John Deere 4WD Loaders WL53 Operation and Test Service Manual (TM13255X19)
Complete Operation and Test manual with Electrical Wiring Diagrams for John Deere WL53 4WD Loader (SN.D100008—100079)(PIN: 1YNWL53***D100008—100079), with all the workshop information to maintain, diagnose, and rebuild like professional mechanics.
John Deere WL53 4WD Loader workshop service 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.
tm13255x19 - WL53 4WD Loader (PIN: 1YNWL53_ __D100008—100079) Technical Manual (Operation and Test).pdf
tm13255x19 - WL53 4WD Loader (PIN: 1YNWL53_ __D100008—100079) Technical Manual (Operation and Test).epub
Total Pages: 625 pages
File Format: PDF/EPUB/MOBI/AZW (PC/Mac/Android/Kindle/iPhone/iPad; bookmarked, ToC, Searchable, Printable)
Language: English
MAIN SECTIONS
Foreword
Manual Identification-READ THIS FIRST!
General Information
Safety
Diagnostics
Engine Control Unit (ECU) Diagnostic Trouble Codes
JDLink (JDL) Diagnostic Trouble Codes
Operational Checkout Procedure
Operational Checkout Procedure
Engine
Theory of Operation
Diagnostic Information
Adjustments
Tests
Electrical System
System Information
System Diagrams
Sub-System Diagnostics
References
Power Train
Theory of Operation
Diagnostic Information
Adjustments
Tests
Hydraulic System
Theory of Operation
Diagnostic Information
Adjustments
Tests
Heating and Air Conditioning
Theory of Operation
Diagnostic Information
Tests
TABLE OF CONTENTS........1
Section 9000: General Information........16
Group 01: Safety........16
Recognize Safety Information........19
Follow Safety Instructions........20
Operate Only If Qualified........21
Wear Protective Equipment........22
Avoid Unauthorized Machine Modifications........23
Add Cab Guarding for Special Uses........24
Inspect Machine........25
Stay Clear of Moving Parts........26
Avoid High-Pressure Fluids........27
Avoid High-Pressure Oils........28
Work In Ventilated Area........29
Prevent Fires........30
Clean Debris from Machine........31
Prevent Battery Explosions........32
Handle Chemical Products Safely........33
Dispose of Waste Properly........34
Prepare for Emergencies........35
Use Steps and Handholds Correctly........36
Start Only From Operator's Seat........37
Use and Maintain Seat Belt........38
Prevent Unintended Machine Movement........39
Avoid Work Site Hazards........40
Use Special Care When Operating Loader........42
Keep Riders Off Machine........43
Avoid Backover Accidents........44
Avoid Machine Tip Over........45
Operating on Slopes........47
Operating or Traveling On Public Roads........48
Inspect and Maintain ROPS........49
Add and Operate Attachments Safely........50
Park and Prepare for Service Safely........51
Service Cooling System Safely........52
Follow Tire Recommendations........53
Service Tires Safely........54
Remove Paint Before Welding or Heating........55
Make Welding Repairs Safely........56
Drive Metal Pins Safely........57
Section 9001: Diagnostics........58
Group 10: Engine Control Unit (ECU) Diagnostic Trouble Codes........60
Engine Control Unit (ECU) Diagnostic Trouble Codes........60
000091.03 - Primary Analog Throttle Out of Range High........58
000091.04 - Engine Throttle Open or Short........58
000190.00 - Engine Speed Extremely High........58
Group 20: JDLink (JDL) Diagnostic Trouble Codes........74
JDLink (JDL) Diagnostic Trouble Codes........74
002251.09 - JDLink Network Antenna........58
520638.00 - Modular Telematic Gateway (MTG) Vandalism........58
520638.15 - Remote Start Inhibit (RSI) Active........58
520638.16 - Remote Start Inhibit (RSI) Active........58
520649.00 - Remote Start Inhibit (RSI) Active........58
Section 9005: Operational Checkout Procedure........80
Group 10: Operational Checkout Procedure........80
Operational Checkout........102
Section 9010: Engine........123
Group 05: Theory of Operation........123
John Deere Engine........158
Group 10: System Diagrams........123
Engine Fuel System Component Location........128
Engine Cooling System Component Location........130
Engine Intake and Exhaust Component Location........132
Diesel Fired Coolant Heater (A4) Component Location—If Equipped........134
Group 15: Diagnostic Information........123
John Deere Engine........158
Engine Cranks/Will Not Start........123
Engine Misfires-Runs Irregularly........123
Engine Does Not Develop Full Power........123
Engine Emits Excessive White Exhaust Smoke........123
Engine Emits Excessive Black or Gray Exhaust Smoke........123
Engine Will Not Crank........123
Engines Idles Poorly........123
Abnormal Engine Noise........123
Excessive Fuel Consumption........123
Fuel in Oil........123
Low Pressure Fuel System Check........123
Group 20: Adjustments........123
John Deere Engine........158
Group 25: Tests........123
John Deere Engine........158
Section 9015: Electrical System........159
Group 05: Theory of Operation........159
Start and Charge Circuits Theory of Operation........167
