John Deere Tractors 5325N, 5425N, 5525N Diagnosis and Tests Service Technical Manual (TM2198)

tm2198 - 5325N, 5425N and 5525N Tractors Diagnostic Technical Manual.pdf

Complete Diagnosis & Tests Technical Manual with electrical wiring diagrams for John Deere Tractors 5325N, 5425N and 5525N (Worldwide), with all the shop information to maintain, diagnose, repair, rebuild like professional mechanics.

John Deere Tractors Models 5325N, 5425N and 5525N workshop Diagnosis & Tests technical 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.

Total Pages: 1,644 pages
File Format: PDF (bookmarked, ToC, Searchable, Printable, high quality)
Language: English

MAIN SECTIONS
   Foreword
   GENERAL
      Safety
      General Specifications
      General References
   DIAGNOSTIC TROUBLE CODES
      CCU Code Diagnostics
      HCU Code Diagnostics
      PTR Code Diagnostics
   OBSERVABLE SYMPTOMS
      Engines
      Fuel and Air
      Electrical
      Control Units
      PowrReverser™ Transmissions
      Drive Systems
      Steering and Brakes
      Hydraulics
      Operator Station
   SYSTEM DIAGNOSIS
      Starting, Charging and Start Aid
      PowrReverser™ Transmission
      Differential Lock
      MFWD
      Rear PTO
      Steering
      Rear Brakes
      Rear SCV System Diagnosis
      Mid-Mount Control Valve System Diagnosis
      Rear Hitch System Diagnosis
      Air Conditioning
   ENGINES
      General Information
      Tests and Adjustments
      Engine System Theory of Operation
   FUEL AND AIR
      General Information
      Fuel and Air Theory of Operation
   ELECTRICAL
      Load Center Fuses and Relays
      Tests and Adjustments
      Theory of Operation
      Functional Schematics
      Connector Information
   CONTROL UNITS
      General References
      Tests and Adjustments
      CCU
      HCU
      PTR
   POWRREVERSER™ TRANSMISSION
      General Information
      Preliminary and Operational Checks
      Tests and Adjustments
      Theory of Operation
      Schematics and Diagrams
   DRIVE SYSTEMS
      General Information
      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
      Operational and Preliminary Checks
      Tests and Adjustments
      Theory of Operation
      Schematics and Diagrams
   OPERATOR STATION
      General information
      Preliminary and Operational Checks
      Tests and Adjustments
      Theory of Operation
   SERVICE TOOLS
      Dealer Fabricated Tools
      Service Tools and Kits

