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450J

(Serial No. 159987 - 216242)

550J, 650J

(Serial No. 159987 -

)

Crawler Dozer Operation and Test

TECHNICAL MANUAL 450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test TM10721 03SEP14

(ENGLISH)

For complete service information also see: 450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Repair ..............

TM10722

450J, 550J and 650J Crawler Dozer Operator's Manual (S.N. 159987— ) ......................................

OMT227285

PowerTech™ 4.5 L and 6.8 L Diesel Engines—Base Engine .......................................

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TM114519 SP326VOL1

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Worldwide Construction And Forestry Division LITHO IN U.S.A.

Introduction Foreword This manual is written for an experienced technician. Essential tools required in performing certain service work are identified in this manual and are recommended for use. Live with safety: Read the safety messages in the introduction of this manual and the cautions presented throughout the text of the manual.

Information is organized in groups for the various components requiring service instruction. At the beginning of each group are summary listings of all applicable essential tools, service equipment and tools, other materials needed to do the job, service parts kits, specifications, wear tolerances, and torque values.

This is the safety-alert symbol. When you see this symbol on the machine or in this manual, be alert to the potential for personal injury.

Technical Manuals are concise guides for specific machines. They are on-the-job guides containing only the vital information needed for diagnosis, analysis, testing, and repair.

Technical manuals are divided in two parts: repair and operation and tests. Repair sections tell how to repair the components. Operation and tests sections help you identify the majority of routine failures quickly.

Fundamental service information is available from other sources covering basic theory of operation, fundamentals of troubleshooting, general maintenance, and basic type of failures and their causes. DX,TMIFC -19-15APR14-1/1

TM10721 (03SEP14)

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=2

Introduction

Technical Information Feedback Form We need your help to continually improve our technical publications. Please copy this page and FAX or mail your comments, ideas and improvements. SEND TO:

John Deere Dubuque Works 18600 South John Deere Road Attn: Publications, Dept. 324 Dubuque, IA 52004-0538 USA

FAX NUMBER: 1-563-589-5800 (USA) Publication Number: Page Number: Ideas, Comments:

Name: Phone: Email Address: THANK YOU! TX,TM,FAX -19-03JUL01-1/1

TM10721 (03SEP14)

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=3

Introduction

TM10721 (03SEP14)

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=4

Contents Section 9000—General Information Group 01—Safety

Section 9001—Diagnostic Trouble Codes (DTC) Group 10—Standard Display Monitor (SDM) Diagnostic Trouble Codes Group 20—Engine Control Unit (ECU) Diagnostic Trouble Codes Group 30—Transmission Control Unit (TCU) Diagnostic Trouble Codes Group 40—Electrohydraulic Controller (EHC) Diagnostic Trouble Codes Group 50—Blade Control Joystick (BCJ) Diagnostic Trouble Codes

Section 9005—Operational Checkout Procedure Group 10—System Operational Checks

Section 9010—Engine Group 05—Theory Of Operation Group 15—Diagnostic Information Group 25—Tests

Section 9015—Electrical System Group 05—System Information Group 10—System Diagrams Group 15—Sub-System Diagnostics Group 16—Monitor Operation Group 20—References

Section 9025—Hydraulic System Group 05—Theory of Operation Group 15—Diagnostic Information Group 20—Adjustments Group 25—Tests

Section 9026—Hydrostatic System Group 05—Theory of Operation Group 15—Diagnostic Information Group 25—Test

Section 9031—Heating and Air Conditioning Group 05—Theory of Operation Group 15—Diagnostic Information Group 25—Test

Original Instructions. All information, illustrations and specifications in this manual are based on the latest information available at the time of publication. The right is reserved to make changes at any time without notice. COPYRIGHT © 2014 DEERE & COMPANY Moline, Illinois All rights reserved. A John Deere ILLUSTRUCTION ® Manual Previous Editions Copyright © 2008, 2009, 2010, 2011, 2012, 2013

TM10721 (03SEP14)

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=1

Contents

TM10721 (03SEP14)

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=2

Contents

Section 9000 General Information

Page

Group 01—Safety Recognize Safety Information ................... 9000-01-1 Follow Safety Instructions.......................... 9000-01-1 Operate Only If Qualified ........................... 9000-01-1 Wear Protective Equipment....................... 9000-01-2 Avoid Unauthorized Machine Modifications.......................................... 9000-01-2 Inspect Machine ........................................ 9000-01-2 Stay Clear of Moving Parts........................ 9000-01-2 Avoid High-Pressure Fluids ....................... 9000-01-3 Avoid High-Pressure Oils .......................... 9000-01-3 Beware of Exhaust Fumes ........................ 9000-01-4 Prevent Fires ............................................. 9000-01-4 Prevent Battery Explosions ....................... 9000-01-4 Handle Chemical Products Safely.............. 9000-01-5 Dispose of Waste Properly ........................ 9000-01-5 Prepare for Emergencies........................... 9000-01-5 Add Cab Guarding For Special Uses ...................................................... 9000-01-6 Start Only From Operator's Seat ............... 9000-01-6 Prevent Unintended Machine Movement.............................................. 9000-01-6 Avoid Work Site Hazards........................... 9000-01-7 Keep Riders Off Machine .......................... 9000-01-7 Avoid Backover Accidents ......................... 9000-01-8 Avoid Machine Tip Over ............................ 9000-01-8 Prevent Unintended Detonation of Explosive Devices ................................. 9000-01-9 Park And Prepare For Service Safely..................................................... 9000-01-9 Service Cooling System Safely ................. 9000-01-9 Remove Paint Before Welding or Heating ................................................ 9000-01-10 Make Welding Repairs Safely ................. 9000-01-10 Drive Metal Pins Safely ........................... 9000-01-10

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Group 01

Safety Recognize Safety Information T133555 —UN—15APR13

This is the safety alert symbol. When you see this symbol on your machine or in this manual, be alert for the potential of personal injury. Follow the precautions and safe operating practices highlighted by this symbol. A signal word — DANGER, WARNING, or CAUTION — is used with the safety alert symbol. DANGER identifies the most serious hazards.

T133588 —19—28AUG00

On your machine, DANGER signs are red in color, WARNING signs are orange, and CAUTION signs are yellow. DANGER and WARNING signs are located near specific hazards. General precautions are on CAUTION labels.

TX03679,00016CC -19-05FEB10-1/1

Follow Safety Instructions T133556 —UN—24AUG00

Read the safety messages in this manual and on the machine. Follow these warnings and instructions carefully. Review them frequently. Keep safety signs in good condition. Replace missing or damaged safety signs. Be sure new equipment components and repair parts include the current safety signs. Replacement safety signs are available from your John Deere dealer. Be sure all operators of this machine understand every safety message. Replace operator's manual and safety labels immediately if missing or damaged.

TX03679,00016F9 -19-14JAN08-1/1

Operate Only If Qualified Do not operate this machine unless the operator's manual has been read carefully, and you have been qualified by supervised training and instruction. Operator should be familiar with the job site and surroundings before operating. Try all controls and

machine functions with the machine in an open area before starting to work. Know and observe all safety rules that may apply to every work situation and work site. TX03679,00016FA -19-03JAN07-1/1

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Safety

Wear Protective Equipment Guard against injury from flying pieces of metal or debris; wear goggles or safety glasses.

TS206 —UN—15APR13

Wear close fitting clothing and safety equipment appropriate to the job. Prolonged exposure to loud noise can cause impairment or loss of hearing. Wear suitable hearing protection such as earmuffs or earplugs to protect against objectionable or uncomfortable loud noises.

TX03679,00016D0 -19-05MAY10-1/1

Avoid Unauthorized Machine Modifications John Deere recommends using only genuine John Deere replacement parts to ensure machine performance. Never substitute genuine John Deere parts with alternate parts not intended for the application as these can create hazardous situations or hazardous performance. Non-John Deere Parts, or any damage or failures resulting from their use are not covered by any John Deere warranty. Modifications of this machine, or addition of unapproved products or attachments, may affect machine stability or

reliability, and may create a hazard for the operator or others near the machine. The installer of any modification which may affect the electronic controls of this machine is responsible for establishing that the modification does not adversely affect the machine or its performance. Always contact an authorized John Deere dealer before making machine modifications that change the intended use, weight or balance of the machine, or that alter machine controls, performance or reliability. AM40430,00000A9 -19-14JAN08-1/1

Inspect Machine

Keep all guards and shields in good condition and properly installed. Fix damage and replace worn or broken parts immediately. Pay special attention to hydraulic hoses and electrical wiring.

T6607AQ —UN—15APR13

Inspect machine carefully each day by walking around it before starting.

TX03679,0001734 -19-08JAN08-1/1

Entanglements in moving parts can cause serious injury. Stop engine before examining, adjusting or maintaining any part of machine with moving parts. Keep guards and shields in place. Replace any guard or shield that has been removed for access as soon as service or repair is complete.

T133592 —UN—15APR13

Stay Clear of Moving Parts

TX03679,00016D2 -19-08JAN08-1/1

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450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=10

Safety

Avoid High-Pressure Fluids

X9811 —UN—23AUG88

Inspect hydraulic hoses periodically – at least once per year – for leakage, kinking, cuts, cracks, abrasion, blisters, corrosion, exposed wire braid or any other signs of wear or damage. Replace worn or damaged hose assemblies immediately with John Deere approved replacement parts. Escaping fluid under pressure can penetrate the skin causing serious injury. Avoid the hazard by relieving pressure before disconnecting hydraulic or other lines. Tighten all connections before applying pressure. Search for leaks with a piece of cardboard. Protect hands and body from high-pressure fluids. If an accident occurs, see a doctor immediately. Any fluid injected into the skin must be surgically removed within a few hours or gangrene may result. Doctors unfamiliar

with this type of injury should reference a knowledgeable medical source. Such information is available in English from Deere & Company Medical Department in Moline, Illinois, U.S.A., by calling 1-800-822-8262 or +1 309-748-5636. DX,FLUID -19-12OCT11-1/1

Avoid High-Pressure Oils

Never search for leaks with your hands. Protect hands. Use a piece of cardboard to find location of escaping oil. Stop engine and relieve pressure before disconnecting lines or working on hydraulic system.

T133840 —UN—20SEP00

If hydraulic oil penetrates your skin, see a doctor immediately. Injected oil must be removed surgically within hours or gangrene may result. Contact a knowledgeable medical source or the Deere & Company Medical Department in Moline, Illinois, U.S.A.

T133509 —UN—15APR13

This machine uses a high-pressure hydraulic system. Escaping oil under pressure can penetrate the skin causing serious injury.

TX03679,00016D3 -19-11JAN08-1/1

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Safety

Beware of Exhaust Fumes T133546 —UN—24AUG00

Prevent asphyxiation. Engine exhaust fumes can cause sickness or death. If you must operate in an enclosed space, provide adequate ventilation. Use an exhaust pipe extension to remove the exhaust fumes or open doors and windows to bring outside air into the area.

TX03679,00016D4 -19-23JUN08-1/1

T133552 —UN—15APR13

Prevent Fires Handle Fuel Safely: Store flammable fluids away from fire hazards. Never refuel machine while smoking or when near sparks or flame. Clean Machine Regularly: Keep trash, debris, grease and oil from accumulating in engine compartment, around fuel lines, hydraulic lines, exhaust components and electrical wiring. Never store oily rags or flammable materials inside a machine compartment.

T133553 —UN—07SEP00

Maintain Hoses and Wiring: Replace hydraulic hoses immediately if they begin to leak, and clean up any oil spills. Examine electrical wiring and connectors frequently for damage. Keep A Fire Extinguisher Available: Always keep a multi-purpose fire extinguisher on or near the machine. Know how to use extinguisher properly.

T133554 —UN—07SEP00

TX03679,00016F5 -19-26JUN09-1/1

Prevent Battery Explosions Battery gas can explode. Keep sparks, lighted matches, and open flame away from the top of battery.

Do not charge a frozen battery; it may explode. Warm battery to 16°C (60°F).

TS204 —UN—15APR13

Never check battery charge by placing a metal object across the posts. Use a voltmeter or hydrometer.

TX03679,000174A -19-08JAN08-1/1

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Safety

Exposure to hazardous chemicals can cause serious injury. Under certain conditions, lubricants, coolants, paints and adhesives used with this machine may be hazardous. If uncertain about safe handling or use of these chemical products, contact your authorized dealer for a Material Safety Data Sheet (MSDS) or go to internet website http://www.jdmsds.com. The MSDS describes physical and health hazards, safe use procedures, and emergency response techniques for chemical substances. Follow MSDS recommendations to handle chemical products safely.

T133580 —UN—25AUG00

Handle Chemical Products Safely

TX03679,00016D7 -19-03JAN07-1/1

Improper disposal of waste can threaten the environment. Fuel, oils, coolants, filters and batteries used with this machine may be harmful if not disposed of properly. Never pour waste onto the ground, down a drain, or into any water source. Air conditioning refrigerants can damage the atmosphere. Government regulations may require using a certified service center to recover and recycle used refrigerants.

T133567 —UN—25AUG00

Dispose of Waste Properly

If uncertain about the safe disposal of waste, contact your local environmental or recycling center or your authorized dealer for more information. TX03679,0001733 -19-08JAN08-1/1

Prepare for Emergencies Be prepared if an emergency occurs or a fire starts.

Keep emergency numbers for doctors, ambulance service, hospital, and fire department near your telephone.

TS291 —UN—15APR13

Keep a first aid kit and fire extinguisher handy.

TX03679,000174B -19-08JAN08-1/1

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Safety

Add Cab Guarding For Special Uses

T139005 —UN—05MAR01

Special work situations or machine attachments may expose the operator to intruding or flying objects. Using this machine in a forestry application or woods environment, or with attachments such as a winch, requires added guarding to protect the operator. Forestry protection packages or special screens should be installed when working in areas where logs or branches may strike the operator. A rear screen should always be used with a winch to protect against a snapping cable. Contact your authorized dealer for information on protective guarding before operating in any hazardous environment.

TX03768,0000B77 -19-14JAN08-1/1

T133715 —UN—15APR13

Start Only From Operator's Seat Avoid unexpected machine movement. Before starting engine, sit in operator's seat. Ensure park lock lever is in “lock” position. Never attempt to start engine from the ground or tracks. Do not attempt to start engine by shorting across the starter solenoid terminals.

TX03768,0000B71 -19-03NOV08-1/1

Always move the park lock lever to the “lock” position before leaving the operator's seat for any reason. Be careful not to accidentally actuate controls when co-workers are present. Engage park lock and lower work equipment to the ground during work interruptions. Stop the engine before allowing anyone to approach the machine. Follow these same precautions before standing up, leaving the operator's seat, or exiting the machine.

(LOCKED) UP POSITION

(UNLOCKED) DOWN POSITION

T159027 —19—30AUG02

Prevent Unintended Machine Movement

TX03768,0000B72 -19-14JAN08-1/1

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Safety

Avoid Work Site Hazards Avoid contact with gas lines, buried cables and water lines. Call utility line location services to identify all underground utilities before starting work. T139002 —UN—05MAR01

Prepare work site properly. Avoid operating near structures or objects that could fall onto the machine. Clear away debris that could move unexpectedly if run over. Avoid boom or attachment contact with overhead obstacles or overhead electrical lines. Never move machine closer than 3 m (10 ft) plus twice the line insulator length to overhead wires.

T139003 —UN—05MAR01

Keep bystanders clear at all times. Keep bystanders away from raised booms, attachments, and unsupported loads. Avoid swinging or raising booms, attachments, or loads over or near personnel. Use barricades or a signal person to keep vehicles and pedestrians away. Use a signal person if moving machine in congested areas or where visibility is restricted. Always keep signal person in view. Coordinate hand signals before starting machine. Operate only on solid footing with strength sufficient to support machine. Be especially alert working near embankments or excavations. Avoid working under over-hanging embankments or stockpiles that could collapse under or on machine. Reduce machine speed when operating with tool on or near ground when obstacles may be hidden (e.g., during snow removal or clearing mud, dirt, etc.). At high speeds

hitting obstacles (rocks, uneven concrete or manholes) can cause a sudden stop. Always wear your seat belt. VD76477,00013A2 -19-11SEP09-1/1

Keep Riders Off Machine Riders are subject to injury. They may fall from machine, be caught between machine parts, or be struck by foreign objects. Riders may obstruct operator’s view or impair his ability to operate machine safely.

T137580 —UN—22FEB01

Only allow operator on machine.

TX03768,0000B73 -19-03NOV08-1/1

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Safety

Before moving machine, be sure all persons are clear of the machine path. Turn around and look directly for best visibility. Use mirror to assist in checking behind the machine. Keep windows and mirror clean and in good repair. Be certain backup warning alarm is working properly. Use a signal person when backing if view is obstructed or when in close quarters. Keep signal person in view at all times. Use prearranged hand signals to communicate.

T138441 —UN—22FEB01

Avoid Backover Accidents

TX03768,0000B69 -19-14JUN11-1/1

Do not jump if the machine tips. You will be unlikely to jump clear and the machine may crush you. Load and unload from trucks or trailers carefully. Be sure truck is wide enough and secured on a firm level surface. Use loading ramps and attach them properly to truck bed. Avoid trucks with steel beds because tracks slip more easily on steel. Be careful on slopes. Use extra care on soft, rocky or frozen ground because machine may slip sideways in these conditions. When traveling up or down steep slopes, keep the bucket or blade on uphill side and just above ground level.

T138415 —UN—22FEB01

Ensure solid footing. Use extra care when operating on stockpile materials, or near banks or excavations that may cave-in and cause machine to tip or fall.

T138416 —UN—22FEB01

Use seat belt at all times.

T133716 —19—17APR13

Avoid Machine Tip Over

TX03768,0000B6B -19-03NOV08-1/1

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450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=16

Safety

Avoid serious injury or death from an explosion hazard. Deactivate all cellular or radio frequency devices on equipment stored or operating in an area, such as a blasting zone, where the use of radio transmitting devices are prohibited.

TX1023216 —UN—07MAY07

Prevent Unintended Detonation of Explosive Devices

VD76477,0001543 -19-08JAN08-1/1

Park And Prepare For Service Safely Warn others of service work. Always park and prepare your machine for service or repair properly. and attachments to the ground.

• Place park lock lever in “lock” position. Stop engine and remove key.

• Attach a “Do Not Operate” tag in an obvious place in the operator's station.

Securely support machine or attachment before working under it.

T133332 —19—17APR13

• Park machine on a level surface and lower blade/bucket

• Do not support machine with blade/bucket or attachments.

• Do not support machine with cinder blocks or wooden pieces that may crumble or crush.

• Do not support machine with a single jack or other Understand service procedures before beginning repairs. Keep service area clean and dry. Use two people whenever the engine must be running for service work.

TS229 —UN—23AUG88

devices that may slip out of place.

TX03768,0000B6A -19-19OCT09-1/1

Service Cooling System Safely

Do not service radiator through the radiator cap. Only fill through the surge tank filler cap. Shut off engine. Only remove surge tank filler cap when cool enough to touch with bare hands. Slowly loosen cap to relieve pressure before removing completely.

TS281 —UN—15APR13

Explosive release of fluids from pressurized cooling system can cause serious burns.

TX,SURGE -19-19JAN11-1/1

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Safety

Remove Paint Before Welding or Heating Avoid potentially toxic fumes and dust. Hazardous fumes can be generated when paint is heated by welding, soldering, or using a torch. TS220 —UN—15APR13

Remove paint before heating:

• Remove paint a minimum of 100 mm (4 in.) from area

to be affected by heating. If paint cannot be removed, wear an approved respirator before heating or welding. • If you sand or grind paint, avoid breathing the dust. Wear an approved respirator. • If you use solvent or paint stripper, remove stripper with soap and water before welding. Remove solvent or paint stripper containers and other flammable material from area. Allow fumes to disperse at least 15 minutes before welding or heating.

Do not use a chlorinated solvent in areas where welding will take place.

Do all work in an area that is well ventilated to carry toxic fumes and dust away. Dispose of paint and solvent properly. DX,PAINT -19-24JUL02-1/1

Make Welding Repairs Safely

Avoid welding or heating near pressurized fluid lines. Flammable spray may result and cause severe burns if pressurized lines fail as a result of heating. Do not let heat go beyond work area to nearby pressurized lines. Remove paint properly. Do not inhale paint dust or fumes. Use a qualified welding technician for structural repairs.

T133547 —UN—15APR13

IMPORTANT: Disable electrical power before welding. Turn off main battery switch or disconnect positive battery cable. Separate harness connectors to engine and vehicle microprocessors.

Make sure there is good ventilation. Wear eye protection and protective equipment when welding. TX03679,00016D5 -19-11SEP09-1/1

Always wear protective goggles or safety glasses and other protective equipment before striking hardened parts. Hammering hardened metal parts such as pins and bucket teeth may dislodge chips at high velocity. Use a soft hammer or a brass bar between hammer and object to prevent chipping.

T133738 —UN—15APR13

Drive Metal Pins Safely

OUO1065,0000090 -19-03NOV08-1/1

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Section 9001 Diagnostic Trouble Codes (DTC) Contents Page Page

Group 10—Standard Display Monitor (SDM) Diagnostic Trouble Codes Standard Display Monitor (SDM) Diagnostic Trouble Codes ..................... 9001-10-1 000096.03 — Fuel Level Sender Open or Short .................................................9001-10-1 Fuel Level Sensor Open or Short Diagnostic Procedure............................9001-10-1 000096.04 — Fuel Level Sender Short to Gnd ...................................................9001-10-2 Fuel Level Sensor Open or Short......................................................9001-10-3 000107.03 — Eng Air Filter Short to Power ....................................................9001-10-3 Engine Air Filter Restriction Switch Short to Power Diagnostic Procedure..............................................9001-10-3 000107.04 — Eng Air Filter Restricted ..............................................9001-10-4 Engine Air Filter Restricted Diagnostic Procedure..............................................9001-10-4 000177.03 — Trans Oil Temp Open or Short to Power ......................................9001-10-5 Transmission Oil Temperature Sensor Open or Short to Power Diagnostic Procedure..............................................9001-10-5 000177.04 — Trans Oil Temp Short to Gnd .......................................................9001-10-6 Transmission Oil Temperature Sensor Short to Ground Diagnostic Procedure..............................................9001-10-6 000177.16 — Transmission Oil Temperature High..................................9001-10-6 Transmission Oil Temperature High.......................................................9001-10-6 000609.09 — CAN Comm No TCU Msg .......................................................9001-10-7 CAN Communication Error (No TCU Message) Diagnostic Procedure..............................................9001-10-7 001638.00 — Hydraulic Oil High Temp .....................................................9001-10-8 Hydraulic Oil Temperature High Diagnostic Procedure............................9001-10-8 001638.03 — Hydraulic Oil Temp Short to Power ................................................9001-10-8 Hydraulic Oil Temperature Sensor Short to Power Diagnostic Procedure..............................................9001-10-9 001638.04 — Hydraulic Oil Temp Short to Gnd ...................................................9001-10-9

Hydraulic Oil Temperature Sensor Short to Ground Diagnostic Procedure..............................................9001-10-9 001713.31 — Hydraulic Oil Filter Restricted ............................................9001-10-10 Hydraulic Oil Filter Restricted Diagnostic Procedure..........................9001-10-10 002000.09 — CAN Comm No ECU Config..................................................9001-10-11 CAN Communication Error (No ECU Configuration) Diagnostic Procedure............................................9001-10-11 003156.09 — CAN Blade Mode Missing From EHC ..............................9001-10-12 SDM Not Receiving Blade Mode Signal From EHC Diagnostic Procedure............................................9001-10-12 003359.31 — Trans Oil Filter Restricted ............................................9001-10-13 Transmission Oil Filter Restricted Diagnostic Procedure..........................9001-10-13 Group 20—Engine Control Unit (ECU) Diagnostic Trouble Codes Engine Control Unit (ECU) Diagnostic Trouble Codes ..................... 9001-20-1 000091.09 — CAN Throttle Missing from TCU...............................................9001-20-1 No Throttle Sensor Signal from TCU Diagnostic Procedure............................9001-20-1 Group 30—Transmission Control Unit (TCU) Diagnostic Trouble Codes Transmission Control Unit (TCU) Diagnostic Trouble Codes ..................... 9001-30-1 000070.00 — Park Lock Lever Inputs Both On .................................................9001-30-1 Park Lock Lever Inputs Both On Diagnostic Procedure............................9001-30-1 000070.01 — Park Lock Lever Inputs Both Off .................................................9001-30-2 Park Lock Lever Inputs Both Off Diagnostic Procedure............................9001-30-2 000091.00 — Throttle Sensor Input Greater Than Max Cal...........................9001-30-3 Engine Speed Control Input Signal Greater Than Maximum Calibration Diagnostic Procedure............................9001-30-4 000091.01 — Throttle Sensor Input Less Than Min Cal ................................9001-30-4

Continued on next page

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Contents

Page

Engine Speed Control Input Less Than Minimum Calibration Value Diagnostic Procedure............................9001-30-4 000091.03 — Throttle Sensor Short to Power ....................................................9001-30-5 Engine Speed Control Voltage Short to Power Diagnostic Procedure.................9001-30-5 000091.04 — Throttle Sensor Open or Short......................................................9001-30-6 Throttle Sensor Voltage Below Normal Open Circuit Diagnostic Procedure..............................................9001-30-6 000091.15 — Throttle Sensor Min Cal Too High ................................................9001-30-7 Throttle Sensor Minimum Calibration Too High Diagnostic Procedure..............................................9001-30-8 000091.16 — Throttle Sensor Max Cal Too High ................................................9001-30-8 Throttle Sensor Maximum Calibration Value Too High Diagnostic Procedure..............................................9001-30-9 000091.17 — Throttle Sensor Min Cal Too Low.................................................9001-30-9 Throttle Sensor Minimum Calibration Value Too Low Diagnostic Procedure............................................9001-30-10 000091.18 — Throttle Sensor Max Cal Too Low...............................................9001-30-10 Throttle Sensor Maximum Calibration Value Too Low Diagnostic Procedure............................................9001-30-11 000158.03 — TCU System Volts Too High.....................................................9001-30-11 Transmission Control Unit System Voltage Is Too High Diagnostic Procedure............................................9001-30-12 000158.04 — TCU System Volts Too Low......................................................9001-30-12 Transmission Control Unit System Voltage Is Too Low Diagnostic Procedure............................................9001-30-12 000177.00 — Transmission Overtemp ............................................9001-30-13 Transmission Temperature Is Above Normal Operating Range Diagnostic Procedure............................................9001-30-14 000190.09 — CAN Comm No Engine Speed..................................................9001-30-14 CAN Communication Error, No Engine Speed Message Received from ECU Diagnostic Procedure .................9001-30-14 000521.00 — Decel Sensor Input Greater Than Max Cal.........................9001-30-15 Decelerator Sensor Input Voltage Is Greater Than Maximum Calibration Value Diagnostic Procedure ................9001-30-15

000521.01 — Decel Sensor Input Less Than Min Cal.......................................9001-30-15 Decelerator Sensor Input Voltage Is Less Than Minimum Calibration Value Diagnostic Procedure ................9001-30-15 000521.03 — Decel Sensor Short to Power ..................................................9001-30-16 Decelerator Sensor Voltage Short to Power Diagnostic Procedure...............9001-30-16 000521.04 — Decel Sensor Open or Short....................................................9001-30-17 Decelerator Sensor Voltage Is Open or Short Diagnostic Procedure ................9001-30-17 000521.05 — Decel Sensor Brake Cal Too Low...............................................9001-30-19 Decelerator Sensor Brake Calibration Is Too Low Diagnostic Procedure............................................9001-30-19 000521.06 — Decel Sensor Brake Cal Too High ..............................................9001-30-20 Decelerator Sensor Brake Calibration Is Too High Diagnostic Procedure............................................9001-30-20 000521.15 — Decel Sensor Min Cal Too High ..............................................9001-30-21 Decelerator Sensor Minimum Calibration Is Too High Diagnostic Procedure............................................9001-30-21 000521.16 — Decel Sensor Max Cal Too High ..............................................9001-30-22 Decelerator Sensor Maximum Calibration Value Is Too High Diagnostic Procedure..........................9001-30-22 000521.17 — Decel Sensor Min Cal Too Low...............................................9001-30-23 Decelerator Sensor Minimum Calibration Is Too Low Diagnostic Procedure............................................9001-30-23 000521.18 — Decel Sensor Max Cal Too Low...............................................9001-30-24 Decelerator Sensor Maximum Calibration Is Too Low Diagnostic Procedure............................................9001-30-24 000581.00 — Speed Buttons Input Greater Than Max Cal.........................9001-30-25 Transmission Speed Control Sensor Input Voltage Is Above Maximum Calibration Value Diagnostic Procedure............................................9001-30-25 000581.01 — Speed Buttons Input Less Than Min Cal ..............................9001-30-26 Transmission Speed Control Sensor Input Voltage Is Below Minimum Calibration Value Diagnostic Procedure............................................9001-30-26 000581.03 — Speed Buttons Short to Power ..................................................9001-30-27

Continued on next page

TM10721 (03SEP14)

9001-2

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=2

Contents

Page

Speed Buttons Short to Power Diagnostic Procedure..........................9001-30-27 000581.04 — Speed Buttons Open or Short....................................................9001-30-28 Transmission Speed Control Sensor Open or Short Diagnostic Procedure............................................9001-30-28 000581.15 — Speed Buttons Min Cal Too High ..............................................9001-30-30 Transmission Speed Control Sensor Minimum Calibration Value Too High Diagnostic Procedure..........................9001-30-30 000581.16 — Speed Buttons Max Cal Too High ..............................................9001-30-31 Transmission Speed Control Sensor Maximum Calibration Value Too High Diagnostic Procedure .................9001-30-31 000581.17 — Speed Buttons Min Cal Too Low...............................................9001-30-32 Transmission Speed Control Sensor Minimum Calibration Value Too Low Diagnostic Procedure..........................9001-30-32 000581.18 — Speed Buttons Max Cal Too Low...............................................9001-30-33 Transmission Speed Control Sensor Maximum Calibration Value Too Low Diagnostic Procedure..........................9001-30-33 000604.03 — TCL Neut Switch Open Circuit ..................................................9001-30-34 Neutral Switch Open Circuit Diagnostic Procedure............................................9001-30-34 000604.04 — TCL Neut Switch Short Circuit ..................................................9001-30-35 Neutral Switch Short Circuit Diagnostic Procedure............................................9001-30-35 000604.15 — TCL Neut Switch Min Cal Too High........................................9001-30-36 Neutral Start Switch Minimum Calibration Value Too High Diagnostic Procedure..........................9001-30-37 000604.16 — TCL Neut Switch Max Cal Too High........................................9001-30-37 Neutral Start Switch Maximum Calibration Value Too High Diagnostic Procedure..........................9001-30-38 000604.17 — TCL Neut Switch Min Cal Too Low ........................................9001-30-38 Neutral Switch Minimum Calibration Value Too Low Diagnostic Procedure............................................9001-30-39 000604.18 — TCL Neut Switch Max Cal Too Low ........................................9001-30-39 Neutral Start Switch Maximum Calibration Value Too Low Diagnostic Procedure..........................9001-30-40 000619.05 — Park Brake Solenoid No Response ............................................9001-30-40

Park Brake Solenoid No Response Diagnostic Procedure..........................9001-30-40 000620.03 — Sensor Supply Short to Power ..................................................9001-30-42 Sensor Supply Short to Power Diagnostic Procedure..........................9001-30-42 000620.04 — Sensor Supply Short to Gnd .....................................................9001-30-43 Sensor Supply Short to Ground Diagnostic Procedure..........................9001-30-43 000907.03 — Left Speed Sensor Short to Power ..............................................9001-30-44 Left Speed Sensor Short to Power Diagnostic Procedure..........................9001-30-44 000907.04 — Left Speed Sensor Short....................................................9001-30-45 Left Speed Sensor Short Diagnostic Procedure............................................9001-30-45 000907.07 — Left Speed Sensor No Response ............................................9001-30-46 Left Speed Sensor No Response Diagnostic Procedure..........................9001-30-46 000907.12 — Left Speed Sensor Open ...................................................9001-30-48 Left Speed Sensor Open Diagnostic Procedure............................................9001-30-48 000908.03 — Right Speed Sensor Short to Power ....................................9001-30-50 Right Speed Sensor Short to Power Diagnostic Procedure..........................9001-30-50 000908.04 — Right Speed Sensor Short....................................................9001-30-51 Right Speed Sensor Short Diagnostic Procedure............................................9001-30-51 000908.07 — Right Speed Sensor No Response ............................................9001-30-52 Right Speed Sensor No Response Diagnostic Procedure..........................9001-30-52 000908.12 — Right Speed Sensor Open ...................................................9001-30-54 Right Speed Sensor Open Diagnostic Procedure............................................9001-30-54 002660.00 — Steer Sensor Input Greater Than Max Cal.........................9001-30-55 Left Steer Sensor Input Greater Than Maximum Calibration Value Diagnostic Procedure..........................9001-30-55 002660.01 — Steer Sensor Input Less Than Min Cal.......................................9001-30-56 Steer Sensor Input Less Than Minimum Calibration Value Diagnostic Procedure..........................9001-30-56 002660.03 — Steer Sensor Short to Power ..................................................9001-30-57 Steer Sensor Short to Power Diagnostic Procedure..........................9001-30-57 002660.04 — Steer Sensor Open or Short....................................................9001-30-57 Continued on next page

TM10721 (03SEP14)