Controller Area Network (CAN) Circuits Theory of Operation........173
Engine Control Unit (ECU) Circuits Theory of Operation........175
Display Unit Circuits Theory of Operation........180
JDLink™ Circuit Theory of Operation—IF Equipped........183
Group 10: System Diagrams........159
Electrical Diagram Information........189
Electrical Schematic Symbols........193
System Functional Schematic, Wiring Diagram, and Component Location Master Legend........196
System Functional Schematic........201
Power and Ground Cables (W20) Component Location........210
Load Center Harness (W21) Component Location........211
Load Center Harness (W21) Wiring Diagram........213
Engine-Transmission Harness (W22) Component Location........216
Engine-Transmission Harness (W22) Wiring Diagram........218
Loader Frame Harness (W23) Component Location........219
Loader Frame Harness (W23) Wiring Diagram........221
Rear Frame Harness (W24) Component Location........222
Rear Frame Harness (W24) Wiring Diagram........224
Roof Harness (W25) Component Location........225
Roof Harness (W25) Wiring Diagram........226
Radio Harness (W27) Component Location........227
Radio Harness (W27) Wiring Diagram........228
Return-to-Dig (RTD) and Boom Height Kickout (BHKO) Harness (W28) Component Location—If Equipped........229
Return to Dig (RTD) and Boom Height Kickout (BHKO) Harness (W28) Wiring Diagram—If Equipped........230
Air Heater Harness (W29, W30, W34) Component Location—If Equipped........231
Air Heater Harness (W29, W30, W34) Wiring Diagram—If Equipped........232
JDLink™ Harness (W31) Component Location—If Equipped........234
JDLink™ Harness (W31) Wiring Diagram—If Equipped........235
Clutch Cut-off Harness (W32) Component Location—If Equipped........237
Clutch Cut-off Harness (W32) Wiring Diagram—If Equipped........238
Heater and Air Conditioner Harness (W33, W38) Component Location........239
Heater and Air Conditioner Harness (W33, W38) Wiring Diagram........241
Diesel Fired Coolant Heater Harness (W35, W36) Component Location—If Equipped........242
Diesel Fired Coolant Heater Harness (W35, W36) Wiring Diagram—If Equipped........243
Auxiliary Fuel Filter Harness (W37) Component Location—If Equipped........245
Auxiliary Fuel Filter Harness (W37) Wiring Diagram—If Equipped........246
Group 15: Diagnostic Information........160
Service ADVISOR™ Diagnostic Application........249
Service ADVISOR™ Connection Procedure........250
Reading Diagnostic Trouble Codes with Service ADVISOR™ Diagnostic Application........253
Intermittent Diagnostic Trouble Code (DTC) Diagnostics........256
Diagnostic Trouble Codes—After Machine Repair........257
Group 20: Adjustments........160
Boom Height Kickout (BHKO) Adjustment........259
Return-to-Dig Adjustment........260
Group 25: Tests........160
Electrical Component Specifications........266
Fuse and Relay Specifications........269
Alternator Test........272
Connector Terminal Test........274
Section 9020: Power Train........277
Group 05: Theory of Operation........277
AR15MTL Inboard Planetary Axle........280
Power Train Operation........281
Torque Converter Operation........282
Overrunning Clutch Operation........284
Transmission Operation........286
Park Brake Operation........291
Group 10: System Diagrams........277
Transmission System Schematic—Neutral........294
Power Train Component Location........296
Transmission Component Location........297
Transmission Hydraulic System and Transmission Control Valve Component Operation........298
Group 15: Diagnostic Information........277
Transmission Clutch Slippage........277
Machine Will Not Move in Either Direction........277
Machine Will Not Shift Correctly........277
Transmission System Pressure Is Low in Neutral........277
Transmission Pressure Is Low........277
Transmission Shifts Too Slow........277
Transmission Shifts Too Fast........277
Machine Creeps in Neutral........277
Transmission Hydraulic System Overheats........277
Transmission Excessive Noise........277
Oil Aerated........277
Oil Ejected from Filler Tube........277
Machine Vibrates........277
Machine Power and Acceleration Low........277
Torque Converter Stall RPM........277
Differential Oil Level Rises........277
Differential Oil Level Low........277
Differential and Axle Noise Excessive........277
Axle Overheats........278
Service Brakes Poor or Do Not Apply........278
Service Brakes Aggressive........278
Service Brakes Dragging........278
Service Brakes Lock Up........278
Service Brakes Chatter........278
Service Brake Warning Light On........278
Driveline Excessive Vibration or Noise........278
Park Brake Will Not Hold........278
Park Brake Will Not Release........382
Park Brake Overheats........278
Park Brake Light Does Not Come On........278
Park Brake Will Not Apply........278
Group 20: Adjustments........278
Service Brake Bleeding Procedure........391
External Service Brake Inspection........393
Service Brake Accumulator........396