tm2198 - 5325N, 5425N and 5525N Tractors Diagnostic Technical Manual

Table of Contents

Foreword

Section 210: GENERAL

Group 05: Safety

Recognize Safety Information

Understand Signal Words

Follow Safety Instructions

Handle Fluids Safely—Avoid Fires

Prevent Battery Explosions

Prepare for Emergencies

Prevent Acid Burns

Service and Operate Chemical Sprayers Safely

Handle Chemical Products Safely

Avoid High-Pressure Fluids

Park Machine Safely

Support Machine Properly

Wear Protective Clothing

Work in Clean Area

Service Machines Safely

Work In Ventilated Area

Illuminate Work Area Safely

Replace Safety Signs

Use Proper Lifting Equipment

Remove Paint Before Welding or Heating

Avoid Heating Near Pressurized Fluid Lines

Keep ROPS Installed Properly

Service Tires Safely

Avoid Harmful Asbestos Dust

Practice Safe Maintenance

Use Proper Tools

Dispose of Waste Properly

Prevent Machine Runaway

Handle Starting Fluid Safely

Service Cooling System Safely

Stay Clear of Rotating Drivelines

Protect Against High Pressure Spray

Construct Dealer-Made Tools Safely

Clean Vehicle of Hazardous Pesticides

Live With Safety

Group 10: General Specifications

Reference 210-10-001, General Specifications

Reference 210-10-002, General Reference List

Group 15: General References

Reference 210-15-002, Bolt and Cap Screw Torque Values

Reference 210-15-003, Glossary of Terms

Reference 210-15-004, JIC Hydraulic Symbols

Reference 210-15-005, Wiring Diagram and Schematic Information

Reference 210-15-006, Electrical Schematic Symbols

Reference 210-15-007, Reading Wiring Schematics and Diagrams

Reference 210-15-008, Visually Inspect Electrical System

Reference 210-15-009, Seven-Step Electrical Procedure

Reference 210-15-010, Using a Probe Light

Reference 210-15-011, Circuit Types

Reference 210-15-012, Circuit Malfunctions

Reference 210-15-013, Troubleshooting Circuit Malfunctions

Reference 210-15-014, Understanding Electrical vs. Electronic Circuits

Reference 210-15-015, Intermittent Electronic Problems

Reference 210-15-016, Relay Circuit Types

Reference 210-15-017, Using a Digital Multimeter

Reference 210-15-101, Troubleshooting Unresolved Problems

Section 211: DIAGNOSTIC TROUBLE CODES

Group CCU: CCU Code Diagnostics

CCU 000629.12 - CCU Control Unit Fault

CCU 001638.00 - Hydraulic Oil Temperature Very Hot

CCU 001638.03 - Hydraulic Oil Temperature Sensor Circuit Voltage high

CCU 001638.04 - Hydraulic Oil Temperature Sensor Circuit Voltage Low

CCU 001883.01 - Rear PTO Underspeed

CCU 524016.04 - CCU Switched Supply Voltage Low

CCU 524037.02 - MFWD Switch Circuit Fault

CCU 524224.14 - Rear PTO Disabled

CCU 524235.05 - MFWD Solenoid Circuit Fault

CCU 524252.05 - Rear PTO Solenoid Circuit Fault

Group HCU: HCU Code Diagnostics

HCU 000158.04 - HCU Switched Supply Voltage Low

HCU 000168.04 - HCU Unswitched Supply Voltage low

HCU 000190.02 - Rear Hitch Calibration Fault/Engine Speed Low

HCU 000629.12 - HCU Control Unit Fault

HCU 000630.13 - HCU Calibration Fault/Not Calibrated

HCU 001079.03 - HCU Sensor Supply Voltage high

HCU 001079.04 - HCU Sensor Supply Voltage Low

HCU 001638.02 - HCU Calibration Fault/Hydraulic Oil Temperature Low

HCU 001873.03 - Rear Hitch Position Sensor Circuit Voltage high

HCU 001873.04 - Rear Hitch Position Sensor Circuit Voltage Low

HCU 001873.13 - HCU Calibration Fault/Rear Hitch Position Sensor Circuit

HCU 001881.03 - Rear Hitch Draft Sensor Circuit Voltage high

HCU 001881.04 - Rear Hitch Draft Sensor Circuit Voltage Low

HCU 001881.13 - HCU Calibration Fault/Rear Hitch Draft Sensor Circuit

HCU 521000.31 - Rear Hitch External Switch Circuit Fault

HCU 521001.02 - HCU Calibration Fault/Rear Hitch Raise Valve Gain

HCU 521001.05 - Rear Hitch Raise Solenoid Current Low

HCU 521001.06 - Rear Hitch Raise Solenoid Current high

HCU 521001.07 - HCU Calibration Fault/Rear Hitch Raise Valve

HCU 521001.11 - HCU Calibration Fault/Rear Hhitch Raise Valve

HCU 521001.13 - HCU Calibration Fault/Rear Hitch Raise Valve

HCU 521002.05 - Rear Hitch Lower Solenoid Current Low

HCU 521002.06 - Rear Hitch Lower Solenoid Current high

HCU 521002.07 - HCU Calibration Fault/Rear Hitch Lower Valve

HCU 521002.11 - HCU Calibration Fault/Rear Hitch Lower Valve

HCU 521002.13 - HCU Calibration Fault/Rear Hitch Return Valve

HCU 523832.03 - Rear Hitch Rate-of-Drop Sensor Circuit Voltage high

HCU 523832.04 - Rear Hitch Rate-of-Drop Sensor Circuit Voltage Low

HCU 523833.03 - Rear Hitch Height-Limit Sensor Circuit Voltage high

HCU 523833.04 - Rear Hitch Height-Limit Sensor Circuit Voltage Low

HCU 523834.03 - Rear Hitch Control Lever Sensor Circuit Voltage high

HCU 523834.04 - Rear Hitch Control Lever Sensor Circuit Voltage Low

HCU 523834.13 - Hitch Calibration Fault/hitch Control Lever

HCU 523842.03 - Rear Hitch Load/Depth Sensor Circuit Voltage high

HCU 523842.04 - Rear Hitch Load/Depth Sensor Circuit Voltage Low

HCU 523843.02 - Rear Raise/Lower Switch Circuit Fault

HCU 523910.02 - HCU Control Unit Fault

HCU 523952.31 - Rear Hitch Disabled/HCU Configuration

HCU 524016.04 - HCU Switched Supply Voltage Low/Rear hitch Solenoids

Group PTR: PTR Code Diagnostics

PTR 000162.02 - Hi/Lo Switch Circuit Conflict

PTR 000162.30 - Hi/Lo Switch Stuck On

PTR 000168.01 - PTR Unswitched Supply Voltage Low

PTR 000190.18 - Engine Speed Low

PTR 000191.00 - Transmission Overspeed During Calibration

PTR 000191.17 - Transmission Underspeed

PTR 000598.02 - Clutch Pedal Switch/Sensor Circuit Conflict

PTR 000598.04 - Clutch Pedal Switch/Transmission Enable Sensor Circuit Conflict

PTR 000628.02 - EOL Data Fault

PTR 000630.07 - PTR Calibration Fault/Tractor Movement

PTR 000630.14 - PTR Not Calibrated

PTR 000734.05 - Forward Solenoid Circuit Fault

PTR 000735.05 - Reverse Solenoid Circuit Fault

PTR 000736.05 - Hi/Lo Solenoid Circuit Fault

PTR 000752.03 - Infinitely Variable Shuttle Control Circuit Voltage high

PTR 000752.04 - Infinitely Variable Shuttle Control Circuit Voltage Low

PTR 001079.03 - Sensor Reference Circuit Voltage high

PTR 001079.04 - Sensor Reference Circuit Voltage Low

PTR 001504.30 - Seat Switch Circuit Fault

PTR 523959.31 - Operator Left Seat with Directional Reverser Lever in Gear

PTR 523960.31 - Operator Not Seated During a Directional Reverser Lever Command

PTR 524017.07 - Gearshift Lever in Park with Directional Reverser Lever in Gear