9001-3

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=3

Contents

Page

Steer Sensor Open or Short Diagnostic Procedure............................................9001-30-58 002660.15 — Steer Sensor Min Cal Too High ..............................................9001-30-60 Right Steer Sensor Minimum Calibration Value Too High Diagnostic Procedure..........................9001-30-60 002660.16 — Steer Sensor Max Cal Too High ..............................................9001-30-61 Steer Sensor Maximum Calibration Value Too High Diagnostic Procedure............................................9001-30-61 002660.17 — Steer Sensor Min Cal Too Low...............................................9001-30-62 Steer Sensor Minimum Calibration Value Too Low Diagnostic Procedure............................................9001-30-62 002660.18 — Steer Sensor Max Cal Too Low...............................................9001-30-63 Steer Sensor Maximum Calibration Value Too Low Diagnostic Procedure............................................9001-30-63 002661.00 — TCL Input Greater Than Max Cal ...............................................9001-30-64 TCL Sensor Input Greater Than Maximum Calibration Value Diagnostic Procedure..........................9001-30-64 002661.01 — TCL Input Less Than Min Cal ................................................9001-30-64 TCL Input Less Than Minimum Calibration Value Diagnostic Procedure............................................9001-30-64 002661.03 — TCL Sensor Short to Power ..................................................9001-30-65 TCL Sensor Short to Power Diagnostic Procedure............................................9001-30-65 002661.04 — TCL Sensor Open or Short....................................................9001-30-66 TCL Sensor Open or Short Diagnostic Procedure............................................9001-30-66 002661.15 — TCL Sensor Min Cal Too High.....................................................9001-30-67 TCL Sensor Minimum Calibration Value Too High Diagnostic Procedure............................................9001-30-67 002661.16 — TCL Sensor Max Cal Too High ..............................................9001-30-68 TCL Sensor Maximum Calibration Value Too High Diagnostic Procedure............................................9001-30-68 002661.17 — TCL Sensor Min Cal Too Low......................................................9001-30-69 TCL Sensor Minimum Calibration Value Too Low Diagnostic Procedure............................................9001-30-69 002661.18 — TCL Sensor Max Cal Too Low...............................................9001-30-70

TCL Sensor Maximum Calibration Value Too Low Diagnostic Procedure............................................9001-30-70 522444.00 — Charge Pressure High.....................................................9001-30-71 Charge Pressure High Diagnostic Procedure............................................9001-30-71 522444.01 — Charge Pressure Low......................................................9001-30-72 Charge Pressure Low Diagnostic Procedure............................................9001-30-72 522444.03 — Charge Pressure Short to Power ..............................................9001-30-72 Charge Pressure Short to Power Diagnostic Procedure..........................9001-30-72 522444.04 — Charge Pressure Open or Short ...............................................9001-30-73 Charge Pressure Open or Short Diagnostic Procedure..........................9001-30-73 522447.05 — Right Fwd Pump Coil Open ...................................................9001-30-75 Right Forward Pump Coil Open Diagnostic Procedure..........................9001-30-75 522447.06 — Right Fwd Pump Coil Short....................................................9001-30-76 Right Forward Pump Coil Short Diagnostic Procedure..........................9001-30-76 522447.15 — Right Fwd Pump Thresh Cal High ..............................................9001-30-77 Right Forward Pump Threshold Calibration Value Too High Diagnostic Procedure..........................9001-30-77 522447.16 — Right Fwd Pump Max Spd Cal High .......................................9001-30-77 Right Forward Pump Max Speed Calibration Value Too High Diagnostic Procedure..........................9001-30-78 522447.17 — Right Fwd Pump Thresh Cal Low ...............................................9001-30-78 Right Forward Pump Threshold Calibration Value Too Low Diagnostic Procedure..........................9001-30-78 522447.18 — Right Fwd Pump Max Spd Cal Low........................................9001-30-78 Right Forward Pump Max Speed Calibration Value Too Low Diagnostic Procedure..........................9001-30-78 522448.05 — Right Rev Pump Coil Open ...................................................9001-30-78 Right Reverse Pump Coil Open Diagnostic Procedure..........................9001-30-79 522448.06 — Right Rev Pump Coil Short....................................................9001-30-80 Right Reverse Pump Coil Short Diagnostic Procedure..........................9001-30-80 522448.15 — Right Rev Pump Thresh Cal High ..............................................9001-30-81

Continued on next page

TM10721 (03SEP14)

9001-4

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=4

Contents

Page

Right Reverse Pump Threshold Calibration Value Too High Diagnostic Procedure..........................9001-30-81 522448.16 — Right Rev Pump Max Spd Cal High .......................................9001-30-81 Right Reverse Pump Max Speed Calibration Value Too High Diagnostic Procedure..........................9001-30-81 522448.17 — Right Rev Pump Thresh Cal Low ...............................................9001-30-81 Right Reverse Pump Threshold Calibration Value Too Low Diagnostic Procedure..........................9001-30-81 522448.18 — Right Rev Pump Max Spd Cal Low........................................9001-30-82 Right Reverse Pump Max Speed Calibration Value Too Low Diagnostic Procedure..........................9001-30-82 522449.05 — Left Rev Pump Coil Open ...................................................9001-30-82 Left Reverse Pump Coil Open Diagnostic Procedure..........................9001-30-82 522449.06 — Left Rev Pump Coil Short....................................................9001-30-83 Left Reverse Pump Coil Open Diagnostic Procedure..........................9001-30-83 522449.15 — Left Rev Pump Thresh Cal High ..............................................9001-30-84 Left Reverse Pump Threshold Calibration Value Too High Diagnostic Procedure..........................9001-30-84 522449.16 — Left Rev Pump Max Spd Cal High ..............................................9001-30-85 Left Reverse Pump Max Speed Calibration Value Too High Diagnostic Procedure..........................9001-30-85 522449.17 — Left Rev Pump Thresh Cal Low ...............................................9001-30-85 Left Reverse Pump Threshold Calibration Value Too Low Diagnostic Procedure..........................9001-30-85 522449.18 — Left Rev Pump Max Spd Cal Low ...............................................9001-30-85 Left Reverse Pump Max Speed Calibration Value Too Low Diagnostic Procedure..........................9001-30-85 522450.05 — Left Fwd Pump Coil Open ...................................................9001-30-86 Left Forward Pump Coil Open Diagnostic Procedure..........................9001-30-86 522450.06 — Left Fwd Pump Coil Short....................................................9001-30-87 Left Forward Pump Coil Short Diagnostic Procedure..........................9001-30-87 522450.15 — Left Fwd Pump Thresh Cal High ..............................................9001-30-88

Left Forward Pump Threshold Calibration Value Too High Diagnostic Procedure..........................9001-30-88 522450.16 — Left Fwd Pump Max Spd Cal High ..............................................9001-30-88 Left Forward Pump Max Speed Calibration Value Too High Diagnostic Procedure..........................9001-30-88 522450.17 — Left Fwd Pump Thresh Cal Low ...............................................9001-30-88 Left Forward Pump Threshold Calibration Value Too Low Diagnostic Procedure..........................9001-30-88 522450.18 — Left Fwd Pump Max Spd Cal Low ...............................................9001-30-89 Left Forward Pump Max Speed Calibration Value Too Low Diagnostic Procedure..........................9001-30-89 523108.13 — TCU High Speed Not Calibrated............................................9001-30-89 TCU High Speed Not Calibrated Diagnostic Procedure..........................9001-30-89 523108.14 — Sensor or Pump Speed Not Calibrated .....................................9001-30-89 Sensor or Pump Speed Not Calibrated Diagnostic Procedure..........................9001-30-89 523577.09 — Left Motor Sol No Response ............................................9001-30-90 Left Motor Solenoid No Response Diagnostic Procedure..........................9001-30-90 523578.09 — Right Motor Sol No Response ............................................9001-30-91 Right Motor Solenoid No Response Diagnostic Procedure..........................9001-30-91 Group 40—Electrohydraulic Controller (EHC) Diagnostic Trouble Codes Electrohydraulic Controller (EHC) Diagnostic Trouble Codes ..................... 9001-40-1 000158.03 — EHC System Volts Too High.......................................................9001-40-1 EHC System Voltage Too High Diagnostic Procedure............................9001-40-1 000158.04 — EHC System Volts Too Low........................................................9001-40-1 EHC System Voltage Too Low Diagnostic Procedure............................9001-40-1 000620.03 — Sensor Short to Power ....................................................9001-40-3 Sensor 5-Volt Supply Short to Power Diagnostic Procedure............................9001-40-4 000620.04 — Sensor Short to GND ......................................................9001-40-4 5-Volt Sensor Supply Short to Ground Diagnostic Procedure............................9001-40-4 001903.00 — Aux 1 PVE Open Circuit ....................................................9001-40-6

Continued on next page

TM10721 (03SEP14)

9001-5

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=5

Contents

Page

Auxiliary 1 Electrohydraulic Actuator Open Circuit Diagnostic Procedure..............................................9001-40-6 001903.01 — Aux 1 PVE Low or Open Circuit ....................................................9001-40-7 Auxiliary 1 Electrohydraulic Actuator Open or Short to Ground Diagnostic Procedure..............................................9001-40-7 001903.03 — Aux 1 PVE Short to Power ....................................................9001-40-8 Auxiliary 1 Electrohydraulic Actuator Short to Power Diagnostic Procedure..............................................9001-40-8 001903.04 — Aux 1 PVE Short to GND ......................................................9001-40-8 Auxiliary 1 Electrohydraulic Actuator Short to Ground Diagnostic Procedure..............................................9001-40-8 001903.31 — Aux 1 PVE Spool Pos Error ......................................................9001-40-9 Auxiliary 1 Electrohydraulic Actuator Spool Position Error Diagnostic Procedure............................................9001-40-10 001915.00 — Aux 2 PVE Open Circuit ..................................................9001-40-11 001915.01 — Aux 2 PVE Low or Open Circuit ..................................................9001-40-12 001915.03 — Aux 2 PVE Short to Power ..................................................9001-40-12 001915.04 — Aux 2 PVE Short to GND ....................................................9001-40-12 001915.31 — Aux 2 PVE Spool Pos Error ....................................................9001-40-12 002697.09 — CAN Joystick Pos Missing From BCJ...............................9001-40-12 CAN Joystick Position Signal Missing from Blade Control Joystick Diagnostic Procedure..........................9001-40-12 002712.00 — Hyd Enable Sw Inputs Both On ...............................................9001-40-12 Hydraulic Enable Switch Inputs Both On Diagnostic Procedure ....................9001-40-12 002712.01 — Hyd Enable Sw Inputs Both Off ...............................................9001-40-13 Hydraulic Enable Switch Inputs Both Off Diagnostic Procedure ....................9001-40-13 003157.03 — Incr / Decr Buttons Short to Power ..............................................9001-40-14 Blade Height Increment / Decrement Buttons Short to Power Diagnostic Procedure............................................9001-40-14 003157.04 — Incr / Decr Buttons Open or Short ...............................................9001-40-15 Blade Height Increment/Decrement Buttons Open or Short Diagnostic Procedure............................................9001-40-15 003157.31 — Incr / Decr Buttons Invalid Output ......................................9001-40-16

Blade Increment/Decrement Buttons Abnormal Value Diagnostic Procedure............................................9001-40-16 522442.03 — Blade Buttons Short to Power ..................................................9001-40-17 Blade Buttons Short to Power Diagnostic Procedure..........................9001-40-17 522442.04 — Blade Buttons Open or Short to Ground...................................9001-40-18 Blade Buttons Open or Short to Ground Diagnostic Procedure..........................9001-40-18 522442.31 — Blade Buttons Invalid Output .................................................9001-40-19 Blade Angle Buttons Invalid Output Diagnostic Procedure..........................9001-40-19 523779.00 — Blade Rotate Current Above Max ..........................................9001-40-20 Blade Angle Buttons Current Above Maximum Diagnostic Procedure............................................9001-40-20 523779.01 — Blade Rotate Current Below Min............................................9001-40-21 Blade Angle Actuator Current Below Minimum Diagnostic Procedure............................................9001-40-21 523780.00 — Tilt PVE Open Circuit ..................................................9001-40-23 Blade Tilt Actuator Open Circuit ..............9001-40-23 523780.01 — Tilt PVE Low or Open Circuit ..................................................9001-40-25 Blade Tilt Actuator Open Circuit ..............9001-40-25 523780.03 — Tilt PVE Short to Power ..................................................9001-40-26 Blade Tilt Actuator Short to Power Diagnostic Procedure..........................9001-40-26 523780.04 — Tilt PVE Short to GND ....................................................9001-40-27 Blade Tilt Actuator Short to Ground Diagnostic Procedure..........................9001-40-27 523780.31 — Tilt PVE Spool Pos Error ....................................................9001-40-28 Blade Tilt Actuator Spool Position Error Diagnostic Procedure..........................9001-40-28 523781.00 — Height PVE Open Circuit ..................................................9001-40-30 Blade Lift Hydraulic Actuator Open Circuit Diagnostic Procedure...............9001-40-30 523781.01 — Height PVE Low or Open Circuit ..................................................9001-40-31 Blade Lift Hydraulic Actuator Open Circuit Diagnostic Procedure...............9001-40-31 523781.03 — Height PVE Short to Power ..................................................9001-40-33 Blade Lift Actuator Short to Power Diagnostic Procedure..........................9001-40-33 523781.04 — Height PVE Short to GND ....................................................9001-40-34

Continued on next page

TM10721 (03SEP14)

9001-6

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=6

Contents

Page

Blade Lift Actuator Short to Ground Diagnostic Procedure..........................9001-40-34 523781.31 — Height PVE Spool Pos Error ....................................................9001-40-36 Blade Lift Actuator Spool Position Error Diagnostic Procedure..........................9001-40-36 524059.00 — Aux 2 Jstk Sensor 2 Volts High ............................................9001-40-38 524059.01 — Aux 2 Jstk Sensor 2 Volts Low.............................................9001-40-38 524059.03 — Aux 2 Jstk Sensor 2 Short to Power ....................................9001-40-38 524059.04 — Aux 2 Jstk Sensor 2 Short to GND.......................................9001-40-38 524059.31 — Aux 2 Jstk Sensor 2 Invalid Output ......................................9001-40-38 524062.00 — Aux 1 Jstk Sensor 2 Volts High ............................................9001-40-38 Sensor 2 of Auxiliary Joystick 1 Diagnostic Procedure..........................9001-40-38 524062.01 — Aux 1 Jstk Sensor 2 Volts Low.............................................9001-40-39 Sensor 2 of Auxiliary Joystick 1 Diagnostic Procedure..........................9001-40-39 524062.03 — Aux 1 Jstk Sensor 2 Short to Power ....................................9001-40-41 Sensor 2 of Auxiliary Joystick 1 Diagnostic Procedure..........................9001-40-41 524062.04 — Aux 1 Jstk Sensor 2 Short to GND.......................................9001-40-42 Sensor 2 of Auxiliary Joystick 1 Diagnostic Procedure..........................9001-40-42 524062.31 — Aux 1 Jstk Sensor 2 Invalid Output ......................................9001-40-43 Sensor 2 of Auxiliary Joystick 1 Diagnostic Procedure..........................9001-40-43 524085.00 — Aux 2 Jstk Sensor 1 Volts High ............................................9001-40-44 524085.01 — Aux 2 Jstk Sensor 1 Volts Low.............................................9001-40-44 524085.03 — Aux 2 Jstk Sensor 1 Short to Power ....................................9001-40-45 524085.04 — Aux 2 Jstk Sensor 1 Short to GND.......................................9001-40-45 524085.14 — Aux 2 Jstk Sensor Mismatch.............................................9001-40-45 524085.31 — Aux 2 Jstk Sensor 1 Invalid Output ......................................9001-40-45 524086.00 — Aux 1 Jstk Sensor 1 Volts High ............................................9001-40-45 Sensor 1 of Auxiliary Joystick 1 Diagnostic Procedure..........................9001-40-45 524086.01 — Aux 1 Jstk Sensor 1 Volts Low.............................................9001-40-46 Sensor 1 of Auxiliary Joystick 1 Diagnostic Procedure..........................9001-40-46 524086.03 — Aux 1 Jstk Sensor 1 Short to Power ....................................9001-40-48 Sensor 1 of Auxiliary Joystick 1 Diagnostic Procedure..........................9001-40-48

524086.04 — Aux 1 Jstk Sensor 1 Short to GND.......................................9001-40-49 Sensor 1 of Auxiliary Joystick 1 Diagnostic Procedure..........................9001-40-49 524086.14 — Aux 1 Jstk Sensor Mismatch.............................................9001-40-50 Auxiliary Joystick 1 Diagnostic Procedure............................................9001-40-50 524086.31 — Aux 1 Jstk Sensor 1 Invalid Output ......................................9001-40-52 Sensor 1 of Auxiliary Joystick 1 Diagnostic Procedure..........................9001-40-52

TM10721 (03SEP14)

Group 50—Blade Control Joystick (BCJ) Diagnostic Trouble Codes Blade Control Joystick (BCJ) Diagnostic Trouble Codes ..................... 9001-50-1 002697.03 — X-Axis Sensor Out of Range High ...........................................9001-50-1 Joystick Diagnostic Procedure ..................9001-50-1 002697.04 — X-Axis Sensor Out of Range Low ............................................9001-50-1 Joystick Diagnostic Procedure ..................9001-50-1 002697.12 — X-Axis Joystick Internal Failure ...................................................9001-50-2 Joystick Diagnostic Procedure ..................9001-50-2 002697.13 — X-Axis Joystick Setup Failure ...................................................9001-50-2 Joystick Diagnostic Procedure ..................9001-50-2 002697.14 — X-Axis Joystick Sensor Failure ...................................................9001-50-2 Joystick Diagnostic Procedure ..................9001-50-2 002698.03 — Y-Axis Sensor Out of Range High ...........................................9001-50-3 Joystick Diagnostic Procedure ..................9001-50-3 002698.04 — Y-Axis Sensor Out of Range Low ............................................9001-50-3 Joystick Diagnostic Procedure ..................9001-50-3 002698.12 — Y-Axis Joystick Internal Failure ...................................................9001-50-3 Joystick Diagnostic Procedure ..................9001-50-4 002698.13 — Y-Axis Joystick Setup Failure ...................................................9001-50-4 Joystick Diagnostic Procedure ..................9001-50-4 002698.14 — Y-Axis Joystick Sensor Failure ...................................................9001-50-4 Joystick Diagnostic Procedure ..................9001-50-4

9001-7

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=7

Contents

TM10721 (03SEP14)

9001-8

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=8

Group 10

Standard Display Monitor (SDM) Diagnostic Trouble Codes Standard Display Monitor (SDM) Diagnostic Trouble Codes

• Service ADVISOR™ system. See Reading Diagnostic

Trouble Codes with Service ADVISOR™ Diagnostic Application. (Group 9015-20.) • Standard display monitor (SDM). See Standard Display Monitor (SDM) Menu Structure—Service Mode. (Group 9015-16.)

The diagnostic trouble code number is indicated by a suspect parameter number (SPN) and a failure mode indicator (FMI) number. In the example 000096.03, 96 is the SPN and 03 is the FMI number. To view diagnostic trouble codes, use one of the following methods:

NOTE: For in-depth diagnostics on all SDM diagnostic trouble codes, see specific code diagnostic procedure. (Group 9001-10.)

Service ADVISOR is a trademark of Deere & Company TW73308,00000FC -19-21DEC07-1/1

000096.03 — Fuel Level Sender Open or Short There is an open or short to power present on the fuel level sensor circuit. AA95137,0001212 -19-14JAN08-1/6

Fuel Level Sensor Open or Short Diagnostic Procedure Alarm Level: No Warning Lamp AA95137,0001212 -19-14JAN08-2/6

• 1

Component Check

Turn key switch OFF.

Disconnect fuel level sensor (B35). See Transmission Harness (W7) Component Location. (Group 9015-10.) Check resistance of sensor across pins. Compare resistance to specification. See Electrical Component Specifications. (Group YES: Go to Short Circuit 9015-20.) Check. Is sensor within specification?

NO: Replace the fuel level sensor. Continued on next page

TM10721 (03SEP14)

9001-10-1

AA95137,0001212 -19-14JAN08-3/6

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=27

Standard Display Monitor (SDM) Diagnostic Trouble Codes

• 2

Short Circuit Check

Turn key switch OFF.

Disconnect fuel level sensor (B35). See Transmission Harness (W7) Component Location. (Group 9015-10.) Disconnect standard display monitor (SDM) connector (X6). See Main Cab/Canopy Harness (W5) Component Location. (Group 9015-10.) Turn key switch ON.

YES: Short to power between pin A of fuel level sensor and pin N of SDM (H1) connector (X6). Repair or replace harness(es).

Check for voltage at pin A (wire Y33 YEL) at fuel level sensor (B35) connector. See Transmission Harness (W7) Wiring Diagram. (Group 9015-10.)

NO: Go to next step in this check.

Fuel level sensor (B35) disconnected. SDM connector (X6) disconnected. Key switch on. Check for voltage at pin B (wire R04 BLK) at fuel level sensor (B10) connector. See Transmission Harness (W7) Wiring Diagram. (Group 9015-10.)

YES: Short to power between pin B of fuel level sensor and pin B of SDM (H1) connector (X6). Repair or replace harness(es).

Is system voltage present?

NO: Go to Open Circuit Check. AA95137,0001212 -19-14JAN08-4/6

• 3

Open Circuit Check

Turn key switch OFF.

Disconnect fuel level sensor (B35). See Transmission Harness (W7) Component Location. (Group 9015-10.) Disconnect SDM (H1) connector (X6). See Main Cab/Canopy Harness (W5) Component Location. (Group 9015-10.) Check continuity between pin A of fuel level sensor (B35) connector and pin N of SDM (H1) connector (X6). See Transmission Harness (W7) Wiring Diagram and see Main Cab/Canopy Harness (W5) Wiring Diagram. (Group 9015-10.)

YES: Go to Reprogram Controller.

Is continuity indicated?

NO: Open circuit between pin A of sensor (B35) connector and pin N of connector (X6). Repair or replace harness(es). AA95137,0001212 -19-14JAN08-5/6

• 4

Reprogram Controller

Reprogram standard display monitor (SDM) (H1).

Check for active codes.

YES: Replace controller.

Is SDM code 000096.03 still present?

NO: Checks complete. AA95137,0001212 -19-14JAN08-6/6

000096.04 — Fuel Level Sender Short to Gnd There is a short to ground present on the fuel level sensor circuit. Continued on next page

TM10721 (03SEP14)

9001-10-2

AA95137,0001213 -19-24JAN08-1/5

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=28

Standard Display Monitor (SDM) Diagnostic Trouble Codes Fuel Level Sensor Open or Short Alarm Level: No Warning Lamp AA95137,0001213 -19-24JAN08-2/5

• 1

Component Check

Turn key switch off.

NO: Replace the fuel level sensor. AA95137,0001213 -19-24JAN08-3/5

• 2

Short Circuit Check

Turn key switch OFF.

Disconnect fuel level sensor (B35). See Transmission Harness (W7) Component Location. (Group 9015-10.) Check for ground at pin A (wire Y33 YEL) on fuel level sensor (B35) connector. See Transmission Harness (W7) Wiring Diagram and see Main Cab/Canopy Harness (W5) Wiring Diagram. (Group 9015-10.)

YES: Short to ground at pin A sensor (B35) connector and pin N of SDM (H1) connector (X6). Repair or replace harness(es).

Is ground present?

NO: Go to Replace Controller. AA95137,0001213 -19-24JAN08-4/5

• 3

Replace Controller

Reprogram standard display monitor (SDM) (H1).

Check for active codes.

YES: Replace controller.

Is SDM code 000096.04 active?

NO: Checks complete. AA95137,0001213 -19-24JAN08-5/5

000107.03 — Eng Air Filter Short to Power There is a short to power present on the air filter restriction switch. AA95137,0001214 -19-14JAN08-1/5

Engine Air Filter Restriction Switch Short to Power Diagnostic Procedure Alarm Level: No Warning Lamp Continued on next page

TM10721 (03SEP14)

9001-10-3

AA95137,0001214 -19-14JAN08-2/5

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=29

Standard Display Monitor (SDM) Diagnostic Trouble Codes

• 1

Component Check

Turn key switch OFF.

Remove engine air filter restriction switch (B18). See Engine Harness (W6) Component Location. (Group 9015-10.) Check continuity across pins A and B on air filter restriction switch (B18).

YES: Replace engine air filter restriction switch (B18).

Is continuity indicated?

NO: Go to Short Circuit Check. AA95137,0001214 -19-14JAN08-3/5

• 2

Short Circuit Check

Turn key switch OFF.

Disconnect engine air filter restriction switch (B18). See Engine Harness (W6) Component Location. (Group 9015-10.) Check voltage at pin A of air filter restriction switch (B18) connector. See Engine Harness (W6) Wiring Diagram and see Main Cab/Canopy Harness (W5) Wiring Diagram. (Group 9015-10.)

YES: Short to power between pin A of fuel level sensor connector and pin E of standard display monitor (SDM) connector (X5). Repair or replace harness(es).

Is system voltage present?

NO: Go to Reprogram Controller. AA95137,0001214 -19-14JAN08-4/5

• 3

Reprogram Controller

Reprogram standard display monitor (SDM) (H1).

Check for active codes.

YES: Replace controller.

Is SDM code 000107.03 still present?

NO: Checks complete. AA95137,0001214 -19-14JAN08-5/5

000107.04 — Eng Air Filter Restricted There is a restriction in the engine air filter. WS68074,0001076 -19-04APR07-1/4

Engine Air Filter Restricted Diagnostic Procedure Alarm Level: No Warning Lamp WS68074,0001076 -19-04APR07-2/4

• 1

Air Intake System Restriction Check

Check air filter for excessive debris or clogging.

YES: Replace air filter element. See Replace Air Cleaner Elements. (Operator's Manual.)

Is debris clogging the air filter?

NO: Go to Component Circuit Check. Continued on next page

TM10721 (03SEP14)

9001-10-4

WS68074,0001076 -19-04APR07-3/4

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=30

Standard Display Monitor (SDM) Diagnostic Trouble Codes

• 2

Component Check

Remove engine air filter restriction switch (B18). See Engine Harness (W6) Component Location. (Group 9015-10.) Check continuity across pins A and B on air filter restriction switch (B18) See Engine Harness (W6) Component Location. (Group 9015-10.).

YES: Replace engine air filter restriction switch (B18).

Is continuity indicated?

NO: Replace engine air filter. WS68074,0001076 -19-04APR07-4/4

000177.03 — Trans Oil Temp Open or Short to Power

There is an open or short to power present on the transmission oil temperature sensor (B40) circuit. AA95137,0001249 -19-11APR12-1/4

Transmission Oil Temperature Sensor Open or Short to Power Diagnostic Procedure Alarm Level: No Warning Lamp AA95137,0001249 -19-11APR12-2/4

• 1

Transmission Oil Temperature Sensor Check

Turn key switch OFF.

Disconnect transmission oil temperature sensor (B40). See Transmission Harness (W7) Component Location. (Group 9015-10.) Check resistance of sensor across pins A and B. Compare resistance to specification. See Electrical Component Specifications. (Group YES: Go to Short Circuit 9015-20.) Check. Is sensor within specifications?

NO: Replace transmission oil temperature sensor (B40). AA95137,0001249 -19-11APR12-3/4

• 2

Short Circuit Check

Turn key switch OFF.

Disconnect transmission oil temperature sensor (B40). See Transmission Harness (W7) Component Location. (Group 9015-10.) Turn key switch ON. Check voltage at pin A (wire X38 YEL) on transmission oil temperature sensor (B40) connector. See Transmission Harness (W7) Wiring Diagram. (Group 9015-10.)

YES: Short to power between pin A of transmission oil temperature sensor connector and pin A of standard display monitor (SDM) connector (X5). Repair or replace harness(es).

Is there system voltage present?

NO: Program standard display monitor (SDM) (H1). AA95137,0001249 -19-11APR12-4/4

TM10721 (03SEP14)

9001-10-5

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=31

Standard Display Monitor (SDM) Diagnostic Trouble Codes

000177.04 — Trans Oil Temp Short to Gnd There is a short to ground present on the transmission oil temperature sensor (B40) circuit. AA95137,000124A -19-11APR12-1/4

Transmission Oil Temperature Sensor Short to Ground Diagnostic Procedure Alarm Level: No Warning Lamp AA95137,000124A -19-11APR12-2/4

• 1

Component Check

Turn key switch OFF.

NO: Replace transmission oil temperature sensor. AA95137,000124A -19-11APR12-3/4

• 2

Short Circuit Check

Turn key switch OFF.

Disconnect transmission oil temperature sensor (B40). See Transmission Harness (W7) Component Location. (Group 9015-10.) Check for ground at pin A (wire X38 YEL) on transmission oil temperature sensor (B40) YES: Short to ground connector. See Transmission Harness (W7) Wiring Diagram. (Group 9015-10.) between pin A on sensor (B40) connector and pin A of standard display monitor (SDM) connector (X5). Repair or replace harness(es). Is ground present?

NO: Program standard display monitor (SDM) (H1). AA95137,000124A -19-11APR12-4/4

000177.16 — Transmission Oil Temperature High

light shuts off when the temperature drops -15°C, 5°F below transmission high temperature for 5 seconds.

Transmission oil temperature light turns on when the transmission oil temperature is above 99°C, 210°F. The JW40272,0000001 -19-11AUG08-1/3

Transmission Oil Temperature High Alarm Level: Amber Warning Lamp On Continued on next page

TM10721 (03SEP14)

9001-10-6

JW40272,0000001 -19-11AUG08-2/3

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=32

Standard Display Monitor (SDM) Diagnostic Trouble Codes

• 1

Check Service Codes

Is code 000177.16 set.

YES: Perform Cooler Bypass Valve Test. Group (9026-25.) Clean hydrostatic oil cooler. NO: Check complete. JW40272,0000001 -19-11AUG08-3/3

000609.09 — CAN Comm No TCU Msg There is a controller area network (CAN) Communication Error, the standard display monitor (SDM) did not receive a message from the transmission control unit (TCU). AA95137,0001215 -19-24JAN08-1/7

CAN Communication Error (No TCU Message) Diagnostic Procedure Alarm Level: No Warning Lamp AA95137,0001215 -19-24JAN08-2/7

• 1

Component Check

Turn key switch OFF.

Remove fuse F22 and check for continuity. See Fuse and Relay Specifications . (Group 9015-10.)

YES: Go to Circuit Check.

Is continuity indicated?

NO: Replace fuse. AA95137,0001215 -19-24JAN08-3/7

• 2

Circuit Check

Turn key switch OFF.

Disconnect transmission control unit (TCU) connector (X2). See Main Cab/Canopy Harness (W5) Component Location. (Group 9015-10.) Turn key switch ON. Check voltage at pin F1 (wire P12 RED) on TCU connector (X2). See Main Cab/Canopy YES: Go to next step in this Harness (W5) Wiring Diagram. (Group 9015-10.) check. Is voltage present?

NO: Short to ground or an open circuit between pin F1 of connector (X2) and fuse F22. Repair or replace harness(es).

Key switch OFF. Check ground at pin E1 (wire G01 BLK) on TCU connector (X2). See Main Cab/Canopy YES: Go to next step in this Harness (W5) Wiring Diagram. (Group 9015-10.) check. Is ground present?

NO: Open circuit between pin E1 of connector (X2) and ground. Repair or replace harness(es).

Perform CAN Circuit Test. (Group 9015-20.)

YES: Go to Code Check.

Does the CAN circuit check good?

NO: Check and repair CAN circuit as necessary. Continued on next page

TM10721 (03SEP14)

9001-10-7

AA95137,0001215 -19-24JAN08-4/7

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=33

Standard Display Monitor (SDM) Diagnostic Trouble Codes

• 3

Code Check

Check for active engine control unit (ECU) diagnostic trouble codes. See Standard Display Monitor (SDM) Menu Structure—Service Mode. (Group 9015-16.)

YES: Go to Reprogram Transmission Control Unit.

Is ECU code 000091.09 active?

NO: Go to Reprogram Standard Display Monitor. AA95137,0001215 -19-24JAN08-5/7

• 4

Reprogram Transmission Control Unit

Reprogram transmission control unit (TCU).

Check for active codes.

YES: Replace transmission control unit.

Is SDM code 000609.09 still present?

NO: Checks complete. AA95137,0001215 -19-24JAN08-6/7

• 5

Reprogram Controller

Reprogram standard display monitor (SDM) (H1).

Check for active codes.

YES: Replace standard display monitor.

Is SDM code 000609.09 still present?

NO: Checks complete. AA95137,0001215 -19-24JAN08-7/7

001638.00 — Hydraulic Oil High Temp The hydraulic oil temperature is too high. AA95137,000124B -19-14JAN08-1/3

Hydraulic Oil Temperature High Diagnostic Procedure Alarm Level: No Warning Lamp AA95137,000124B -19-14JAN08-2/3

• 1

Hydraulic Oil Temperature Check

Turn key switch OFF.

Disconnect hydraulic oil temperature sensor (B25). See Transmission Harness (W7) Component Location. (Group 9015-10.) Check the resistance of the sensor across pins A and B. Compare resistance to specification. See Electrical Component Specifications. (Group YES: Go to Hydraulic 9015-20.) System Diagnose Malfunctions. (Group 9025-15.) Is sensor within specifications?

NO: Replace hydraulic oil temperature sensor. AA95137,000124B -19-14JAN08-3/3

001638.03 — Hydraulic Oil Temp Short to Power

There is a short to power present on the hydraulic oil temperature sensor circuit. Continued on next page

TM10721 (03SEP14)

9001-10-8

AA95137,000124C -19-14JAN08-1/5

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=34

Standard Display Monitor (SDM) Diagnostic Trouble Codes Hydraulic Oil Temperature Sensor Short to Power Diagnostic Procedure Alarm Level: No Warning Lamp AA95137,000124C -19-14JAN08-2/5

• 1

Component Check

Turn key switch OFF.

