John Deere Loader 524K-II 4WD Operation Test Technical Manual TM14139X19 2021

Description

Contents:
General Information
Safety
Information for European Union Directives and Eurasian Economic Union Technical Regulations Compliance
To the Customer
Sound and Vibration Specifications
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
Work In Ventilated Area
Avoid Static Electricity Risk When Refueling
Prevent Fires
In Case of Machine Fire
Prevent Battery Explosions
High Debris Applications
Clean Debris from Machine
Handle Chemical Products Safely
Handle Starting Fluid Safely
Decommissioning — Proper Recycling and Disposal of Fluids and Components
Prepare for Emergencies
Add Cab Guarding for Special Uses
Use Steps and Handholds Correctly
Start Only From Operator′s Seat
Use and Maintain Seat Belt
Prevent Unintended Machine Movement
Avoid Work Site Hazards
Use Special Care When Operating Loader
Keep Riders Off Machine
Avoid Backover Accidents
Avoid Machine Tip Over and Machine Damage
Avoid Power Lines
Operating on Slopes
Operating or Traveling On Public Roads
Inspect and Maintain ROPS
Travel Safely
Prevent Acid Burns
Add and Operate Attachments Safely
Park and Prepare for Service Safely
Service Machines Safely
Service Cooling System Safely
Service Tires Safely
Use Proper Lifting Equipment
Remove Paint Before Welding or Heating
Make Welding Repairs Safely
Drive Metal Pins Safely
Diagnostics
Engine Control Unit (ECU) Diagnostic Trouble Codes
Engine Control Unit (ECU) Diagnostic Trouble Codes
Eng Throttle Short to Power
Eng Throttle Open or Short
Eng Throttle Sensor Invalid
Engine Air Filter is Extremely Restricted
Intake Air Sensor Short to Power
Intake Air Sensor Open or Short
Engine Speed Extremely High
Starter Relay Open Circuit
Starter Relay High Current
Too Long to Start
Starter Sol Open Circuit
CAN Comm Lost for TCU
CAN Comm Lost for VCU
Ether Starting Aid Circuit Fault
Transmission Control Unit (TCU) Diagnostic Trouble Codes
Transmission Control Unit (TCU) Diagnostic Trouble Codes
Timeout EEC2 Message
Input Speed High
Percent Torque Invalid
Timeout EEC1 Message
Friction Invalid
Timeout EEC3 Message
Reference Torque Invalid
Timeout Engine Configuration Message
Engine Speed Limit Function Does Not Work Properly
Controller Area Network (CAN) Communication Lost for Vehicle Control Unit (VCU)
Controller Area Network (CAN) Communication Lost for Sealed Switch Module (SSM)
Converter Input Speed Sensor Open or Short
Converter Input Speed Sensor Short to Ground
Converter Input Speed Sensor Fault
Torque Converter Overtemperature
Transmission Input Torque Overload
Transmission Clutch Calibration Failed
Transmission Clutch Calibration Fault
Limp Home Mode
Application Invalid
Transmission Control Unit (TCU) Configuration Invalid
Transmission Control Unit (TCU) Memory Failure
Transmission Control Unit (TCU) Valve Power Supply 2 Short Circuit
Transmission Control Unit (TCU) Valve Power Supply 1 Short Circuit
Power Supply High Voltage
Power Supply Low Voltage
Transmission Oil Filter Restricted
Transmission Oil Temperature Over Maximum Value
Park Brake Solenoid Short to Power
Park Brake Solenoid Short to Ground
Park Brake Solenoid Open Circuit
Backup Alarm Short to Power
Backup Alarm Short to Ground
Transmission Clutch KR Slippage
Transmission Reverse Clutch Solenoid Short to Power
Transmission Reverse Clutch Solenoid Short to Ground
Transmission Reverse Clutch Solenoid Open Circuit
Transmission Clutch KV Slippage
Transmission Forward Clutch Solenoid Short to Power
Transmission Forward Clutch Solenoid Short to Ground
Transmission Forward Clutch Solenoid Open Circuit
Transmission Clutch K4 Slippage