PTR 524020.31 - Directional Reverser Lever in Gear at Power-Up

PTR 524021.31 - Directional Reverser Lever Switch Circuit Fault

PTR 524029.02 - Clutch Pedal Sensor Circuit Conflict

PTR 524029.15 - Clutch Pedal Sensor Circuit Voltage high

PTR 524029.16 - Clutch Pedal Sensor Circuit Voltage high, NR

PTR 524029.17 - Clutch Pedal Sensor Circuit Voltage Low

PTR 524029.18 - Clutch Pedal Sensor Circuit Voltage Low, NR

PTR 524060.03 - Transmission Enable Signal high During Operation

PTR 524060.04 - Transmission Enable Signal Low During Operation

PTR 524081.31 - Come-Home Mode Active

PTR 524160.02 - Not Neutral Signal Conflicts with Neutral Signal

PTR 524230.05 - Enable Proportional Valve Circuit Fault

PTR 524230.07 - Enable Valve Stuck Open

PTR 524234.03 - Enable Pressure Sensor Circuit Voltage high

PTR 524234.04 - Enable Pressure Sensor Circuit Voltage Low

Section 212: OBSERVABLE SYMPTOMS

Group 20: Engines

Engine Problems

Group 30: Fuel and Air

Fuel and Air Problems

Group 40: Electrical

12-Volt Electrical Problems

Connector Problems

Group 45: Control Units

Control Unit Problems

Group 55: PowrReverser™ Transmissions

PowrReverser Transmission Problems

Group 56: Drive Systems

Drive System Problems

Group 60: Steering and Brakes

Steering and Brake System Problems

Group 70: Hydraulics

Hitch Problems

Selective Control Valve Problems

Group 90: Operator Station

Air Conditioning Problems

Section 213: SYSTEM DIAGNOSIS

Group 40: Starting, Charging and Start Aid

Reference 213-40-001, Starting, Charging and Start Aid System Diagnosis

Group 55: PowrReverser™ Transmission

Reference 213-55-001, PowrReverser Transmission System Diagnosis

Group 56A: Differential Lock

Reference 213-56A-001, Differential Lock System Diagnosis

Group 56B: MFWD

Reference 213-56B-001, MFWD System Diagnosis

Group 56C: Rear PTO

Reference 213-56C-001, Rear Electro-Hydraulic PTO System Diagnosis

Group 60A: Steering

Reference 213-60A-001, Steering System Diagnosis

Group 60B: Rear Brakes

Reference 213-60B-001, Rear Brake System Diagnosis

Group 70A: Rear SCV System Diagnosis

Reference 213-70A-001, Triple Deluxe Rear SCV System Diagnosis

Reference 213-70A-002, Dual Rear SCV System Diagnosis

Group 70B: Mid-Mount Control Valve System Diagnosis

Reference 213-70B-001, Dual Mid-Mount Control Valve System Diagnosis

Group 70C: Rear Hitch System Diagnosis

Reference 213-70C-001, Rear Electro-Hydraulic Hitch System Diagnosis

Group 90: Air Conditioning

Reference 213-90-001, Air Conditioning System Diagnosis

Section 220: ENGINES

Group 05: General Information

Reference 220-05-001, John Deere Engine Repair—Use CTM301 or CTM104

Reference 220-05-002, General Engine Specifications

Reference 220-05-003, List of All Tractor-Specific Engine Information

Group 15: Tests and Adjustments

Reference 220-15-002, Throttle Lever Adjustment

Reference 220-15-003, Foot Throttle Pedal Stop Adjustment

Group 20: Engine System Theory of Operation

Reference 220-20-001, Overview of 5325N, 5425N, 5525N, 5083EN, 5093EN, and 5101EN Tractor Engines

Section 230: FUEL AND AIR

Group 05: General Information

John Deere Engine Fuel Systems Repair—Use CTM301 or CTM207

Group 20: Fuel and Air Theory of Operation

Reference 230-20-001, Fuel System Operation—5325N

Reference 230-20-002A, Fuel System Operation—5425N and 5525N

Reference 230-20-002B, Fuel System Operation—5083EN, 5093EN, and 5101EN

Reference 230-20-003, Air Intake System Operation (5-Cylinder)

Reference 230-20-004, Air Intake System Operation (4-Cylinder)

Section 240: ELECTRICAL

Group 05: Load Center Fuses and Relays

Reference 240-05-001, Fuse Load Center Diagram Listing

Reference 240-05-002, Load Center Panel—Cab Tractors

Reference 240-05-003, Vehicle Electrical Center—Straddle Mount Tractors

Group 15: Tests and Adjustments

Reference 240-15-001, Starting Circuit Test

Reference 240-15-002, Fuel Shutoff Solenoid Circuit Test

Reference 240-15-003, Battery Inspection Test

Reference 240-15-004, Charging System Test

Reference 240-15-005, Cold Start Circuit Test

Reference 240-15-006, Warning Lights Circuit Test—Cab Tractors

Reference 240-15-007, Warning Lights Circuit Test—Straddle Mount

Reference 240-15-008, Turn Signal Lights Circuit Test—Cab Tractors

Reference 240-15-009, Turn Signal Lights Circuit Test—Straddle Mount

Reference 240-15-010, Accessory Power and Junction Block Circuit Test—Cab Tractors

Reference 240-15-011, Accessory Power and Junction Block Circuit Test—Straddle Mount

Reference 240-15-012, Engine Oil Pressure Switch Circuit Test—Cab Tractors

Reference 240-15-013, Engine Oil Pressure Switch Circuit Test—Straddle Mount

Reference 240-15-014, Air Filter Restriction Switch Circuit Test—Cab Tractors

Reference 240-15-015, Air Filter Restriction Switch Circuit Test—Straddle Mount

Reference 240-15-016, Fuel Level Sender Circuit Test—Cab Tractors

Reference 240-15-017, Fuel Level Sender Circuit Test—Straddle Mount

Reference 240-15-018, Engine Coolant Temperature Sender Circuit Test—Cab Tractors

Reference 240-15-019, Engine Coolant Temperature Sender Circuit Test—Straddle Mount

Reference 240-15-020, Front Work Light Circuit Test—Cab Tractors

Reference 240-15-021, Beacon Light Circuit Test—Cab Tractors

Reference 240-15-022, Rear Work Light Circuit Test—Cab Tractors

Reference 240-15-023, Rear Work Light Circuit Test—Straddle Mount

Reference 240-15-024, Tail Light Circuit Test—Cab Tractors

Reference 240-15-025, Tail Light Circuit Test—Straddle Mount

Reference 240-15-026, Headlight and Backlighting Circuit Test—Cab Tractors

Reference 240-15-027, Headlight Circuit Test—Straddle Mount

Reference 240-15-028, Radio and Dome Light Circuit Test—Cab Tractors

Reference 240-15-029, HVAC Circuit Test—Cab Tractors

Reference 240-15-030, Wiper System Circuit Test—Cab Tractors

Reference 240-15-031, Key Switch Test

Group 20: Theory of Operation

Reference 240-20-200, Starting System Operation

Reference 240-20-201, Cold Start System Operation

Reference 240-20-202, Charging System Operation

Reference 240-20-203, Lighting System Operation—Turn Signals—Cab Tractors

Reference 240-20-204, Lighting System Operation—Turn Signals—Straddle Mount Tractors

Reference 240-20-205, Lighting System Operation—Warning Lights—Cab Tractors

Reference 240-20-206, Lighting System Operation—Warning Lights—Straddle Mount Tractors