Disconnect hydraulic oil temperature sensor (B25). See Transmission Harness (W7) Component Location. (Group 9015-10.) Check resistance of sensor across pins A and B. Compare resistance to specification. See Electrical Component Specifications. (Group YES: Go to Short Circuit 9015-20.) Check. Is sensor within specifications?

NO: Replace hydraulic oil temperature sensor. AA95137,000124C -19-14JAN08-3/5

• 2

Short Circuit Check

Turn key switch OFF.

Disconnect hydraulic oil temperature sensor (B25). See Transmission Harness (W7) Component Location. (Group 9015-10.) Turn key switch ON. Check for voltage at pin A (wire X12 YEL) on hydraulic oil temperature sensor (B25) connector. See Transmission Harness (W7) Wiring Diagram. (Group 9015-10.)

YES: Short to power between pin A of sensor (B25) and pin K of standard display monitor (SDM) connector (X5). Repair or replace harness(es).

Is system voltage present?

NO: Go to Reprogram Controller. AA95137,000124C -19-14JAN08-4/5

• 3

Reprogram Controller

Reprogram standard display monitor (SDM) (H1).

Check for active codes.

YES: Replace controller.

Is SDM code 001683.03 still present?

NO: Checks complete. AA95137,000124C -19-14JAN08-5/5

001638.04 — Hydraulic Oil Temp Short to Gnd There is a short to ground present on the hydraulic oil temperature sensor circuit. AA95137,0001216 -19-14JAN08-1/5

Hydraulic Oil Temperature Sensor Short to Ground Diagnostic Procedure Alarm Level: No Warning Lamp Continued on next page

TM10721 (03SEP14)

9001-10-9

AA95137,0001216 -19-14JAN08-2/5

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=35

Standard Display Monitor (SDM) Diagnostic Trouble Codes

• 1

Component Check

Turn key switch OFF.

Disconnect hydraulic oil temperature sensor (B25). See Transmission Harness (W7) Component Location. (Group 9015-10.) Check the resistance of the sensor across sensor pins A and B. Compare resistance to specification. See Electrical Component Specifications. (Group YES: Go to Short Circuit 9015-20.) Check. Is sensor within specifications?

NO: Replace hydraulic oil temperature sensor. AA95137,0001216 -19-14JAN08-3/5

• 2

Short Circuit Check

Turn key switch OFF.

Disconnect hydraulic oil temperature sensor (B25). See Transmission Harness (W7) Component Location. (Group 9015-10.) Check ground at pin A (wire X12 YEL) on hydraulic oil temperature sensor (B25) YES: Short to ground connector.See Transmission Harness (W7) Wiring Diagram and see Main Cab/Canopy between pin A of sensor Harness (W5) Wiring Diagram. (Group 9015-10.) (B25) and pin K of standard display monitor (SDM) connector (X5). Repair or replace harness(es). Is ground present?

NO: Go to Reprogram Controller. AA95137,0001216 -19-14JAN08-4/5

• 3

Reprogram Controller

Reprogram standard display monitor (SDM) (H1).

Check for active codes.

YES: Replace controller.

Is SDM code 001683.04 still present?

NO: Checks complete. AA95137,0001216 -19-14JAN08-5/5

001713.31 — Hydraulic Oil Filter Restricted There is a restriction in the hydraulic oil filter. AA95137,000124D -19-24JAN08-1/6

Hydraulic Oil Filter Restricted Diagnostic Procedure Alarm Level: Hydraulic Oil Filter Icon AA95137,000124D -19-24JAN08-2/6

• 1

Filter Restriction Check

Remove hydraulic oil filter.

Check filter for excessive debris or flow restrictions.

YES: Change hydraulic oil filter. See Change Hydraulic Oil and Filter. (Operator's Manual.)

Is hydraulic oil filter restricted?

NO: Go to Component Check. Continued on next page

TM10721 (03SEP14)

9001-10-10

AA95137,000124D -19-24JAN08-3/6

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=36

Standard Display Monitor (SDM) Diagnostic Trouble Codes

• 2

Component Check

Turn key switch OFF.

Disconnect hydraulic oil filter restriction switch (B16). See Transmission Harness (W7) Component Location. (Group 9015-10.) Check for ground at terminal on hydraulic oil filter restriction switch (B16).

YES: Replace hydraulic oil filter restriction switch (B16).

Is ground present?

NO: Go to Short Circuit Check. AA95137,000124D -19-24JAN08-4/6

• 3

Short Circuit Check

Turn key switch OFF.

Disconnect hydraulic oil filter restriction switch (B16). See Transmission Harness (W7) Component Location. (Group 9015-10.) Check circuit N03 YEL for ground at ring terminal.

YES: Circuit N03 YEL is short to ground. Repair circuit or replace harness. See Transmission Harness (W7) Wiring Diagram. (Group 9015-10.)

Is ground present?

NO: Go to Reprogram Controller. AA95137,000124D -19-24JAN08-5/6

• 4

Reprogram Controller

Reprogram standard display monitor (SDM).

Check for active codes.

YES: Replace controller.

Is SDM code 001713.31 present?

NO: Checks complete. AA95137,000124D -19-24JAN08-6/6

002000.09 — CAN Comm No ECU Config There is a controller area network (CAN) communication error, the engine control unit (ECU) is not configured. TW73308,0000115 -19-14JAN08-1/4

CAN Communication Error (No ECU Configuration) Diagnostic Procedure Alarm Level: Check Service Code TW73308,0000115 -19-14JAN08-2/4

• 1

ECU Configuration Check

Enter service mode on standard display monitor (SDM). See Standard Display Monitor (SDM) Menu Structure—Service Mode. (Group 9015-16.)

Go to DIAGNOSTICS and view CONTROLLER INFO. Record ECU software and hardware.

YES: Go to CAN Circuit Test. (Group 9015-20.)

Does ECU have correct software and hardware version?

NO: Go to Reprogram Controller.

Continued on next page

TM10721 (03SEP14)

9001-10-11

TW73308,0000115 -19-14JAN08-3/4

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=37

Standard Display Monitor (SDM) Diagnostic Trouble Codes

• 2

Reprogram Controller

Reprogram engine control unit (ECU) (A3).

Check for active codes.

YES: Replace controller.

Is SDM code 002000.09 still present?

NO: Checks complete. TW73308,0000115 -19-14JAN08-4/4

003156.09 — CAN Blade Mode Missing From EHC

The standard display monitor (SDM) did not receive the blade mode information from the electrohydraulic controller (EHC). TW73308,0000116 -19-14JAN08-1/6

SDM Not Receiving Blade Mode Signal From EHC Diagnostic Procedure Alarm Level: Check Service Code TW73308,0000116 -19-14JAN08-2/6

• 1

Function Check

Operate blade functions in manual and auto mode.

YES: Go to Blade Control Joystick (BCJ) Check.

Do blade functions operate?

NO: Go to Integrated Grade Control (IGC) Diagnose Malfunctions—If Equipped. (Group 9015-20.) TW73308,0000116 -19-14JAN08-3/6

• 2

Blade Control Joystick Observe 4-way axis movement of the joystick as a percentage by accessing the (BCJ) Check Diagnostic / Live Values / Performance menu in the SDM menu structure. See Standard Display Monitor (SDM) Menu Structure—Service Mode. (Group 9015-16.) Slowly move the joystick handle through complete range in all four axes.

YES: Go to Electrohydraulic Controller (EHC) Check.

Do the joystick values in the SDM menu correspond with the joystick movements?

NO: Perform CAN Circuit Test. (Group 9015-20.) TW73308,0000116 -19-14JAN08-4/6

• 3

Electrohydraulic Controller (EHC) Check

Start engine.

Observe the blade functions by accessing the Diagnostic / Live Values / Blade Angle and Blade Icr/Dcr menu in the SDM menu structure. See Standard Display Monitor (SDM) Menu Structure—Service Mode. (Group 9015-16.)

YES: Go to Reprogram Controller.

Is EHC blade information displayed?

NO: Perform CAN Circuit Test. (Group 9015-10.) Continued on next page

TM10721 (03SEP14)

9001-10-12

TW73308,0000116 -19-14JAN08-5/6

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=38

Standard Display Monitor (SDM) Diagnostic Trouble Codes

• 4

Reprogram Controller

Reprogram standard display monitor (SDM).

Check for active codes.

YES: Replace controller.

Is SDM code 003156.09 present?

NO: Checks complete. TW73308,0000116 -19-14JAN08-6/6

003359.31 — Trans Oil Filter Restricted There is a restriction in the transmission oil filter resurrection circuit. AA95137,000124E -19-24JAN08-1/6

Transmission Oil Filter Restricted Diagnostic Procedure Alarm Level: Transmission Oil Filter Icon AA95137,000124E -19-24JAN08-2/6

• 1

Filter Restriction Check

Remove transmission oil filter.

Check filter for excessive debris or flow restrictions.

YES: Change transmission oil filter. See Change Transmission Oil and Filter. (Operator's Manual.)

Is transmission oil filter restricted?

NO: Go to Component Check. AA95137,000124E -19-24JAN08-3/6

• 2

Component Check

Turn key switch OFF.

Disconnect transmission oil filter restriction switch (B15). See Transmission Harness (W7) Component Location. (Group 9015-10.) Check for ground at terminal on transmission oil filter restriction switch (B15).

YES: Replace transmission oil filter restriction switch (B15).

Is ground present?

NO: Go to Short Circuit Check. AA95137,000124E -19-24JAN08-4/6

• 3

Short Circuit Check

Turn key switch OFF.

Disconnect transmission oil filter restriction switch (B15). See Transmission Harness (W7) Component Location. (Group 9015-10.) Check circuit N04 YEL for ground at ring terminal.

YES: Circuit N04 YEL is short to ground. Repair circuit or replace harness. See Transmission Harness (W7) Wiring Diagram. (Group 9015-10.)

Is ground present?

NO: Go to Reprogram Controller. Continued on next page

TM10721 (03SEP14)

9001-10-13

AA95137,000124E -19-24JAN08-5/6

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=39

Standard Display Monitor (SDM) Diagnostic Trouble Codes

• 4

Reprogram Controller

Reprogram standard display monitor (SDM).

Check for active codes.

YES: Replace controller.

Is SDM code 003359.31 present?

NO: Checks complete. AA95137,000124E -19-24JAN08-6/6

TM10721 (03SEP14)

9001-10-14

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=40

Group 20

Engine Control Unit (ECU) Diagnostic Trouble Codes Engine Control Unit (ECU) Diagnostic Trouble Codes The diagnostic trouble code number is indicated by a suspect parameter number (SPN) and a failure mode indicator (FMI) number. In the example 000091.03, 000091 is the SPN and 03 is the FMI number. M44215 —UN—07SEP88

To view diagnostic trouble codes, use one of the following methods:

• Service ADVISOR™ system. See Reading Diagnostic

Trouble Codes with Service ADVISOR™ Diagnostic Application. (Group 9015-20.) • Standard Display Monitor (SDM). See Standard Display Monitor (SDM) Menu Structure—Service Mode. (Group 9015-16.)

Engine diagnostic trouble codes (DTCs) for this machine are covered in the engine component technical manuals (CTMs).

• PowerTech™ 4.5L & 6.8L Diesel Engines—Base

For additional engine information on John Deere engines and components, see the following CTMs:

16 Electronic Fuel System with Denso HPCR. (CTM502.)

Engine. (CTM104.)

• POWERTECH E™ 4.5 and 6.8 L Diesel Engines—Level

Service ADVISOR is a trademark of Deere & Company TW73308,0000117 -19-14JAN08-1/1

000091.09 — CAN Throttle Missing from TCU There is a CAN communication error, The ECU did not receive the throttle signal from the TCU. TW73308,00000FE -19-04JAN08-1/7

No Throttle Sensor Signal from TCU Diagnostic Procedure Alarm Level: Check Service Code TW73308,00000FE -19-04JAN08-2/7

• 1

Component Check

Start engine.

Observe the blade functions by accessing the Diagnostic / Live Values / Speeds menu in the SDM menu structure. See Standard Display Monitor (SDM) Menu Structure—Service Mode. (Group 9015-16.)

YES: Reprogram standard display monitor (SDM) (H1). If code 000091.09 is still active, replace SDM controller.

Is TCU speed information displayed?

NO: Go to Code Check. TW73308,00000FE -19-04JAN08-3/7

• 2

Code Check

Check for active transmission control unit (TCU) codes.

YES: Diagnose TCU codes. See Transmission Control Unit (TCU) Diagnostic Trouble Codes. (Group 9001-20.)

Are any TCU codes active?

NO: Go to Fuse Check. Continued on next page

TM10721 (03SEP14)

9001-20-1

TW73308,00000FE -19-04JAN08-4/7

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=41

Engine Control Unit (ECU) Diagnostic Trouble Codes

• 3

Fuse Check

Turn key switch OFF.

Remove fuse (F22). see Fuse and Relay Specifications . (Group 9015-10.) Check continuity of fuse (F22).

YES: Go to Circuit Check.

Is continuity indicated?

NO: Replace fuse (F22). TW73308,00000FE -19-04JAN08-5/7

• 4

Circuit Check

Turn key switch OFF.

Disconnect transmission control unit (TCU) connector (X2). See Main Cab/Canopy Harness (W5) Component Location. (Group 9015-10.) Check voltage at pin F1 (wire P12 RED) on connector (X2). See Main Cab/Canopy Harness (W5) Wiring Diagram. (Group 9015-10.)

YES: Go to next step in this check.

Is system voltage present?

NO: Open circuit between TCU connector (X2) and fuse (F22). Repair or replace harness(es).

Perform CAN circuit Test. (Group 9015-20.)

YES: Go to Reprogram Controller.

Did the CAN circuit test good?

NO: Repair or replace the CAN circuit wiring. TW73308,00000FE -19-04JAN08-6/7

• 5

Reprogram Controller

Reprogram transmission control unit (TCU) (A1).

Check for active ECU codes.

YES: Replace controller.

Is ECU code 000091.09 still present?

NO: Checks complete. TW73308,00000FE -19-04JAN08-7/7

TM10721 (03SEP14)

9001-20-2

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=42

Group 30

Transmission Control Unit (TCU) Diagnostic Trouble Codes Transmission Control Unit (TCU) Diagnostic Trouble Codes

• Standard Display Monitor (SDM). See Standard Display

The diagnostic trouble code is indicated by a Suspect Parameter Number (SPN) and a Failure Mode Indicator (FMI) number. In the example 000091.01, 91 is the SPN and 01 is the FMI number.

Monitor (SDM) Menu Structure—Service Mode. (Group 9015-16.)

To view diagnostic trouble codes, use one of the following methods:

NOTE: For in-depth diagnostics on all TCU diagnostic trouble codes, see specific code diagnostic procedure. (Group 9001-30.)

• Service ADVISOR™ system. See Reading Diagnostic Trouble Codes with Service ADVISOR™ Diagnostic Application. (Group 9015-20.)

Service ADVISOR is a trademark of Deere & Company TW73308,0000118 -19-21DEC07-1/1

000070.00 — Park Lock Lever Inputs Both On The park lock inputs are above normal operating range (both on). AA95137,000119F -19-11JAN08-1/5

Park Lock Lever Inputs Both On Diagnostic Procedure Alarm Level: Check Service Code AA95137,000119F -19-11JAN08-2/5

• 1

Component Check

Turn key switch OFF.

Disconnect park lock lever switch (S20). See Main Cab/Canopy Harness (W5) Component Location. (Group 9015-10.) Turn key switch ON.

YES: Go to Short Circuit Check.

Is transmission control unit (TCU) code 000070.00 active?

NO: Replace switch.

Continued on next page

TM10721 (03SEP14)

9001-30-1

AA95137,000119F -19-11JAN08-3/5

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=43

Transmission Control Unit (TCU) Diagnostic Trouble Codes

• 2

Short Circuit Check

Turn key switch OFF.

Disconnect the TCU connector (X1). See Main Cab/Canopy Harness (W5) Wiring Diagram. (Group 9015-10.) Check for continuity between pin B (wire T33 BLU) and pin C (wire E07 WHT) on switch connector.

YES: Short circuit between wires T33 BLU and E07 WHT. Repair or replace harness. See Main Cab/Canopy Harness (W5) Wiring Diagram. (Group 9015-15.)

Is continuity indicated?

NO: Go to next step in this check.

Check for ground at pin B (wire T33 BLU) on park lock switch connector.

YES: Short circuit between wire T33 BLU and ground. Repair or replace harness. See Main Cab/Canopy Harness (W5) Wiring Diagram. (Group 9015-15.)

Is ground present at pin B?

NO: Go to next step in this check.

Check for ground at pin C (wire E07 WHT) on park lock switch connector.

YES: Short circuit between wire E07 WHT and ground. Repair or replace harness. See Main Cab/Canopy Harness (W5) Wiring Diagram. (Group 9015-15.)

Is ground present at pin C?

NO: Go to Reprogram Controller. AA95137,000119F -19-11JAN08-4/5

• 3

Reprogram Controller

Reprogram transmission control unit (TCU) (A1).

Check for active codes.

YES: Replace controller.

Is TCU code 000070.00 still present?

NO: Checks complete. AA95137,000119F -19-11JAN08-5/5

000070.01 — Park Lock Lever Inputs Both Off Machine will intermittently not move or come to abrupt stop. Transmission control unit (TCU) code F3P5 appears and machine will not move forward or reverse. Unable to get into calibration. This diagnostic trouble code

indicates that both park lock lever switch (S20) wires (T33 BLU and E07 WHT) are open. Both wires from park lock switch cannot have open circuits at the same time or the TCU will generate this code and prevent forward and reverse movement of machine. AA95137,00011A0 -19-15APR10-1/5

Park Lock Lever Inputs Both Off Diagnostic Procedure Alarm Level: Check Service Code Continued on next page

TM10721 (03SEP14)

9001-30-2

AA95137,00011A0 -19-15APR10-2/5

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=44

Transmission Control Unit (TCU) Diagnostic Trouble Codes

• 1

Connector Check

Check park lock lever switch (S20) connector, transmission control unit (TCU) YES: Go to Park Lock connector (X1), and transmission control unit (TCU) connector (X2) for corrosion, loose Lever Switch (S20) Check. fit, bent/pushed out terminals or crimp malfunctions. See Main Cab/Canopy Harness (W5) Component Location. (Group 9015-10.) Are connectors in good condition?

NO: Repair or replace connector(s) or terminal(s) as needed. AA95137,00011A0 -19-15APR10-3/5

• 2

Park Lock Lever Switch (S20) Check

Turn key switch OFF.

Disconnect park lock lever switch (S20). See Main Cab/Canopy Harness (W5) Wiring Diagram. (Group 9015-15.) Check park lock lever switch (S20).

• When park lock lever is in the LOCK position, check for continuity between pins A and C on park lock lever switch (S20).

• When park lock lever is in the UNLOCK position, check for continuity between pins A YES: Go to Open Circuit and B on park lock lever switch (S20).

Check.

Is continuity indicated?

NO: Replace switch. AA95137,00011A0 -19-15APR10-4/5

• 3

Open Circuit Check

Verify that ground wire (G04 BLK) has a good connection and good continuity (low resistance) from park lock lever switch (S20) to ground location. Turn key switch OFF. Disconnect park lock lever switch (S20). See Main Cab/Canopy Harness (W5) Wiring Diagram. (Group 9015-10.) Check for ground at pin A on park lock lever switch (S20) connector (wire G04 BLK).

YES: Go to next step in this check.

Is ground present at pin A?

NO: Open circuit on wire G04 BLK. Repair or replace harness.

Disconnect transmission control unit (TCU) connector (X1). See Main Cab/Canopy Harness (W5) Wiring Diagram. (Group 9015-10.) Check continuity between pin B (wire T33 BLU) on park lock lever switch (S20) connector and pin E2 on TCU connector (X1).

YES: Go to next step in this check.

Is continuity indicated?

NO: Open circuit on wire T33 BLU. Repair or replace harness.

Disconnect transmission control unit (TCU) connector (X2). See Main Cab/Canopy Harness (W5) Wiring Diagram. (Group 9015-10.) Check continuity between pin C (wire E07 WHT) on park lock lever switch (S20) connector and pin B3 on TCU connector (X2).

YES: Checks complete.

Is continuity indicated?

NO: Open circuit on wire E07 WHT. Repair or replace harness. AA95137,00011A0 -19-15APR10-5/5

000091.00 — Throttle Sensor Input Greater Than Max Cal

The input from engine speed control is greater than the stored maximum calibration value. Continued on next page

TM10721 (03SEP14)

9001-30-3

TW73308,0000119 -19-03DEC09-1/4

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=45

Transmission Control Unit (TCU) Diagnostic Trouble Codes Engine Speed Control Input Signal Greater Than Maximum Calibration Diagnostic Procedure Alarm Level: Check Service Code TW73308,0000119 -19-03DEC09-2/4

• 1

Calibration Check

Perform Transmission Control Unit (TCU) Calibration. (Group 9015-20.)

Check for active codes. See Standard Display Monitor (SDM) Menu Structure—Service YES: See TCU code Mode. (Group 9015-16.) 000091.15—Throttle Sensor Min Cal Too High or 000091.16—Throttle Sensor Max Cal Too High Is transmission control unit (TCU) code 000091.15 or 000091.16 still present?

NO: Go to next step in this check. YES: Go to Reprogram Controller.

Is TCU code 000091.00 still present?

NO: Checks complete. TW73308,0000119 -19-03DEC09-3/4

• 2

Reprogram Controller

Reprogram transmission control unit (TCU) (A1).

Check for active codes.

YES: Replace controller.

Is TCU code 000091.00 still present?

NO: Checks complete. TW73308,0000119 -19-03DEC09-4/4

000091.01 — Throttle Sensor Input Less Than Min Cal

The input from engine speed control is less than the stored minimum calibration value. AA95137,00011A2 -19-03DEC09-1/4

Engine Speed Control Input Less Than Minimum Calibration Value Diagnostic Procedure Alarm Level: Check Service Code AA95137,00011A2 -19-03DEC09-2/4

• 1

Calibration Check

Perform Transmission Control Unit (TCU) Calibration. (Group 9015-20.)

Check for diagnostic trouble codes (DTC).

YES: See TCU code 000091.17—Throttle Sensor Min Cal Too Low or 000091.18—Throttle Sensor Max Cal Too Low

Is TCU code 000091.17 or 000091.18 still present?

NO: Checks complete. YES: Go to Reprogram Controller.

Is TCU code 000091.01 still present?

NO: Checks complete. Continued on next page

TM10721 (03SEP14)

9001-30-4

AA95137,00011A2 -19-03DEC09-3/4

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=46

Transmission Control Unit (TCU) Diagnostic Trouble Codes

• 2

Reprogram Controller

Reprogram transmission control unit (TCU) (A1).

Check for active codes.

YES: Replace controller.

Is TCU code 000091.01 still present?

NO: Checks complete. AA95137,00011A2 -19-03DEC09-4/4

000091.03 — Throttle Sensor Short to Power The signal voltage from the engine speed control is more than 4.95 volts. AA95137,00011A3 -19-11JAN08-1/6

Engine Speed Control Voltage Short to Power Diagnostic Procedure Alarm Level: Check Service Code AA95137,00011A3 -19-11JAN08-2/6

• 1

Code Check

Check for active codes. See Standard Display Monitor (SDM) Menu Structure—Service YES: Repair code Mode. (Group 9015-16.) 000620.03 first. See 000620.03—Sensor Supply Short to Power. (Group 9001-30.) Is transmission control unit (TCU) code 000620.03 present?

NO: Go to Component Check. AA95137,00011A3 -19-11JAN08-3/6

• 2

Component Check

Turn key switch OFF.

Disconnect engine speed control (R10). See Main Cab/Canopy Harness (W5) Component Location. (Group 9015-15.) Turn key switch ON.

YES: Go to Short Circuit Check.

Is TCU code 000091.03 still present?

NO: Replace engine speed control (R10). Calibrate TCU, See Transmission Control Unit (TCU) Calibration. (Group 9015-20.) Continued on next page

TM10721 (03SEP14)

9001-30-5

AA95137,00011A3 -19-11JAN08-4/6

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=47

Transmission Control Unit (TCU) Diagnostic Trouble Codes

• 3

Short Circuit Check

Turn key switch OFF.

Disconnect the engine speed control (R10). Turn key switch ON. Check voltage at pin B (wire T09 BLU) on engine speed control connector. See Main Cab/Canopy Harness (W5) Wiring Diagram. (Group 9015-15.)

YES: Short to power between pin B on engine speed control connector and pin G2 on TCU connector (X1). Repair or replace harness. See Main Cab/Canopy Harness (W5) Wiring Diagram. (Group 9015-15.)

Is there voltage present?

NO: Go to Reprogram Controller. AA95137,00011A3 -19-11JAN08-5/6

• 4

Reprogram Controller

Reprogram transmission control unit (TCU) (A1).

Check for active codes.

YES: Replace controller.

Is TCU code 000091.03 still present?

NO: Checks complete. AA95137,00011A3 -19-11JAN08-6/6

000091.04 — Throttle Sensor Open or Short The engine speed control input voltage is less than 0.05 volts. AA95137,00011A4 -19-11JAN08-1/6

Throttle Sensor Voltage Below Normal Open Circuit Diagnostic Procedure Alarm Level: Check Service Code AA95137,00011A4 -19-11JAN08-2/6

• 1

Component Check

Turn key switch OFF.

Disconnect engine speed control (R10). See Main Cab/Canopy Harness (W5) Component Location. (Group 9015-15.) Check resistance of engine speed control (R10). Compare resistance to specification. See Electrical Component Specifications. (Group YES: Go to Short Circuit 9015-20.) Check. Is resistance within specification?

NO: Replace engine speed control (R10) and calibrate transmission control unit (TCU), See Transmission Control Unit (TCU) Calibration. (Group 9015-20.) Continued on next page

TM10721 (03SEP14)

9001-30-6

AA95137,00011A4 -19-11JAN08-3/6

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=48

Transmission Control Unit (TCU) Diagnostic Trouble Codes

• 2

Short Circuit Check

Turn key switch OFF.

Disconnect transmission control unit (TCU) connector (X1). See Main Cab/Canopy Harness (W5) Component Location. (Group 9015-15.) Check for ground at pin A (wire T08 BLU) on engine speed control (R10) connector. See Main Cab/Canopy Harness (W5) Wiring Diagram. (Group 9015-15.)

YES: Short to ground between pin A on engine speed control (R10) connector and pin G1 on TCU connector (X1).

Is ground present?

NO: Go to next step in this check.

Check ground at pin B (wire T09 BLU) on engine speed control (R10) connector. See Main Cab/Canopy Harness (W5) Wiring Diagram. (Group 9015-15.)

YES: Short to ground between pin B on engine speed control (R10) connector and pin G2 on TCU connector (X1).

Is ground present?

NO: Go to Open Circuit Check. AA95137,00011A4 -19-11JAN08-4/6

• 3

Open Circuit Check

Check continuity between pin A (wire T08 BLU) on engine speed control (R10) connector and pin G1 on TCU connector (X1). See Main Cab/Canopy Harness (W5) Wiring Diagram. (Group 9015-15.)

YES: Go to next step in this check.

Is continuity indicated?

NO: Open circuit between pin A on engine speed control (R10) connector and pin G1 on TCU connector (X1).

Key switch OFF. Check continuity between pin B (wire T09 BLU) on engine speed control (R10) connector and pin G2 on TCU connector (X1). See Main Cab/Canopy Harness (W5) Wiring Diagram. (Group 9015-15.)

YES: Go to next step in this check.

Is continuity indicated?

NO: Open circuit between pin B on engine speed control (R10) connector and pin G2 on TCU connector (X1).

Check continuity between pin C (wire Z07 GRY) on engine speed control (R10) connector and pin G3 on TCU connector (X1). See Main Cab/Canopy Harness (W5) Wiring Diagram. (Group 9015-15.)

YES: Go to Reprogram Controller.

Is continuity indicated?

NO: Open circuit between pin C on engine speed control (R10) connector and pin G3 on TCU connector (X1). AA95137,00011A4 -19-11JAN08-5/6

• 4

Reprogram Controller

Reprogram transmission control unit (TCU) (A1).

YES: Replace controller.

Is TCU code 000091.04 still present?

NO: Checks complete. AA95137,00011A4 -19-11JAN08-6/6

000091.15 — Throttle Sensor Min Cal Too High

The engine speed control stored calibration voltage for fast idle position is greater than 1.22 volts. Continued on next page

TM10721 (03SEP14)

9001-30-7

AA95137,00011A5 -19-07JAN08-1/5

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=49

Transmission Control Unit (TCU) Diagnostic Trouble Codes Throttle Sensor Minimum Calibration Too High Diagnostic Procedure Alarm Level: Check Service Code AA95137,00011A5 -19-07JAN08-2/5

• 1

Calibration Check

Observe the input voltage from engine speed control (R10) by accessing the DIAGNOSTIC / LIVE VALUES / INPUTS / ENGINE THROTTLE menu on the standard display monitor (SDM). See Standard Display Monitor (SDM) Menu Structure—Service Mode. (Group 9015-16.) Record voltage with engine speed control (R10) at fast idle. Specification Engine Speed Control (R10)—Calibration Limits........................................................................................ 0.45—1.22 V at Fast Idle Is voltage reading greater than 1.22 volts?

YES: Go to Component Check.

NO: Go to Reprogram Controller. AA95137,00011A5 -19-07JAN08-3/5

• 2

Component Check

Turn key switch OFF.

Disconnect engine speed control (R10). See Main Cab/Canopy Harness (W5) Component Location. (Group 9015-15.) Check resistance between pins A and C on engine speed control (R10) connector. Compare resistance to specification. See Electrical Component Specifications. (Group YES: Go to next check in 9015-20.) this step. Is resistance within specifications?

NO: Replace engine speed control (R10). Perform TCU calibration. See Transmission Control Unit (TCU) Calibration. (Group 9015-20.)

Check resistance between pins A and B while turning engine speed control (R10).

YES: Go to Reprogram Controller.

Is resistance change proportional to rotation of speed control?

NO: Replace engine speed control (R10). Perform TCU calibration. See Transmission Control Unit (TCU) Calibration. (Group 9015-20.) AA95137,00011A5 -19-07JAN08-4/5

• 3

Reprogram Controller

Reprogram transmission control unit (TCU) (A1).

Check for active codes.

YES: Replace controller.

Is TCU code 000091.15 still present?

NO: Checks complete. AA95137,00011A5 -19-07JAN08-5/5

000091.16 — Throttle Sensor Max Cal Too High

The engine speed control stored calibration voltage for slow idle position is greater than 4.15 volts. Continued on next page

TM10721 (03SEP14)

9001-30-8

AA95137,00011A6 -19-07JAN08-1/5

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=50

Transmission Control Unit (TCU) Diagnostic Trouble Codes Throttle Sensor Maximum Calibration Value Too High Diagnostic Procedure Alarm Level: Check Service Code AA95137,00011A6 -19-07JAN08-2/5

• 1

Calibration Check

Turn key switch ON.

Observe the input voltage from engine speed control (R10) by accessing the DIAGNOSTIC / LIVE VALUES / INPUTS / ENGINE THROTTLE menu on the standard display monitor (SDM). See Standard Display Monitor (SDM) Menu Structure—Service Mode. (Group 9015-16.) Record voltage with engine speed control (R10) at slow idle. Specification Engine Speed Control (R10)—Calibration Limits........................................................................................2.96—4.15 V at Slow Idle Is voltage reading greater than 4.15 volts?

YES: Go to Component Check.

NO: Go to Reprogram Controller. AA95137,00011A6 -19-07JAN08-3/5

• 2

Component Check

Turn key switch OFF.

Disconnect engine speed control (R10). See Main Cab/Canopy Harness (W5) Component Location. (Group 9015-15.) Check resistance between pins A and C on engine speed control (R10) connector. Compare resistance to specification. See Electrical Component Specifications. (Group YES: Go to next step in this 9015-20.) check. Is resistance within specification?

NO: Replace engine speed control (R10). Perform TCU calibration. See Transmission Control Unit (TCU) Calibration. (Group 9015-20.)

Check resistance between pins A and B while turning engine speed control (R10).

YES: Go to Reprogram Controller.

Is resistance change proportional to rotation of speed control?

NO: Replace engine speed control (R10). Perform TCU calibration. See Transmission Control Unit (TCU) Calibration. (Group 9015-20.) AA95137,00011A6 -19-07JAN08-4/5

• 3

Reprogram Controller

Reprogram transmission control unit (TCU) (A1).

Check for active codes.

YES: Replace controller.

Is TCU code 000091.16 still present?

NO: Checks complete. AA95137,00011A6 -19-07JAN08-5/5

000091.17 — Throttle Sensor Min Cal Too Low The engine speed control stored calibration voltage for fast idle position is less than 0.45 volts. Continued on next page

TM10721 (03SEP14)

9001-30-9

AA95137,00011A7 -19-07JAN08-1/5

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=51

Transmission Control Unit (TCU) Diagnostic Trouble Codes Throttle Sensor Minimum Calibration Value Too Low Diagnostic Procedure Alarm Level: Check Service Code AA95137,00011A7 -19-07JAN08-2/5

• 1

Calibration Check

Observe the input voltage from engine speed control (R10) by accessing the DIAGNOSTIC / LIVE VALUES / INPUTS / THROTTLE VOLTAGE menu on the standard display monitor (SDM). See Standard Display Monitor (SDM) Menu Structure—Service Mode. (Group 9015-16.) Record voltage with engine speed control (R10) at fast idle. Specification Engine Speed Control (R10)—Calibration Limits........................................................................................ 0.45—1.22 V at Fast Idle Is voltage reading less than 0.45 volts?