Transmission Clutch K4 Solenoid Short to Power
Transmission Clutch K4 Solenoid Short to Ground
Transmission Clutch K4 Solenoid Open Circuit
Transmission Clutch K3 Slippage
Transmission Clutch K3 Solenoid Short to Power
Transmission Clutch K3 Solenoid Short to Ground
Transmission Clutch K3 Solenoid Open Circuit
Transmission Clutch K2 Slippage
Transmission Clutch K2 Solenoid Short to Power
Transmission Clutch K2 Solenoid Short to Ground
Transmission Clutch K2 Solenoid Open Circuit
Transmission Clutch K1 Slippage
Transmission Clutch K1 Solenoid Short to Power
Transmission Clutch K1 Solenoid Short to Ground
Transmission Clutch K1 Solenoid Open Circuit
Transmission Output Shaft Speed Sensor Fault
Transmission Output Shaft Open or Short to Power
Transmission Output Shaft Short to Ground
Transmission Output Shaft Fault
Transmission Output Shaft Overspeed
Clutch Speed Sensor Open or Short
Transmission Clutch Speed Sensor Short to Ground
Transmission Clutch Speed Sensor Fault
Transmission Clutch Cut-Off Sensor Short to Power
Transmission Clutch Cut-Off Sensor Open or Short to Ground
2nd FNR (Pilot Control Joystick FNR) Open Circuit
2nd FNR (Pilot Control Joystick FNR) Multiple Inputs
1st FNR Open Circuit
1st FNR Multiple Inputs
Gear Selection Error
Transmission Clutch Cut-Off Disabled
Manual Down Shift Disabled
Automatic to 1st Disabled
Transmission Output Torque Exceeded
Transmission Input Torque Exceeded
Configure Machine Model
Communication Error
Vehicle Control Unit (VCU) Diagnostic Trouble Codes
Vehicle Control Unit (VCU) Diagnostic Trouble Codes
Front Axle Oil High Temperature
Front Axle Oil Temp Sensor Short to Ground
Fuel Level Short to Ground
Fuel Level Open or Short
Alternator High Voltage
Alternator Low Voltage
High Battery Voltage
Ambient Air Short to Ground
Invalid Transmission Control Unit (TCU) Software Revision
Brake Pedal High Voltage
Rear Axle Oil High Temperature
Rear Axle Oil Temp Sensor Short to Ground
Controller Not Programmed
Vehicle Control Unit (VCU) Watchdog Time Out
Vehicle Control Unit (VCU) Controller Area Network (CAN) Failure
Vehicle Control Unit (VCU) Controller Area Network (CAN) 1 Bus Off
Differential Lock Solenoid Short to Power
Differential Lock Solenoid Open
Differential Lock Solenoid High Current
Pilot Solenoid Short to Power
Pilot Solenoid Open or Short
Pilot Solenoid High Current
Brake Lights Short to Power
Brake Lights Open or Short
Brake Lights High Current
Reversing Fan Solenoid Short to Power
Reversing Fan Solenoid Open or Short
Reversing Fan Solenoid High Current
Tire Size Incorrect
Proportional Fan Solenoid High Side (HS) Short to Power
Proportional Fan Solenoid High Side (HS) Open or Short
Proportional Fan Solenoid High Side (HS) High Current
Proportional Fan Solenoid Out of Calibration
Proportional Fan Solenoid Low Side (LS) High Current
Proportional Fan Solenoid Low Side (LS) Open or Short
Proportional Fan Solenoid Low Side (LS) Short to Power
Vehicle Control Unit (VCU) Controller Area Network (CAN) 2 Failure
Vehicle Control Unit (VCU) Controller Area Network (CAN) 2 Bus Off
Air Conditioner Clutch Short to Power
Air Conditioner Clutch High Current
Hydraulic Oil High Temperature
Hydraulic Oil Temperature Sensor Short to Ground
Fan Speed Sensor Out of Synchronization
Fan Speed Sensor Short to Ground
Fan Speed Sensor Open Circuit
Fan Speed Did Not Lower During Reversal
Fan Speed Sensor No Signal
Fan Speed Sensor Fault
Fan Speed Sensor Out of Calibration
Hydraulic Oil Filter Restricted
Hydraulic Pressure Sensor Short to Power
Hydraulic Pressure Sensor Open or Short
Blackout Brake Lights Short to Power
Blackout Brake Lights Open or Short
Blackout Brake Lights High Current