Reference 240-20-207, Lighting System Operation—Tail Lights

Reference 240-20-208, Lighting System Operation—Headlights and Loader Lights

Reference 240-20-209, Work Light and Beacon Light Operation—Cab Tractors

Reference 240-20-210, Work Light Operation—Straddle Mount

Reference 240-20-211, Instrument Cluster Operation—Tachometer/Hour Meter

Reference 240-20-212, Instrument Cluster Operation—Fuel Gauge

Reference 240-20-213, Instrument Cluster Operation—Coolant Temperature Gauge

Reference 240-20-214, Air Filter Restriction Indicator Operation

Reference 240-20-215, Accessory Power and Junction Block Power Operation

Reference 240-20-216, Blower Motor Operation—Cab Tractors

Reference 240-20-217, A/C Compressor Operation—Cab Tractors

Reference 240-20-218, Front Wiper/Washer Operation—Cab Tractors

Reference 240-20-219, Rear Wiper/Washer Operation—Cab Tractors

Reference 240-20-220, Dome Light Operation—Cab Tractors

Reference 240-20-221, Convenience Outlet Operation

Group 25: Functional Schematics

Reference 240-25-001, Functional Schematics Listing

Reference 240-25-100, Schematic and Component Identification Legend

Reference 240-25-101, SE1—Starting Motor And Charging, SE2—Cold Start, SE3—PTO And Fuel Shutoff, SE4—Accessory Power, And SE5—Optional Horn Circuits

Reference 240-25-102, SE6—Light Switch, SE7—Headlights And Optional Loader Lights, SE8—Front Work Lights And Optional Beacon Light, And SE9—Rear Work Lights Circuits

Reference 240-25-103, SE10—Tail/Turn Lights, SE11—Turn Signal Switch And Hazard Warning Lights, SE12—Power Source, SE13—Trailer Interface, And SE14—Power Outlet Circuits

Reference 240-25-104, SE15—HVAC Narrow Cab, SE16—Front Wiper, SE17—Rear Wiper, SE18—Console Light, Dome Light And Door Switch, And SE19—Radio Circuits

Reference 240-25-105, SE20—Instrumentation Circuit

Reference 240-25-106, SE21—ELX Relay And Fuses, SE22—MFWD Option, SE23—Seat Switch And Wheel Speed, And SE24—Brake Switch Circuits

Reference 240-25-107, SE25—Backup Alarm Option, And SE26—PowrReverser™ Transmission Circuits

Reference 240-25-108, SE27—Electro-Hydraulic Control, SE28—Electro-Hydraulic hitch Control, And SE29—Power And Service Advisor Circuits

Reference 240-25-109, Cold Start Circuit Diagnostic Wiring Diagram—Cab Tractors

Reference 240-25-110, Cold Start Circuit Diagnostic Wiring Diagram—Straddle Mount

Reference 240-25-111, Charging Circuit Diagnostic Wiring Diagram—Cab Tractors

Reference 240-25-112, Charging Circuit Diagnostic Wiring Diagram—Straddle Mount

Reference 240-25-113, Starting Circuit Diagnostic Wiring Diagram—Cab Tractors

Reference 240-25-114, Starting Circuit Diagnostic Wiring Diagram—Straddle Mount

Reference 240-25-115, Horn Circuit Diagnostic Wiring Diagram—Cab Tractors

Reference 240-25-116, Horn Circuit Diagnostic Wiring Diagram—Straddle Mount

Reference 240-25-117, Headlight and Loader Light Diagnostic Wiring Diagram—Cab Tractors

Reference 240-25-118, Headlight and Loader Light Diagnostic Wiring Diagram—Straddle Mount

Reference 240-25-119, Front Work Lights and Beacon Light Cab Diagnostic Wiring Diagram—Cab Tractors

Reference 240-25-120, Rear Work Lights Diagnostic Wiring Diagram—Cab Tractors

Reference 240-25-121, Rear Work Lights Diagnostic Wiring Diagram—Straddle Mount

Reference 240-25-122, Turn Signal and Warning Lights Diagnostic Wiring Diagram—Cab Tractors

Reference 240-25-123, Turn Signal and Warning Lights Diagnostic Wiring Diagram—Straddle Mount

Reference 240-25-124, Tail Lights Diagnostic Wiring Diagram—Cab Tractors

Reference 240-25-125, Tail Lights Diagnostic Wiring Diagram—Straddle Mount

Reference 240-25-126, Junction Block Diagnostic Wiring Diagram—Cab Tractors

Reference 240-25-127, Junction Block Diagnostic Wiring Diagram—Straddle Mount

Reference 240-25-128, Radio and Dome Light Diagnostic Wiring Diagram—Cab Tractors

Reference 240-25-129, Engine Oil Pressure Switch Diagnostic Wiring Diagram—Cab Tractors

Reference 240-25-130, Engine Oil Pressure Switch Diagnostic Wiring Diagram—Straddle Mount

Reference 240-25-131, Air Filter Restriction Switch Diagnostic Wiring Diagram—Cab Tractors

Reference 240-25-132, Air Filter Restriction Switch Diagnostic Wiring Diagram—Straddle Mount

Reference 240-25-133, Fuel Level Sender Diagnostic Wiring Diagram—Cab Tractors

Reference 240-25-134, Fuel Level Sender Diagnostic Wiring Diagram—Straddle Mount

Reference 240-25-135, Engine Coolant Temperature Sender Diagnostic Wiring Diagram—Cab Tractors

Reference 240-25-136, Engine Coolant Temperature Sender Diagnostic Wiring Diagram—Straddle Mount

Reference 240-25-137, HVAC Diagnostic Wiring Diagram—Cab Tractors

Reference 240-25-138, Wiper System Diagnostic Wiring Diagram—Cab Tractors

Group 30: Connector Information

Reference 240-30-001, Cab-to-Engine Connector X1, Cab Tractors

Reference 240-30-002, Chassis-to- Engine Connector X1, Straddle Mount

Reference 240-30-003, Cab-to-Chassis Connector X3—Cab Tractors

Reference 240-30-004, Cab-to-Chassis Connector X4—Cab Tractors

Reference 240-30-005, Cab-to-Roof Connector X9—Cab Tractors

Reference 240-30-006, Vehicle Electrical Center (VEC) Connectors X22—X25, Straddle Mount

Reference 240-30-007, Roof-to-HVAC Connector X26—Cab Tractors

Reference 240-30-008, Electro-Hydraulic Controller Connectors A6J1—A6J3, Cab Tractors

Reference 240-30-009, Electro-Hydraulic Controller Connectors A6J1—A6J3, Straddle Mount