YES: Go to Reprogram Controller.

NO: Go to Component Check. AA95137,00011A7 -19-07JAN08-3/5

• 2

Component Check

Turn key switch OFF.

NO: Replace engine speed control (R10). Perform TCU calibration. See Transmission Control Unit (TCU) Calibration. (Group 9015-20.)

Engine speed control (R10) disconnected. Check resistance between pins A and B while turning engine speed control (R10).

YES: Go to Reprogram Controller.

Is resistance change proportional to rotation of speed control?

NO: Replace engine speed control (R10). Perform TCU calibration. See Transmission Control Unit (TCU) Calibration. (Group 9015-20.) AA95137,00011A7 -19-07JAN08-4/5

• 3

Reprogram Controller

Reprogram transmission control unit (TCU) (A1).

Check for active codes.

YES: Replace controller.

Is TCU code 000091.17 still present?

NO: Checks complete. AA95137,00011A7 -19-07JAN08-5/5

000091.18 — Throttle Sensor Max Cal Too Low

The engine speed control stored calibration voltage for slow idle position is less than 2.96 volts. Continued on next page

TM10721 (03SEP14)

9001-30-10

AA95137,00011A8 -19-07JAN08-1/5

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=52

Transmission Control Unit (TCU) Diagnostic Trouble Codes Throttle Sensor Maximum Calibration Value Too Low Diagnostic Procedure Alarm Level: Check Service Code AA95137,00011A8 -19-07JAN08-2/5

• 1

Calibration Check

Observe the input voltage from engine speed control (R10) by accessing the DIAGNOSTIC / LIVE VALUES / INPUTS / ENGINE THROTTLE menu on the SDM. See Standard Display Monitor (SDM) Menu Structure—Service Mode. (Group 9015-16.) Record voltage with engine speed control at slow idle. Specification Engine Speed Control (R10)—Calibration Limits........................................................................................2.96—4.15 V at Slow Idle Is voltage reading less than 2.96 volts?

YES: Go to Component Check.

NO: Go to Reprogram Controller. AA95137,00011A8 -19-07JAN08-3/5

• 2

Component Check

Turn key switch OFF.

NO: Replace engine speed control (R10). Perform TCU calibration. See Transmission Control Unit (TCU) Calibration. (Group 9015-20.)

Engine speed control (R10) disconnected. Check resistance between pins A and B while turning engine speed control (R10).

YES: Go to Reprogram Controller.

Is resistance change proportional to rotation of speed control?

NO: Replace engine speed control (R10). Perform TCU calibration. See Transmission Control Unit (TCU) Calibration. (Group 9015-20.) AA95137,00011A8 -19-07JAN08-4/5

• 3

Reprogram Controller

Reprogram transmission control unit (TCU) (A1).

Check for active codes.

YES: Replace controller.

Is TCU code 000091.18 still active?

NO: Checks complete. AA95137,00011A8 -19-07JAN08-5/5

000158.03 — TCU System Volts Too High The transmission control unit (TCU) system voltage is greater than 16.5 volts. Continued on next page

TM10721 (03SEP14)

9001-30-11

AA95137,00011A9 -19-10DEC07-1/5

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=53

Transmission Control Unit (TCU) Diagnostic Trouble Codes Transmission Control Unit System Voltage Is Too High Diagnostic Procedure Alarm Level: Check Service Code AA95137,00011A9 -19-10DEC07-2/5

• 1

Alternator Check

Perform Alternator Test. (Group 9015-20.)

YES: Go to Battery Check.

Does alternator test good?

NO: Repair or replace alternator. AA95137,00011A9 -19-10DEC07-3/5

• 2

Battery Check

Test batteries. See Handling, Checking and Servicing Batteries Carefully and see Check Battery Electrolyte Level and Terminals. (Operator's Manual.)

YES: Go to Reprogram Controller.

Do batteries test good?

NO: Replace batteries. AA95137,00011A9 -19-10DEC07-4/5

• 3

Reprogram Controller

Reprogram transmission control unit (TCU) (A1).

Check for active codes.

YES: Replace controller.

Is TCU code 000158.03 still present?

NO: Checks complete. AA95137,00011A9 -19-10DEC07-5/5

000158.04 — TCU System Volts Too Low The transmission control unit (TCU) system voltage is less than 9 volts. AA95137,00011AA -19-11JAN08-1/8

Transmission Control Unit System Voltage Is Too Low Diagnostic Procedure Alarm Level: Check Service Code AA95137,00011AA -19-11JAN08-2/8

• 1

Fuse Check

Turn key switch OFF.

Remove fuse (F22). See Fuse and Relay Specifications. (Group 9015-20.) Check continuity of fuse (F22).

YES: Go to Relay Check.

Is continuity indicated?

NO: Replace fuse. Continued on next page

TM10721 (03SEP14)

9001-30-12

AA95137,00011AA -19-11JAN08-3/8

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=54

Transmission Control Unit (TCU) Diagnostic Trouble Codes

• 2

Relay Check

Turn key switch OFF.

Disconnect TCU/SDM relay (K4). See Fuse and Relay Specifications. (Group 9015-10.) Apply 24 volts and ground to the coil of relay (K4). Check for continuity across relay contacts.

YES: Go to Alternator Check

Is continuity indicated?

NO: Relay (K4) malfunction. Replace relay. AA95137,00011AA -19-11JAN08-4/8

• 3

Alternator Check

Perform Alternator Test. (Group 9015-20.)

YES: Go to Battery Check.

Does alternator test good?

NO: Replace alternator. AA95137,00011AA -19-11JAN08-5/8

• 4

Battery Check

Test batteries. See Handling, Checking and Servicing Batteries Carefully and see Check Battery Electrolyte Level and Terminals. (Operator's Manual.)

YES: Go to Open Circuit Check.

Do the batteries pass test?

NO: Replace batteries. AA95137,00011AA -19-11JAN08-6/8

• 5

Open Circuit Check

Turn key switch OFF.

Disconnect transmission control unit (TCU) connector (X2). See Main Cab/Canopy Harness (W5) Component Location. (Group 9015-10.) Turn key switch ON. Check for voltage at pin F1 (wire P12 RED) on connector (X2).

YES: Go to Reprogram Controller.

Is system voltage present?

NO: Open circuit on wire P12 RED on the main cab/canopy harness. Repair or replace harness if necessary. See Main Cab/Canopy Harness (W5) Wiring Diagram. (Group 9015-10.) AA95137,00011AA -19-11JAN08-7/8

• 6

Reprogram Controller

Reprogram transmission control unit (TCU) (A1).

Check for active codes.

YES: Replace controller.

Is TCU code 000158.04 still present?

NO: Checks complete. AA95137,00011AA -19-11JAN08-8/8

000177.00 — Transmission Overtemp The transmission temperature is over 102°C (215°F). Continued on next page

TM10721 (03SEP14)

9001-30-13

AA95137,00011AB -19-11JAN08-1/3

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=55

Transmission Control Unit (TCU) Diagnostic Trouble Codes Transmission Temperature Is Above Normal Operating Range Diagnostic Procedure Alarm Level: No Warning Lamp AA95137,00011AB -19-11JAN08-2/3

• 1

Component Check

Disconnect transmission oil temperature sensor (B40). See Engine Harness (W6) Component Location. (Group 9015-10.) Check resistance between pins A and B on transmission oil temperature sensor (B40). Compare resistance to specification. See Electrical Component Specifications. (Group YES: See Overheating 9015-20.) Malfunctions. (Group 9026-15.) Is resistance within specification?

NO: Replace sensor. AA95137,00011AB -19-11JAN08-3/3

000190.09 — CAN Comm No Engine Speed There is a controller area network (CAN) communication error, no engine speed message received from engine control unit (ECU). AA95137,00011AC -19-11JAN08-1/5

CAN Communication Error, No Engine Speed Message Received from ECU Diagnostic Procedure Alarm Level: Check Service Code AA95137,00011AC -19-11JAN08-2/5

• 1

Component Check

Start engine.

Observe the engine speed by accessing the DIAGNOSTIC / LIVE VALUES / SPEEDS menu on the standard display monitor (SDM). See Standard Display Monitor (SDM) Menu Structure—Service Mode. (Group 9015-16.)

YES: Go to next step in this check.

Is engine speed displayed?

NO: Go to Code Check.

Perform CAN Circuit Test. (Group 9015-20.)

YES: Go to Reprogram Controller.

Is transmission control unit (TCU) code 000190.09 still present?

NO: Check complete. AA95137,00011AC -19-11JAN08-3/5

• 2

Code Check

Check for active engine control unit (ECU) codes. See Standard Display Monitor (SDM) YES: Correct ECU codes. Menu Structure—Service Mode. (Group 9015-16.) See Engine Control Unit (ECU) Diagnostic Trouble Codes. (Group 9001-20.) Are ECU codes active?

NO: Perform CAN Circuit Test. (Group 9015-20.) AA95137,00011AC -19-11JAN08-4/5

• 3

Reprogram Controller

Reprogram transmission control unit (TCU) (A1).

Check for active codes.

YES: Replace controller.

Is TCU code 000190.09 still present?

NO: Checks complete. AA95137,00011AC -19-11JAN08-5/5

TM10721 (03SEP14)

9001-30-14

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=56

Transmission Control Unit (TCU) Diagnostic Trouble Codes

000521.00 — Decel Sensor Input Greater Than Max Cal

The decelerator sensor input voltage is greater than maximum calibration value. AA95137,00011AD -19-03DEC09-1/4

Decelerator Sensor Input Voltage Is Greater Than Maximum Calibration Value Diagnostic Procedure Alarm Level: Check Service Code AA95137,00011AD -19-03DEC09-2/4

• 1

Calibration Check

Perform Transmission Control Unit (TCU) Calibration. (Group 9015-20.)

Check for active codes. See Standard Display Monitor (SDM) Menu Structure—Service YES: See TCU code Mode. (Group 9015-16.) 000521.06—Decel Sensor Brake Cal Too High, 000521.15—Decel Sensor Min Cal Too High, or 000521.16—Decel Sensor Max Cal Too High. (Group 9001-30.) Is TCU code 000521.06, 000521.15, or 000521.16 active?

NO: Go to next step in this check. YES: Go to Reprogram Controller.

Is TCU code 000521.00 still present?

NO: Checks complete. AA95137,00011AD -19-03DEC09-3/4

• 2

Reprogram Controller

Reprogram transmission control unit (TCU) (A1).

Check for active codes.

YES: Replace controller.

Is TCU code 000521.00 still present?

NO: Checks complete. AA95137,00011AD -19-03DEC09-4/4

000521.01 — Decel Sensor Input Less Than Min Cal

The decelerator sensor input voltage is less than minimum calibration value. AA95137,00011AE -19-03DEC09-1/4

Decelerator Sensor Input Voltage Is Less Than Minimum Calibration Value Diagnostic Procedure Alarm Level: Check Service Code Continued on next page

TM10721 (03SEP14)

9001-30-15

AA95137,00011AE -19-03DEC09-2/4

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=57

Transmission Control Unit (TCU) Diagnostic Trouble Codes

• 1

Calibration Check

Perform Transmission Control Unit (TCU) Calibration. (Group 9015-20.)

Check for active codes. See Standard Display Monitor (SDM) Menu Structure—Service YES: See TCU code Mode. (Group 9015-16.) 000521.05—Decel Sensor Brake Cal Too Low, 000521.17—Decel Sensor Min Cal Too Low, or 000521.18—Decel Sensor Max Cal Too Low. (Group 9001-30.) Is TCU code 000521.05, 000521.17, or 000521.18 active?

NO: Go to next step in this check. YES: Go to Reprogram Controller.

Is TCU code 000521.01 active?

NO: Checks complete. AA95137,00011AE -19-03DEC09-3/4

• 2

Reprogram Controller

Reprogram transmission control unit (TCU) (A1).

Check for active codes.

YES: Replace controller.

Is TCU code 000521.01 active?

NO: Checks complete. AA95137,00011AE -19-03DEC09-4/4

000521.03 — Decel Sensor Short to Power The decelerator sensor input voltage is more than 4.95 volts. AA95137,00011AF -19-11JAN08-1/6

Decelerator Sensor Voltage Short to Power Diagnostic Procedure Alarm Level: Check Service Code AA95137,00011AF -19-11JAN08-2/6

• 1

Code Check

Check for active codes. See Standard Display Monitor (SDM) Menu Structure—Service YES: Repair code Mode. (Group 9015-16.) 000620.03 first. See TCU code 000620.03—Sensor Supply Short to Power. (Group 9001-30.) Is transmission control unit (TCU) 0code 000620.03 active?

Continued on next page

TM10721 (03SEP14)

9001-30-16

NO: Go to Component Check. AA95137,00011AF -19-11JAN08-3/6

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=58

Transmission Control Unit (TCU) Diagnostic Trouble Codes

• 2

Component Check

Turn key switch OFF.

Disconnect decelerator sensor (B1). See Main Cab/Canopy Harness (W5) Component Location. (Group 9015-15.) Turn key switch ON.

YES: Go to Short Circuit Check.

Is TCU code 000521.03 active?

NO: Replace decelerator sensor (B1). Calibrate the TCU. See Transmission Control Unit (TCU) Calibration. (Group 9015-20.) AA95137,00011AF -19-11JAN08-4/6

• 3

Short Circuit Check

Disconnect decelerator sensor (B1). See Main Cab/Canopy Harness (W5) Component Location. (Group 9015-15.) Turn key switch ON. Check voltage at pin B (wire T06 BLU) on decelerator sensor (B1) connector. See Transmission Harness (W7) Wiring Diagram. (Group 9015-10.)

YES: Short circuit on wire T06 BLU between pins B on decelerator sensor (B1) connector and pin F2 on TCU connector (X1).

Is voltage over 1 volt?

NO: Go to Reprogram Controller. AA95137,00011AF -19-11JAN08-5/6

• 4

Reprogram Controller

Reprogram transmission control unit (TCU) (A1).

Check for active codes.

YES: Replace controller.

Is TCU code 000521.03 active?

NO: Checks complete. AA95137,00011AF -19-11JAN08-6/6

000521.04 — Decel Sensor Open or Short The decelerator sensor input voltage is below 0.05 volts. AA95137,00011B0 -19-11JAN08-1/5

Decelerator Sensor Voltage Is Open or Short Diagnostic Procedure Alarm Level: Check Service Code Continued on next page

TM10721 (03SEP14)

9001-30-17

AA95137,00011B0 -19-11JAN08-2/5

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=59

Transmission Control Unit (TCU) Diagnostic Trouble Codes

• 1

Open Circuit Check

Turn key switch OFF.

Disconnect decelerator sensor (B1). See Main Cab/Canopy Harness (W5) Component Location. (Group 9015-15.) Turn key switch ON. Check voltage at pin A (wire T05 BLU) on decelerator sensor (B1) connector. See Main YES: Go to next step in this Cab/Canopy Harness (W5) Wiring Diagram. (Group 9015-15.) check. Is voltage approximately 5 volts?

NO: Go to Short Circuit Check.

Key switch OFF. Decelerator sensor (B1) disconnected. Disconnect transmission control unit (TCU) connector (X1). See Main Cab/Canopy Harness (W5) Component Location. (Group 9015-15.) Check continuity between pin B (wire T06 BLU) on decelerator sensor (B1) connector and pin F2 on TCU connector (X1). See Main Cab/Canopy Harness (W5) Wiring Diagram. (Group 9015-15.)

YES: Go to next step in this check.

Is continuity indicated?

NO: Open circuit between pin B on decelerator sensor (B1) connector and pin F2 on TCU connector (X1). Repair or replace harness.

Key switch OFF. Decelerator sensor (B1) disconnected. TCU connector (X1) disconnected. Check continuity between pin C (wire Z03 GRY) on decelerator sensor (B1) connector and pin F3 on TCU connector (X1). See Main Cab/Canopy Harness (W5) Wiring Diagram. (Group 9015-15.)

YES: Go to Short Circuit Check.

Is continuity indicated?

NO: Open circuit between pin C on decelerator sensor (B1) connector and pin F3 on TCU connector (X1). Repair or replace harness. Continued on next page

TM10721 (03SEP14)

9001-30-18

AA95137,00011B0 -19-11JAN08-3/5

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=60

Transmission Control Unit (TCU) Diagnostic Trouble Codes

• 2

Short Circuit Check

Key switch OFF.

Disconnect decelerator sensor (B1). See Main Cab/Canopy Harness (W5) Component Location. (Group 9015-15.) Disconnect TCU connector (X1). See Main Cab/Canopy Harness (W5) Component Location. (Group 9015-15.) Check for ground at pin B (wire T06 BLU) on decelerator sensor (B1) connector. See Main Cab/Canopy Harness (W5) Wiring Diagram. (Group 9015-10.)

YES: Short to ground between pin B on decelerator sensor (B1) connector and pin F2 of TCU connector (X1). Repair or replace harness.

Is ground present?

NO: Go to next step in this check.

Key switch OFF. Decelerator sensor (B1) disconnected. TCU connector (X1) disconnected. Check for ground at pin A (wire T05 BLU) on decelerator sensor (B1) connector. See Main Cab/Canopy Harness (W5) Wiring Diagram. (Group 9015-10.)

YES: Short to ground between pin A on decelerator sensor (B1) connector and pin F1 of TCU connector (X1). Repair or replace harness.

Is ground present?

NO: Replace decelerator sensor (B1). Calibrate the TCU. See Transmission Control Unit (TCU) Calibration. (Group 9015-20.) If code 000521.04 is active after replacing sensor, go to Reprogram Controller. AA95137,00011B0 -19-11JAN08-4/5

• 3

Reprogram Controller

Reprogram transmission control unit (TCU) (A1).

YES: Replace controller.

Is TCU code 000521.04 active?

NO: Checks complete. AA95137,00011B0 -19-11JAN08-5/5

000521.05 — Decel Sensor Brake Cal Too Low The decelerator sensor stored calibration value for the brake position is less than 3.79 volts. AA95137,00011B1 -19-11DEC07-1/6

Decelerator Sensor Brake Calibration Is Too Low Diagnostic Procedure Alarm Level: Check Service Code Continued on next page

TM10721 (03SEP14)

9001-30-19

AA95137,00011B1 -19-11DEC07-2/6

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=61

Transmission Control Unit (TCU) Diagnostic Trouble Codes

• 1

Calibration Check

Observe the input voltage from decelerator sensor (B1) by accessing the DIAGNOSTIC / LIVE VALUES / INPUTS menu on the standard display monitor (SDM). See Standard Display Monitor (SDM) Menu Structure—Service Mode. (Group 9015-16.) Record voltage with decelerator pedal at brake position. Specification Decelerator Sensor (B1)—Calibration Limits............................................................................... 3.79—3.99 V at Brake Position Is voltage less than 3.79 volts?

YES: Go to Component Adjustment

NO: Go to Reprogram Controller. AA95137,00011B1 -19-11DEC07-3/6

• 2

Component Adjustment

Adjust decelerator sensor (B1). See Decelerator/Brake Pedal Adjustment. (Group 9015-20.)

Calibrate the TCU. See Transmission Control Unit (TCU) Calibration. (Group 9015-20.) YES: Go to Component Check. Is TCU code 000521.05 active?

NO: Repair complete. AA95137,00011B1 -19-11DEC07-4/6

• 3

Component Check

Remove the decelerator sensor (B1). See Main Cab/Canopy Harness (W5) Component Location. (Group 9015-10.) Verify the shaft is turning.

YES: Go to Reprogram Controller.

Does shaft on decelerator sensor turn?

NO: Replace sensor. Calibrate the TCU. See Transmission Control Unit (TCU) Calibration. (Group 9015-20.) AA95137,00011B1 -19-11DEC07-5/6

• 4

Reprogram Controller

Reprogram transmission control unit (TCU) (A1).

Check for active codes.

YES: Replace controller.

Is TCU code 000521.05 active?

NO: Checks complete. AA95137,00011B1 -19-11DEC07-6/6

000521.06 — Decel Sensor Brake Cal Too High

The decelerator sensor stored calibration value for brake position is more than 3.99 volts. AA95137,00011B2 -19-11DEC07-1/6

Decelerator Sensor Brake Calibration Is Too High Diagnostic Procedure Alarm Level: Check Service Code Continued on next page

TM10721 (03SEP14)

9001-30-20

AA95137,00011B2 -19-11DEC07-2/6

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=62

Transmission Control Unit (TCU) Diagnostic Trouble Codes

• 1

Calibration Check

Observe the input voltage from decelerator sensor (B1) by accessing the DIAGNOSTIC / LIVE VALUES / INPUTS menu on the standard display monitor (SDM). See Standard Display Monitor (SDM) Menu Structure—Service Mode. (Group 9015-16.) Record decelerator voltage with decelerator at brake position. Specification Decelerator Sensor (B1)—Calibration Limits............................................................................... 3.79—3.99 V at Brake Position Is voltage reading greater than 3.99 volts?

YES: Go to Component Adjustment.

NO: Go to Reprogram Controller. AA95137,00011B2 -19-11DEC07-3/6

• 2

Component Adjustment

Adjust decelerator sensor (B1). See Decelerator/Brake Pedal Adjustment. (Group 9015-20.)

Calibrate the TCU. See Transmission Control Unit (TCU) Calibration. (Group 9015-20.) YES: Go to Component Check. Is TCU code 000521.06 active?

NO: Repair complete. AA95137,00011B2 -19-11DEC07-4/6

• 3

Component Check

Remove the decelerator sensor (B1). See Main Cab/Canopy Harness (W5) Component Location. (Group 9015-10.) Verify the shaft is turning.

YES: Go to Reprogram Controller.

Does shaft on decelerator sensor turn?

NO: Replace sensor. Calibrate the TCU. See Transmission Control Unit (TCU) Calibration. (Group 9015-20.) AA95137,00011B2 -19-11DEC07-5/6

• 4

Reprogram Controller

Reprogram transmission control unit (TCU) (A1).

Check for active codes.

YES: Replace controller.

Is TCU code 000521.06 active?

NO: Checks complete. AA95137,00011B2 -19-11DEC07-6/6

000521.15 — Decel Sensor Min Cal Too High The decelerator sensor stored minimum calibration value for pedal up position is greater than 1.75 volts. AA95137,00011B3 -19-02JAN08-1/6

Decelerator Sensor Minimum Calibration Is Too High Diagnostic Procedure Alarm Level: Check Service Code Continued on next page

TM10721 (03SEP14)

9001-30-21

AA95137,00011B3 -19-02JAN08-2/6

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=63

Transmission Control Unit (TCU) Diagnostic Trouble Codes

• 1

Calibration Check

Observe the input voltage from decelerator sensor (B1) by accessing the DIAGNOSTIC / LIVE VALUES / INPUTS menu on the standard display monitor (SDM). See Standard Display Monitor (SDM) Menu Structure—Service Mode. (Group 9015-16.) Record decelerator voltage at high decelerator position. Specification Decelerator Sensor (B1)—Calibration Limits....................................................................................................... 1.25—1.75 V at High Decel Position (pedal up) Is the voltage reading greater than 1.75 volts?

YES: Go to Component Adjustment.

NO: Go to Reprogram Controller. AA95137,00011B3 -19-02JAN08-3/6

• 2

Component Adjustment

Adjust decelerator sensor (B1). See Decelerator/Brake Pedal Adjustment. (Group 9015-20.)

Calibrate the TCU. See Transmission Control Unit (TCU) Calibration. (Group 9015-20.) YES: Go to Component Check. Is TCU code 000521.15 active?

NO: Repair complete. AA95137,00011B3 -19-02JAN08-4/6

• 3

Component Check

Remove the decelerator sensor (B1). See Main Cab/Canopy Harness (W5) Component Location. (Group 9015-10.) Verify the shaft is turning.

YES: Go to Reprogram Controller.

Does shaft on decelerator sensor turn?

NO: Replace sensor. Calibrate the TCU. See Transmission Control Unit (TCU) Calibration. (Group 9015-20.) AA95137,00011B3 -19-02JAN08-5/6

• 4

Reprogram Controller

Reprogram transmission control unit (TCU) (A1).

Check for active codes.

YES: Replace controller.

Is TCU code 000521.15 active?

NO: Checks complete. AA95137,00011B3 -19-02JAN08-6/6

000521.16 — Decel Sensor Max Cal Too High The decelerator sensor stored maximum calibration value for pedal down position is greater than 3.75 volts. AA95137,00011B4 -19-02JAN08-1/6

Decelerator Sensor Maximum Calibration Value Is Too High Diagnostic Procedure Continued on next page

TM10721 (03SEP14)

9001-30-22

AA95137,00011B4 -19-02JAN08-2/6

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=64

Transmission Control Unit (TCU) Diagnostic Trouble Codes

• 1

Calibration Check

Observe the input voltage from decelerator sensor (B1) by accessing the DIAGNOSTIC / LIVE VALUES / INPUTS menu on the standard display monitor (SDM). See Standard Display Monitor (SDM) Menu Structure—Service Mode. (Group 9015-16.) Record decelerator voltage with decelerator pedal at low decelerator position. Specification Decelerator Sensor (B1)—Calibration Limits........................................................................3.25—3.75 V at Low Decel Position Is voltage reading greater than 3.75 volts?

YES: Go to Component Adjustment.

NO: Go to Reprogram Controller. AA95137,00011B4 -19-02JAN08-3/6

• 2

Component Adjustment

Adjust decelerator sensor (B1). See Decelerator/Brake Pedal Adjustment. (Group 9015-20.)

Calibrate the TCU. See Transmission Control Unit (TCU) Calibration. (Group 9015-20.) YES: Go to Component Check. Is TCU code 000521.16 active?

NO: Repair complete. AA95137,00011B4 -19-02JAN08-4/6

• 3

Component Check

Remove the decelerator sensor (B1).

Verify the shaft is turning.

YES: Go to Reprogram Controller.

Does shaft on decelerator sensor turn?

NO: Replace sensor. Calibrate the TCU. See Transmission Control Unit (TCU) Calibration. (Group 9015-20.) AA95137,00011B4 -19-02JAN08-5/6

• 4

Reprogram Controller

Reprogram transmission control unit (TCU) (A1).

Check for active codes.

YES: Replace controller.

Is TCU code 000521.16 active?

NO: Checks complete. AA95137,00011B4 -19-02JAN08-6/6

000521.17 — Decel Sensor Min Cal Too Low The decelerator sensor stored minimum calibration value for pedal up position is less than 1.25 volts. AA95137,00011B5 -19-02JAN08-1/6

Decelerator Sensor Minimum Calibration Is Too Low Diagnostic Procedure Alarm Level: Check Service Code Continued on next page

TM10721 (03SEP14)

9001-30-23

AA95137,00011B5 -19-02JAN08-2/6

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=65

Transmission Control Unit (TCU) Diagnostic Trouble Codes

• 1

Calibration Check

Observe the input voltage from decelerator sensor (B1) by accessing the DIAGNOSTIC / LIVE VALUES / INPUTS menu on the standard display monitor (SDM). See Standard Display Monitor (SDM) Menu Structure—Service Mode. (Group 9015-16.) Record decelerator voltage with decelerator at high decelerator position. Specification Decelerator Sensor (B1)—Calibration Limits.......................................................................1.25—1.75 V at High Decel Position Is the voltage reading less than 1.25 volts?

YES: Go to Component Adjustment.

NO: Go to Reprogram Controller. AA95137,00011B5 -19-02JAN08-3/6

• 2

Component Adjustment

Adjust decelerator sensor (B1). See Decelerator/Brake Pedal Adjustment. (Group 9015-20.)

Calibrate the TCU. See Transmission Control Unit (TCU) Calibration. (Group 9015-20.) YES: Go to Component Check. Is TCU code 000521.16 active?

NO: Repair complete. AA95137,00011B5 -19-02JAN08-4/6

• 3

Component Check

Remove the decelerator sensor (B1). See Main Cab/Canopy Harness (W5) Component Location. (Group 9015-10.) Verify the shaft is turning.

YES: Go to Reprogram Controller.

Does shaft on decelerator sensor turn?

NO: Replace sensor. Calibrate the TCU. See Transmission Control Unit (TCU) Calibration. (Group 9015-20.) AA95137,00011B5 -19-02JAN08-5/6

• 4

Reprogram Controller

Reprogram transmission control unit (TCU) (A1).

Check for active codes.

YES: Replace controller.

Is TCU code 000521.16 active?

NO: Checks complete. AA95137,00011B5 -19-02JAN08-6/6

000521.18 — Decel Sensor Max Cal Too Low The decelerator sensor stored maximum calibration value for pedal down position is less than 3.25 volts. AA95137,00011B6 -19-02JAN08-1/6

Decelerator Sensor Maximum Calibration Is Too Low Diagnostic Procedure Alarm Level: Check Service Code Continued on next page

TM10721 (03SEP14)

9001-30-24

AA95137,00011B6 -19-02JAN08-2/6

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=66

Transmission Control Unit (TCU) Diagnostic Trouble Codes

• 1

Calibration Check

Observe the input voltage from decelerator sensor (B1) by accessing the DIAGNOSTIC / LIVE VALUES / INPUTS menu on the standard display monitor (SDM). See Standard Display Monitor (SDM) Menu Structure—Service Mode. (Group 9015-16.) Record voltage with decelerator pedal at low decel position. Specification Decelerator Sensor (B1)—Calibration Limits........................................................................3.25—3.75 V at Low Decel Position Is the voltage reading less than 3.25 volts?

YES: Go to Component Adjustment.

NO: Go to Reprogram Controller. AA95137,00011B6 -19-02JAN08-3/6

• 2

Component Adjustment

Adjust decelerator sensor (B1). See Decelerator/Brake Pedal Adjustment. (Group 9015-20.)

Calibrate the TCU. See Transmission Control Unit (TCU) Calibration. (Group 9015-20.) YES: Go to Component Check. Is TCU code 000521.18 active?

NO: Repair complete. AA95137,00011B6 -19-02JAN08-4/6

• 3

Component Check

Remove the decelerator sensor (B1). See Main Cab/Canopy Harness (W5) Component Location. (Group 9015-10.) Verify the shaft is turning.

YES: Go to Reprogram Controller.

Does shaft on decelerator sensor turn?

NO: Replace sensor. Calibrate the TCU. See Transmission Control Unit (TCU) Calibration. (Group 9015-20.) AA95137,00011B6 -19-02JAN08-5/6

• 4

Reprogram Controller

Reprogram transmission control unit (TCU) (A1).

Check for active codes.

YES: Replace controller.

Is TCU code 000521.18 active?

NO: Checks complete. AA95137,00011B6 -19-02JAN08-6/6

000581.00 — Speed Buttons Input Greater Than Max Cal

The transmission speed control sensor input voltage is greater than 3.50 volts. AA95137,00011B7 -19-03DEC09-1/4

Transmission Speed Control Sensor Input Voltage Is Above Maximum Calibration Value Diagnostic Procedure Alarm Level: No Warning Lamp Continued on next page

TM10721 (03SEP14)

9001-30-25

AA95137,00011B7 -19-03DEC09-2/4

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=67

Transmission Control Unit (TCU) Diagnostic Trouble Codes

• 1

Calibration Check

Perform Transmission Control Unit (TCU) Calibration. (Group 9015-20.)

Check for active codes. See Standard Display Monitor (SDM) Menu Structure—Service YES: See TCU code Mode. (Group 9015-16.) 000581.15—Speed Buttons Min Cal Too High or 000581.16—Speed Buttons Max Cal Too High Is TCU code 000581.15 or 000581.16 active?

NO: Go to next check in this step. YES: Go to Reprogram Controller.

Is TCU code 000581.00 active?

NO: Checks complete. AA95137,00011B7 -19-03DEC09-3/4

• 2

Reprogram Controller

Reprogram transmission control unit (TCU) (A1).

Check for active codes.

YES: Replace controller.

Is TCU code 000581.00 active?

NO: Checks complete. AA95137,00011B7 -19-03DEC09-4/4

000581.01 — Speed Buttons Input Less Than Min Cal

The transmission speed control sensor voltage is less than 0.50 volts. AA95137,00011B8 -19-03DEC09-1/4

Transmission Speed Control Sensor Input Voltage Is Below Minimum Calibration Value Diagnostic Procedure Alarm Level: No Warning Lamp AA95137,00011B8 -19-03DEC09-2/4

• 1

Calibration Check

Perform Transmission Control Unit (TCU) Calibration. (Group 9015-20.)

Check for active codes. See Standard Display Monitor (SDM) Menu Structure—Service YES: See TCU code Mode. (Group 9015-16.) 000581.17—Speed Buttons Min Cal Too Low or 000581.18—Speed Buttons Max Cal Too Low Is TCU code 000581.17 or 000581.18 active?

NO: Go to next check in this step. YES: Go to Reprogram Controller.

Is TCU code 000581.01 active?

NO: Checks complete. AA95137,00011B8 -19-03DEC09-3/4

• 2

Reprogram Controller

Reprogram transmission control unit (TCU) (A1).

Check for active codes.

YES: Replace controller.

Is TCU code 000581.01 active?

NO: Checks complete. AA95137,00011B8 -19-03DEC09-4/4

TM10721 (03SEP14)

9001-30-26

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=68

Transmission Control Unit (TCU) Diagnostic Trouble Codes

000581.03 — Speed Buttons Short to Power Transmission speed control sensor input voltage is greater than 4.95 volts. AA95137,00011B9 -19-11JAN08-1/6

Speed Buttons Short to Power Diagnostic Procedure Alarm Level: No Warning Lamp AA95137,00011B9 -19-11JAN08-2/6

• 1

Code Check

NO: Go to Component Check. AA95137,00011B9 -19-11JAN08-3/6

• 2

Component Check

Disconnect transmission speed control sensor (B4). See Main Cab/Canopy Harness (W5) Component Location. (Group 9015-10.) Check resistance between pins A and C on sensor (B4) connector while pressing button up and down. Compare resistance to specification. See Electrical Component Specifications. (Group YES: Go to Short Circuit 9015-20.) Check. Is sensor within specification?