Blackout Lights Short to Power
Blackout Lights Open or Short
Blackout Lights High Current
Controller Area Network (CAN) Communication Lost for Engine Control Unit (ECU)
Controller Area Network (CAN) Communication Lost for Transmission Control Unit (TCU)
Flexpower Handshaking Error
Controller Area Network (CAN) Communication Lost for Advanced Displaying Unit (ADU)
Controller Area Network (CAN) Communication Lost for Tire Pressure Monitoring System (TPMS)
Controller Area Network (CAN) Communication Lost for Radar Object Detection (ROD)
Controller Area Network (CAN) Communication Lost for Sealed Switch Module (SSM)
Controller Area Network (CAN) Communication Lost for Ground Speed Radar (RDR)
Controller Area Network (CAN) Lost for JDLink
Drive Lamps Short to Power
Drive Lamps Open or Short
Drive Lamps High Current
Front Work Lights Short to Power
Front Work Lights Open or Short
Front Work Lights High Current
Front Work Lights Short to Power
Front Work Lights Open or Short
Front Work Lights High Current
Machine Work Lights Short to Power
Machine Work Lights Open or Short
Machine Work Lights High Current
Rear Work Lights Short to Power
Rear Work Lights Open or Short
Rear Work Lights High Current
Left Turn Switch Short to Ground
Left Turn Lights Short to Power
Left Turn Lights Open or Short
Left Turn Lights High Current
Right Turn Switch Short to Ground
Right Turn Lights Short to Power
Right Turn Lights Open or Short
Right Turn Lights High Current
Marker/Tail Lights Short to Power
Marker/Tail Lights Open Circuit
Marker/Tail Lights High Current
Beacon Light Short to Power
Beacon Light High Current
Lockout Fan Solenoid Short to Power
Lockout Fan Solenoid Open or Short
Lockout Fan Solenoid High Current
Return-to-Carry (RTC)/Float Detent Short to Power
Return-to-Carry (RTC)/Float Detent Open or Short
Return-to-Carry (RTC)/Float Detent High Current
Return-to-Dig (RTD) Detent Short to Power
Return-to-Dig (RTD) Detent Open or Short
Return-to-Dig (RTD) Detent High Current
Boom Height Kickout (BHKO) Detent Short to Power
Boom Height Kickout (BHKO) Detent Open or Short
Boom Height Kickout (BHKO) Detent High Current
Hazard Wakeup Short to Ground
Vehicle Control Unit (VCU) Sensor 1 Voltage Low
Vehicle Control Unit (VCU) Sensor 2 Voltage Low
Vehicle Control Unit (VCU) Sensor 3 Voltage Low
7 V Supply Voltage Low
HPM Pressure Sensor Short to Power
HPM Pressure Sensor Open or Short
Invalid Vehicle Identification Number (VIN)
Engine Tier Level Invalid
Central Processing Unit (CPU) Switched Power Voltage Low
Brake Pressure Low
Heated Mirror Short to Power
Heated Mirror Open Circuit
Heated Mirror High Current
Rear Wiper Park Short to Ground
Front Wiper Park Short to Ground
Memory Test Failure
Rear Wiper High Speed Short to Power
Rear Wiper High Speed Open Circuit
Rear Wiper High Speed High Current
Rear Wiper Low Speed Short to Power
Rear Wiper Low Speed Open Circuit
Rear Wiper Low Speed High Current
Front Wiper Low Speed Short to Power
Front Wiper Low Speed Open Circuit
Front Wiper Low Speed High Current
Front Wiper High Speed Short to Power
Front Wiper High Speed Open Circuit
Front Wiper High Speed High Current
Bucket Position Short to Power
Bucket Position Open or Short
Return-to-Dig (RTD) Switch Short to Ground
Pin Disconnect Solenoid Short to Power
Pin Disconnect Solenoid Open or Short
Pin Disconnect Solenoid High Current
Boom Cylinder Rod Pressure Sensor Open or Short
Boom Cylinder Rod Pressure Sensor Short to Ground
Boom Cylinder Head Pressure Sensor Open or Short
Boom Cylinder Head Pressure Sensor Short to Ground
Vehicle Horn Short to Power
Vehicle Horn Open Circuit
Vehicle Horn High Current
Rear Washer Pump Short to Power