Section 245: CONTROL UNITS

Group 05: General References

Reference 245-05-001, Electro-Hydraulic Controller General Information

Reference 245-05-002, Performance Monitor General Operation

Reference 245-05-003, Diagnostic Trouble Code Listing

Reference 245-05-003A, PRF Code List

Reference 245-05-003B, CCU Code List

Reference 245-05-003C, HCU Code List

Reference 245-05-003D, PTR Code List

Reference 245-05-004, Control Unit Addresses

Reference 245-05-004A, CCU Address List

Reference 245-05-004B, HCU Address List

Reference 245-05-004C, PTR Address List

Reference 245-05-005, Programming Control Units

Reference 245-05-006, CAN Network Voltage Checks

Reference 245-05-200, CAN Communication System Theory of Operation

Reference 245-05-201, VIN Security Fault Diagnosis

Reference 245-05-300, CAN Communication System Diagnostic Wiring Diagram Listing

Reference 245-05-301, CAN System Diagnostic Wiring Diagram—Straddle Mount Tractors

Reference 245-05-302, CAN System Diagnostic Wiring Diagram—Cab Tractors

Group 15: Tests and Adjustments

Reference 245-15-001, Electro-Hydraulic Controller Switched Supply Voltage and Ground Test

Reference 245-15-002, Electro-Hydraulic Controller Unswitched Supply Voltage and Ground Test

Reference 245-15-301, Electro-Hydraulic Controller Power Supply Wiring Diagram—Straddle Mount Tractors

Reference 245-15-302, Electro-Hydraulic Controller Power Supply Wiring Diagram—Cab Tractors

Group CCU: CCU

CCU - Chassis Control Unit (CCU) Calibration

CCU - CCU Beep Mode Test With Speed Sensors

CCU - Beep Mode Test Without Speed Sensors

CCU - Hydraulic Oil Temperature Sensor Circuit Test

Reference 245-CCU-005, Engine Speed Sensor Circuit Test

CCU - Wheel Speed Sensor Circuit Test

CCU - EH MFWD Switch Circuit Test

CCU - EH MFWD Solenoid Circuit Test

CCU - Brake Switch Assembly Circuit Test

Reference 245-CCU-010, Rear EH PTO Switch Circuit Test

CCU - Rear EH PTO Solenoid Circuit Test

CCU - Rear EH PTO Speed Sensor Circuit Test

CCU - Controller Theory of Operation

CCU - Hydraulic Oil Temperature Sensor Theory of Operation

Reference 245-CCU-203, Engine Speed Sensor Theory of Operation

CCU - Wheel Speed Sensor Theory of Operation

CCU - EH MFWD Switch Theory of Operation

CCU - MFWD Solenoid Theory of Operation

CCU - Brake Switch Assembly Theory of Operation

CCU - Rear EH PTO Switch Theory of Operation

CCU - Rear EH PTO Solenoid Theory of Operation

CCU - Rear EH PTO Speed Sensor Theory of Operation

Reference 245-CCU-301, Hydraulic Oil Temperature Sensor Diagnostic Wiring Diagram

Reference 245-CCU-302A, Engine Speed Sensor Diagnostic Wiring Diagram—Straddle Mount Tractors

Reference 245-CCU-302B, Engine Speed Sensor Diagnostic Wiring Diagram—Cab Tractors

Reference 245-CCU-303A, Wheel Speed Sensor Diagnostic Wiring Diagram—Straddle Mount Tractors

Reference 245-CCU-303B, Wheel Speed Sensor Diagnostic Wiring Diagram—Cab Tractors

Reference 245-CCU-304A, MFWD Diagnostic Wiring Diagram—Straddle Mount Tractors

Reference 245-CCU-304B, MFWD Diagnostic Wiring Diagram—Cab Tractors

Reference 245-CCU-305A, Brake Switch Assembly Diagnostic Wiring Diagram—Straddle Mount Tractors

Reference 245-CCU-305B, Brake Switch Assembly Diagnostic Wiring Diagram—Cab Tractors

Reference 245-CCU-306A, Rear EH PTO Switch Diagnostic Wiring Diagram—Straddle Mount Tractors

Reference 245-CCU-306B, Rear EH PTO Switch Diagnostic Wiring Diagram—Cab Tractors

Reference 245-CCU-307, Rear EH PTO Solenoid Diagnostic Wiring Diagram

Reference 245-CCU-308A, Rear EH PTO Speed Sensor Diagnostic Wiring Diagram—Straddle Mount Tractors

Reference 245-CCU-308B, Rear EH PTO Speed Sensor Diagnostic Wiring Diagram—Cab Tractors

Group HCU: HCU

Reference 245-HCU-001, HCU Control Unit Calibration

Reference 245-HCU-002, HCU Beep Mode Test

Reference 245-HCU-003, Rear Hitch Control Lever Circuit Test

Reference 245-HCU-004, Rear Hitch Raise/Lower Switch Circuit Test

Reference 245-HCU-005, Rear Hitch Height-Limit Control Circuit Test

Reference 245-HCU-006, Rear Hitch Rate-of-Drop Control Circuit Test

Reference 245-HCU-007, Rear Hitch Load/Depth Control Circuit Test

Reference 245-HCU-008, Rear Hitch Left External Switch Circuit Test

Reference 245-HCU-010, Rear Hitch Raise Solenoid Circuit Test

Reference 245-HCU-011, Rear Hitch Lower Solenoid Circuit Test

Reference 245-HCU-012, Rear Hitch Position Sensor Circuit Test

Reference 245-HCU-013, Rear Hitch Draft Sensor Circuit Test

Reference 245-HCU-201, HCU Control Unit Theory of Operation

Reference 245-HCU-202, Rear Hitch Control Lever Theory of Operation

Reference 245-HCU-203, Rear Hitch Raise/Lower Switch Theory of Operation

Reference 245-HCU-204, Rear Hitch Height-Limit Control Theory of Operation

Reference 245-HCU-205, Rear Hitch Rate-of-Drop Control Theory of Operation

Reference 245-HCU-206, Rear Hitch Load/Depth Control Theory of Operation

Reference 245-HCU-207, Rear Hitch Left External Switch Theory of Operation

Reference 245-HCU-208, Rear Hitch Raise and Lower Solenoids Theory of Operation

Reference 245-HCU-209, Rear Hitch Position Sensor Theory of Operation

Reference 245-HCU-210, Rear Hitch Draft Sensor Theory of Operation

Reference 245-HCU-301A, Rear Hitch Control Assembly Diagnostic Wiring Diagram—Straddle Mount Tractors

Reference 245-HCU-301B, Rear Hitch Control Assembly Diagnostic Wiring Diagram—Cab Tractors

