (Park Brake ON)

Hydrostatic System Component Location

Hydrostatic System Diagram—Park Brake On (Neutral)

Hydrostatic System Diagram—Forward (Slow Speed)

Hydrostatic System Diagram—Reverse (Fast Speed)

Overheating Malfunctions

High/Low Charge Pressure Malfunctions

Mistrack/Index Malfunctions

Machine Full Speed Malfunctions

Low Power Malfunctions

Track Malfunctions

TCU Calibration Malfunctions

Group 25: Test

JT05800 Digital Thermometer Installation

Digital Pressure And Temperature Analyzer Installation

Hydraulic Oil Cleanup Procedure

Ultra Clean® Hand Launcher

Transmission Oil Warmup Procedure

Hydrostatic Oil Sampling Procedure—If Equipped

Releasing Park Brake to Tow the Machine

Hydrostatic Pump and Motor Initial Start-Up Procedure

Hydrostatic Pump Flushing Procedure

Pressure Control Pilot (PCP) Manual Override Test

Pressure Control Pilot (PCP) Test

Pressure Control Pilot (PCP) Internal Adjustment

Multi-Function Relief Valve Test

Transmission Efficiency Test

Neutral Charge Relief and Operating Charge Relief Pressure Test

Pump Displacement Control Valve (PDCV) Neutral (Null) Adjustment

Pump Servo Pressure Test

Hydrostatic Motor Min./Max. Angle Servo Piston Pressure Test

Hydrostatic Motor Min. Angle Stop Adjustment

Charge Pump Flow Test

Cooler Bypass Valve Test

Section 9031: Heating and Air Conditioning

Group 05: Theory of Operation

Air Conditioning System Cycle Of Operation

Group 15: Diagnostic Information

Air Conditioning System Diagnose Malfunctions

Heater System Diagnose Malfunctions

Group 25: Test

Proper Refrigerant Handling

R134a Refrigerant Cautions

R134a Oil Charge Capacity

R134a Refrigerant Charge Capacity

Refrigerant Hoses And Tubing Inspection

Operating Pressure Diagnostic Chart

Air Conditioner High/Low Pressure (Binary) Switch Test

Freeze Control Switch Test

Leak Testing

John Deere Crawler Dozer 450J, 550J, 650J Operation & Test Service Manual (TM10721)