Rear Washer Pump Open or Short
Rear Washer Pump High Current
Front Washer Pump Short to Power
Front Washer Pump Open or Short
Front Washer Pump High Current
Steering System Pressure Low
Steering Pressure Sensor Short to Power
Steering Pressure Sensor Short to Ground
Steering Pressure Sensor Open Circuit
Steering Pressure Sensor Invalid
Switched Power Voltage Low
Unswitched Power Voltage Low
Secondary Steering Pump Shorted to Power
Secondary Steering Pump Open or Short Circuit
Secondary Steering Pump High Current
Differential Lock Switch Short to Ground
Boom Position Sensor Short to Power
Boom Position Sensor Short to Ground
Brake Pressure Low—Rear
Rear Brake Pressure Sensor Short to Power
Rear Brake Pressure Open or Short
Brake Pressure Low—Front
Front Brake Pressure Sensor Short to Power
Front Brake Pressure Sensor Open or Short
Add Truck Switch Short to Ground
Counter Switch Short to Ground
Add Bucket Switch Short to Ground
Hydraulic Power Management Solenoid High Side Short to Power
Hydraulic Power Management Solenoid High Side Open Circuit
Hydraulic Power Management Solenoid High Side High Current
Hydraulic Power Management System Out of Calibration
Hydraulic Power Management Solenoid Low Side High Current
Hydraulic Power Management Solenoid Low Side Open Circuit
Hydraulic Power Management Solenoid Low Side Short to Power
Ride Control Solenoid Short to Power
Ride Control Solenoid Open Circuit
Ride Control Solenoid High Current
Axle Oil Filter Restricted
Axle Oil Filter Short to Power
Inspect Park Brake
Checksum Error
Sealed Switch Module (SSM) Diagnostic Trouble Codes
Sealed Switch Module (SSM) Diagnostic Trouble Codes
Sealed Switch Module (SSM) Watchdog Time Out
Controller Area Network (CAN) Communication Lost For Vehicle Control Unit (VCU)
Sealed Switch Module (SSM) Ignition Relay Signal Short to Ground
Sealed Switch Module (SSM) Ignition Relay Signal Open Circuit
Button 17 Keypad Stuck
Button 17 Light-Emitting Diode (LED) Message
Front Washer Keypad Stuck
Front Wiper Keypad Stuck
Lost Front Wiper Light-Emitting Diode (LED) Message
Drive Lights Keypad Stuck
Lost Drive Lights Light-Emitting Diode (LED) Message
Work Lights Keypad Stuck
Lost Work Lights Light-Emitting Diode (LED) Message
Rear Wiper Keypad Stuck
Lost Rear Wiper Light-Emitting Diode (LED) Message
Rear Washer Keypad Stuck
Axle Disconnect Keypad Stuck
Lost Axle Disconnect Light-Emitting Diode (LED) Message
Button 21 Keypad Stuck
Button 21 Light-Emitting Diode (LED) Message
Air Conditioner Keypad Stuck
Lost Air Conditioner Light-Emitting Diode (LED) Message
Pin Disconnect Keypad Stuck
Lost Pin Disconnect Light-Emitting Diode (LED) Message
Spin Control Keypad Stuck
Lost Spin Control Light-Emitting Diode (LED) Message
Differential Lock Keypad Stuck
Lost Differential Lock Light-Emitting Diode (LED) Message
Return To Carry Keypad Stuck
Lost Return To Carry Light-Emitting Diode (LED) Message
Boom Height Kick Out Keypad Stuck
Lost Boom Height Kick Out Light-Emitting Diode (LED) Message
Clutch Cut-Off Keypad Stuck
Lost Clutch Cut-Off Light-Emitting Diode (LED) Message
Ride Control Keypad Stuck
Lost Ride Control Light-Emitting Diode (LED) Message
Auto Transmission Keypad Stuck
Lost Auto Transmission Light-Emitting Diode (LED) Message
Return To Dig Keypad Stuck
Lost Return To Dig Light-Emitting Diode (LED) Message
Park Brake Keypad Stuck
Lost Park Brake Light-Emitting Diode (LED) Message
Pilot Enable Keypad Stuck
Lost Pilot Enable Light-Emitting Diode (LED) Message
Hazards Keypad Stuck
Lost Hazard Light-Emitting Diode (LED) Message
Beacon Light Keypad Stuck
Lost Beacon Light-Emitting Diode (LED) Message
Ignition Off Keypad Stuck
Lost Ignition Off Light-Emitting Diode (LED) Message