Reference 245-HCU-302A, Hitch Load/Depth Control Diagnostic Wiring Diagram—Straddle Mount Tractors

Reference 245-HCU-302B, Hitch Load/Depth Control Diagnostic Wiring Diagram—Cab Tractors

Reference 245-HCU-303A, Rear Hitch Left External Switch Diagnostic Wiring Diagram—Straddle Mount Tractors

Reference 245-HCU-303B, Rear Hitch Left External Switch Diagnostic Wiring Diagram—Cab Tractors

Reference 245-HCU-305, Rear Hitch Raise and Lower Solenoids Diagnostic Wiring Diagram

Reference 245-HCU-306, Rear Hitch Position Sensor Diagnostic Wiring Diagram

Reference 245-HCU-307, Rear Hitch Draft Sensor Diagnostic Wiring Diagram

Group PTR: PTR

Reference 245-PTR-001, PTR Control Unit Calibration

Reference 245-PTR-002, PTR Control Unit Beep Mode Test With Speed Sensors

Reference 245-PTR-003, PTR Control Unit Beep Mode Test Without Speed Sensors

Reference 245-PTR-004, Directional Reverser Switch Circuit Test

Reference 245-PTR-005, Clutch Disengaged Switch Circuit Test

Reference 245-PTR-006, Optional Hi/Lo Switch Circuit Test

Reference 245-PTR-007, Optional Infinitely Variable Shuttle Control Circuit Test

Reference 245-PTR-008, Park Switch Circuit Test

Reference 245-PTR-009, Seat Switch Circuit Test

Reference 245-PTR-010, Forward Solenoid Circuit Test

Reference 245-PTR-011, Reverse Solenoid Circuit Test

Reference 245-PTR-012, Clutch Enable Proportional Valve Circuit Test

Reference 245-PTR-013, Optional Hi/Lo Solenoid Circuit Test

Reference 245-PTR-014, Clutch Pedal Position Sensor Circuit Test

Reference 245-PTR-015, Enable Pressure Sensor Circuit Test

Reference 245-PTR-016, Countershaft Speed Sensor Circuit Test

Reference 245-PTR-201, PTR Control Unit Theory of Operation

Reference 245-PTR-202, Come-Home Mode Theory of Operation

Reference 245-PTR-203, Directional Reverser Switch Theory of Operation

Reference 245-PTR-204, Clutch Disengaged Switch Theory of Operation

Reference 245-PTR-205, Optional Hi/Lo Switch Theory of Operation

Reference 245-PTR-206, Optional Infinitely Variable Shuttle Control Theory of Operation

Reference 245-PTR-207, Park Switch Theory of Operation

Reference 245-PTR-208, Seat Switch Theory of Operation

Reference 245-PTR-209, Forward Solenoid Theory of Operation

Reference 245-PTR-210, Reverse Solenoid Theory of Operation

Reference 245-PTR-211, Clutch Enable Proportional Valve Theory of Operation

Reference 245-PTR-212, Optional Hi/Lo Solenoid Theory of Operation

Reference 245-PTR-213, Clutch Pedal Position Sensor Theory of Operation

Reference 245-PTR-214, Enable Pressure Sensor Theory of Operation

Reference 245-PTR-215, Countershaft Speed Sensor Theory of Operation

Reference 245-PTR-301A, Directional Reverser Switch Circuit Diagnostic Wiring Diagram—Straddle Mount Tractors

Reference 245-PTR-301B, Directional Reverser Switch Circuit Diagnostic Wiring Diagram—Cab Tractors

Reference 245-PTR-302A, Clutch Disengaged Switch Diagnostic Wiring Diagram—Straddle Mount Tractors

Reference 245-PTR-302B, Clutch Disengaged Switch Diagnostic Wiring Diagram—Cab Tractors

Reference 245-PTR-303A, Optional Hi/Lo Switch and Solenoid Diagnostic Wiring Diagram—Straddle Mount Tractors

Reference 245-PTR-303B, Optional Hi/Lo Switch and Solenoid Diagnostic Wiring Diagram—Cab Tractors

Reference 245-PTR-304A, Optional Infinitely Variable Shuttle Control Diagnostic Wiring Diagram—Straddle Mount Tractors

Reference 245-PTR-304B, Optional Infinitely Variable Shuttle Control Diagnostic Wiring Diagram—Cab Tractors

Reference 245-PTR-305A, Park Switch Diagnostic Wiring Diagram—Straddle Mount Tractors

Reference 245-PTR-305B, Park Switch Diagnostic Wiring Diagram—Cab Tractors

Reference 245-PTR-306A, Seat Switch Diagnostic Wiring Diagram—Straddle Mount Tractors

Reference 245-PTR-306B, Seat Switch Diagnostic Wiring Diagram—Cab Tractors

Reference 245-PTR-307A, Forward Solenoid Diagnostic Wiring Diagram—Straddle Mount Tractors

Reference 245-PTR-307B, Forward Solenoid Diagnostic Wiring Diagram—Cab Tractors

Reference 245-PTR-308A, Reverse Solenoid Diagnostic Wiring Diagram—Straddle Mount Tractors

Reference 245-PTR-308B, Reverse Solenoid Diagnostic Wiring Diagram—Cab Tractors

Reference 245-PTR-309, Clutch Enable Proportional Valve Diagnostic Wiring Diagram

Reference 245-PTR-310A, Clutch Pedal Position Sensor Diagnostic Wiring Diagram—Straddle Mount Tractors

Reference 245-PTR-310B, Clutch Pedal Position Sensor Diagnostic Wiring Diagram—Cab Tractors

Reference 245-PTR-311, Enable Pressure Sensor Diagnostic Wiring Diagram

Reference 245-PTR-312A, Countershaft Speed Sensor Diagnostic Wiring Diagram—Straddle Mount Tractors

Reference 245-PTR-312B, Countershaft Speed Sensor Diagnostic Wiring Diagram—Cab Tractors

