John Deere Crawler Dozers 450J, 550J, 650J Operation and Test Service Manual (TM10292)
Complete diagnostics service manual with Electrical Wiring Diagrams for John Deere Crawler Dozers 450J, 550J, 650J (S.N. 141667—159986), with workshop information to maintain, diagnose, and service like professional mechanics.
John Deere Crawler Dozers 450J, 550J, 650J workshop Operation and 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.
TM10292 - John Deere 450G, 455G, 550G, 555G, 650G Crawler Dozer Technical Manual (Operation and Test).PDF
TM10292 - John Deere 450G, 455G, 550G, 555G, 650G Crawler Dozer Technical Manual (Operation and Test).EPUB
Total Pages: 1,020 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
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
System Diagnostic Information
Tests
Electrical System
System Information
System Diagrams
Sub-System Diagnostics
References
Hydraulic System
Theory of Operation
Diagnostic Information
Adjustments
Tests
Hydrostatic System
Theory of Operation
Diagnostic Information
Test
Heating and Air Conditioning
Theory of Operation
Diagnostic Information
Test
tm10292 - 450J, 550J, 650J Crawler Dozer (SN 141667-159986)
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 Oil
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
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 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
!CAL - Calibrate TCU
F311 - Sensor Supply Short to Gnd
F314 - Sensor Supply Short to Power
F321 - TCU System Volts Too Low
F324 - TCU System Volts Too High
F330 - FNR Sensor Open or Short
F331 - FNR Input Less Than Min Cal
F334 - FNR Input Greater Than Max Cal
F335 - FNR Sensor Short to Power
F336 - FNR Sensor Min Cal Too Low
F337 - FNR Sensor Min Cal Too High
F338 - FNR Sensor Max Cal Too Low
F339 - FNR Sensor Max Cal Too High
F340 - Steer Sensor Open or Short
F341 - Steer Sensor Input Less Than Min Cal
F344 - Steer Sensor Input Greater Than Max Cal
F345 - Steer Sensor Short to Power
F346 - Steer Sensor Min Cal Too Low
F347 - Steer Sensor Min Cal Too High
F348 - Steer Sensor Max Cal Too Low
F349 - Steer Sensor Max Cal Too High
F350 - Decelerator Sensor Open or Short
F351 - Decelerator Sensor Input Less Than Min Cal
F354 - Decelerator Sensor Input Greater Than Max Cal
F355 - Decelerator Sensor Short to Power
F356 - Decelerator Sensor Min Cal Too Low
F357 - Decelerator Sensor Min Cal Too High
F358 - Decelerator Sensor Max Cal Too Low
F359 - Decelerator Sensor Max Cal Too High
F370 - Left Speed Sensor Short
F372 - Left Speed Sensor Open
F373 - Left Speed Sensor No Response
F375 - Left Speed Sensor Short to Power
F380 - Right Speed Sensor Short
F382 - Right Speed Sensor Signal Open
F383 - Right Speed Sensor No Response
F385 - Right Speed Sensor Short to Power
F393 - CAN Comm No Engine Speed
F3A0 - Left Fwd Pump Coil Short
F3A5 - Left Fwd Pump Coil Open
F3A6 - Left Fwd Pump Thresh Cal Low
F3A7 - Left Fwd Pump Thresh Cal High
F3A8 - Left Fwd Pump Max Spd Cal Low
F3A9 - Left Fwd Pump Max Spd Cal High
F3B3 - Brake Solenoid No Response
F3B8 - Decelerator Sensor Brake Cal Too Low
F3B9 - Decelerator Sensor Brake Cal Too High
F3C0 - Right Fwd Pump Coil Short
F3C5 - Right Fwd Pump Coil Open
F3C6 - Right Fwd Pump Thresh Cal Low
F3C7 - Right Fwd Pump Thresh Cal High
F3C8 - Right Fwd Pump Max Spd Cal Low
F3C9 - Right Fwd Pump Max Spd Cal High
F3D0 - Right Rev Pump Coil Short
F3D5 - Right Rev Pump Coil Open
F3D6 - Right Rev Pump Thresh Cal Low