NO: Replace sensor. Calibrate the TCU. See Transmission Control Unit (TCU) Calibration. (Group 9015-20.) AA95137,00011B9 -19-11JAN08-4/6

• 3

Short Circuit Check

Disconnect transmission speed control sensor (B4). See Main Cab/Canopy Harness (W5) Component Location. (Group 9015-15.) Turn key switch ON. Check voltage at pin B (wire T04 BLU) on transmission speed control sensor (B4) connector. See Main Cab/Canopy Harness (W5) Wiring Diagram. (Group 9015-15.)

YES: Go to Reprogram Controller.

Is voltage approximately 0 volts?

NO: Check wire T04 BLU for short to power between pins B on transmission speed control sensor (B4) connector and pin C2 on TCU connector (X1). AA95137,00011B9 -19-11JAN08-5/6

• 4

Reprogram controller

Reprogram transmission control unit (TCU) (A1).

Check for active codes.

YES: Replace controller.

Is TCU code 000581.03 active?

NO: Checks complete. AA95137,00011B9 -19-11JAN08-6/6

TM10721 (03SEP14)

9001-30-27

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=69

Transmission Control Unit (TCU) Diagnostic Trouble Codes

000581.04 — Speed Buttons Open or Short The transmission speed control sensor voltage is less than 0.05 volts. AA95137,00011BA -19-02JAN08-1/6

Transmission Speed Control Sensor Open or Short Diagnostic Procedure Alarm Level: No Warning Lamp AA95137,00011BA -19-02JAN08-2/6

• 1

Component Check

Disconnect transmission speed control sensor (B4). See Main Cab/Canopy Harness (W5) Component Location. (Group 9015-10.) Check resistance between pins A and C on sensor (B4) connector while pressing button up and down. Compare resistance to specification. See Electrical Component Specifications. (Group YES: Go to Open Circuit 9015-10.) Check. Is sensor within specification?

NO: Replace sensor. Calibrate the TCU. See Transmission Control Unit (TCU) Calibration. (Group 9015-20.) Continued on next page

TM10721 (03SEP14)

9001-30-28

AA95137,00011BA -19-02JAN08-3/6

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=70

Transmission Control Unit (TCU) Diagnostic Trouble Codes

• 2

Open Circuit Check

Turn key switch OFF.

Disconnect transmission speed control sensor (B4). See Main Cab/Canopy Harness (W5) Component Location. (Group 9015-10.) Turn key switch ON. Check voltage at pin A (wire T07 BLU) on transmission speed control sensor (B4) connector. See Main Cab/Canopy Harness (W5) Wiring Diagram. (Group 9015-10.)

YES: Go to next step in this check.

Is voltage approximately 5 volts?

NO: Open circuit between pin A on transmission speed control sensor (B4) connector and pin C1 on TCU connector (X1). Repair or replace harness.

Key switch OFF. Transmission speed control sensor (B4) disconnected. Disconnect TCU connector (X1). See Main Cab/Canopy Harness (W5) Component Location. (Group 9015-10.) Check wire T04 BLU for continuity between pin B on transmission speed control sensor YES: Go to next step in this (B4) connector and pin C2 on TCU connector (X1). See Main Cab/Canopy Harness check. (W5) Wiring Diagram. (Group 9015-10.) Is continuity indicated?

NO: Check T04 BLU for an open circuit between pin B on transmission speed control sensor (B4) connector and pin C2 on TCU connector (X1). Repair or replace harness.

Key switch OFF. Transmission speed control sensor (B4) disconnected. TCU connector (X1) disconnected. Check for continuity between pin C (wire Z04 GRY) on transmission speed control sensor (B4) connector and pin C3 on TCU connector (X1). See Main Cab/Canopy Harness (W5) Wiring Diagram. (Group 9015-10.)

YES: Go to Short Circuit Check.

Is continuity indicated?

NO: Open circuit between pin C on transmission speed control sensor (B4) connector and pin C3 on TCU connector (X1). Repair or replace harness. Continued on next page

TM10721 (03SEP14)

9001-30-29

AA95137,00011BA -19-02JAN08-4/6

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=71

Transmission Control Unit (TCU) Diagnostic Trouble Codes

• 3

Short Circuit Check

Key switch OFF.

Transmission speed control sensor (B4) disconnected. TCU connector (X1) disconnected. Check for ground at pin B (wire T04 BLU) on transmission speed control sensor (B4) connector.

YES: Short to ground between pin B on transmission speed control sensor (B4) connector and pin C2 on TCU connector (X1). Repair or replace harness.

Is ground present?

NO: Replace transmission speed control switch (B4). If code 000581.04 is active after replacing switch, go to Reprogram Controller. AA95137,00011BA -19-02JAN08-5/6

• 4

Reprogram Controller

Reprogram transmission control unit (TCU) (A1).

Check for active codes.

YES: Replace controller.

Is TCU code 000581.04 active?

NO: Checks complete. AA95137,00011BA -19-02JAN08-6/6

000581.15 — Speed Buttons Min Cal Too High The stored minimum calibration value for the transmission speed control sensor is greater than 1.22 volts. AA95137,00011BB -19-11JAN08-1/5

Transmission Speed Control Sensor Minimum Calibration Value Too High Diagnostic Procedure Alarm Level: Check Service Code AA95137,00011BB -19-11JAN08-2/5

• 1

Calibration Check

Observe the input voltage from transmission speed control sensor (B4) by accessing the DIAGNOSTIC / LIVE VALUES / INPUTS menu on the standard display monitor (SDM). See Standard Display Monitor (SDM) Menu Structure—Service Mode. (Group 9015-16.) Record voltage with up button pushed on transmission speed control sensor. Specification Transmission Speed Control Sensor (B4)—Calibration Limits........................................... 0.50—1.22 V w/ Up button pressed Is the voltage greater than 1.22 volts?

NO: Go to Reprogram Controller. Continued on next page

TM10721 (03SEP14)

YES: Go to Component Check.

9001-30-30

AA95137,00011BB -19-11JAN08-3/5

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=72

Transmission Control Unit (TCU) Diagnostic Trouble Codes

• 2

Component Check

Disconnect transmission speed control sensor (B4). See Main Cab/Canopy Harness (W5) Component Location. (Group 9015-10.) Check resistance between pins A and C on sensor (B4) connector while pressing button up and down. Compare resistance to specification. See Electrical Component Specifications. (Group YES: Go to Reprogram 9015-20.) Controller. Is sensor within specification?

NO: Replace sensor. Calibrate the transmission control unit (TCU). See Transmission Control Unit (TCU) Calibration. (Group 9015-20.) AA95137,00011BB -19-11JAN08-4/5

• 3

Reprogram Controller

Reprogram transmission control unit (TCU) (A1).

Check for active codes.

YES: Replace controller.

Is TCU code 000581.15 active?

NO: Checks complete. AA95137,00011BB -19-11JAN08-5/5

000581.16 — Speed Buttons Max Cal Too High

The stored maximum calibration value for the transmission speed control sensor is greater than 3.50 volts. AA95137,00011BC -19-11JAN08-1/5

Transmission Speed Control Sensor Maximum Calibration Value Too High Diagnostic Procedure Alarm Level: Check Service Code AA95137,00011BC -19-11JAN08-2/5

• 1

Calibration Check

Observe the input voltage from transmission speed control sensor (B4) by accessing the DIAGNOSTIC / LIVE VALUES / INPUTS menu on the standard display monitor (SDM). See Standard Display Monitor (SDM) Menu Structure—Service Mode. (Group 9015-16.) Record voltage with down button pressed on the transmission speed control sensor (B4). YES: Go to Component Check. Specification Transmission Speed Control Sensor (B4)—Calibration Limits.......................................2.66—3.50 V w/ Down button pressed Is the voltage reading greater than 3.50 volts?

NO: Go to Reprogram Controller.

Continued on next page

TM10721 (03SEP14)

9001-30-31

AA95137,00011BC -19-11JAN08-3/5

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=73

Transmission Control Unit (TCU) Diagnostic Trouble Codes

• 2

Component Check

Disconnect transmission speed control sensor (B4). See Main Cab/Canopy Harness (W5) Component Location. (Group 9015-10.) Check resistance between pins A and C on sensor (B4) connector while pressing button up and down. Compare resistance to specification. See Electrical Component Specifications. (Group YES: Go to Reprogram 9015-20.) Controller. Is sensor within specification?

NO: Replace sensor. Calibrate the TCU. See Transmission Control Unit (TCU) Calibration. (Group 9015-20.) AA95137,00011BC -19-11JAN08-4/5

• 3

Reprogram Controller

Reprogram transmission control unit (TCU) (A1).

Check for active codes.

YES: Replace controller.

Is TCU code 000581.16 active?

NO: Checks complete. AA95137,00011BC -19-11JAN08-5/5

000581.17 — Speed Buttons Min Cal Too Low The stored minimum calibration value for the transmission speed control sensor is less than 0.50 volts. AA95137,00011BD -19-11JAN08-1/5

Transmission Speed Control Sensor Minimum Calibration Value Too Low Diagnostic Procedure Alarm Level: Check Service Code AA95137,00011BD -19-11JAN08-2/5

• 1

Calibration Check

YES: Go to Component Check.

Specification Transmission Speed Control Sensor (B4)—Calibration Limits........................................... 0.50—1.22 V w/ Up button pressed Is the voltage reading less than 0.50 volts?

NO: Go to Reprogram Controller.

Continued on next page

TM10721 (03SEP14)

9001-30-32

AA95137,00011BD -19-11JAN08-3/5

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=74

Transmission Control Unit (TCU) Diagnostic Trouble Codes

• 2

Component Check

Disconnect transmission speed control sensor (B4). See Main Cab/Canopy Harness (W5) Component Location. (Group 9015-10.) Check resistance between pins A and C on sensor (B4) connector while pressing button up and down. Compare resistance to specification. See Electrical Component Specifications. (Group YES: Go to Reprogram 9015-20.) Controller. Is sensor within specifications?

NO: Replace sensor. Calibrate the transmission control unit (TCU). See Transmission Control Unit (TCU) Calibration. (Group 9015-20.) AA95137,00011BD -19-11JAN08-4/5

• 3

Reprogram Controller

Reprogram transmission control unit (TCU) (A1).

Check for active codes.

YES: Replace controller.

Is TCU code 000581.17 active?

NO: Checks complete. AA95137,00011BD -19-11JAN08-5/5

000581.18 — Speed Buttons Max Cal Too Low The stored maximum calibration value for the transmission speed control sensor is less than 2.66 volts. AA95137,00011BE -19-11JAN08-1/5

Transmission Speed Control Sensor Maximum Calibration Value Too Low Diagnostic Procedure Alarm Level: Check Service Code AA95137,00011BE -19-11JAN08-2/5

• 1

Calibration Check

Observe the input voltage from transmission speed control sensor (B4) by accessing the DIAGNOSTIC / LIVE VALUES / INPUTS menu on the standard display monitor (SDM). See Standard Display Monitor (SDM) Menu Structure—Service Mode. (Group 9015-16.) Record voltage with the down button pressed on the transmission speed control sensor. YES: Go to Component Check. Specification Transmission Speed Control Sensor (B4)—Calibration Limits.......................................2.66—3.50 V w/ Down button pressed Is the voltage reading less than 2.66 volts?

NO: Go to Reprogram Controller.

Continued on next page

TM10721 (03SEP14)

9001-30-33

AA95137,00011BE -19-11JAN08-3/5

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=75

Transmission Control Unit (TCU) Diagnostic Trouble Codes

• 2

Component Check

Disconnect transmission speed control sensor (B4). See Main Cab/Canopy Harness (W5) Component Location. (Group 9015-10.) Check resistance between pins A and C on sensor (B4) connector while pressing button up and down. Compare resistance to specification. See Electrical Component Specifications. (Group YES: Go to Reprogram 9015-20.) Controller. Is sensor within specifications?

NO: Replace sensor. Calibrate the transmission control unit (TCU). See Transmission Control Unit (TCU) Calibration. (Group 9015-20.) AA95137,00011BE -19-11JAN08-4/5

• 3

Reprogram Controller

Reprogram transmission control unit (TCU) (A1).

Check for active codes.

YES: Replace controller.

Is TCU code 000581.18 active?

NO: Checks complete. AA95137,00011BE -19-11JAN08-5/5

000604.03 — TCL Neut Switch Open Circuit

(B2). Neutral start switch indicates out of neutral and TCL sensor output voltage indicates neutral.

Neutral start switch (S3) input circuit is open or mismatch exists between neutral start switch and TCL sensor AA95137,00011BF -19-02MAY13-1/6

Neutral Switch Open Circuit Diagnostic Procedure Alarm Level: Check Service Code AA95137,00011BF -19-02MAY13-2/6

• 1

Code Check

Check for active codes. See Standard Display Monitor (SDM) Menu Structure—Service YES: Diagnose Mode. (Group 9015-16.) transmission control unit (TCU) codes 002661.03 and 0002661.04 first. Is transmission control unit (TCU) code 002661.03 or 0002661.04 active?

NO: Go to Component Check. AA95137,00011BF -19-02MAY13-3/6

• 2

Component Check

Disconnect neutral start switch (S3). See Main Cab/Canopy Harness (W5) Component Location. (Group 9015-10.) Check switch continuity at pins A and B on neutral start switch (S3) while moving transmission control lever (TCL).

YES: Go to TCL Sensor Check.

Is continuity indicated in the neutral state only?

NO: Replace neutral start switch (S3). Calibrate the transmission control unit (TCU). See Transmission Control Unit (TCU) Calibration. (Group 9015-20.)

Continued on next page

TM10721 (03SEP14)

9001-30-34

AA95137,00011BF -19-02MAY13-4/6

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=76

Transmission Control Unit (TCU) Diagnostic Trouble Codes

• 3

TCL Sensor Check

Check function of TCL sensor (B2) in transmission control lever (TCL). See Transmission Control Lever (TCL) Adjustment. (Group 9015-20.)

YES: Go to Open Circuit Check.

Are TCL sensor output voltages within specifications for all TCL positions?

NO: Adjust TCL sensor linkage or replace TCL sensor. AA95137,00011BF -19-02MAY13-5/6

• 4

Open Circuit Check

Turn key switch OFF.

Disconnect neutral start switch (S3) and transmission control unit (TCU) connector (X1). See Main Cab/Canopy Harness (W5) Component Location. (Group 9015-10.) Check continuity (wire E03 WHT) at pin A of neutral start switch (S3) and pin E2 of TCU connector (X1).

YES: Go to next step in this check.

Is continuity indicated?

NO: Open circuit between pin A on neutral start switch (S3) connector and pin E2 on TCU connector (X1). Repair or replace harness. See Main Cab/Canopy Harness (W5) Wiring Diagram. (Group 9015-10.)

Key switch OFF. Neutral start switch (S3) disconnected. Check for continuity (wire G01 BLK) between pin B on neutral start switch (S3) connector YES: Checks complete. and ground. See Main Cab/Canopy Harness (W5) Wiring Diagram. (Group 9015-10.) Is continuity indicated?

NO: Open circuit on wire G01 WHT between pin B on neutral start switch (S3) connector and pin ground. Repair or replace harness. See Main Cab/Canopy Harness (W5) Wiring Diagram. (Group 9015-10.) AA95137,00011BF -19-02MAY13-6/6

000604.04 — TCL Neut Switch Short Circuit

sensor (B2). Neutral start switch indicates neutral and TCL sensor voltage indicates out of neutral.

Neutral start switch (S3) input has short circuit or mismatch exists between neutral start switch and TCL AA95137,00011C0 -19-02MAY13-1/7

Neutral Switch Short Circuit Diagnostic Procedure Alarm Level: Check Service Code AA95137,00011C0 -19-02MAY13-2/7

• 1

Code Check

NO: Go to Connector Check.

Continued on next page

TM10721 (03SEP14)

9001-30-35

AA95137,00011C0 -19-02MAY13-3/7

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=77

Transmission Control Unit (TCU) Diagnostic Trouble Codes

• 2

Connector Check

Check neutral start switch (S3) connector and TCU 18-pin connector (X2) for corrosion, YES: Go to Component loose fit, bent/pushed out terminals, or crimp malfunctions. See Main Cab/Canopy Check. Harness (W5) Component Location. (Group 9015-10.) Are connectors in good condition?

NO: Repair or replace connector(s) or terminal(s) as needed. AA95137,00011C0 -19-02MAY13-4/7

• 3

Component Check

Disconnect neutral start switch (S3). . (Group 9015-10.)

Check switch (S3) for continuity at pins A and B while moving transmission control lever (TCL). See Main Cab/Canopy Harness (W5) Component Location. (Group 9015-10.)

YES: Go to TCL Sensor Check.

Is continuity indicated in the neutral state only?

NO: Replace neutral start switch (S3). Calibrate the transmission control unit (TCU). See Transmission Control Unit (TCU) Calibration. (Group 9015-20.) AA95137,00011C0 -19-02MAY13-5/7

• 4

TCL Sensor Check

Check function of TCL sensor (B2) in transmission control lever (TCL). See Transmission Control Lever (TCL) Adjustment. (Group 9015-20.)

YES: Go to Short Circuit Check.

Are TCL sensor output voltages within specifications for all TCL positions?

NO: Adjust TCL sensor linkage or replace TCL sensor. AA95137,00011C0 -19-02MAY13-6/7

• 5

Short Circuit Check

Turn key switch OFF.

Disconnect neutral start switch (S3). See Main Cab/Canopy Harness (W5) Component Location. (Group 9015-10.) Check for ground at pin A (wire E03 WHT) of neutral start switch (S3).

YES: Short to ground between pin A on neutral start switch (S3) connector and ground. Repair or replace harness. See Main Cab/Canopy Harness (W5) Wiring Diagram. (Group 9015-10.)

Is ground present?

NO: Checks complete. AA95137,00011C0 -19-02MAY13-7/7

000604.15 — TCL Neut Switch Min Cal Too High

The neutral start switch stored calibration value is too high (reverse). Continued on next page

TM10721 (03SEP14)

9001-30-36

AA95137,00011C1 -19-11JAN08-1/6

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=78

Transmission Control Unit (TCU) Diagnostic Trouble Codes Neutral Start Switch Minimum Calibration Value Too High Diagnostic Procedure Alarm Level: Check Service Code AA95137,00011C1 -19-11JAN08-2/6

• 1

Calibration Check

Record stored forward SW calibration voltage from transmission control lever (TCL) sensor (B2) by accessing the DIAGNOSTIC / CALIBRATED VALUES / INPUTS menu on the standard display monitor (SDM). See Standard Display Monitor (SDM) Menu Structure—Service Mode. (Group 9015-16.) Record the neutral input voltage from TCL sensor by accessing the DIAGNOSTIC / LIVE VALUES / INPUTS menu on the standard display monitor (SDM). Subtract 0.074 from the TCL sensor live neutral voltage.

YES: Go to Component Check.

Is subtracted value less than stored calibration voltage?

NO: Go to Reprogram Controller. AA95137,00011C1 -19-11JAN08-3/6

• 2

Component Check

Disconnect neutral start switch (S3). See Main Cab/Canopy Harness (W5) Component Location. (Group 9015-10.) Check switch (S3) for continuity at pins A and B while moving TCL lever.

YES: Go to Component Adjustment.

Is continuity indicated in the neutral state only?

NO: Replace neutral switch (S3). Calibrate the transmission control unit (TCU). See Transmission Control Unit (TCU) Calibration. (Group 9015-20.) AA95137,00011C1 -19-11JAN08-4/6

• 3

Component Adjustment

Adjust TCL linkage. See Transmission Control Lever (TCL) Adjustment. (Group 90215-20.)

Calibrate the TCU. See Transmission Control Unit (TCU) Calibration. (Group 9015-20.) YES: Go to Reprogram Controller. Is TCU code 000604.15 active?

NO: Repair complete. AA95137,00011C1 -19-11JAN08-5/6

• 4

Reprogram Controller

Reprogram transmission control unit (TCU) (A1).

YES: Replace controller.

Is TCU code 000604.15 still active?

NO: Checks complete. AA95137,00011C1 -19-11JAN08-6/6

000604.16 — TCL Neut Switch Max Cal Too High

The neutral start switch stored calibration value is too high (forward). Continued on next page

TM10721 (03SEP14)

9001-30-37

AA95137,00011C2 -19-11JAN08-1/6

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=79

Transmission Control Unit (TCU) Diagnostic Trouble Codes Neutral Start Switch Maximum Calibration Value Too High Diagnostic Procedure Alarm Level: Check Service Code AA95137,00011C2 -19-11JAN08-2/6

• 1

Calibration Check

Record stored forward SW calibration voltage from transmission control lever (TCL) sensor (B2) by accessing the DIAGNOSTIC / CALIBRATED VALUES / INPUTS menu on the standard display monitor (SDM). See Standard Display Monitor (SDM) Menu Structure—Service Mode. (Group 9015-16.) Record the neutral input voltage from TCL sensor by accessing the DIAGNOSTIC / LIVE VALUES / INPUTS menu in the SDM menu structure. Add 0.354 to the TCL sensor live neutral voltage.

YES: Go to Component Check.

Is added value less than stored calibration voltage?

NO: Go to next step in this check. AA95137,00011C2 -19-11JAN08-3/6

• 2

Component Check

Disconnect neutral start switch (S3). See Main Cab/Canopy Harness (W5) Component Location. (Group 9015-10.) Check switch (S3) continuity at pins A and B while moving TCL.

YES: Go to Component Adjustment.

Is continuity indicated in the neutral state?

NO: Replace neutral start switch (S3). Calibrate the transmission control unit (TCU). See Transmission Control Unit (TCU) Calibration. (Group 9015-20.) AA95137,00011C2 -19-11JAN08-4/6

• 3

Component Adjustment

Adjust TCL linkage. See Transmission Control Lever (TCL) Adjustment. (Group 90215-20.)

Calibrate the TCU. See Transmission Control Unit (TCU) Calibration. (Group 9015-20.) YES: Go to Reprogram Controller. Is TCU code 000604.15 active?

NO: Repair complete. AA95137,00011C2 -19-11JAN08-5/6

• 4

Reprogram Controller

Reprogram transmission control unit (TCU) (A1).

YES: Replace controller.

Is TCU code 000604.16 still active?

NO: Checks complete. AA95137,00011C2 -19-11JAN08-6/6

000604.17 — TCL Neut Switch Min Cal Too Low

The neutral switch stored calibration value is too low (reverse). Continued on next page

TM10721 (03SEP14)

9001-30-38

AA95137,00011C3 -19-11JAN08-1/6

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=80

Transmission Control Unit (TCU) Diagnostic Trouble Codes Neutral Switch Minimum Calibration Value Too Low Diagnostic Procedure Alarm Level: Check Service Code AA95137,00011C3 -19-11JAN08-2/6

• 1

Calibration Check

Record stored forward SW calibration voltage from transmission control lever (TCL) sensor by accessing the DIAGNOSTIC / CALIBRATED VALUES / INPUTS menu on the standard display monitor (SDM). See Standard Display Monitor (SDM) Menu Structure—Service Mode. (Group 9015-16. Record the neutral input voltage from TCL sensor by accessing the DIAGNOSTIC / LIVE VALUES / INPUTS menu on the SDM. Subtract 0.354 from the TCL sensor live neutral voltage.

YES: Go to Component Check.

Is subtracted value greater than stored calibration voltage?

NO: Go to Reprogram Controller. AA95137,00011C3 -19-11JAN08-3/6

• 2

Component Check

Disconnect neutral start switch (S3). See Main Cab/Canopy Harness (W5) Component Location. (Group 9015-10.) Check switch (S3) continuity at pins A and B while moving TCL.

YES: Go to Component Adjustment.

Is continuity indicated in the neutral state?

NO: Replace neutral start switch (S3). Calibrate the transmission control unit (TCU). See Transmission Control Unit (TCU) Calibration. (Group 9015-20.) AA95137,00011C3 -19-11JAN08-4/6

• 3

Component Adjustment

Adjust TCL linkage. See Transmission Control Lever (TCL) Adjustment. (Group 90215-20.)

Calibrate the TCU. See Transmission Control Unit (TCU) Calibration. (Group 9015-20.) YES: Go to Reprogram Controller. Is TCU code 000604.15 active?

NO: Repair complete. AA95137,00011C3 -19-11JAN08-5/6

• 4

Reprogram Controller

Reprogram transmission control unit (TCU) (A1).

YES: Replace controller.

Is TCU code 000604.17 still active?

NO: Checks complete. AA95137,00011C3 -19-11JAN08-6/6

000604.18 — TCL Neut Switch Max Cal Too Low

The neutral start switch stored calibration value is too low (forward). Continued on next page

TM10721 (03SEP14)

9001-30-39

AA95137,00011C4 -19-11JAN08-1/6

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=81

Transmission Control Unit (TCU) Diagnostic Trouble Codes Neutral Start Switch Maximum Calibration Value Too Low Diagnostic Procedure Alarm Level: Check Service Code AA95137,00011C4 -19-11JAN08-2/6

• 1

Calibration Check

Record stored forward SW calibration voltage from transmission control lever (TCL) sensor by accessing the DIAGNOSTIC / CALIBRATED VALUES / INPUTS menu on the standard display monitor (SDM). See Standard Display Monitor (SDM) Menu Structure—Service Mode. (Group 9015-16.) Record the neutral input voltage from TCL sensor by accessing the DIAGNOSTIC / LIVE VALUES / INPUTS menu on the SDM. Add 0.074 to the TCL sensor live neutral voltage.

YES: Go to Component Check.

Is added value greater than stored calibration voltage?

NO: Go to Reprogram Controller. AA95137,00011C4 -19-11JAN08-3/6

• 2

Component Check

Disconnect neutral start switch (S3). See Main Cab/Canopy Harness (W5) Component Location. (Group 9015-10.) Check switch continuity at pins A and B while moving TCL.

YES: Go to Component Adjustment.

Is continuity indicated in the neutral state?

NO: Replace neutral start switch (S3). Calibrate the transmission control unit (TCU). See Transmission Control Unit (TCU) Calibration. (Group 9015-20.) AA95137,00011C4 -19-11JAN08-4/6

• 3

Component Adjustment

Adjust TCL linkage. See Transmission Control Lever (TCL) Adjustment. (Group 90215-20.)

YES: Go to Reprogram Controller.

Is TCU code 000604.15 active?

NO: Repair complete. AA95137,00011C4 -19-11JAN08-5/6

• 4

Reprogram Controller

Reprogram transmission control unit (TCU) (A1).

YES: Replace controller.

Is TCU code 000604.18 still active?

NO: Checks complete. AA95137,00011C4 -19-11JAN08-6/6

000619.05 — Park Brake Solenoid No Response

The park brake solenoid is not responding. AA95137,00011C5 -19-30NOV09-1/6

Park Brake Solenoid No Response Diagnostic Procedure Alarm Level: Check Service Code Continued on next page

TM10721 (03SEP14)

9001-30-40

AA95137,00011C5 -19-30NOV09-2/6

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=82

Transmission Control Unit (TCU) Diagnostic Trouble Codes

• 1

Service Code Check

Clean and check connector pins. Connect the park brake solenoid (Y11). See Transmission Harness (W7) Component Location. (Group 9015-10.) Clean and check connector pins. Connect the TCU connector (X2). See Main Cab/Canopy Harness (W5) Component Location. (Group 9015-10.) Check for active codes.

YES: Go to Component Check.

Is TCU code 000619.05 active?

NO: Checks complete. AA95137,00011C5 -19-30NOV09-3/6

• 2

Component Check

Disconnect park brake solenoid (Y11). See Transmission Harness (W7) Component Location. (Group 9015-10.) Check resistance across pins 1 and 2 of park brake solenoid (Y11). Compare resistance to specification. See Electrical Component Specifications. (Group YES: Go to Open Circuit 9015-20.) Check. Is solenoid within specification?

NO: Replace solenoid. AA95137,00011C5 -19-30NOV09-4/6

• 3

Open Circuit Check

Key switch OFF.

Disconnect park brake solenoid (Y11). See Transmission Harness (W7) Component Location. (Group 9015-10.) Disconnect transmission control unit (TCU) connector (X2). See Main Cab/Canopy Harness (W5) Component Location. (Group 9015-10.) Check continuity (wire T52 BLU) between pin 1 on park brake solenoid (Y11) connector YES: Go to next step in this pin E3 on TCU connector (X2). check. Is continuity indicated?

NO: Open circuit between pin 1 on park brake solenoid (Y11) connector pin E3 on TCU connector (X2). Repair or replace harness. See Main Cab/Canopy Harness (W5) Wiring Diagram and see Transmission Harness (W7) Wiring Diagram. (Group 9015-10.)

Key switch OFF. Park brake solenoid (Y11) disconnected. Check continuity (wire G01 BLK) between pin 2 on park brake solenoid (Y11) connector YES: Go to Short Circuit and ground. Check. Is continuity indicated?

NO: Open circuit on G01 BLK between pin 2 on park brake solenoid (Y11) connector and ground. Repair or replace harness. See Transmission Harness (W7) Wiring Diagram. (Group 9015-10.) Continued on next page

TM10721 (03SEP14)

9001-30-41

AA95137,00011C5 -19-30NOV09-5/6

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=83

Transmission Control Unit (TCU) Diagnostic Trouble Codes

• 4

Short Circuit Check

Key switch OFF.

Disconnect the park brake solenoid (Y11). See Transmission Harness (W7) Component Location. (Group 9015-10.) Disconnect TCU connector (X2). See Main Cab/Canopy Harness (W5) Component Location. (Group 9015-10.) Check for ground at pin 1 (wire T52 BLU) on park brake solenoid (Y11) connector.

YES: Short to ground on wire T52 BLU. Repair or replace harness. See Main Cab/Canopy Harness (W5) Wiring Diagram and see Transmission Harness (W7) Wiring Diagram. (Group 9015-10.)

Is continuity to ground present?

NO: Checks complete. AA95137,00011C5 -19-30NOV09-6/6

000620.03 — Sensor Supply Short to Power Sensor supply voltage is greater than 5.5 volts. AA95137,00011C6 -19-24SEP09-1/5

Sensor Supply Short to Power Diagnostic Procedure AA95137,00011C6 -19-24SEP09-2/5

• 1

Component Check

NOTE: The key switch must be ON to perform this test. To prevent the risk of controller damage, turn key switch OFF when disconnecting and connecting sensors. For component location and wiring information, see the following:

• See Main Cab/Canopy Harness (W5) Component Location. (Group 9015-10.) • See Main Cab/Canopy Harness (W5) Wiring Diagram. (Group 9015-10.) • See Transmission Harness (W7) Component Location. (Group 9015-10.) • See Transmission Harness (W7) Wiring Diagram. (Group 9015-10.) The charge pressure sensor is B33 for (S.N. —173344) and B41 for (S.N. 173345— ). Charge pressure sensor harness (W25) is used with B41 (S.N. 173345— ). Disconnect the following sensors and check for voltage: Sensor Reference Voltage Check Sensor and Harness Location

Wire

Pin (Sensor Connector)

TCL Sensor (B2) (W5)

T01 BLU

Right Motor Speed Sensor (B3) (W7)

T03 BLU

Transmission Speed Control Sensor (B4) (W5)

T07 BLU

Steer Sensor (B5) (W5)

T10 BLU

Charge Pressure Sensor (B33 or B41) (W7)

T20 BLU

Decelerator Sensor (B1) (W5)

T05 BLU

Engine Speed Control (R10) (W5)

T08 BLU

Left Motor Speed Sensor (B7) (W7)

T18 BLU

Is voltage 5.5 volts or greater?

NO: Go to Code Check. Continued on next page

TM10721 (03SEP14)

YES: Repair short to power on circuit with excessive voltage.

9001-30-42

AA95137,00011C6 -19-24SEP09-3/5

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=84

Transmission Control Unit (TCU) Diagnostic Trouble Codes

• 2

Code Check

Check for active codes. See Standard Display Monitor (SDM) Menu Structure—Service YES: Go to related code Mode. (Group 9015-16.) found in group 9001-30. Are there any active codes that correspond to the previous sensors in the table?

NO: Go to Reprogram Controller. AA95137,00011C6 -19-24SEP09-4/5

• 3

Reprogram Controller

Reprogram transmission control unit (TCU) (A1).

YES: Replace controller.

Is TCU code 000620.03 active?

NO: Checks complete. AA95137,00011C6 -19-24SEP09-5/5

000620.04 — Sensor Supply Short to Gnd Sensor supply voltage is less than 4.81 volts. AA95137,00011C7 -19-24SEP09-1/5

Sensor Supply Short to Ground Diagnostic Procedure AA95137,00011C7 -19-24SEP09-2/5

• 1

Component Check

NOTE: For component location and wiring information, see the following:

• See Main Cab/Canopy Harness (W5) Component Location. (Group 9015-10.) • See Main Cab/Canopy Harness (W5) Wiring Diagram. (Group 9015-10.) • See Transmission Harness (W7) Component Location. (Group 9015-10.) • See Transmission Harness (W7) Wiring Diagram. (Group 9015-10.) The charge pressure sensor is B33 for (S.N. —173344) and B41 for (S.N. 173345— ). Charge pressure sensor harness (W25) is used with B41 (S.N. 173345— ). Turn key switch OFF. Disconnect the following sensors. Sensor Reference Voltage Check Sensor and Harness Location

Wire

Pin (Sensor Connector)

TCL Sensor (B2) (W5)

T01 BLU

Right Motor Speed Sensor (B3) (W7)

T03 BLU

Transmission Speed Control Sensor (B4) (W5)

T07 BLU

Steer Sensor (B5) (W5)

T10 BLU

Charge Pressure Sensor (B33 or B41) (W7)

T20 BLU

Decelerator Sensor (B1) (W5)

T05 BLU

Engine Speed Control (R10) (W5)

T08 BLU

Left Motor Speed Sensor (B7) (W7)

T18 BLU

Turn key switch ON. Check for voltage at the sensor pins listed in the table.