Section 255: POWRREVERSER™ TRANSMISSION

Group 05: General Information

Reference 255-05-001, Install Test Equipment

Group 10: Preliminary and Operational Checks

Reference 255-10-001, Transmission Preliminary Checks

Reference 255-10-002, Transmission Operational Checks

Group 15: Tests and Adjustments

Reference 255-15-001, PowrReverser Control Valve Tests

Reference 255-15-002, PowrReverser Pump Flow Test

Reference 255-15-003, Electro-Hydraulic (EH) Hi/Lo Valve Pressure Test

Reference 255-15-004, PowrReverser Main Pressure Relief Valve Adjustment

Group 20: Theory of Operation

Reference 255-20-001, PowrReverser Transmission Theory of Operation Information Reference Listing

Reference 255-20-002, PowrReverser General Information

Reference 255-20-003, PowrReverser Operation in Forward (Without Electro-Hydraulic Hi/Lo)

Reference 255-20-004, PowrReverser Operation in Reverse (Without Electro-Hydraulic Hi/Lo)

Reference 255-20-005, PowrReverser Operation in Forward/Low (With Electro-Hydraulic Hi/Lo)

Reference 255-20-006, PowrReverser Operation in Forward/high (With Electro-Hydraulic Hi/Lo)

Reference 255-20-007, PowrReverser Operation in Reverse/Low (With Electro-Hydraulic Hi/Lo)

Reference 255-20-008, PowrReverser Operation in Reverse/high (With Electro-Hydraulic Hi/Lo)

Reference 255-20-009, PowrReverser Control Valve Operation—Electro-Hydraulic Directional Reverser in Neutral

Reference 255-20-010, PowrReverser Control Valve Operation—Electro-Hydraulic Directional Reverser in Forward

Reference 255-20-011, PowrReverser Control Valve Operation—Electro-Hydraulic Directional Reverser in Reverse

Reference 255-20-012, Electro-Hydraulic Hi/Lo Valve Operation—Low Position

Reference 255-20-013, Electro-Hydraulic Hi/Lo Valve Operation—high Position

Reference 255-20-014, PowrReverser Transmission—Gearshift Power Flow

Reference 255-20-015, PowrReverser Transmission—Range Shift Power Flow

Reference 255-20-016, Gearshift Synchronizer Operation

Reference 255-20-017, PowrReverser Transmission Lubrication System (Without Electro-Hydraulic Hi/Lo)

Reference 255-20-018, PowrReverser Transmission Lubrication System (With Electro-Hydraulic Hi/Lo)

Group 25: Schematics and Diagrams

Reference 255-25-001, PowrReverser™ Transmission Component Location Listing

Reference 255-25-002, PowrReverser™ Transmission Hydraulic Schematic (Without Electro-Hydraulic Hi/Lo)

Reference 255-25-003, PowrReverser™ Transmission Hydraulic Schematic (With Electro-Hydraulic Hi/Lo)

Reference 255-25-004, Power Train Components—Straddle Mount

Reference 255-25-005, Power Train Components—Cab Tractors

Reference 255-25-006, PowrReverser™ Components (Without Electro-Hydraulic Hi/Lo)

Reference 255-25-007, PowrReverser™ Components (With Electro-Hydraulic Hi/Lo)

Reference 255-25-008, Transmission Components (Without Electro-Hydraulic Hi/Lo)

Reference 255-25-009, Transmission Components (With Electro-Hydraulic Hi/Lo)

Section 256: DRIVE SYSTEMS

Group 05: General Information

Reference 256-05-001, Install Test Equipment

Group 10: Preliminary and Operational Checks

Reference 256-10-001, Preliminary Checks

Reference 256-10-002, Rear Differential Lock Operational Check

Reference 256-10-003, EH PTO Operational Checks

Reference 256-10-004, MFWD Operational Checks

Group 15: Tests and Adjustments

Reference 256-15-001, Electro-Hydraulic PTO Test

Reference 256-15-002, MFWD Clutch Test

Reference 256-15-003, PTO 540/540E Lever and Linkage Adjustment

Group 20: Theory of Operation

Reference 256-20-001, Drive Systems Theory of Operation Reference Listing

Reference 256-20-002 Differential Power Flow

Reference 256-20-003, Differential Lock Operation

Reference 256-20-004, Final Drive Operation

Reference 256-20-005, Valve Block Operation (Without Electro-Hydraulic Hi/Lo)

Reference 256-20-006, Optional Mechanical Front Wheel Drive (MFWD) Operation

Reference 256-20-007, Optional Mechanical Front Wheel Drive (MFWD) Drop Gearbox Operation