F3D7 - Right Rev Pump Thresh Cal High
F3D8 - Right Rev Pump Max Spd Cal Low
F3D9 - Right Rev Pump Max Spd Cal High
F3E0 - Left Rev Pump Coil Short
F3E5 - Left Rev Pump Coil Open
F3E6 - Left Rev Pump Thresh Cal Low
F3E7 - Left Rev Pump Thresh Cal High
F3E8 - Left Rev Pump Max Spd Cal Low
F3E9 - Left Rev Pump Max Spd Cal High
F3H1 - FNR Neut Switch Short Circuit
F3H4 - FNR Neut Switch Open Circuit
F3H6 - FNR Neut Switch Min Cal Too Low
F3H7 - FNR Neut Switch Min Cal Too High
F3H8 - FNR Neut Switch Max Cal Too Low
F3H9 - FNR Neut Switch Max Cal Too High
F3K3 - Right Motor Sol No Response
F3K8 - Right Motor Max Cal Too Low
F3K9 - Right Motor Max Cal Too High
F3L3 - Left Motor Sol No Response
F3L8 - Left Motor Max Cal Too Low
F3L9 - Left Motor Max Cal Too High
F3P0 - Park Lock Lever Inputs Both On
F3P5 - Park Lock Lever Inputs Both Off
F3T0 - Speed Buttons Open or Short
F3T1 - Speed Buttons Input Less Than Min Cal
F3T4 - Speed Buttons Input Greater Than Max Cal
F3T5 - Speed Buttons Short to Power
F3T6 - Speed Buttons Min Cal Too Low
F3T7 - Speed Buttons Min Cal Too High
F3T8 - Speed Buttons Max Cal Too Low
F3T9 - Speed Buttons Max Cal Too High
F3U0 - Throttle Sensor Open or Short
F3U1 - Throttle Sensor Input Less Than Min Cal
F3U4 - Throttle Sensor Input Greater Than Max Cal
F3U5 - Throttle Sensor Short to Power
F3U6 - Throttle Sensor Min Cal Too Low
F3U7 - Throttle Sensor Min Cal Too High
F3U8 - Throttle Sensor Max Cal Too Low
F3U9 - Throttle Sensor Max Cal Too High
F3X0 - Charge Pressure Open or Short
F3X1 - Charge Pressure Low
F3X4 - Charge Pressure High
F3X5 - Charge Pressure Short to Power
F3Y4 - Transmission Overtemp
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
522442.31 - 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 (DTC)
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 POWERTECH is a trademark of Deere & Company 4.5 L (4045) John Deere Engine
Cold Weather Starting Aid Operation
Group 15: System Diagnostic Information
Diagnose Engine Malfunctions
Group 25: Tests
Slow and Fast Idle Test
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 (S.N. 141667—153832)
Fuse and Relay Specifications (S.N. 153833— )
System Functional Schematic, Wiring Diagram, and Component Location Legend
System Functional Schematic and Schematic Legend
JDLink™ System Functional Schematic—MIG/GTT
JDLink™ System Functional Schematic—MTG/SAT
Canopy Harness (W4) Component Location
Canopy Harness (W4) Wiring Diagram
Cab Harness (W5) Component Location
Cab 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
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 (S.N. 153833— )
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
Group 20: References
Diagnostic Trouble Codes (DTC) Quick Reference List
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
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
Transmission Control Unit (TCU) Menu Structure
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—Normal
Hydraulic Filter Operation Continued—Restricted
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 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—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 Warm-up Procedure
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 Conditioner System Cycle Of Operation
Group 15: Diagnostic Information
Air Conditioner 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 Dozers 450J, 550J, 650J Operation and Test Service Manual (TM10292)