Ignition On Keypad Stuck
Lost Ignition On Light-Emitting Diode (LED) Message
Advanced Display Unit (ADU) Diagnostic Trouble Codes
Advanced Display Unit (ADU) Diagnostic Trouble Codes
Switched Power Voltage High
Switched Power Voltage Low
High Battery Voltage
Low Battery Voltage
Display Temp High
Display Temp Low
LCD Backlight Failure
5 Volt Power Supply Invalid
1.5 Volt Power Supply Invalid
3.3 Volt Power Supply Invalid
ADU Watchdog Time Out
Memory Error
Memory Stack Overflow
CAN HIGH Voltage High
CAN HIGH Voltage Low
CAN LOW Voltage High
CAN LOW Voltage Low
Information Button Stuck
Back Key Button Stuck
Menu Select Button Stuck
Down Arrow Button Stuck
Up Arrow Button Stuck
Radar Object Detection (ROD) Diagnostic Trouble Codes
Radar Object Detection (ROD) Diagnostic Trouble Codes
000896.12— ROD Unit Failure
Ground Speed Radar (RDR) Diagnostic Trouble Codes
Ground Speed Radar (RDR) Diagnostic Trouble Codes
000628.12— Controller Not Programmed
Operational Checkout Procedure
Operational Checkout Procedure
Operational Checkout
Engine
Theory of Operation
John Deere Engine
Cold Start Aid System Theory of Operation—If Equipped
System Diagrams
Engine Cooling System Component Location
Engine Fuel System Component Location
Engine Fuel System Component Location—Standard Fuel Filter
Engine Fuel System Component Location—Auxiliary Fuel Filter
Engine Intake and Exhaust Component Location
Diagnostic Information
John Deere Engine
Engine Cranks/Will Not Start
Engine Misfires/Runs Irregularly
Engine Does Not Develop Full Power
Engine Emits Excessive White Exhaust Smoke
Engine Emits Excessive Black or Gray Exhaust Smoke
Engine Will Not Crank
Engine Idles Poorly
Abnormal Engine Noise
Low-Pressure Fuel System Check
Excessive Fuel Consumption
Fuel in Oil
Tests
John Deere Engine
Fluid Sampling Procedure—If Equipped
MACHINE PREPARATION
Priming Sample Valve
Obtaining Fluid Sample
Engine Idle Speeds and Auto Shutdown Check
Engine Slow Idle Speed Adjustment
Electrical System
Theory of Operation
Start and Charge Circuits Theory of Operation
Controller Area Network (CAN) Circuit Theory of Operation
Engine Control Unit (ECU) Circuit Theory of Operation
Vehicle Control Unit (VCU) Circuit Theory of Operation
Transmission Control Unit (TCU) Circuit Theory of Operation
Park Brake Circuit Theory of Operation
Advanced Display Unit (ADU) Circuit Theory of Operation
Radar Object Detection (ROD) Circuit Theory of Operation
Auto-Differential Lock Circuit Theory of Operation
Embedded Payload Scale (EPS) Circuit Theory of Operation
JDLink™ Circuit Theory of Operation
System Diagrams
Electrical Diagram Information
System Functional Schematic Diagram
Wiring Diagram
Component Location Diagram
Connector End View Diagram
Electrical Schematic Symbols
Fuse and Relay Specifications
System Functional Schematic, Wiring Diagram, and Component Location Master Legend
System Functional Schematic
Power and Ground Cables (W1) Component Location
Loader Frame Harness (W2) Component Location
Loader Frame Harness (W2) Component Location—Z-Bar
Loader Frame Harness (W2) Wiring Diagram
Load Center Harness (W3) Component Location
Load Center Harness (W3) Wiring Diagram
Front Console Harness (W4) Component Location
Front Console Harness (W4) Wiring Diagram
Engine Frame Harness (W5) Component Location
Engine Frame Harness (W5) Wiring Diagram
Engine Harness (W6) Component Location
Engine Harness (W6) Wiring Diagram
Low-Pressure Fuel Pump Harness (W7) Component Location—If Equipped
Low-Pressure Fuel Pump Harness (W7) Wiring Diagram—If Equipped
Transmission Harness (W10) Component Location
Transmission Harness (W10) Wiring Diagram