Reference 256-20-008, Electro-Hydraulic PTO Operation

Reference 256-20-009, Electro-Hydraulic PTO Valve Operation

Reference 256-20-010, 540/540E Electro-Hydraulic PTO Clutch Operation

Reference 256-20-011, 540/1000 PTO Lock-Out Operation

Group 25: Schematics and Diagrams

Reference 256-25-001, Drive Systems Component Location Listing

Reference 256-25-002, Final Drive Components

Reference 256-25-003, 540/540E EH PTO Components

Reference 256-25-004, 540/1000 EH PTO Components

Section 260: STEERING AND BRAKES

Group 05: General Information

Reference 260-05-001, Install Test Equipment

Group 10: Preliminary And Operational Checks

Reference 260-10-001, Steering Preliminary Check

Reference 260-10-002, Steering Operational Check

Reference 260-10-003, Rear Brakes Preliminary Check

Reference 260-10-004, Rear Brake Operational Test

Group 15: Test And Adjustments

Reference 260-15-001, Steering Pump Flow Test

Reference 260-15-002, Steering Valve Relief Test

Reference 260-15-003, Steering Leak Test

Reference 260-15-004, Checking Toe-In—Adjustable Front Axle

Reference 260-15-005, Adjusting Toe-In—Adjustable Front Axle

Reference 260-15-006, Checking Toe-In—MFWD Axle

Reference 260-15-007, Adjusting Toe-In—MFWD Tractor

Reference 260-15-008, Set MFWD Steering Stops—MFWD Axle

Reference 260-15-009, Bleed Rear Brakes

Reference 260-15-010, Rear Brake Valve Leak Test

Reference 260-15-011, Brake Pedal Adjustment

Reference 260-15-012, Adjust Brake Retractors

Group 20: Theory Of Operation

Reference 260-20-001, Steering Valve Operation—Neutral and Manual Turning

Reference 260-20-002, Steering Valve Operation—Power Turning

Reference 260-20-003, Brake System Operation

Reference 260-20-004, Brake Valve Operation

Section 270: HYDRAULICS

Group 05: General Information

Reference 270-05-001, Install Test Equipment

Reference 270-05-002, Warming Transmission/Hydraulic System Oil

Group 10: Operational and Preliminary Checks

Reference 270-10-001, Hydraulic System Preliminary Checks

Reference 270-10-002, Hydraulic System Operational Checks

Group 15: Tests and Adjustments

Reference 270-15-002, Pump Flow Test

Reference 270-15-003, Main Relief Valve Test

Reference 270-15-004, Rockshaft Load Sense Relief Valve Test

Reference 270-15-005, SCV Leakage Test

Reference 270-15-006, Triple Deluxe Rear SCV Functional Test

Reference 270-15-007, Triple Deluxe Rear SCV Flow Control Test

Reference 270-15-008, Rockshaft Leakage Test

Reference 270-15-009, Rockshaft Lift Cycle Test

Reference 270-15-010, Mid-Mount Control Valve Cable Adjustment

Reference 270-15-011, Rear Selective Control Valve (SCV) Cable Adjustment

Reference 270-15-012, Load Sensing Relief Valve Adjustment

Group 20: Theory of Operation

Reference 270-20-001, Hydraulic System Theory of Operation Information Reference Listing

Reference 270-20-002, Hydraulic System Operation

Reference 270-20-003, Main Hydraulic Filter Operation

Reference 270-20-004, Hydraulic Pump Operation

Reference 270-20-005, Electro-Hydraulic Hitch Control Valve Operation—Neutral

Reference 270-20-006, Electro-Hydraulic Hitch Control Valve Operation—Raise

Reference 270-20-007, Electro-Hydraulic Hitch Control Valve Operation—Lower

Reference 270-20-008, Electro-Hydraulic Hitch Main Relief Valve Operation

Reference 270-20-009, Dual Rear SCV Operation—Neutral Position

Reference 270-20-010, Dual Rear SCV Operation—Extend and Retract Positions

Reference 270-20-011, Dual Rear SCV Operation—Float Position

Reference 270-20-016, Dual Mid-Mount Control Valve Operation—Neutral Position

Reference 270-20-017, Dual Mid-Mount Control Valve Operation—Extend and Retract Positions

Reference 270-20-018, Dual Mid-Mount Control Valve Operation—Float Position

Reference 270-20-019, Dual Mid-Mount Control Valve Operation—Regenerative Position

Reference 270-20-020, Quick Disconnect Coupler Operation

Group 25: Schematics and Diagrams

Reference 270-25-001, Hydraulic System Schematic and Diagram Listing

Reference 270-25-002, Hydraulic System Schematic—POWRREVERSER Transmission without Electro-Hydraulic Hi/Lo

Reference 270-25-003, Hydraulic System Schematic—POWRREVERSER Transmission with Electro-Hydraulic Hi/Lo

Reference 270-25-004, Hydraulic System Schematic—POWRREVERSER Transmission with Electro-Hydraulic hitch (with Dual Rear SCV)

Reference 270-25-005, Hydraulic System Schematic—POWRREVERSER Transmission with Electro-Hydraulic hitch (with Triple Deluxe Rear SCV)

Reference 270-25-006, Hydraulic System Schematic—POWRREVERSER Transmission with Electro-Hydraulic hitch (with Mid-Mount Control Valve and Dual Rear SCV)

Reference 270-25-007, Hydraulic System Schematic—POWRREVERSER Transmission with Electro-Hydraulic hitch (with Mid-Mount Control Valve and Triple Deluxe Rear SCV)

Section 290: OPERATOR STATION

Group 05: General information

Reference 290-05-001, Install Test Equipment

Group 10: Preliminary and Operational Checks

Reference 290-10-001, A/C System Preliminary Checks

Reference 290-10-002, Air Conditioning Operational Checks

Group 15: Tests and Adjustments

Reference 290-15-001, HVAC Circulation Blower Motor Circuit Test

Reference 290-15-002, HVAC Compressor Clutch Engagement and Cycle Test

Reference 290-15-003, HVAC System Pressure Check

Reference 290-15-004, HVAC Temperature Drop Check

Reference 290-15-005, Summary of A/C Testing

Reference 290-15-006, A/C System Moisture Removal Procedure

Group 20: Theory of Operation

Reference 290-20-001, Air Conditioning Theory of Operation

Section 299: SERVICE TOOLS

Group 05: Dealer Fabricated Tools

DFRW26—Test Lead for Automotive-Style Fuses

DFRW51—Electronic Circuit Load Tester

DFRW126—Modified Tap Out Harness

DFRW133—Tap Out Harness

Group 10: Service Tools and Kits

AR94522—ISO SCV Coupler

JDG774—Solenoid Test Harness

JT02051—Manifold with Gauges

JT02081 — Halogen Leak Detector

JT02153 — Current Clamp-On Probe

JT03043—Adapter 1/2 M NPT x 1-1/16 M 37°

JT03044—Adapter 3/4 M NPT x 1-1/16 M 37°

JT03051—Adapter 1-1/16 F 37° x 1-1/16 F 37°

JT03059—90° Elbow, 1 1/16-12 M 37° x 1 1/16-12 F 37° Sw

JT03110—Adapter

JT03262—Adapter

JT03345—Gauge

JT03364—Hose with Coupler

JT03367—Connector

JT03481—Kit

JT03481-1—Adapter Male Quick Coupler Plug x 1/4 M NPT

JT03481-3—Straight Fitting 3/4-14 F NPT x M20 x 1.5 ORB

JT03481-4—Straight Fitting 1/8 M BSPT X 1/8 F NPT

JT03520—Special Adapter

JT05473—Gauge w/Quick Coupler, 0-35,000 kPa (0-5000 psi)

JT05483—Elbow 7/16-20 M 37 X 7/16-20 F 37 Sw

JT05494—7/16-20 M 37° x 3/4-16 M ORB

JT05498—Hose 508 mm (20 in.)

JT05634—Pressure Gauge

JT05685—Battery Load Tester

JT05791—Digital Multimeter

JT05843 — Hydrometer

JT07032—Gauge 400 kPa (60 psi)

JT07041—Gauge 2800 kPa (400 psi)

JT07148—Digital Hydraulic Tester

LVB24862—Wiring Harness

RE200690—Performance Monitor