YES: Repair short to ground on circuit with less than 4.8 volts.

Is voltage 4.8 volts or less?

NO: Go to Code Check. Continued on next page

TM10721 (03SEP14)

9001-30-43

AA95137,00011C7 -19-24SEP09-3/5

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=85

Transmission Control Unit (TCU) Diagnostic Trouble Codes

• 2

Code Check

NO: Go to Reprogram Controller. AA95137,00011C7 -19-24SEP09-4/5

• 3

Reprogram Controller

Reprogram transmission control unit (TCU) (A1).

YES: Replace controller.

Is TCU code 000620.04 active?

NO: Checks complete. AA95137,00011C7 -19-24SEP09-5/5

000907.03 — Left Speed Sensor Short to Power

The left motor speed sensor signal voltage is greater than 4.81 volts. AA95137,00011C8 -19-11JAN08-1/5

Left Speed Sensor Short to Power Diagnostic Procedure Alarm Level: No Warning Lamp AA95137,00011C8 -19-11JAN08-2/5

• 1

Component Check

Turn key switch OFF.

Disconnect left speed sensor (B7). See Transmission Harness (W7) Component Location. (Group 9015-15.) Turn key switch ON.

YES: Go to Short Circuit Check.

Is transmission control unit (TCU) code 000907.03 active?

NO: Replace left speed sensor (B7). Calibrate TCU. See Transmission Control Unit (TCU) Calibration. (Group 9015-20.)

Continued on next page

TM10721 (03SEP14)

9001-30-44

AA95137,00011C8 -19-11JAN08-3/5

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=86

Transmission Control Unit (TCU) Diagnostic Trouble Codes

• 2

Short Circuit Check

Disconnect the left speed sensor (B7). See Transmission Harness (W7) Component Location. (Group 9015-15.) Check voltage at pin A (wire T18 BLU) on left speed sensor (B7) connector.

YES: Go to next step in this check.

Is voltage approximately 5 volts?

NO: Short to power on wire T18 BLU between pin A on left speed sensor (B7) connector and pin H1 on TCU connector (X1). See Transmission Harness (W7) Wiring Diagram and see Main Cab/Canopy Harness (W5) Wiring Diagram. (Group 9015-15.)

Turn key switch ON. Check voltage at pin B (wire T17 BLU) on left speed sensor (B7) connector.

YES: Go to Reprogram Controller.

Is voltage approximately 0 volts?

NO: Short to power on wire T17 BLU between pins B on left speed sensor (B7) connector and pin H2 on TCU connector (X1). See Transmission Harness (W7) Wiring Diagram and see Main Cab/Canopy Harness (W5) Wiring Diagram. (Group 9015-15.) AA95137,00011C8 -19-11JAN08-4/5

• 3

Reprogram Controller

Reprogram transmission control unit (TCU) (A1).

YES: Replace controller.

Is TCU code 000907.03 active?

NO: Checks complete. AA95137,00011C8 -19-11JAN08-5/5

000907.04 — Left Speed Sensor Short The left motor speed sensor signal voltage is below 0.11 volts. AA95137,00011C9 -19-12DEC07-1/4

Left Speed Sensor Short Diagnostic Procedure Alarm Level: No Warning Lamp Continued on next page

TM10721 (03SEP14)

9001-30-45

AA95137,00011C9 -19-12DEC07-2/4

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=87

Transmission Control Unit (TCU) Diagnostic Trouble Codes

• 1

Short Circuit Check

Turn key switch OFF.

Disconnect left speed sensor (B7). See Main Cab/Canopy Harness (W5) Component Location. (Group 9015-10.) Check ground at pin A (wire T18 BLU) on left speed sensor (B7) connector.

YES: Short to ground on wire T18 BLU between pins A on left speed sensor (B2) connector and pin H1 on TCU connector (X1). See Transmission Harness (W7) Wiring Diagram and see Main Cab/Canopy Harness (W5) Wiring Diagram. (Group 9015-10.)

Is ground present?

NO: Go to next step in this check.

Left speed sensor (B7) disconnected. Turn key switch ON. Check ground at pin B (wire T17 BLU) on left speed sensor (B7) connector. See Transmission Harness (W7) Wiring Diagram. (Group 9015-10.)

YES: Short to ground on wire T17 BLU between pins B on left speed sensor (B7) connector and pin H2 on TCU connector (X1). See Transmission Harness (W7) Wiring Diagram and see Main Cab/Canopy Harness (W5) Wiring Diagram. (Group 9015-10.)

Is ground present?

NO: Replace left speed sensor (B7). Calibrate TCU. See Transmission Control Unit (TCU) Calibration. (Group 9015-20.) If code 000907.04 is active after sensor replacement, go to Reprogram Controller. AA95137,00011C9 -19-12DEC07-3/4

• 2

Reprogram Controller

Reprogram transmission control unit (TCU) (A1).

YES: Replace TCU.

Is TCU code 000907.04 active?

NO: Checks complete. AA95137,00011C9 -19-12DEC07-4/4

000907.07 — Left Speed Sensor No Response The left motor speed sensor is not responding. AA95137,00011CA -19-02JAN08-1/4

Left Speed Sensor No Response Diagnostic Procedure Alarm Level: No Warning Lamp Continued on next page

TM10721 (03SEP14)

9001-30-46

AA95137,00011CA -19-02JAN08-2/4

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=88

Transmission Control Unit (TCU) Diagnostic Trouble Codes

• 1

Circuit Check

Disconnect left speed sensor (B7). See Transmission Harness (W7) Component Location. (Group 9015-15.) Check voltage at pin A (wire T18 BLU) on left speed sensor (B7) connector.

YES: Go to next step in check.

Is voltage approximately 5 volts?

NO: Short to ground or open circuit on wire T18 BLU between pin A on left speed sensor (B7) connector and pin H1 on TCU connector (X1). See Transmission Harness (W7) Wiring Diagram and see Main Cab/Canopy Harness (W5) Wiring Diagram. (Group 9015-10.)

Left speed sensor (B7) disconnected. Check for ground at pin C (wire Z08 GRY) on left speed sensor (B7) connector.

YES: Go to next step in check.

Is ground present?

NO: Short to ground or open circuit between pin C on left speed sensor (B7) connector and pin H3 on TCU connector (X1). See Transmission Harness (W7) Wiring Diagram and see Main Cab/Canopy Harness (W5) Wiring Diagram. (Group 9015-10.)

Left speed sensor (B7) disconnected. Disconnect TCU connector (X1). See Main Cab/Canopy Harness (W5) Component Location. (Group 9015-10.) Check continuity (wire T17 BLU) between pin B on left speed sensor (B7) connector and pin H2 on TCU connector (X1).

YES: Replace left speed sensor (B7). Calibrate TCU. See Transmission Control Unit (TCU) Calibration. (Group 9015-20.) If code 000907.07 is still active after repair, go to Reprogram Controller.

Is continuity indicated?

NO: Open circuit between pin B on left speed sensor (B7) connector and pin H2 on TCU connector (X1). See Transmission Harness (W7) Wiring Diagram and see Main Cab/Canopy Harness (W5) Wiring Diagram. (Group 9015-10.) AA95137,00011CA -19-02JAN08-3/4

• 2

Reprogram Controller

Reprogram transmission control unit (TCU) (A1).

YES: Replace controller.

Is TCU code 000907.07 active?

NO: Checks complete. AA95137,00011CA -19-02JAN08-4/4

TM10721 (03SEP14)

9001-30-47

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=89

Transmission Control Unit (TCU) Diagnostic Trouble Codes

000907.12 — Left Speed Sensor Open The motor speed sensor left signal voltage is between 1.10—3.81 volts. AA95137,00011CB -19-12DEC07-1/4

Left Speed Sensor Open Diagnostic Procedure Alarm Level: No Warning Lamp Continued on next page

TM10721 (03SEP14)

9001-30-48

AA95137,00011CB -19-12DEC07-2/4

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=90

Transmission Control Unit (TCU) Diagnostic Trouble Codes

• 1

Open Circuit Check

Turn key switch OFF.

Disconnect left speed sensor (B7). See Transmission Harness (W7) Component Location. (Group 9015-10.) Turn key switch ON. Check voltage at pin A (wire T18 BLU) on left speed sensor (B7) connector.

YES: Go to next step in this check.

Is voltage approximately 5 volts?

NO: Open circuit between left speed sensor (B7) connector and pin H1 on TCU connector (X1). Repair or replace harness. See Main Cab/Canopy Harness (W5) Wiring Diagram and see Transmission Harness (W7) Wiring Diagram. (Group 9015-10.)

Key switch OFF. Left speed sensor (B7) disconnected. Disconnect TCU connector (X1). See Main Cab/Canopy Harness (W5) Component Location. (Group 9015-10.) Check continuity (wire T17 BLU) between pin B on left speed sensor (B7) connector and pin 20 on TCU connector (X1). See Main Cab/Canopy Harness (W5) Wiring Diagram. (Group 9015-10.)

YES: Go to next step in this check.

Is continuity indicated?

NO: Open circuit on T17 BLU between pin B on left speed sensor (B7) connector and pin H2 on TCU connector (X1). Repair or replace harness. See Main Cab/Canopy Harness (W5) Wiring Diagram. (Group 9015-10.)

Key switch OFF. Disconnect left speed sensor (B7). Disconnect TCU connector (X1). Check continuity (wire Z08 GRY) between pin C on left speed sensor (B7) connector and pin H3 on TCU connector (X1).

YES: Replace left motor speed sensor. Calibrate the TCU. See Transmission Control Unit (TCU) Calibration. (Group 9015-20.) If code 000907.12 still exists after replacing the sensor, go to Reprogram Controller.

Is continuity indicated?

NO: Open circuit between pin C (wire Z08 GRY) on left speed sensor (B7) connector and pin H3 on TCU connector (X1). Repair or replace harness. See Main Cab/Canopy Harness (W5) Wiring Diagram. (Group 9015-10.) Continued on next page

TM10721 (03SEP14)

9001-30-49

AA95137,00011CB -19-12DEC07-3/4

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=91

Transmission Control Unit (TCU) Diagnostic Trouble Codes

• 2

Reprogram Controller

Reprogram transmission control unit (TCU) (A1).

YES: Replace controller.

Is TCU code 000907.12 active?

NO: Checks complete. AA95137,00011CB -19-12DEC07-4/4

000908.03 — Right Speed Sensor Short to Power

Right speed sensor input voltage is greater than 4.81 volts. AA95137,00011CC -19-11JAN08-1/5

Right Speed Sensor Short to Power Diagnostic Procedure Alarm Level: No Warning Lamp AA95137,00011CC -19-11JAN08-2/5

• 1

Component Check

Turn key switch OFF.

Disconnect right speed sensor (B3). See Transmission Harness (W7) Component Location. (Group 9015-15.) Turn key switch ON.

YES: Go to Short Circuit Check.

Is transmission control unit (TCU) code 000908.03 active?

NO: Replace right speed sensor (B3). Calibrate the TCU. See Transmission Control Unit (TCU) Calibration. (Group 9015-20.)

Continued on next page

TM10721 (03SEP14)

9001-30-50

AA95137,00011CC -19-11JAN08-3/5

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=92

Transmission Control Unit (TCU) Diagnostic Trouble Codes

• 2

Short Circuit Check

Right speed sensor (B3) disconnected.

Turn key switch ON. Check voltage at pin A (wire T03 BLU) on right speed sensor (B3) connector.

YES: Go to next step in this check.

Is voltage approximately 5 volts?

NO: Short to power on wire T03 BLU between pin A on right speed sensor (B3) connector and pin B1 on TCU connector (X1). See Transmission Harness (W7) Wiring Diagram and see Main Cab/Canopy Harness (W5) Wiring Diagram. (Group 9015-10.)

Right speed sensor (B3) disconnected. Turn key switch ON. Check voltage at pin B (wire T19 BLU) on right speed sensor (B3).

YES: Go to Reprogram Controller.

Is voltage approximately 0 volts?

NO: Short to power on wire T19 BLU between pin B on right speed sensor (B3) connector and pin J2 on TCU connector (X1). See Transmission Harness (W7) Wiring Diagram and see Main Cab/Canopy Harness (W5) Wiring Diagram. (Group 9015-10.) AA95137,00011CC -19-11JAN08-4/5

• 3

Reprogram Controller

Reprogram transmission control unit (TCU) (A1).

YES: Replace controller.

Is TCU code 000908.03 active?

NO: Checks complete. AA95137,00011CC -19-11JAN08-5/5

000908.04 — Right Speed Sensor Short Right speed sensor signal voltage is less than .11 volts. AA95137,00011CD -19-12DEC07-1/4

Right Speed Sensor Short Diagnostic Procedure Alarm Level: No Warning Lamp Continued on next page

TM10721 (03SEP14)

9001-30-51

AA95137,00011CD -19-12DEC07-2/4

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=93

Transmission Control Unit (TCU) Diagnostic Trouble Codes

• 1

Short Circuit Check

Disconnect right speed sensor (B3). See Transmission Harness (W7) Component Location. (Group 9015-10.) Check for ground at pin A (wire T03 BLU) on right speed sensor (B3) connector.

YES: Short to ground on wire T03 BLU between pin A on right speed sensor (B3) connector and pin B1 on TCU connector (X1). See Transmission Harness (W7) Wiring Diagram and see Main Cab/Canopy Harness (W5) Wiring Diagram. (Group 9015-10.)

Is ground present?

NO: Go to next step in this check.

Right speed sensor (B3) disconnected. Turn key switch ON. Check for ground at pin B (wire T19 BLU) on right speed sensor (B3) connector.

YES: Short to ground on wire T19 BLU between pin B on right speed sensor (B3) connector and pin J2 on TCU connector (X1). See Transmission Harness (W7) Wiring Diagram and see Main Cab/Canopy Harness (W5) Wiring Diagram. (Group 9015-10.)

Is ground present?

NO: Replace sensor. Calibrate the TCU. See Transmission Control Unit (TCU) Calibration. (Group 9015-20.) If code 000908.04 is still active after repair, go to Reprogram Controller. AA95137,00011CD -19-12DEC07-3/4

• 2

Reprogram Controller

Reprogram transmission control unit (TCU) (A1).

YES: Replace controller.

Is TCU code 000908.04 active?

NO: Checks complete. AA95137,00011CD -19-12DEC07-4/4

000908.07 — Right Speed Sensor No Response

The right speed sensor is not responding. AA95137,00011CE -19-12DEC07-1/4

Right Speed Sensor No Response Diagnostic Procedure Alarm Level: No Warning Lamp Continued on next page

TM10721 (03SEP14)

9001-30-52

AA95137,00011CE -19-12DEC07-2/4

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=94

Transmission Control Unit (TCU) Diagnostic Trouble Codes

• 1

Circuit Check

Turn key switch OFF.

Disconnect right speed sensor (B3). See Transmission Harness (W7) Component Location. (Group 9015-10.) Turn key switch ON. Check voltage at pin A (wire T03 BLU) on right speed sensor (B3) connector.

YES: Go to next step in this check.

Is voltage approximately 5 volts?

NO: Open or short circuit between pin A (wire T03 BLU) on right speed sensor (B3) and pin B1 on TCU connector (X1). Repair or replace harness. See Transmission Harness (W7) Wiring Diagram and see Main Cab/Canopy Harness (W5) Wiring Diagram. (Group 9015-10.)

Key switch OFF. Right speed sensor (B3) disconnected. Disconnect transmission control unit (TCU) connector (X1). See Main Cab/Canopy Harness (W5) Component Location. (Group 9015-10.) Check wire T19 BLU for continuity between pin B on right speed sensor (B3) connector YES: Go to next step in this and pin J2 on TCU connector (X1). check. Is continuity indicated?

NO: Open circuit on T19 BLU between pin B on right speed sensor (B3) connector and pin J2 on TCU connector (X1). Repair or replace harness. See Transmission Harness (W7) Wiring Diagram and see Main Cab/Canopy Harness (W5) Wiring Diagram. (Group 9015-10.)

Key switch OFF. Right speed sensor (B3) and TCU connector (X1) disconnected. Check for continuity between pin C (wire Z02 BLK) on right speed sensor (B3) connector and pin B3 on TCU connector (X1).

YES: Replace sensor. Calibrate the TCU. See Transmission Control Unit (TCU) Calibration. (Group 9015-20.) If code 000908.07 is still active after repair, go to Reprogram Controller.

Is continuity indicated?

NO: Open circuit between pin C on right speed sensor (B3) connector and pin B3 on TCU connector (X1). Repair or replace harness. See Transmission Harness (W7) Wiring Diagram and see Main Cab/Canopy Harness (W5) Wiring Diagram. (Group 9015-10.) Continued on next page

TM10721 (03SEP14)

9001-30-53

AA95137,00011CE -19-12DEC07-3/4

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=95

Transmission Control Unit (TCU) Diagnostic Trouble Codes

• 2

Reprogram Controller

Reprogram transmission control unit (TCU) (A1).

YES: Replace controller.

Is TCU code 000908.07 active?

NO: Checks complete. AA95137,00011CE -19-12DEC07-4/4

000908.12 — Right Speed Sensor Open Right speed sensor signal voltage is between 1.10—3.81 volts. AA95137,00011CF -19-12DEC07-1/4

Right Speed Sensor Open Diagnostic Procedure Alarm Level: No Warning Lamp AA95137,00011CF -19-12DEC07-2/4

• 1

Circuit Check

Disconnect right speed sensor (B3). See Transmission Harness (W7) Component Location. (Group 9015-15.) Check voltage at pin A (wire T03 BLU) on right speed sensor (B3) connector.

YES: Go to next step in check.

Is voltage approximately 5 volts?

NO: Short to ground or open circuit on wire T03 BLU between pins A on right speed sensor (B3) connector and pin 3 on TCU connector (X1). See Transmission Harness (W7) Wiring Diagram and see Main Cab/Canopy Harness (W5) Wiring Diagram. (Group 9015-10.)

Right speed sensor (B3) disconnected. Check for ground at pin C (wire Z02 BLK) on right speed sensor (B3) connector.

YES: Replace sensor. Calibrate the TCU. See Transmission Control Unit (TCU) Calibration. (Group 9015-20.) If code 000908.12 is still active after repair, go to Reprogram controller.

Is ground present?

NO: Short to ground or open circuit between pin C on right speed sensor (B3) connector and pin B3 on TCU connector (X1). See Transmission Harness (W7) Wiring Diagram and see Main Cab/Canopy Harness (W5) Wiring Diagram. (Group 9015-10.) Continued on next page

TM10721 (03SEP14)

9001-30-54

AA95137,00011CF -19-12DEC07-3/4

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=96

Transmission Control Unit (TCU) Diagnostic Trouble Codes

• 2

Reprogram Controller

Reprogram transmission control unit (TCU) (A1).

YES: Replace controller.

Is TCU code 000908.12 active?

NO: Checks complete. AA95137,00011CF -19-12DEC07-4/4

002660.00 — Steer Sensor Input Greater Than Max Cal

Left steer sensor input voltage is greater than the stored calibration value. AA95137,00011D0 -19-11JAN08-1/6

Left Steer Sensor Input Greater Than Maximum Calibration Value Diagnostic Procedure Alarm Level: No Warning Lamp AA95137,00011D0 -19-11JAN08-2/6

• 1

Calibration Check

Observe the input voltage from steer sensor (B5) by accessing the DIAGNOSTIC / LIVE VALUES / INPUTS menu on the standard display monitor (SDM). See Standard Display Monitor (SDM) Menu Structure—Service Mode. (Group 9015-16.) Record voltage readings while moving transmission control lever (TCL) to right and left steer positions. Specification Steer Sensor (B5)—Calibration Limits..............................2.3—2.7 V at Neutral Position 1.52—1.94 V at Right Steer Position 1.40—1.78 V at Right Counter Rotate Position 3.06—3.48 V at Left Steer Position 3.22—3.60 V at Left Counter Rotate Position Is voltage within specifications?

YES: Calibrate the transmission control unit (TCU). See Transmission Control Unit (TCU) Calibration. (Group 9015-20.)

NO: Go to Sensor Adjustment. AA95137,00011D0 -19-11JAN08-3/6

• 2

Sensor Adjustment

Adjust TCL sensor linkage. See Transmission Control Lever (TCL) Adjustment. (Group 9015-20.) Calibrate the TCU. See Transmission Control Unit (TCU) Calibration. (Group 9015-20.) YES: Go to Component Check. Is TCU code 002661.00 still active?

NO: Repair complete. AA95137,00011D0 -19-11JAN08-4/6

• 3

Component Check

Remove steer sensor (B5). See Main Cab/Canopy Harness (W5) Component Location. (Group 9015-10.) Verify shaft is turning.

YES: Go to Reprogram Controller.

Is steer sensor shaft turning?

NO: Replace steer sensor. Calibrate TCU. See Transmission Control Unit (TCU) Calibration. (Group 9015-20.) Continued on next page

TM10721 (03SEP14)

9001-30-55

AA95137,00011D0 -19-11JAN08-5/6

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=97

Transmission Control Unit (TCU) Diagnostic Trouble Codes

• 4

Reprogram Controller

Reprogram transmission control unit (TCU) (A1).

YES: Replace controller.

Is TCU code 002660.00 still active?

NO: Checks complete. AA95137,00011D0 -19-11JAN08-6/6

002660.01 — Steer Sensor Input Less Than Min Cal

Steer sensor input voltage is less than the stored calibration value. AA95137,00011D1 -19-11JAN08-1/6

Steer Sensor Input Less Than Minimum Calibration Value Diagnostic Procedure Alarm Level: Check Service Code AA95137,00011D1 -19-11JAN08-2/6

• 1

Calibration Check

YES: Calibrate the transmission control unit (TCU). See Transmission Control Unit (TCU) Calibration. (Group 9015-20.)

NO: Go to Sensor Adjustment. AA95137,00011D1 -19-11JAN08-3/6

• 2

Sensor Adjustment

NO: Repair complete. AA95137,00011D1 -19-11JAN08-4/6

• 3

Component Check

Remove steer sensor (B5). See Main Cab/Canopy Harness (W5) Component Location. (Group 9015-10.) Verify shaft is turning.

YES: Go to Reprogram Controller.

Is steer sensor shaft turning?

NO: Replace steer sensor. Calibrate TCU. See Transmission Control Unit (TCU) Calibration. (Group 9015-20.) Continued on next page

TM10721 (03SEP14)

9001-30-56

AA95137,00011D1 -19-11JAN08-5/6

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=98

Transmission Control Unit (TCU) Diagnostic Trouble Codes

• 4

Reprogram Controller

Reprogram transmission control unit (TCU) (A1).

YES: Replace controller.

Is TCU code 002660.01 still active?

NO: Checks complete. AA95137,00011D1 -19-11JAN08-6/6

002660.03 — Steer Sensor Short to Power Steer sensor signal voltage is greater than 4.95 volts. AA95137,00011D2 -19-11JAN08-1/5

Steer Sensor Short to Power Diagnostic Procedure Alarm Level: Check Service Code AA95137,00011D2 -19-11JAN08-2/5

• 1

Component Check

Turn key switch OFF.

Disconnect steer sensor (B5). See Main Cab/Canopy Harness (W5) Component Location. (Group 9015-15.) Turn key switch ON.

YES: Go to Short Circuit Check.

Is transmission control unit (TCU) code 002660.03 active?

NO: Replace steer sensor. Calibrate the TCU. See Transmission Control Unit (TCU) Calibration. (Group 9015-20.) AA95137,00011D2 -19-11JAN08-3/5

• 2

Short Circuit Check

Disconnect steer sensor (B5). See Main Cab/Canopy Harness (W5) Component Location. (Group 9015-15.) Turn key switch ON. Check voltage at pin B (wire T11 BLU) on steer sensor (B5) connector.

YES: Go to Reprogram Controller.

Is voltage approximately 0 volts?

NO: Short to power on wire T11 BLU between pin B on steer sensor (B5) connector and pin D2 on TCU connector (X1). Repair circuit or replace harness. See Transmission Harness (W7) Wiring Diagram. (Group 9015-10.) AA95137,00011D2 -19-11JAN08-4/5

• 3

Reprogram Controller

Reprogram transmission control unit (TCU) (A1).

YES: Replace controller.

Is TCU code 002660.03 active?

NO: Checks complete. AA95137,00011D2 -19-11JAN08-5/5

002660.04 — Steer Sensor Open or Short Steer sensor signal voltage is less than .05 volts. Continued on next page

TM10721 (03SEP14)

9001-30-57

AA95137,00011D3 -19-08SEP09-1/5

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=99

Transmission Control Unit (TCU) Diagnostic Trouble Codes Steer Sensor Open or Short Diagnostic Procedure Alarm Level: Check Service Code AA95137,00011D3 -19-08SEP09-2/5

• 1

Short Circuit Check

Turn key switch OFF.

Disconnect steer sensor (B5) and transmission control unit (TCU) connector (X1). See Main Cab/Canopy Harness (W5) Component Location. (Group 9015-15.) Check for ground at pin A (wire T10 BLU) on steer sensor (B5) connector.

YES: Short to ground between pin A on steer sensor (B5) connector and pin D1 on TCU connector (X1). Repair circuit or replace harness. See Main Cab/Canopy Harness (W5) Wiring Diagram. (Group 9015-15.)

Is ground present?

NO: Go to next step in this check.

Key switch OFF. Steer sensor (B5) disconnected. Check for ground at pin B (wire T11 BLU) on steer sensor (B5) connector.

YES: Short to ground between pin B on steer sensor (B5) connector and pin D2 on TCU connector (X1). Repair or replace harness. See Main Cab/Canopy Harness (W5) Wiring Diagram. (Group 9015-15.)

Is ground present?

NO: Go to Open Circuit Check. Continued on next page

TM10721 (03SEP14)

9001-30-58

AA95137,00011D3 -19-08SEP09-3/5

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=100

Transmission Control Unit (TCU) Diagnostic Trouble Codes

• 2

Open Circuit Check

Turn key switch OFF.

Disconnect steer sensor (B5) and transmission control unit (TCU) connector (X1). See Main Cab/Canopy Harness (W5) Component Location. (Group 9015-15.) Check continuity between pin A (wire T10 BLU) on steer sensor (B5) connector and pin D1 on TCU connector (X1).

YES: Go to next step in this check.

Is continuity indicated?

NO: Open circuit between pin A on steer sensor (B5) connector and pin D1 on TCU connector (X1). Repair circuit or replace harness. See Main Cab/Canopy Harness (W5) Wiring Diagram. (Group 9015-15.)

Key switch OFF. Steer sensor (B5) disconnected. TCU connector (X1) disconnected. Check continuity between pin B (wire T11 BLU) on steer sensor (B5) connector and pin D2 on TCU connector (X1).

YES: Go to next step in this check.

Is continuity indicated?

NO: Open circuit between pin B on steer sensor (B5) connector and pin D2 on TCU connector (X1). Repair circuit or replace harness. See Main Cab/Canopy Harness (W5) Wiring Diagram. (Group 9015-15.)

Key switch OFF. Steer sensor (B5) disconnected. TCU connector (X1) disconnected. Check continuity between pin C (wire Z05 GRY) on steer sensor (B5) connector and pin D3 on TCU connector (X1).

YES: Replace steer sensor. Calibrate TCU. See Transmission Control Unit (TCU) Calibration. (Group 9015-20.)

Is continuity indicated?

NO: Open circuit between pin C on steer sensor (B5) connector and pin D3 on TCU connector (X1). Repair circuit or replace harness. See Main Cab/Canopy Harness (W5) Wiring Diagram. (Group 9015-15.)

Go to Reprogram Controller.

AA95137,00011D3 -19-08SEP09-4/5

• 3

Reprogram Controller

Reprogram transmission control unit (TCU) (A1).

YES: Replace controller.

Is TCU code 002660.04 active?

NO: Checks complete. AA95137,00011D3 -19-08SEP09-5/5

TM10721 (03SEP14)

9001-30-59

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=101

Transmission Control Unit (TCU) Diagnostic Trouble Codes

002660.15 — Steer Sensor Min Cal Too High The right steer sensor stored calibration value is more than 1.78 v or right counter-rotate minimum value is more than 1.94 volts. AA95137,00011D4 -19-11JAN08-1/6

Right Steer Sensor Minimum Calibration Value Too High Diagnostic Procedure Alarm Level: Check Service Code AA95137,00011D4 -19-11JAN08-2/6

• 1

Calibration Check

Observe the input voltage from steer sensor (B5) by accessing the DIAGNOSTIC / LIVE VALUES / INPUTS menu on the standard display monitor (SDM). See Standard Display Monitor (SDM) Menu Structure—Service Mode. (Group 9015-16.) Compare voltage to specification. Specification Steer Sensor (B5)—Calibration Limits..............................2.3—2.7 V at Neutral Position 1.52—1.94 V at Right Steer Position 1.40—1.78 V at Right Counter Rotate Position 3.06—3.48 V at Left Steer Position 3.22—3.60 V at Left Counter Rotate Position Are readings within specification?

YES: Go to Reprogram Controller.

NO: Go to Sensor Adjustment. AA95137,00011D4 -19-11JAN08-3/6

• 2

Sensor Adjustment

Adjust TCL sensor linkage. See Transmission Control Lever (TCL) Adjustment. (Group 9015-20.) Calibrate the transmission control unit (TCU). See Transmission Control Unit (TCU) Calibration. (Group 9015-20.)

YES: Go to Component Check.

Is TCU code 002661.15 still active?

NO: Repair complete. AA95137,00011D4 -19-11JAN08-4/6

• 3

Component Check

Remove steer sensor (B5). See Main Cab/Canopy Harness (W5) Component Location. (Group 9015-10.) Verify shaft is turning.

YES: Go to Reprogram Controller.

Is steer sensor shaft turning?

NO: Replace steer sensor. Calibrate the TCU. See Transmission Control Unit (TCU) Calibration. (Group 9015-20.) AA95137,00011D4 -19-11JAN08-5/6

• 4

Reprogram Controller

Reprogram transmission control unit (TCU) (A1).

YES: Replace controller.

Is TCU code 002660.15 still active?

NO: Checks complete. AA95137,00011D4 -19-11JAN08-6/6

TM10721 (03SEP14)

9001-30-60

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=102

Transmission Control Unit (TCU) Diagnostic Trouble Codes

002660.16 — Steer Sensor Max Cal Too High The left steer sensor stored calibration value is more than 3.48 v or left counter-rotate maximum calibration value is more than 3.60 volts. AA95137,00011D5 -19-11JAN08-1/6

Steer Sensor Maximum Calibration Value Too High Diagnostic Procedure Alarm Level: Check Service Code AA95137,00011D5 -19-11JAN08-2/6

• 1

Calibration Check

YES: Go to Reprogram Controller.

Specification Steer Sensor (B5)—Calibration Limits..............................2.3—2.7 V at Neutral Position 1.52—1.94 V at Right Steer Position 1.40—1.78 V at Right Counter Rotate Position 3.06—3.48 V at Left Steer Position 3.22—3.60 V at Left Counter Rotate Position Are readings within specifications?

NO: Go to Sensor Adjustment. AA95137,00011D5 -19-11JAN08-3/6

• 2

Sensor Adjustment

YES: Go to Component Check.

Is TCU code 002661.00 still active?

NO: Repair complete. AA95137,00011D5 -19-11JAN08-4/6

• 3

Component Check

Remove steer sensor (B5). See Main Cab/Canopy Harness (W5) Component Location. (Group 9015-10.) Verify shaft is turning.

YES: Go to Reprogram Controller.

Is steer sensor shaft turning?

NO: Replace steer sensor. Calibrate the TCU. See Transmission Control Unit (TCU) Calibration. (Group 9015-20.) AA95137,00011D5 -19-11JAN08-5/6

• 4

Reprogram Controller

Reprogram transmission control unit (TCU) (A1).

YES: Replace controller.

Is TCU code 002660.16 still active?

NO: Checks complete. AA95137,00011D5 -19-11JAN08-6/6

TM10721 (03SEP14)

9001-30-61

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=103

Transmission Control Unit (TCU) Diagnostic Trouble Codes

002660.17 — Steer Sensor Min Cal Too Low The right steer sensor stored calibration value is less than 1.52 volts or right counter-rotate minimum value is less than 1.40 volts. AA95137,00011D6 -19-11JAN08-1/6

Steer Sensor Minimum Calibration Value Too Low Diagnostic Procedure Alarm Level: Check Service Code AA95137,00011D6 -19-11JAN08-2/6

• 1

Calibration Check

Observe the input voltage from steer sensor (B5) by accessing the DIAGNOSTIC / LIVE VALUES / INPUTS menu on the standard display monitor (SDM). See Standard Display Monitor (SDM) Menu Structure—Service Mode. (Group 9015-16.) Compare readings to specifications. Specification Steer Sensor (B5)—Calibration Limits..............................2.3—2.7 V at Neutral Position 1.52—1.94 V at Right Steer Position 1.40—1.78 V at Right Counter Rotate Position 3.06—3.48 V at Left Steer Position 3.22—3.60 V at Left Counter Rotate Position Are readings within specifications?

YES: Go to Reprogram Controller.

NO: Go to Sensor Adjustment. AA95137,00011D6 -19-11JAN08-3/6

• 2

Sensor Adjustment

YES: Go to Component Check.

Is TCU code 002661.17 still active?