Rear Frame Harness (W13) Component Location
Rear Frame Harness (W13) Wiring Diagram
Secondary Steering Harness (W17) Component Location—If Equipped
Secondary Steering Harness (W17) Wiring Diagram
Cab Roof Harness (W19) Component Location
Cab Roof Harness (W19) Wiring Diagram
Heater and Air Conditioner Harness (W20) Component Location
Heater and Air Conditioner Harness (W20) Wiring Diagram
Radar Object Detection (ROD) Harness (W21) Component Location
Radar Object Detection (ROD) Harness (W21) Wiring Diagram
Radio Harness (W23) Component Location
Radio Harness (W23) Wiring Diagram
Ground Speed Radar (RDR) Harness (W31) Component Location
Ground Speed Radar (RDR) Harness (W31) Wiring Diagram
Auxiliary Radio Input Harness (W41) Component Location—
Auxiliary Radio Input Harness (W41) Wiring Diagram
Satellite Radio Harness (W44) Component Location
Satellite Radio Harness (W44) Wiring Diagram
Starter Excitation Jumper Harness (W52) Component Location
Starter Excitation Jumper Harness (W52) Wiring Diagram
Modular Telematics Gateway (MTG) and Satellite (SAT) Harness (W6002 and W6003) Component Location
Modular Telematics Gateway (MTG) Harness (W6002) Wiring Diagram
Satellite (SAT) Harness (W6003) Wiring Diagram
Diagnostic Information
Service ADVISOR™ Diagnostic Application
Service ADVISOR™ Connection Procedure
Reading Diagnostic Trouble Codes with Service ADVISOR™ Diagnostic Application
Intermittent Diagnostic Trouble Code (DTC) Diagnostics
Diagnostic Trouble Codes—After Machine Repair
JDLink™ Connection Procedure
JDLink™ Connection Procedure
Embedded Payload Scale (EPS) Diagnostics
Monitor Operation
Advanced Display Unit (ADU)—Service Mode
Advanced Display Unit (ADU)—Clear Codes
Advanced Display Unit (ADU)—Auto-Idle
Advanced Display Unit (ADU)—Auto Shutdown
Advanced Display Unit (ADU)—Enable Options
Advanced Display Unit (ADU)—Tire Size
Advanced Display Unit (ADU)—Fan Speed
Advanced Display Unit (ADU)—Maximum High Gear
Advanced Display Unit (ADU)—Transmission Clutch Calibration
Advanced Display Unit (ADU)—Low Idle Adjust
Advanced Display Unit (ADU)—Main Menu
Diagnostic Test Box
Setup and Functional Test
Diagnostic Test Box—Overview and Functionality
Before Connecting JDG10273 Diagnostic Test Box
JDG10273 Diagnostic Test Box—User Instructions
JDG10273 Diagnostic Test Box—Operational Test Procedure
Test Leads
Two Wire Sensor Circuit Check—Out of Range High
Two Wire Sensor Circuit Check—Out of Range Low
Three Wire Sensor Circuit Check—Out of Range High
Three Wire Sensor Circuit Check—Out of Range Low
Adjustments
Boom Height Kickout (BHKO) Adjustment
Return-to-Carry (RTC) Adjustment
Return-to-Dig (RTD) Adjustment—Z-Bar Linkage
Return-to-Dig (RTD) Adjustment—Powerllel Linkage
Boom Height Kickout/Return-to-Carry (BHKO/RTC) Position Sensor Calibration
Change Backup Alarm Volume
Tests
Electrical Component Specifications
CAN Circuit Test
Alternator Test
Hydraulic Pressure Sensor Test
Transmission Control Valve Solenoid Check
Clutch Cut-Off Sensor Check
Connector Terminal Test
Power Train
Theory of Operation
TeamMate™ Axles
Power Train Operation
Torque Converter Operation
Transmission Operation
Transmission Operation—First Gear Forward
Transmission Clutch Pack Engagement and Solenoids Activated
Transmission Filter Bypass Valve Operation
Transmission Control Valve Component Operation
Transmission Clutch Modulation Operation
Thermal Bypass Valve Operation
Standard Differential Operation
Differential Lock Operation
Axle Circulation Dual Pump Operation
Park Brake Operation
System Diagrams
Transmission System Schematic—First Forward
Power Train Component Location
Power Train Cooling System Component Location
Transmission Component Location