Group 25: Tests........278
Transmission Oil Warm-Up Procedure........399
Transmission Pump Flow Test........401
Transmission System Pressure Test........403
Transmission Reverse Clutch Pressure Test........405
Torque Converter-Out Pressure Test........408
Torque Converter-In Pressure Test........411
Torque Converter-Out Flow Test........414
Torque Converter Stall Speed Test........416
Transmission Oil Cooler Restriction Test........418
Axle Breather Test........421
Section 9025: Hydraulic System........423
Group 05: Theory of Operation........423
Loader Hydraulic System Operation........427
Loader Hydraulic Pump Operation........428
Hydraulic Pump Manifold Operation........430
Steering System Component Operation........432
Steering Valve Operation........433
Pilot Pressure Reducing Valve Operation........435
Service Brake Hydraulic System Operation........436
Service Brake Accumulator Operation........437
Service Brake Valve Operation........438
Pilot Control Lever Operation........440
Loader Control Valve Operation........444
Boom Section Operation—Boom Down and Steering........446
Bucket Section Operation........448
Main Relief Valve Operation........450
Circuit Relief With Anticavitation Valve Operation........453
Anticavitation Valve Operation........453
Hydraulic Return Filter Operation........454
Group 10: System Diagrams........423
Hydraulic System Schematic........457
Steering Circuit Component Location........459
Loader Circuit Component Location........460
Service Brake Component Location........462
Hydraulic Pump Manifold (Hydraulic System Component Location)........463
Group 15: Diagnostic Information........423
No Hydraulic Functions........423
Hydraulic Functions Slow........423
Loader Hydraulic Pump Noisy........423
Steering/Loader Hydraulic Pump Noisy........423
No Steering Function........423
Boom Float Function Not Working........423
One Hydraulic Function Not Working........424
Hydraulic Function Drifts Down........424
Boom Down Does Not Work (Engine Off)........424
Oil Overheats........424
Hydraulic Oil Foams........424
Constant Steering Required to Maintain Straight Travel........424
Slow Steering Wheel Movement Will Not Cause Frame Movement........424
Steering Wheel Turns Without Resistance and Causes No Frame Movement........424
Steering Erratic........424
Steering Wheel Free Play........424
Orbital Steering Valve Binds or Locks Up........424
Steering Wheel Turns By Itself........424
Machine Turns in Opposite Direction as Steering Wheel........424
Steering Wheel Kickback........424
Steering Jerky........424
Group 20: Adjustments........424
Pilot Control Lever Adjustment........516
Accumulator Precharge........517
Group 25: Tests........424
Hydraulic Oil Sampling Procedure........520
Hydraulic Oil Warm-Up Procedure........521
Vacuum Pump Installation........523
Hydraulic System Pressure and Accumulators Discharge........524
JT02156A Digital Pressure and Temperature Analyzer Kit Installation........525
Steering/Loader Hydraulic Pump Flow Test........529
Loader Hydraulic Pump Flow Test........529
Main Relief Valve Pressure Test........532
Circuit Relief With Anticavitation Valve Pressure Test........536
Loader Cylinder Drift Test........540
Boom, Bucket, and Steering Cylinder Leakage Test........543
Hydraulic Oil Cooler Restriction Test........545
Orbital Steering Valve Leakage Test........548
Steering Cylinder Drift Test........552
Pilot Control Valve Pressure Test........556
Pilot Pressure Reducing Valve Pressure Test........562
Pilot Accumulator Gas Precharge Test........565
Cycle Time Test........568
Service Brake Accumulator Low Brake Pressure Warning Test........569
Service Brake Valve Pressure Test........572
Service Brake Valve Leakage Test........575
Hydraulic Oil Filter Inspection Procedure........578
Section 9031: Heating and Air Conditioning........579
Group 05: Theory of Operation........579
Air Conditioning System Cycle of Operation........582
Group 10: System Diagrams........579
Air Conditioner and Heater Component Location........585
Group 15: Diagnostic Information........579
Air Conditioning System Does Not Operate........579
Air Conditioner Does Not Cool Interior of Cab........579
Air Conditioning Runs Constantly, Too Cold........579
Heater System Does Not Operate........579
Heater Does Not Warm Interior of Cab........579
Interior Windows Continue to Fog........579
Group 25: Tests........579
Refrigerant Cautions and Proper Handling........610
R134a Refrigerant Cautions........611
R134a Oil Charge Capacity........612
R134a Refrigerant Charge Capacity........613
Refrigerant Hoses and Tubing Inspection........614
R134a Air Conditioning System Test........615
Operating Pressure Diagnostic Chart........618
Air Conditioning High/Low Pressure Switch Test........620
Freeze Control Switch Test........622
Refrigerant Leak Testing........623
John Deere 4WD Loaders WL53 Operation and Test Service Manual (TM13255X19)