NO: Repair complete. AA95137,00011D6 -19-11JAN08-4/6

• 3

Component Check

Remove steer sensor (B5). See Main Cab/Canopy Harness (W5) Component Location. (Group 9015-10.) Verify shaft is turning.

YES: Go to Reprogram Controller.

Is steer sensor shaft turning?

NO: Replace steer sensor. Calibrate the TCU. See Transmission Control Unit (TCU) Calibration. (Group 9015-20.) AA95137,00011D6 -19-11JAN08-5/6

• 4

Reprogram Controller

Reprogram transmission control unit (TCU) (A1).

YES: Replace controller.

Is TCU code 002660.17 still active?

NO: Checks complete. AA95137,00011D6 -19-11JAN08-6/6

TM10721 (03SEP14)

9001-30-62

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=104

Transmission Control Unit (TCU) Diagnostic Trouble Codes

002660.18 — Steer Sensor Max Cal Too Low The left steer sensor stored calibration value is less than 3.06 volts or left counter-rotate maximum calibration value is less than 3.22 volts. AA95137,00011D7 -19-11JAN08-1/6

Steer Sensor Maximum Calibration Value Too Low Diagnostic Procedure Alarm Level: Check Service Code AA95137,00011D7 -19-11JAN08-2/6

• 1

Calibration Check

Observe the input voltage from steer sensor (B5) by accessing the DIAGNOSTIC / LIVE VALUES / INPUTS menu on the standard display monitor (SDM). See Standard Display Monitor (SDM) Menu Structure—Service Mode. (Group 9015-16.) Compare voltage to specifications. Specification Steer Sensor (B5)—Calibration Limits..............................2.3—2.7 V at Neutral Position 1.52—1.94 V at Right Steer Position 1.40—1.78 V at Right Counter Rotate Position 3.06—3.48 V at Left Steer Position 3.22—3.60 V at Left Counter Rotate Position Are readings within specifications?

YES: Go to Reprogram Controller.

NO: Go to Sensor Adjustment. AA95137,00011D7 -19-11JAN08-3/6

• 2

Sensor Adjustment

YES: Go to Component Check.

Is TCU code 002661.18 still active?

NO: Repair complete. AA95137,00011D7 -19-11JAN08-4/6

• 3

Component Check

Remove steer sensor (B5). See Main Cab/Canopy Harness (W5) Component Location. (Group 9015-10.) Verify shaft is turning.

YES: Go to Reprogram Controller.

Is steer sensor shaft turning?

NO: Replace steer sensor. Calibrate the TCU. See Transmission Control Unit (TCU) Calibration. (Group 9015-20.) AA95137,00011D7 -19-11JAN08-5/6

• 4

Reprogram Controller

Reprogram transmission control unit (TCU) (A1).

YES: Replace controller.

Is TCU code 002660.18 still active?

NO: Checks complete. AA95137,00011D7 -19-11JAN08-6/6

TM10721 (03SEP14)

9001-30-63

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=105

Transmission Control Unit (TCU) Diagnostic Trouble Codes

002661.00 — TCL Input Greater Than Max Cal The transmission control lever (TCL) sensor input is greater than the stored calibration value. AA95137,00011D8 -19-03DEC09-1/4

TCL Sensor Input Greater Than Maximum Calibration Value Diagnostic Procedure Alarm Level: Check Service Code AA95137,00011D8 -19-03DEC09-2/4

• 1

Calibration Check

Perform Transmission Control Unit (TCU) Calibration. (Group 9015-20.)

YES: See TCU code 002661.15—TCL Sensor Min Cal Too High or 002661.16—TCL Sensor Max Cal Too High. (Group 9001-30.)

Is TCU code 002661.15 or 002661.16 active?

NO: Go to next step in this check. YES: Go to Reprogram Controller.

Is TCU code 002661.00 active?

NO: Checks complete. AA95137,00011D8 -19-03DEC09-3/4

• 2

Reprogram Controller

Reprogram transmission control unit (TCU) (A1).

YES: Replace controller.

Is TCU code 002661.00 still active?

NO: Checks complete. AA95137,00011D8 -19-03DEC09-4/4

002661.01 — TCL Input Less Than Min Cal The transmission control lever (TCL) sensor input voltage less than stored calibration value. AA95137,00011D9 -19-03DEC09-1/4

TCL Input Less Than Minimum Calibration Value Diagnostic Procedure Alarm Level: Check Service Code AA95137,00011D9 -19-03DEC09-2/4

• 1

Calibration Check

Perform Transmission Control Unit (TCU) Calibration. (Group 9015-20.)

YES: See TCU code 002661.17—TCL Sensor Min Cal Too Low or 002661.18—TCL Sensor Max Cal Too Low. (Group 9001-30.)

Is TCU code 002661.17 or 002661.18 active?

NO: Go to next step in this check. YES: Go to Reprogram Controller.

Is TCU code 002661.01 active?

NO: Checks complete. Continued on next page

TM10721 (03SEP14)

9001-30-64

AA95137,00011D9 -19-03DEC09-3/4

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=106

Transmission Control Unit (TCU) Diagnostic Trouble Codes

• 2

Reprogram Controller

Reprogram transmission control unit (TCU) (A1).

YES: Replace controller.

Is TCU code 002661.01 still active?

NO: Checks complete. AA95137,00011D9 -19-03DEC09-4/4

002661.03 — TCL Sensor Short to Power The transmission control lever (TCL) sensor input voltage is greater than 4.95 volts. AA95137,00011DA -19-11JAN08-1/5

TCL Sensor Short to Power Diagnostic Procedure Alarm Level: Check Service Code AA95137,00011DA -19-11JAN08-2/5

• 1

Component Check

Turn key switch OFF.

Disconnect TCL sensor (B2). See Main Cab/Canopy Harness (W5) Component Location. (Group 9015-15.) Turn key switch ON.

YES: Go to Short Circuit Check.

Is transmission control unit (TCU) code 002661.03 active?

NO: Replace TCL sensor (B2). Calibrate the TCU. See Transmission Control Unit (TCU) Calibration. (Group 9015-20.) AA95137,00011DA -19-11JAN08-3/5

• 2

Short Circuit Check

Turn key switch OFF.

Disconnect TCL sensor (B2). See Main Cab/Canopy Harness (W5) Component Location. (Group 9015-15.) Turn key switch ON. Check voltage at pin B (wire T02 BLU) on TCL sensor (B2) connector.

YES: Go to Reprogram Controller.

Is voltage approximately 0 volts?

NO: Short to power on wire T02 BLU between pins B on TCL sensor (B2) connector and pin A2 on TCU connector (X1). Repair circuit or replace harness. See Main Cab/Canopy Harness (W5) Wiring Diagram. (Group 9015-10.) AA95137,00011DA -19-11JAN08-4/5

• 3

Reprogram Controller

Reprogram transmission control unit (TCU) (A1).

YES: Replace controller.

Is TCU code 002661.03 active?

NO: Checks complete. AA95137,00011DA -19-11JAN08-5/5

TM10721 (03SEP14)

9001-30-65

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=107

Transmission Control Unit (TCU) Diagnostic Trouble Codes

002661.04 — TCL Sensor Open or Short The transmission control lever (TCL) sensor input voltage is less than .05 volts. AA95137,00011DB -19-12DEC07-1/5

TCL Sensor Open or Short Diagnostic Procedure Alarm Level: Check Service Code AA95137,00011DB -19-12DEC07-2/5

• 1

Open Circuit Check

Turn key switch OFF.

Disconnect TCL sensor (B2) connector. See Main Cab/Canopy Harness (W5) Component Location. (Group 9015-10.) Turn key switch ON. Check voltage at pin A (wire T01 BLU) on TCL sensor (B2) connector.

YES: Go to next step in this check.

Is voltage approximately 5 volts?

NO: Open circuit on wire T01 BLU between pin A on TCL sensor (B2) connector and pin A1 on TCU connector (X1). Repair or replace harness. See Main Cab/Canopy Harness (W5) Wiring Diagram. (Group 9015-10.)

Key switch OFF. TCL sensor (B2) disconnected. Disconnect transmission control unit (TCU) connector (X1). See Main Cab/Canopy Harness (W5) Component Location. (Group 9015-10.) Check continuity (wire T02 BLU) between pin B on TCL sensor (B2) connector and pin A2 on TCU connector (X1).

YES: Go to next step in this check.

Is continuity indicated?

NO: Open circuit between pin B on TCL sensor (B2) connector and pin A2 on TCU connector (X1). Repair or replace harness. See Main Cab/Canopy Harness (W5) Wiring Diagram. (Group 9015-10.)

Key switch OFF. TCL sensor (B2) and TCU connector (X1) disconnected. Check continuity (wire Z01 BLK) between pin C on TCL sensor (B2) connector and pin A3 on TCU connector (X1).

YES: Go to Short Circuit Check.

Is continuity indicated?

NO: Open circuit between pin C on TCL sensor (B2) connector and pin A3 on TCU connector (X1). Repair or replace harness. See Main Cab/Canopy Harness (W5) Wiring Diagram. (Group 9015-10.) Continued on next page

TM10721 (03SEP14)

9001-30-66

AA95137,00011DB -19-12DEC07-3/5

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=108

Transmission Control Unit (TCU) Diagnostic Trouble Codes

• 2

Short Circuit Check

Turn key switch OFF.

Disconnect TCL sensor (B2) and TCU connector (X1). See Main Cab/Canopy Harness (W5) Component Location. (Group 9015-15.) Check for ground (wire T02 BLU) at pin B on TCL sensor (B2) connector.

YES: Short to ground between pin B on TCL sensor (B2) connector and pin A2 on TCU connector (X1). Repair or replace harness. See Main Cab/Canopy Harness (W5) Wiring Diagram. (Group 9015-10.)

Is ground present?

NO: Replace TCL sensor. Calibrate the TCU. See Transmission Control Unit (TCU) Calibration. (Group 9015-20.) If code 002661.04 is active after repair,go to Reprogram Controller. AA95137,00011DB -19-12DEC07-4/5

• 3

Reprogram Controller

Reprogram transmission control unit (TCU) (A1).

YES: Replace controller.

Is TCU code 002661.04 active?

NO: Checks complete. AA95137,00011DB -19-12DEC07-5/5

002661.15 — TCL Sensor Min Cal Too High The transmission control lever (TCL) sensor minimum calibration value too high (reverse). AA95137,00011DC -19-11JAN08-1/6

TCL Sensor Minimum Calibration Value Too High Diagnostic Procedure Alarm Level: Check Service Code AA95137,00011DC -19-11JAN08-2/6

• 1

Calibration Check

Record stored reverse calibration voltage from TCL sensor by accessing the DIAGNOSTIC / CALIBRATED VALUES / INPUTS menu on the standard display monitor (SDM). See Standard Display Monitor (SDM) Menu Structure—Service Mode. (Group 9015-16.) Record the neutral input voltage from TCL sensor by accessing the DIAGNOSTIC / LIVE VALUES / INPUTS menu on the SDM. Subtract 0.667 from the TCL sensor live neutral voltage.

YES: Go to Sensor Adjustment.

Is subtracted value less than stored calibration voltage?

NO: Go to Reprogram Controller.

Continued on next page

TM10721 (03SEP14)

9001-30-67

AA95137,00011DC -19-11JAN08-3/6

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=109

Transmission Control Unit (TCU) Diagnostic Trouble Codes

• 2

Sensor Adjustment

YES: Go to Component Check.

Is TCU code 002661.15 still active?

NO: Repair complete. AA95137,00011DC -19-11JAN08-4/6

• 3

Component Check

Remove the TCL sensor (B2). See Main Cab/Canopy Harness (W5) Component Location. (Group 9015-10.) Verify the shaft is turning.

YES: Go to Reprogram Controller.

Is TCL sensor shaft turning?

NO: Replace TCL sensor. Calibrate the TCU. See Transmission Control Unit (TCU) Calibration. (Group 9015-20.) AA95137,00011DC -19-11JAN08-5/6

• 4

Reprogram Controller

Reprogram transmission control unit (TCU) (A1).

YES: Replace controller.

Is TCU code 002661.15 still active?

NO: Checks complete. AA95137,00011DC -19-11JAN08-6/6

002661.16 — TCL Sensor Max Cal Too High The transmission control lever (TCL) sensor maximum calibration value is too high (forward). AA95137,00011DD -19-11JAN08-1/6

TCL Sensor Maximum Calibration Value Too High Diagnostic Procedure Alarm Level: Check Service Code AA95137,00011DD -19-11JAN08-2/6

• 1

Calibration Check

Record stored forward calibration voltage from TCL sensor by accessing the DIAGNOSTIC / CALIBRATED VALUES / INPUTS menu on the standard display monitor (SDM). See Standard Display Monitor (SDM) Menu Structure—Service Mode. (Group 9015-16.) Record the neutral input voltage from TCL sensor by accessing the DIAGNOSTIC / LIVE VALUES / INPUTS menu on the SDM. Add 1.408 to the TCL sensor live neutral voltage.

YES: Go to Reprogram Controller.

Is added value less than stored calibration voltage?

NO: Go to Sensor Adjustment. AA95137,00011DD -19-11JAN08-3/6

• 2

Sensor Adjustment

YES: Go to Component Check.

Is TCU code 002661.16 still active?

NO: Repair complete. Continued on next page

TM10721 (03SEP14)

9001-30-68

AA95137,00011DD -19-11JAN08-4/6

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=110

Transmission Control Unit (TCU) Diagnostic Trouble Codes

• 3

Component Check

Remove the TCL sensor (B2). See Main Cab/Canopy Harness (W5) Component Location. (Group 9015-10.) Verify the shaft is turning.

YES: Go to Reprogram Controller.

Is TCL sensor shaft turning?

NO: Replace TCL sensor. Calibrate the TCU. See Transmission Control Unit (TCU) Calibration. (Group 9015-20.) AA95137,00011DD -19-11JAN08-5/6

• 4

Reprogram Controller

Reprogram transmission control unit (TCU) (A1).

YES: Replace controller.

Is TCU code 002661.16 still active?

NO: Checks complete. AA95137,00011DD -19-11JAN08-6/6

002661.17 — TCL Sensor Min Cal Too Low The transmission control lever (TCL) sensor minimum calibration value is too low (reverse). AA95137,00011DE -19-11JAN08-1/6

TCL Sensor Minimum Calibration Value Too Low Diagnostic Procedure Alarm Level: Check Service Code AA95137,00011DE -19-11JAN08-2/6

• 1

Calibration Check

YES: Go to Sensor Adjustment.

Is subtracted value greater than stored calibration voltage?

NO: Go to Reprogram Controller. AA95137,00011DE -19-11JAN08-3/6

• 2

Sensor Adjustment

YES: Go to Component Check.

Is TCU code 002661.17 still active?

NO: Repair complete. Continued on next page

TM10721 (03SEP14)

9001-30-69

AA95137,00011DE -19-11JAN08-4/6

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=111

Transmission Control Unit (TCU) Diagnostic Trouble Codes

• 3

Component Check

Remove the TCL sensor (B2). See Main Cab/Canopy Harness (W5) Component Location. (Group 9015-10.) Verify the shaft is turning.

YES: Go to Reprogram Controller.

Is TCL sensor shaft turning?

NO: Replace TCL sensor. Calibrate the TCU. See Transmission Control Unit (TCU) Calibration. (Group 9015-20.) AA95137,00011DE -19-11JAN08-5/6

• 4

Reprogram Controller

Reprogram transmission control unit (TCU) (A1).

YES: Replace controller.

Is TCU code 002661.17 still active?

NO: Checks complete. AA95137,00011DE -19-11JAN08-6/6

002661.18 — TCL Sensor Max Cal Too Low The transmission control lever (TCL) sensor maximum calibration value too low (forward). AA95137,00011DF -19-11JAN08-1/6

TCL Sensor Maximum Calibration Value Too Low Diagnostic Procedure Alarm Level: Check Service Code AA95137,00011DF -19-11JAN08-2/6

• 1

Calibration Check

YES: Go to Sensor Adjustment.

Is added value greater than stored calibration voltage?

NO: Go to Reprogram Controller. AA95137,00011DF -19-11JAN08-3/6

• 2

Sensor Adjustment

YES: Go to Component Check.

Is TCU code 002661.18 still active?

NO: Repair complete. Continued on next page

TM10721 (03SEP14)

9001-30-70

AA95137,00011DF -19-11JAN08-4/6

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=112

Transmission Control Unit (TCU) Diagnostic Trouble Codes

• 3

Component Check

Remove the TCL sensor (B2). See Main Cab/Canopy Harness (W5) Component Location. (Group 9015-10.) Verify the shaft is turning.

YES: Go to Reprogram Controller.

Is TCL sensor shaft turning?

NO: Replace TCL sensor. Calibrate the TCU. See Transmission Control Unit (TCU) Calibration. (Group 9015-20.) AA95137,00011DF -19-11JAN08-5/6

• 4

Reprogram Controller

Reprogram transmission control unit (TCU) (A1).

YES: Replace controller.

Is TCU code 002661.18 still active?

NO: Checks complete. AA95137,00011DF -19-11JAN08-6/6

522444.00 — Charge Pressure High Engine is running and charge pressure is above 5171 kPa (51.7 bar) (750 psi) or above 3447 kPa (34.5 bar) (500 psi) at operating temperature. AA95137,00011E0 -19-11JAN08-1/4

Charge Pressure High Diagnostic Procedure Alarm Level: Transmission Charge Pressure Icon AA95137,00011E0 -19-11JAN08-2/4

• 1

Code Check

Check for active codes. See Standard Display Monitor (SDM) Menu Structure—Service YES: See Mode. (Group 9015-16.) 522444.04—Charge Pressure Open or Short. (Group 9001-30.) Is transmission control unit (TCU) code 522444.04 active?

NO: Go to Charge Pressure Check. AA95137,00011E0 -19-11JAN08-3/4

• 2

Charge Pressure Check

Check transmission charge pressure by accessing the DIAGNOSTIC / LIVE VALUES / PRESSURES submenu on the SDM. See Standard Display Monitor (SDM) Menu Structure—Service Mode. (Group 9015-16.) Compare charge pressure to specification. Specification Transmission Charge Oil—Pressure (in neutral).................................................................................................. 2034—2377 kPa 20—24 bar 295—345 psi Is charge pressure within specification?

YES: Replace transmission charge pressure sensor.

NO: See Neutral Charge Relief and Operating Charge Relief Pressure Test. (Group 9026-25.) AA95137,00011E0 -19-11JAN08-4/4

TM10721 (03SEP14)

9001-30-71

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=113

Transmission Control Unit (TCU) Diagnostic Trouble Codes

522444.01 — Charge Pressure Low Engine is running and charge pressure is below 1310 kPa (13.1 bar) (190 psi). AA95137,00011E1 -19-11JAN08-1/4

Charge Pressure Low Diagnostic Procedure Alarm Level: Transmission Charge Pressure Icon AA95137,00011E1 -19-11JAN08-2/4

• 1

Code Check

NO: Go to Charge Pressure Check. AA95137,00011E1 -19-11JAN08-3/4

• 2

Charge Pressure Check

YES: Replace transmission charge pressure sensor.

NO: See Neutral Charge Relief and Operating Charge Relief Pressure Test. (Group 9026-25.) AA95137,00011E1 -19-11JAN08-4/4

522444.03 — Charge Pressure Short to Power Charge pressure signal is above 4.95 volts. AA95137,00011E2 -19-24SEP09-1/5

Charge Pressure Short to Power Diagnostic Procedure Alarm Level: No Service Warning Continued on next page

TM10721 (03SEP14)

9001-30-72

AA95137,00011E2 -19-24SEP09-2/5

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=114

Transmission Control Unit (TCU) Diagnostic Trouble Codes

• 1

Component Check

NOTE: The charge pressure sensor is B33 for (S.N. —173344) and B41 for (S.N. 173345— ). Charge pressure sensor harness (W25) is used with B41 (S.N. 173345— ). Turn key switch OFF. Disconnect charge pressure sensor (B33 or B41). See Transmission Harness (W7) Component Location. (Group 9015-10.) Start engine.

YES: Go to Short Circuit Check.

Is transmission control unit (TCU) code 522444.03 active?

NO: Replace charge pressure sensor (B33 or B41). AA95137,00011E2 -19-24SEP09-3/5

• 2

Short Circuit Check

Turn key switch ON.

Disconnect charge pressure sensor (B33 or B41). See Transmission Harness (W7) Component Location. (Group 9015-10.) Check voltage at pin C (wire T21 BLU) on charge pressure sensor (B33 or B41) connector.

YES: Short to power between pin C on charge pressure sensor (B33 or B41) connector and pin K2 on TCU connector (X1). Repair or replace harness. See Main Cab/Canopy Harness (W5) Wiring Diagram and see Transmission Harness (W7) Wiring Diagram. (Group 9015-10.)

Is voltage greater than 1 volt?

NO: Go to Reprogram Controller. AA95137,00011E2 -19-24SEP09-4/5

• 3

Reprogram Controller

Reprogram transmission control unit (TCU) (A1).

YES: Replace controller.

Is TCU code 522444.03 active?

NO: Checks complete. AA95137,00011E2 -19-24SEP09-5/5

522444.04 — Charge Pressure Open or Short Charge pressure sensor signal voltage is less than .05 volts. AA95137,00011E3 -19-24SEP09-1/5

Charge Pressure Open or Short Diagnostic Procedure Alarm Level: No Service Warning Continued on next page

TM10721 (03SEP14)

9001-30-73

AA95137,00011E3 -19-24SEP09-2/5

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=115

Transmission Control Unit (TCU) Diagnostic Trouble Codes

• 1

Open Circuit Check

NOTE: The charge pressure sensor is B33 for (S.N. —173344) and B41 for (S.N. 173345— ). Charge pressure sensor harness (W25) is used with B41 (S.N. 173345— ). Turn key switch OFF. Disconnect charge pressure sensor (B33 or B41) connector. See Transmission Harness (W7) Component Location. (Group 9015-10.) Turn key switch ON. Check voltage at pin B (wire T20 BLU) on charge pressure sensor (B33 or B41) or connector.

YES: Go to next step in this check.

Is voltage approximately 5 volts?

NO: Open circuit between pin B on charge pressure sensor (B33 or B41) connector and pin E1 on TCU connector (X1). Repair or replace harness. See Main Cab/Canopy Harness (W5) Wiring Diagram and see Transmission Harness (W7) Wiring Diagram. (Group 9015-10.)

Key switch OFF. Charge pressure sensor (B33 or B41) disconnected. Disconnect transmission control unit (TCU) connector (X1). See Main Cab/Canopy Harness (W5) Component Location. (Group 9015-10.) Check continuity (wire T21 BLU) between pin C on charge pressure sensor (B33 or B41) connector and pin K2 on TCU connector (X1).

YES: Go to next step in this check.

Is continuity indicated?

NO: Open circuit between pin C on charge pressure sensor (B33 or B41) connector and pin K2 on TCU connector (X1). Repair or replace harness. See Main Cab/Canopy Harness (W5) Wiring Diagram and see Transmission Harness (W7) Wiring Diagram. (Group 9015-10.)

Key switch OFF. Charge pressure sensor (B33 or B41) and TCU connector (X1) disconnected. Check for continuity between pin A (wire Z09 BLK) on charge pressure sensor (B33 or B41) connector and pin E3 on TCU connector (X1).

YES: Go to Short Circuit Check.

Is continuity indicated?

NO: Open circuit between pin A on charge pressure sensor (B33 or B41) connector and pin E3 on TCU connector (X1). Repair or replace harness. See Main Cab/Canopy Harness (W5) Wiring Diagram and see Transmission Harness (W7) Wiring Diagram. (Group 9015-10.) Continued on next page

TM10721 (03SEP14)

9001-30-74

AA95137,00011E3 -19-24SEP09-3/5

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=116

Transmission Control Unit (TCU) Diagnostic Trouble Codes

• 2

Short Circuit Check

Turn key switch OFF.

Disconnect charge pressure sensor (B33 or B41) and TCU connector (X1). See Main Cab/Canopy Harness (W5) Component Location and see Transmission Harness (W7) Wiring Diagram. (Group 9015-15.) Check for ground at pin C (wire T21 BLU) on charge pressure sensor (B33 or B41) connector.

YES: Short to ground (wire T21 BLU) between pin B on charge pressure sensor (B33 or B41) connector and ground. Repair or replace harness. See Main Cab/Canopy Harness (W5) Wiring Diagram and see Transmission Harness (W7) Wiring Diagram. (Group 9015-10.)

Is ground present?

NO: Replace charge pressure sensor (B33 or B41). If code 522444.04 is active after repair, go to Reprogram Controller. AA95137,00011E3 -19-24SEP09-4/5

• 3

Reprogram Controller

Reprogram transmission control unit (TCU) (A1).

YES: Replace controller.

Is TCU code 522444.04 active?

NO: Checks complete. AA95137,00011E3 -19-24SEP09-5/5

522447.05 — Right Fwd Pump Coil Open The front pump pressure control pilot is limited to reverse direction and current draw is too low in forward direction. AA95137,00011E4 -19-23NOV09-1/5

Right Forward Pump Coil Open Diagnostic Procedure Alarm Level: Check Service Code AA95137,00011E4 -19-23NOV09-2/5

• 1

Connector Check

Check pump pressure control pilot (PCP) front (B9) connector, main cab/canopy YES: Go to Component harness-to-engine harness connector (X10), and transmission control unit (TCU) Check. connector (X1) for corrosion, loose fit, bent/pushed out terminals or crimp malfunctions. See Engine Harness (W6) Component Location and see Main Cab/Canopy Harness (W5) Component Location. (Group 9015-10.) Are connectors in good condition?

NO: Repair or replace connector(s) or terminal(s) as needed. Continued on next page

TM10721 (03SEP14)

9001-30-75

AA95137,00011E4 -19-23NOV09-3/5

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=117

Transmission Control Unit (TCU) Diagnostic Trouble Codes

• 2

Component Check

Disconnect pump pressure control pilot (PCP) front (B9). See Engine Harness (W6) Component Location. (Group 9015-10.) Check resistance of PCP across pin 1 and 2. Compare resistance to specification. See Electrical Component Specifications. (Group YES: Go to Open Circuit 9015-20.) Check. Is resistance within specification?

NO: Replace PCP (B9). Calibrate the transmission control unit (TCU). See Transmission Control Unit (TCU) Calibration. (Group 9015-20.) AA95137,00011E4 -19-23NOV09-4/5

• 3

Open Circuit Check

Turn key switch OFF.

Disconnect pump pressure control pilot (PCP) front (B9). See Engine Harness (W6) Component Location. (Group 9015-10.) Disconnect transmission control unit (TCU) connector (X1). See Main Cab/Canopy Harness (W5) Component Location. (Group 9015-10.) Check wire T42 BLU for continuity between pin 2 on pump pressure control pilot (PCP) YES: Checks complete. front (B9) connector and pin K1 on TCU connector (X1). Is continuity indicated?

NO: Open circuit on wire T42 BLU between pin 2 on pump pressure control pilot (PCP) front (B9) and pin K1 on TCU connector (X1). Repair or replace harness. See Main Cab/Canopy Harness (W5) Wiring Diagram and see Engine Harness (W6) Wiring Diagram. (Group 9015-10.) AA95137,00011E4 -19-23NOV09-5/5

522447.06 — Right Fwd Pump Coil Short The front pump pressure control pilot is limited to reverse direction and current draw is too high in forward direction. AA95137,00011E5 -19-23NOV09-1/5

Right Forward Pump Coil Short Diagnostic Procedure Alarm Level: Check Service Code AA95137,00011E5 -19-23NOV09-2/5

• 1

Connector Check

Check pump pressure control pilot (PCP) front (B9) connector, main cab/canopy YES: Go to Component harness-to-engine harness connector (X10), and transmission control unit (TCU) Check. connector (X1) for corrosion, loose fit, bent/pushed out terminals or crimp malfunctions. See Engine Harness (W6) Component Location and See Main Cab/Canopy Harness (W5) Component Location. (Group 9015-10.) Are connectors in good condition?

NO: Repair or replace connector(s) or terminal(s) as needed. Continued on next page

TM10721 (03SEP14)

9001-30-76

AA95137,00011E5 -19-23NOV09-3/5

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=118

Transmission Control Unit (TCU) Diagnostic Trouble Codes

• 2

Component Check

Disconnect pump pressure control pilot (PCP) front (B9). See Engine Harness (W6) Component Location. (Group 9015-10.) Check resistance across pin 1 and 2 of PCP (B9). Compare resistance to specification. See Electrical Component Specifications. (Group YES: Go to Short Circuit 9015-20.) Check. Is resistance within specification?

NO: Replace PCP (B9). Calibrate the transmission control unit (TCU). See Transmission Control Unit (TCU) Calibration. (Group 9015-20.) AA95137,00011E5 -19-23NOV09-4/5

• 3

Short Circuit Check

Turn key switch OFF.

Disconnect pump pressure control pilot (PCP) front (B9). See Engine Harness (W6) Component Location. (Group 9015-10.) Check for ground at pin 2 wire T42 BLU on pump pressure control pilot (PCP) front (B9) connector.

YES: Short to ground on wire T42 BLU between pin 2 on pump pressure control pilot (PCP) front (B9) connector and pin K1 on TCU connector (X1). Repair or replace harness . See Engine Harness (W6) Wiring Diagram and see Transmission Harness (W7) Wiring Diagram. (Group 9015-10.)

Is ground present?

NO: Checks complete. AA95137,00011E5 -19-23NOV09-5/5

522447.15 — Right Fwd Pump Thresh Cal High

The front pump pressure control pilot is limited to the reverse direction and the forward threshold (point of track movement) is too high. AA95137,00011E6 -19-11JAN08-1/3

Right Forward Pump Threshold Calibration Value Too High Diagnostic Procedure Alarm Level: Check Service Code AA95137,00011E6 -19-11JAN08-2/3

• 1

Reprogram Controller

Calibrate the transmission control unit (TCU). See Transmission Control Unit (TCU) Calibration. (Group 9015-20.)

YES: See TCU Calibration Malfunctions. (Group 9026-15.)

Is TCU code 522447.15 active?

NO: Repair complete. AA95137,00011E6 -19-11JAN08-3/3

522447.16 — Right Fwd Pump Max Spd Cal High

The front pump pressure control pilot maximum calibration speed value is too high in forward. Continued on next page

TM10721 (03SEP14)

9001-30-77

AA95137,00011E7 -19-11JAN08-1/3

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=119

Transmission Control Unit (TCU) Diagnostic Trouble Codes Right Forward Pump Max Speed Calibration Value Too High Diagnostic Procedure Alarm Level: Check Service Code AA95137,00011E7 -19-11JAN08-2/3

• 1

Reprogram Controller

Calibrate the transmission control unit (TCU). See Transmission Control Unit (TCU) Calibration. (Group 9015-20.)

YES: See TCU Calibration Malfunctions. (Group 9026-15.)

Is TCU code 522447.16 active?

NO: Repair complete. AA95137,00011E7 -19-11JAN08-3/3

522447.17 — Right Fwd Pump Thresh Cal Low

The front pump pressure control pilot calibration threshold current too low in forward direction. AA95137,00011E8 -19-11JAN08-1/3

Right Forward Pump Threshold Calibration Value Too Low Diagnostic Procedure Alarm Level: Check Service Code AA95137,00011E8 -19-11JAN08-2/3

• 1

Reprogram Controller

Calibrate the transmission control unit (TCU). See Transmission Control Unit (TCU) Calibration. (Group 9015-20.)

YES: See TCU Calibration Malfunctions. (Group 9026-15.)

Is TCU code 522447.17 active?

NO: Repair complete. AA95137,00011E8 -19-11JAN08-3/3

522447.18 — Right Fwd Pump Max Spd Cal Low

Front pump pressure control pilot calibration current too low at maximum speed in forward direction. AA95137,00011E9 -19-11JAN08-1/3

Right Forward Pump Max Speed Calibration Value Too Low Diagnostic Procedure Alarm Level: Check Service Code AA95137,00011E9 -19-11JAN08-2/3

• 1

Reprogram Controller

Calibrate the transmission control unit (TCU). See Transmission Control Unit (TCU) Calibration. (Group 9015-20.)

YES: See TCU Calibration Malfunctions. (Group 9026-15.)

Is TCU code 522447.18 active?

NO: Repair complete. AA95137,00011E9 -19-11JAN08-3/3

522448.05 — Right Rev Pump Coil Open The pump pressure control pilot front is limited to forward direction and current draw is too low in reverse direction. Continued on next page

TM10721 (03SEP14)

9001-30-78

AA95137,00011EA -19-23NOV09-1/5

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=120

Transmission Control Unit (TCU) Diagnostic Trouble Codes Right Reverse Pump Coil Open Diagnostic Procedure Alarm Level: Check Service Code AA95137,00011EA -19-23NOV09-2/5

• 1

Connector Check

Check pump pressure control pilot (PCP) front (B9) connector, main cab/canopy YES: Go to Component harness-to-engine harness connector (X10), and transmission control unit (TCU) Check. connector (X1) for corrosion, loose fit, bent/pushed out terminals or crimp malfunctions. See Engine Harness (W6) Component Location and see Main Cab/Canopy Harness (W5) Wiring Diagram. (Group 9015-10.) Are connectors in good condition?

NO: Repair or replace connector(s) or terminal(s) as needed. AA95137,00011EA -19-23NOV09-3/5

• 2

Component Check

Turn key switch OFF.

Disconnect pump pressure control pilot (PCP) front (B9). See Engine Harness (W6) Component Location. (Group 9015-10.) Check resistance of PCP across pins 1 and 2 on pump pressure control pilot (PCP) front (B9). Compare resistance to specification. See Electrical Component Specifications. (Group YES: Go to Open Circuit 9015-20.) Check. Is the resistance within specification?