Diagnostic Information
Transmission Clutch Slippage
Machine Will Not Move in Either Direction
Machine Will Not Shift Correctly
Transmission System Pressure Is Low in Neutral
Transmission Pressure Is Low (One or Two Gear Ranges)
Transmission Shifts Too Slow
Transmission Shifts Too Fast
Machine Creeps in Neutral
Transmission Hydraulic System Overheats
Transmission Excessive Noise
Oil Aerated
Oil Ejected from Filler Tube
Machine Vibrates
Machine Power and Acceleration Low
Torque Converter Stall RPM
Differential Lock Will Not Engage
Differential Lock Slips and Chatters
Differential Lock Will Not Disengage
Differential Oil Level Rises
Differential Oil Level Low
Differential and Axle Noise Excessive
Axle Wheel Hub Face Seal Leaking
Axle Overheats
Service Brakes Poor or Do Not Apply
Service Brakes Aggressive
Service Brakes Dragging
Service Brakes Lock Up
Service Brakes Chatter
Service Brake Warning Light On
Driveline Excessive Vibration or Noise
Park Brake Will Not Hold
Park Brake Will Not Release
Park Brake Overheats
Park Brake Light Flashes When Shifting From Forward to Reverse
Park Brake Light Flashes During Each Shift
Park Brake Light Does Not Come On
Park Brake Will Not Apply
Adjustments
Service Brake Bleeding Procedure
Transmission Control Unit (TCU)—Electronic Clutch Calibration
Tests
Transmission Oil Sampling Procedure
Transmission Oil Warm-Up Procedure
Park Brake Pressure Test
Park Brake Drag Test
Transmission Pump Flow Test
Transmission System Pressure Test
Transmission Clutch Pressure Test
Transmission Element Leakage Test
Transmission Lube Pressure Test
Torque Converter—In Pressure Test
Torque Converter—Out Pressure Test
Torque Converter Relief Pressure Test
Torque Converter—Out Flow Test
Torque Converter Stall Speed Test
Transmission Oil Cooler Thermal Bypass Valve Temperature Test
Transmission Oil Cooler Thermal Bypass Valve Pressure Test
Transmission Oil Cooler Restriction Test
Axle Circulation Pump Flow Test
Axle Breather Test
Differential Lock Pressure Test
Hydraulic System
Theory of Operation
Loader Hydraulic System Operation
Main Hydraulic Pump Operation
Hydraulic Pump Manifold Operation
Hydraulic Fan Operation
Hydraulic Reversing Fan Operation—If Equipped
Orbital Steering System Component Operation
Orbital Steering Valve Operation
Secondary Steering System Operation
Secondary Steering Valve Operation
Pilot Pressure Reducing Valve Operation
Service Brake Hydraulic System Operation
Service Brake Accumulator Operation
Service Brake Valve Operation
Pin Disconnect Operation
Pilot Control Lever Operation
Control Valve Pilot Orifice Check Valve Operation
Loader Control Valve Operation
Boom Section Operation—Boom Down and Steering
Bucket Section Operation—Boom Raise and Bucket Dump
Bucket Section Operation—Boom Raise and Bucket Dump (High-Lift Option)
Auxiliary Section—Operating and Boom Raise
Auxiliary Section—Spool Stroke Adjuster Operation
Loader Control Valve—Outlet Section Operation
Load Sense Circuit Operation—Neutral
Load Sense Circuit Operation—Steering
Load Sense Circuit Operation—Steering and Boom Down
Load Sense Circuit Operation—Boom Raise and Bucket Dump
Main Relief Valve Operation
Load Sense Relief Valve Operation
Circuit Relief With Anticavitation Valve Operation
Anticavitation Valve Operation
Hydraulic Return Filter Operation
Ride Control Operation
System Diagrams
Hydraulic System Schematic
Steering and Hydraulic Cooling Fan Circuit Component Location
Steering and Hydraulic Cooling Fan Circuit Component Location—Standard Fan
Steering and Hydraulic Cooling Fan Circuit Component Location—Reversing Fan
Loader and Hydraulic Cooling Circuit Component Location
Ride Control, Pin Disconnect, and Hydraulic Filter Circuit Component Location
Hydraulic Pump Manifold
Diagnostic Information
No Hydraulic Functions
Hydraulic Functions Slow
Main Hydraulic Pump Noisy
No Orbital Steering Function
Boom Float Function Not Working
One Hydraulic Function Not Working
Hydraulic Function Drifts Down
Boom Down Does Not Work (Engine Off)
Ride Control Not Working
Oil Overheats
Hydraulic Oil Foams
Pin Disconnect Cylinders Will Not Retract
Constant Steering Required to Maintain Straight Travel
Slow Steering Wheel Movement Will Not Cause Frame Movement
Steering Wheel Turns Without Resistance and Causes No Frame Movement
Steering Erratic
Steering Wheel Free Play
Orbital Steering Valve Binds or Locks Up
Steering Wheel Turns by Itself
Machine Turns in Opposite Direction as Steering Wheel
Steering Wheel Kickback
Orbital Steering Jerky
Secondary Steering Motor Will Not Operate
Secondary Steering Pump Runs But Will Not Steer Machine
Hydraulic Fan Does Not Reach Full Speed
Hydraulic Fan Runs at Full Speed Only
Hydraulic Fan Does Not Spin
Hydraulic Fan Will Not Reverse Direction
Adjustments
Pilot Control Lever Adjustment
Auxiliary Pilot Control Lever Adjustment
Ride Control Accumulator Gas Charge Procedure
Ride Control Accumulator Draining Procedure
Auxiliary Valve Section—Stroke Adjustment
Tests
Hydraulic Oil Sampling Procedure
Hydraulic Oil Warm-Up Procedure
Vacuum Pump Installation
Hydraulic System Pressure and Accumulators Discharge
JT02156A Digital Pressure and Temperature Analyzer Kit Installation
Hydraulic System Operating and Standby Pressure Test
Main Hydraulic Pump Control Valve Test and Adjustment
Load Sense Relief Valve Pressure Test and Adjustment
Main Hydraulic Pump Flow Test
Main Hydraulic Pump Case Drain Test
Main Relief Valve Pressure Test
Circuit Relief With Anticavitation Valve Pressure Test
Loader Cylinder Drift Test
Boom, Bucket, and Steering Cylinder Leakage Test
Hydraulic Oil Cooler Restriction Test
Steering Cylinder Drift Test
Secondary Steering Pump Pressure Relief Valve Test
Secondary Steering Valve—Hydraulic System Isolation Check Valve Leakage Test
Secondary Steering Valve—Secondary Steering Pump Isolation Check Valve Leakage Test—If Equipped
Pilot Control Valve Pressure Test
Auxiliary Pilot Control Valve Pressure Test
Pilot Pressure Reducing Valve Pressure Test
Pilot Accumulator Gas Precharge Test
Cycle Time Test
Service Brake Accumulator Gas Precharge and Low Brake Pressure Warning Test
Service Brake Valve Pressure Test
Service Brake Valve Leakage Test
Service Brake Accumulator Inlet Check Valve Leakage Test
Pin Disconnect Pressure Test—If Equipped
Hydraulic Fan Pump Pressure Test
Hydraulic Fan Motor Speed Test
Hydraulic Fan Pump Flow Test
Hydraulic Fan Motor Case Drain Test
Hydraulic Reversing Fan Test—If Equipped
Hydraulic Oil Filter Inspection Procedure
Heating and Air Conditioning
Theory of Operation
Air Conditioning System Cycle of Operation
System Diagrams
Air Conditioner and Heater Component Location
Diagnostic Information
Air Conditioning System Does Not Operate
Air Conditioning System Does Not Cool Interior of Cab
Air Conditioning System Runs Constantly, Too Cold
Heating System Does Not Operate
Heating Does Not Warm Interior of Cab
Interior Windows Continue to Fog
Tests
R134a Refrigerant Cautions and Proper Handling
R134a Oil Charge Capacity
R134a Refrigerant Charge Capacity
Heater and Air Conditioner Operational Checks
Air Conditioner Compressor Clutch Test
R134a Refrigerant Leak Test
R134a Refrigerant Hoses and Tubing Inspection
Air Conditioner High/Low-Pressure Switch Test
Air Conditioner Freeze Control Sensor Test
Air Conditioning System Test
Operating Pressure Diagnostic Chart