NO: Replace PCP (B9). Calibrate the transmission control unit (TCU). See Transmission Control Unit (TCU) Calibration. (Group 9015-20.) AA95137,00011EA -19-23NOV09-4/5

• 3

Open Circuit Check

Turn key switch OFF.

Disconnect pump pressure control pilot (PCP) front (B9). See Engine Harness (W6) Component Location. (Group 9015-10.) Disconnect TCU connector (X1). See Main Cab/Canopy Harness (W5) Component Location. (Group 9015-10.) Check wire T45 BLU for continuity between pin 1 on pump pressure control pilot (PCP) YES: Checks complete. front (B9) connector and pin K3 on TCU connector (X1). Is continuity indicated?

NO: Open circuit on wire T45 BLU between pin 1 on pump pressure control pilot (PCP) front (B9) connector and pin K3 on TCU connector (X1). Repair or replace harness. See Main Cab/Canopy Harness (W5) Wiring Diagram and see Engine Harness (W6) Wiring Diagram. (Group 9015-10.) AA95137,00011EA -19-23NOV09-5/5

TM10721 (03SEP14)

9001-30-79

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=121

Transmission Control Unit (TCU) Diagnostic Trouble Codes

522448.06 — Right Rev Pump Coil Short The front pump pressure control pilot is limited to forward direction and current draw is too high in reverse direction. AA95137,00011EB -19-23NOV09-1/5

Right Reverse Pump Coil Short Diagnostic Procedure Alarm Level: Check Service Code AA95137,00011EB -19-23NOV09-2/5

• 1

Connector Check

NO: Repair or replace connector(s) or terminal(s) as needed. AA95137,00011EB -19-23NOV09-3/5

• 2

Component Check

Turn key switch OFF.

Disconnect pump pressure control pilot (PCP) front (B9). See Engine Harness (W6) Component Location. (Group 9015-10.) Check resistance across pin 1 and 2 on pump pressure control pilot (PCP) front (B9). Compare resistance to specification. See Electrical Component Specifications. (Group YES: Go to Short Circuit 9015-10.) Check. Is the resistance within specification?

NO: Replace PCP (B9). Calibrate the transmission control unit (TCU). See Transmission Control Unit (TCU) Calibration. (Group 9015-20.) AA95137,00011EB -19-23NOV09-4/5

• 3

Short Circuit Check

Turn key switch OFF.

Disconnect pump pressure control pilot (PCP) front (B9). See Engine Harness (W6) Component Location. (Group 9015-10.) Check for ground at pin 1 wire T45 BLU on pump pressure control pilot (PCP) front (B9) connector.

YES: Short to ground on wire T45 BLU between pin 1 on pump pressure control pilot (PCP) front (B9) connector and pin K3 on TCU connector (X1). Repair or replace harness. See Engine Harness (W6) Wiring Diagram and see Main Cab/Canopy Harness (W5) Wiring Diagram. (Group 9015-10.)

Is ground present?

NO: Checks complete. AA95137,00011EB -19-23NOV09-5/5

TM10721 (03SEP14)

9001-30-80

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=122

Transmission Control Unit (TCU) Diagnostic Trouble Codes

522448.15 — Right Rev Pump Thresh Cal High

The front pump pressure control pilot is limited to the forward direction and the reverse threshold (point of track movement) is too high. AA95137,00011EC -19-11JAN08-1/3

Right Reverse Pump Threshold Calibration Value Too High Diagnostic Procedure Alarm Level: Check Service Code AA95137,00011EC -19-11JAN08-2/3

• 1

Reprogram Controller

Calibrate the transmission control unit (TCU). See Transmission Control Unit (TCU) Calibration. (Group 9015-20.)

YES: See TCU Calibration Malfunctions. (Group 9026-15.)

Is TCU code 522448.15 active?

NO: Repair complete. AA95137,00011EC -19-11JAN08-3/3

522448.16 — Right Rev Pump Max Spd Cal High

The front pump pressure control pilot maximum calibration speed value is too high in reverse. AA95137,00011ED -19-11JAN08-1/3

Right Reverse Pump Max Speed Calibration Value Too High Diagnostic Procedure Alarm Level: Check Service Code AA95137,00011ED -19-11JAN08-2/3

• 1

Reprogram Controller

Calibrate the transmission control unit (TCU). See Transmission Control Unit (TCU) Calibration. (Group 9015-20.)

YES: See TCU Calibration Malfunctions. (Group 9026-15.)

Is TCU code 522448.16 active?

NO: Repair complete. AA95137,00011ED -19-11JAN08-3/3

522448.17 — Right Rev Pump Thresh Cal Low The front pump pressure control pilot is limited to the forward direction and the reverse threshold (point of track movement) is too low. AA95137,00011EE -19-11JAN08-1/3

Right Reverse Pump Threshold Calibration Value Too Low Diagnostic Procedure Alarm Level: Check Service Code AA95137,00011EE -19-11JAN08-2/3

• 1

Reprogram Controller

Calibrate the transmission control unit (TCU). See Transmission Control Unit (TCU) Calibration. (Group 9015-20.)

YES: See TCU Calibration Malfunctions. (Group 9026-15.)

Is TCU code 522448.17 active?

NO: Repair complete. AA95137,00011EE -19-11JAN08-3/3

TM10721 (03SEP14)

9001-30-81

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=123

Transmission Control Unit (TCU) Diagnostic Trouble Codes

522448.18 — Right Rev Pump Max Spd Cal Low

The front pump pressure control pilot maximum calibration speed value is too low in reverse. AA95137,00011EF -19-11JAN08-1/3

Right Reverse Pump Max Speed Calibration Value Too Low Diagnostic Procedure Alarm Level: Check Service Code AA95137,00011EF -19-11JAN08-2/3

• 1

Reprogram Controller

Calibrate the transmission control unit (TCU). See Transmission Control Unit (TCU) Calibration. (Group 9015-20.)

YES: See TCU Calibration Malfunctions. (Group 9026-15.)

Is TCU code 522448.18 active?

NO: Repair complete. AA95137,00011EF -19-11JAN08-3/3

522449.05 — Left Rev Pump Coil Open The rear pump pressure control pilot is limited to forward direction and current draw is too low in reverse direction. AA95137,00011F0 -19-23NOV09-1/5

Left Reverse Pump Coil Open Diagnostic Procedure Alarm Level: Check Service Code AA95137,00011F0 -19-23NOV09-2/5

• 1

Connector Check

Check pump pressure control pilot (PCP) rear (B8) connector, main cab/canopy YES: Go to Component harness-to-engine harness connector (X10), and transmission control unit (TCU) Check. connector (X1) for corrosion, loose fit, bent/pushed out terminals or crimp malfunctions. See Engine Harness (W6) Component Location and see Main Cab/Canopy Harness (W5) Component Location. (Group 9015-10.) Are connectors in good condition?

NO: Repair or replace connector(s) or terminal(s) as needed. AA95137,00011F0 -19-23NOV09-3/5

• 2

Component Check

Turn key switch OFF.

Disconnect pump pressure control pilot (PCP) rear (B8). See Engine Harness (W6) Component Location. (Group 9015-10.) Check resistance across pin 1 and 2 on pump pressure control pilot (PCP) rear (B8). Compare resistance to specification. See Electrical Component Specifications. (Group YES: Go to Open Circuit 9015-20.) Check. Is the resistance within specification?

NO: Replace PCP (B8). Calibrate the transmission control unit (TCU). See Transmission Control Unit (TCU) Calibration. (Group 9015-20.) Continued on next page

TM10721 (03SEP14)

9001-30-82

AA95137,00011F0 -19-23NOV09-4/5

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=124

Transmission Control Unit (TCU) Diagnostic Trouble Codes

• 3

Open Circuit Check

Key switch OFF.

Disconnect pump pressure control pilot (PCP) rear (B8). See Engine Harness (W6) Component Location. (Group 9015-10.) Disconnect TCU connector (X1). See Main Cab/Canopy Harness (W5) Component Location. (Group 9015-10.) Check wire T41 BLU for continuity between pin 1 on pump pressure control pilot (PCP) YES: Checks complete. rear (B8) connector and pin J3 on TCU connector (X1). Is continuity indicated?

NO: Open circuit on wire T41 BLU between pin 1 on pump pressure control pilot (PCP) rear (B8) connector and pin J3 on connector (X1). Repair or replace harness. See Engine Harness (W6) Wiring Diagram and see Main Cab/Canopy Harness (W5) Wiring Diagram. (Group 9015-10.) AA95137,00011F0 -19-23NOV09-5/5

522449.06 — Left Rev Pump Coil Short The rear pump pressure control pilot is limited to forward direction and current draw is too high in reverse direction. AA95137,00011F1 -19-25NOV09-1/5

Left Reverse Pump Coil Open Diagnostic Procedure Alarm Level: Check Service Code AA95137,00011F1 -19-25NOV09-2/5

• 1

Connector Check

NO: Repair or replace connector(s) or terminal(s) as needed. Continued on next page

TM10721 (03SEP14)

9001-30-83

AA95137,00011F1 -19-25NOV09-3/5

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=125

Transmission Control Unit (TCU) Diagnostic Trouble Codes

• 2

Component Check

Turn key switch OFF.

Disconnect pump pressure control pilot (PCP) rear (B8). See Engine Harness (W6) Component Location. (Group 9015-15.) Check resistance across pins 1 and 2 on pump pressure control pilot (PCP) rear (B8). Compare resistance to specification. See Electrical Component Specifications. (Group YES: Go to Short Circuit 9015-20.) Check. Is the resistance within specification?

NO: Replace PCP (B8). Calibrate the transmission control unit (TCU). See Transmission Control Unit (TCU) Calibration. (Group 9015-20.) AA95137,00011F1 -19-25NOV09-4/5

• 3

Short Circuit Check

Key switch OFF.

Disconnect pump pressure control pilot (PCP) rear (B8). See Engine Harness (W6) Component Location. (Group 9015-15.) Check for continuity to ground at pin 1 wire T41 BLU on pump pressure control pilot (PCP) rear (B8) connector.

YES: Short to ground on wire T41 BLU between pin 1 on pump pressure control pilot (PCP) rear (B8) connector and pin J3 on TCU connector (X1). Repair or replace harness. See Main Cab/Canopy Harness (W5) Wiring Diagram and see Engine Harness (W6) Wiring Diagram. (Group 9015-10.)

Is ground present?

NO: Checks complete. AA95137,00011F1 -19-25NOV09-5/5

522449.15 — Left Rev Pump Thresh Cal High The rear pump pressure control pilot is limited to the forward direction and the reverse threshold (point of track movement) is too high. AA95137,00011F2 -19-11JAN08-1/3

Left Reverse Pump Threshold Calibration Value Too High Diagnostic Procedure Alarm Level: Check Service Code AA95137,00011F2 -19-11JAN08-2/3

• 1

Reprogram Controller

Calibrate the transmission control unit (TCU). See Transmission Control Unit (TCU) Calibration. (Group 9015-20.)

YES: See TCU Calibration Malfunctions. (Group 9026-15.)

Is TCU code 522449.15 active?

NO: Repair complete. AA95137,00011F2 -19-11JAN08-3/3

TM10721 (03SEP14)

9001-30-84

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=126

Transmission Control Unit (TCU) Diagnostic Trouble Codes

522449.16 — Left Rev Pump Max Spd Cal High

The front pump pressure control pilot maximum calibration speed value is too high in reverse. AA95137,00011F3 -19-11JAN08-1/3

Left Reverse Pump Max Speed Calibration Value Too High Diagnostic Procedure Alarm Level: Check Service Code AA95137,00011F3 -19-11JAN08-2/3

• 1

Reprogram Controller

Calibrate the transmission control unit (TCU). See Transmission Control Unit (TCU) Calibration. (Group 9015-20.)

YES: See TCU Calibration Malfunctions. (Group 9026-15.)

Is TCU code 522449.16 active?

NO: Repair complete. AA95137,00011F3 -19-11JAN08-3/3

522449.17 — Left Rev Pump Thresh Cal Low The rear pump pressure control pilot is limited to the forward direction and the reverse threshold (point of track movement) is too low. AA95137,00011F4 -19-11JAN08-1/3

Left Reverse Pump Threshold Calibration Value Too Low Diagnostic Procedure Alarm Level: Check Service Code AA95137,00011F4 -19-11JAN08-2/3

• 1

Reprogram Controller

Calibrate the transmission control unit (TCU). See Transmission Control Unit (TCU) Calibration. (Group 9015-20.)

YES: See TCU Calibration Malfunctions. (Group 9026-15.)

Is TCU code 522449.17 active?

NO: Repair complete. AA95137,00011F4 -19-11JAN08-3/3

522449.18 — Left Rev Pump Max Spd Cal Low The rear pump pressure control pilot maximum calibration speed value is too low in reverse. AA95137,00011F5 -19-11JAN08-1/3

Left Reverse Pump Max Speed Calibration Value Too Low Diagnostic Procedure Alarm Level: Check Service Code AA95137,00011F5 -19-11JAN08-2/3

• 1

Reprogram Controller

Calibrate the transmission control unit (TCU). See Transmission Control Unit (TCU) Calibration. (Group 9015-20.)

YES: See TCU Calibration Malfunctions. (Group 9026-15.)

Is TCU code 522449.18 active?

NO: Repair complete. AA95137,00011F5 -19-11JAN08-3/3

TM10721 (03SEP14)

9001-30-85

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=127

Transmission Control Unit (TCU) Diagnostic Trouble Codes

522450.05 — Left Fwd Pump Coil Open The rear pump pressure control pilot is limited to reverse direction and current draw is too low in forward direction. AA95137,00011F6 -19-23NOV09-1/5

Left Forward Pump Coil Open Diagnostic Procedure Alarm Level: Check Service Code AA95137,00011F6 -19-23NOV09-2/5

• 1

Connector Check

NO: Repair or replace connector(s) or terminal(s) as needed. AA95137,00011F6 -19-23NOV09-3/5

• 2

Component Check

Disconnect pump pressure control pilot (PCP) rear (B8). See Engine Harness (W6) Component Location. (Group 9015-10.) Check resistance of PCP (B8) across pins 1 and 2. Compare resistance to specification. See Electrical Component Specifications. (Group YES: Go to Open Circuit 9015-20.) Check. Is resistance within specification?

NO: Replace PCP (B8). Calibrate the transmission control unit (TCU). See Transmission Control Unit (TCU) Calibration. (Group 9015-20.) AA95137,00011F6 -19-23NOV09-4/5

• 3

Open Circuit Check

Turn key switch OFF.

Disconnect pump pressure control pilot (PCP) rear (B8). See Engine Harness (W6) Component Location. (Group 9015-10.) Disconnect TCU connector (X1). See Main Cab/Canopy Harness (W5) Component Location. (Group 9015-10.) Check wire T38 BLU for continuity between pin 2 on pump pressure control pilot (PCP) YES: Checks complete. rear (B8) connector and pin J1 on TCU connector (X1). Is continuity indicated?

NO: Open circuit on wire T38 BLU between pin 2 on pump pressure control pilot (PCP) rear (B8) connector and pin J1 on connector (X1). Repair or replace harness. See Engine Harness (W6) Wiring Diagram and see Main Cab/Canopy Harness (W5) Wiring Diagram. (Group 9015-10.) AA95137,00011F6 -19-23NOV09-5/5

TM10721 (03SEP14)

9001-30-86

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=128

Transmission Control Unit (TCU) Diagnostic Trouble Codes

522450.06 — Left Fwd Pump Coil Short The rear pump pressure control pilot is limited to reverse direction and current draw is too high in forward direction. AA95137,00011F7 -19-23NOV09-1/5

Left Forward Pump Coil Short Diagnostic Procedure Alarm Level: Check Service Code AA95137,00011F7 -19-23NOV09-2/5

• 1

Connector Check

NO: Repair or replace connector(s) or terminal(s) as needed. AA95137,00011F7 -19-23NOV09-3/5

• 2

Component Check

Disconnect pump pressure control pilot (PCP) rear (B8). See Engine Harness (W6) Component Location. (Group 9015-10.) Check resistance of PCP (B8) across pin 1 and 2. Compare resistance to specification. See Electrical Component Specifications. (Group YES: Go to Short Circuit 9015-20.) Check. Is resistance within specification?

NO: Replace PCP (B8). Calibrate the transmission control unit (TCU). See Transmission Control Unit (TCU) Calibration. (Group 9015-20.) AA95137,00011F7 -19-23NOV09-4/5

• 3

Short Circuit Check

Turn key switch OFF.

Disconnect pump pressure control pilot (PCP) rear (B8). See Engine Harness (W6) Component Location. (Group 9015-10.) Disconnect TCU connector (X1). See Main Cab/Canopy Harness (W5) Component Location. (Group 9015-10.) Check for continuity to ground at pin 2 wire T38 BLU on pump pressure control pilot (PCP) rear (B8) connector.

YES: Short circuit to ground on wire T38 BLU between pin 2 on pump pressure control pilot (PCP) rear (B8) connector and pin J1 on TCU connector (X1). Repair or replace harness. See Engine Harness (W6) Wiring Diagram and see Main Cab/Canopy Harness (W5) Wiring Diagram. (Group 9015-10.)

Is continuity indicated?

NO: Checks complete. AA95137,00011F7 -19-23NOV09-5/5

TM10721 (03SEP14)

9001-30-87

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=129

Transmission Control Unit (TCU) Diagnostic Trouble Codes

522450.15 — Left Fwd Pump Thresh Cal High The pump pressure control pilot rear is limited to the reverse direction and the forward threshold (point of track movement) is too high. AA95137,00011F8 -19-11JAN08-1/3

Left Forward Pump Threshold Calibration Value Too High Diagnostic Procedure Alarm Level: Check Service Code AA95137,00011F8 -19-11JAN08-2/3

• 1

Reprogram Controller

Calibrate the transmission control unit (TCU). See Transmission Control Unit (TCU) Calibration. (Group 9015-20.)

YES: See TCU Calibration Malfunctions. (Group 9026-15.)

Is TCU code 522450.15 active?

NO: Repair complete. AA95137,00011F8 -19-11JAN08-3/3

522450.16 — Left Fwd Pump Max Spd Cal High

The rear pump pressure control pilot maximum calibration speed value is too high in forward. AA95137,00011F9 -19-11JAN08-1/3

Left Forward Pump Max Speed Calibration Value Too High Diagnostic Procedure Alarm Level: Check Service Code AA95137,00011F9 -19-11JAN08-2/3

• 1

Reprogram Controller

Calibrate the transmission control unit (TCU). See Transmission Control Unit (TCU) Calibration. (Group 9015-20.)

YES: See TCU Calibration Malfunctions. (Group 9026-15.)

Is TCU code 522450.16 active?

NO: Repair complete. AA95137,00011F9 -19-11JAN08-3/3

522450.17 — Left Fwd Pump Thresh Cal Low The pump pressure control pilot rear is limited to the reverse direction and the forward threshold (point of track movement) is too low. AA95137,00011FA -19-11JAN08-1/3

Left Forward Pump Threshold Calibration Value Too Low Diagnostic Procedure Alarm Level: Check Service Code AA95137,00011FA -19-11JAN08-2/3

• 1

Reprogram Controller

Calibrate the transmission control unit (TCU). See Transmission Control Unit (TCU) Calibration. (Group 9015-20.)

YES: See TCU Calibration Malfunctions. (Group 9026-15.)

Is TCU code 522450.17 active?

NO: Repair complete. AA95137,00011FA -19-11JAN08-3/3

TM10721 (03SEP14)

9001-30-88

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=130

Transmission Control Unit (TCU) Diagnostic Trouble Codes

522450.18 — Left Fwd Pump Max Spd Cal Low The rear pump pressure control pilot maximum calibration speed value is too low in forward. AA95137,00011FB -19-11JAN08-1/3

Left Forward Pump Max Speed Calibration Value Too Low Diagnostic Procedure Alarm Level: Check Service Code AA95137,00011FB -19-11JAN08-2/3

• 1

Reprogram Controller

Calibrate the transmission control unit (TCU). See Transmission Control Unit (TCU) Calibration. (Group 9015-20.)

YES: See TCU Calibration Malfunctions. (Group 9026-15.)

Is TCU code 522450.18 active?

NO: Repair complete. AA95137,00011FB -19-11JAN08-3/3

523108.13 — TCU High Speed Not Calibrated Transmission control unit (TCU) calibration incomplete; motor speed not calibrated. AA95137,0001204 -19-02JAN08-1/3

TCU High Speed Not Calibrated Diagnostic Procedure Alarm Level: No Warning Lamp AA95137,0001204 -19-02JAN08-2/3

• 1

Calibrate Controller

Calibrate the TCU. See Transmission Control Unit (TCU) Calibration. (Group 9015-20.) YES: See TCU Calibration Malfunctions. (Group 9026-15.) Is TCU code 523108.13 active?

NO: Repair complete. AA95137,0001204 -19-02JAN08-3/3

523108.14 — Sensor or Pump Speed Not Calibrated

Transmission control unit (TCU) calibration incomplete; sensor thresholds or pump speed not calibrated. AA95137,0001203 -19-02JAN08-1/3

Sensor or Pump Speed Not Calibrated Diagnostic Procedure Alarm Level: Check Service Code Light AA95137,0001203 -19-02JAN08-2/3

• 1

Calibrate Controller

Calibrate the TCU. See Transmission Control Unit (TCU) Calibration. (Group 9015-20.) YES: See TCU Calibration Malfunctions. (Group 9026-15.) Is TCU code 523108.14 active?

NO: Repair complete. AA95137,0001203 -19-02JAN08-3/3

TM10721 (03SEP14)

9001-30-89

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=131

Transmission Control Unit (TCU) Diagnostic Trouble Codes

523577.09 — Left Motor Sol No Response The left motor shift solenoid is not responding. AA95137,00011FC -19-20NOV09-1/6

Left Motor Solenoid No Response Diagnostic Procedure Alarm Level: No Warning Lamp AA95137,00011FC -19-20NOV09-2/6

• 1

Connector Check

Turn key switch OFF.

Check left motor shift solenoid (Y4) connector, TCU connector (X2), main cab/canopy harness-to-engine harness connector (X10), and main cab/canopy harness-to-transmission harness connector (X11) for corrosion, loose fit, bent/pushed out terminals or crimp malfunctions. See Transmission Harness (W7) Component Location and see Main Cab/Canopy Harness (W5) Component Location. (Group 9015-10.)

YES: Go to Component Check.

Are connectors in good condition?

NO: Repair or replace connectors. AA95137,00011FC -19-20NOV09-3/6

• 2

Component Check

Turn key switch OFF.

Disconnect left motor shift solenoid (Y4). See Transmission Harness (W7) Component Location. (Group 9015-10.) Check resistance of solenoid (Y4) across pins 1 and 2. Compare resistance to specification. See Electrical Component Specifications. (Group YES: Go to Short Circuit 9015-20.) Check. Is resistance within specification?

NO: Replace solenoid (Y4). AA95137,00011FC -19-20NOV09-4/6

• 3

Short Circuit Check

Turn key switch OFF.

Disconnect left motor shift solenoid (Y4) and TCU connector (X2). See Transmission Harness (W7) Component Location. (Group 9015-10.) Check for continuity to ground at pin 1 (wire T50 BLU) of left motor shift solenoid connector (Y4).

YES: Short to ground between pin 1 of left motor solenoid connector (Y4) and pin D2 of transmission control unit TCU connector (X2). Repair or replace harness. See Transmission Harness (W7) Wiring Diagram. (Group 9015-10.)

Is continuity to ground indicated?

NO: Go to Open Circuit Check. Continued on next page

TM10721 (03SEP14)

9001-30-90

AA95137,00011FC -19-20NOV09-5/6

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=132

Transmission Control Unit (TCU) Diagnostic Trouble Codes

• 4

Open Circuit Check

Key switch OFF.

Disconnect left motor shift solenoid (Y4). See Transmission Harness (W7) Component Location. (Group 9015-10.) Disconnect TCU connector (X2). See Main Cab/Canopy Harness (W5) Component Location. (Group 9015-10.) Check for continuity (wire T50 BLU) at pin 1 of left motor solenoid connector (Y4) and pin D2 of TCU connector (X2).

YES: Go to next step in this check.

Is continuity indicated?

NO: Open between pin 1 of left motor solenoid connector (Y4) and pin D2 of TCU connector (X2). Repair or replace harness. See Transmission Harness (W7) Wiring Diagram and see Main Cab/Canopy Harness (W5) Wiring Diagram. (Group 9015-10.)

Key switch OFF. Left motor solenoid connector (Y4) disconnected. TCU connector (X2) disconnected. Check for continuity (wire G01 BLK) at pin 2 of left motor solenoid connector (Y4) and W3 ground.

YES: Checks complete.

Is continuity indicated?

NO: Go to next step in this check.

Key switch OFF. Disconnect main cab/canopy harness-to-transmission harness connector (X11). See Transmission Harness (W7) Wiring Diagram. (Group 9015-10.) Check for continuity to ground at pin 1 (wire G01 BLK) of main cab/canopy harness-to-transmission harness connector (X11).

YES: Open circuit in wire GO1 BLK between left motor shift solenoid (Y4) connector pin 2 and connector (X11) pin 1. Repair or replace harness. See Transmission Harness (W7) Wiring Diagram. (Group 9015-10.)

Is continuity indicated?

NO: Open circuit in wire G01 BLK between connector (X11) pin 1 and machine ground. Repair or replace harness. See Main Cab/Canopy Harness (W5) Wiring Diagram. (Group 9015-10.) AA95137,00011FC -19-20NOV09-6/6

523578.09 — Right Motor Sol No Response The right motor solenoid is not responding AA95137,00011FF -19-23NOV09-1/6

Right Motor Solenoid No Response Diagnostic Procedure Alarm Level: No Warning Lamp Continued on next page

TM10721 (03SEP14)

9001-30-91

AA95137,00011FF -19-23NOV09-2/6

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=133

Transmission Control Unit (TCU) Diagnostic Trouble Codes

• 1

Connector Check

Turn key switch OFF.

Check right motor shift solenoid (Y3) connector, TCU connector (X2), main cab/canopy harness-to-engine harness connector (X10), and main cab/canopy harness-to-transmission harness connector (X11) for corrosion, loose fit, bent/pushed out terminals or crimp malfunctions. See Transmission Harness (W7) Component Location and see Main Cab/Canopy Harness (W5) Component Location. (Group 9015-10.)

YES: Go to Component Check.

Are connectors in good condition?

NO: Repair or replace connectors. AA95137,00011FF -19-23NOV09-3/6

• 2

Component Check

Turn key switch OFF.

Disconnect right motor shift solenoid (Y3). See Transmission Harness (W7) Component Location. (Group 9015-10.) Check resistance of solenoid (Y3) across pins 1 and 2. Compare resistance to specification. See Electrical Component Specifications. (Group YES: Go to Short Circuit 9015-20.) Check. Is resistance within specification?

NO: Replace solenoid (Y3). AA95137,00011FF -19-23NOV09-4/6

• 3

Short Circuit Check

Turn key switch OFF.

Disconnect right motor shift solenoid (Y3). See Transmission Harness (W7) Component Location. (Group 9015-10.) Check for ground (wire T51 BLU) at pin 1 of right motor shift solenoid connector (Y3). See Transmission Harness (W7) Wiring Diagram. (Group 9015-10.)

YES: Short to ground between pin 1 of right motor solenoid connector (Y3) and pin F2 of TCU connector (X2). Repair or replace harness.

Is continuity to ground present?

NO: Go to Open Circuit Check. Continued on next page

TM10721 (03SEP14)

9001-30-92

AA95137,00011FF -19-23NOV09-5/6

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=134

Transmission Control Unit (TCU) Diagnostic Trouble Codes

• 4

Open Circuit Check

Key switch OFF.

Disconnect right motor shift solenoid (Y3). See Transmission Harness (W7) Component Location. (Group 9015-10.) Disconnect TCU connector (X2). See Main Cab/Canopy Harness (W5) Component Location. (Group 9015-10.) Check for continuity (wire T51 BLU) between pin 1 of right motor solenoid connector (Y3) and pin F2 of TCU connector (X2).

YES: Go to next step in this check.

Is continuity indicated?

NO: Open between pin 1 of right motor solenoid connector (Y3) and pin F2 of TCU connector (X2). Repair or replace harness. See Transmission Harness (W7) Wiring Diagram and see Main Cab/Canopy Harness (W5) Wiring Diagram. (Group 9015-10.)

Key switch OFF. Right motor solenoid connector (Y3) and TCU connector (X2) disconnected. Check for continuity (wire G01 BLK) between pin 2 of right motor solenoid connector (Y3) and ground.

YES: Checks complete.

Is continuity indicated?

NO: Go to next step in this check.

YES: Open circuit in wire GO1 BLK between left motor shift solenoid (Y3) connector pin 2 and connector (X11) pin 1. Repair or replace harness. See Transmission Harness (W7) Wiring Diagram. (Group 9015-10.)

Is continuity indicated?

TM10721 (03SEP14)

9001-30-93

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=135

Transmission Control Unit (TCU) Diagnostic Trouble Codes

TM10721 (03SEP14)

9001-30-94

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=136

Group 40 Electrohydraulic Controller (EHC) Diagnostic Trouble Codes Electrohydraulic Controller (EHC) Diagnostic Trouble Codes The diagnostic trouble code number is indicated by a suspect parameter number (SPN) and a failure mode indicator (FMI) number. In the example 000158.03, 158 is the SPN and 03 is the FMI number. To view diagnostic trouble codes, use one of the following methods:

• Standard Display Monitor (SDM). See Standard Display Monitor (SDM) Menu Structure—Service Mode. (Group 9015-16.)

NOTE: For in-depth diagnostics on all EHC diagnostic trouble codes, see specific code diagnostic procedure. (Group 9001-40.)

• Service ADVISOR™ system. See Reading Diagnostic Trouble Codes with Service ADVISOR™ Diagnostic Application. (Group 9015-20.)

Service ADVISOR is a trademark of Deere & Company TW73308,000011A -19-02JAN08-1/1

000158.03 — EHC System Volts Too High The electrohydraulic controller (EHC) system voltage is more than 38 volts. AA95137,0001220 -19-11JAN08-1/4

EHC System Voltage Too High Diagnostic Procedure Alarm Level: Check Service Code AA95137,0001220 -19-11JAN08-2/4

• 1

Component Check

Check alternator output. See Alternator Test. (Group 9015-20.)

YES: Go to Reprogram Controller.

Is alternator output within specifications?

NO: Alternator malfunction. Repair or replace alternator. AA95137,0001220 -19-11JAN08-3/4

• 2

Reprogram Controller

Reprogram electrohydraulic controller.

Check for active codes.

YES: Controller malfunction. Replace controller.

Is EHC code 00158.03 present?

NO: Checks complete. AA95137,0001220 -19-11JAN08-4/4

000158.04 — EHC System Volts Too Low The electrohydraulic controller (EHC) system voltage is less than 9 volts. AA95137,000119A -19-21JAN08-1/7

EHC System Voltage Too Low Diagnostic Procedure Alarm Level: Check Service Code Continued on next page

TM10721 (03SEP14)

9001-40-1

AA95137,000119A -19-21JAN08-2/7

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=137

Electrohydraulic Controller (EHC) Diagnostic Trouble Codes

• 1

Voltage Check

Check system voltage on monitor.

YES: Go to Component Check.

Is system voltage present?

NO: Check alternator. See Alternator Test. (Group 9015-20.) Repair or replace alternator if necessary. NO: Check batteries. See Handling, Checking And Servicing Batteries Carefully. (Operator's Manual.) AA95137,000119A -19-21JAN08-3/7

• 2

Component Check

Check continuity of fuse (F103). See Fuse and Relay Specifications. (Group 9015-10.) YES: Go to Code Check.

Is continuity indicated?

NO: Replace fuse (F103). AA95137,000119A -19-21JAN08-4/7

• 3

Code Check

Key switch ON.

Remove BCJ and EHC Switched Power Relay (K102) and replace IGC switched power relay (K101). See Fuse and Relay Specifications. (Group 9015-10.) Check for active codes.

YES: BCJ and EHC Switched Power Relay (K102) is OK. Go to Harness Check.

Is EHC code 000158.04 present?

NO: Relay malfunction. Replace BCJ and EHC Switched Power Relay (K102). Continued on next page

TM10721 (03SEP14)

9001-40-2

AA95137,000119A -19-21JAN08-5/7

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=138

Electrohydraulic Controller (EHC) Diagnostic Trouble Codes

• 4

Harness Check

Key switch ON.

Disconnect EHC connector (X83). See Integrated Grade Control (IGC) Cab Harness (W22) Component Location—If Equipped. (Group 9015-10.) Measure voltage between circuits P58 RED (X83 pin 18) and G15 BLK (X83 pin 6).

YES: Go to Reprogram Controller.

Is system voltage present?

NO: Go to next step in this check.

Disconnect bulkhead connector (X95) and IGC power connector (X84). See Integrated Grade Control (IGC) Machine Harness (W21) Component Location—If Equipped. (Group 9015-10.) Measure voltage between circuits P58 RED (X95 pin 11) on IGC machine harness and G15 BLK (X84 pin 3) on main cab/canopy harness.

YES: Open circuit in IGC cab harness (W22). Repair or replace harness. See Integrated Grade Control (IGC) Cab Harness (W22) Wiring Diagram—If Equipped. (Group 9015-10.)

Is system voltage present?

NO: Go to next step in this check.

Disconnect bulkhead connector (X95). See Integrated Grade Control (IGC) Machine Harness (W21) Component Location—If Equipped. (Group 9015-10.) Check voltage between circuit P58 RED (X95 pin 11) on IGC machine harness and machine ground.

YES: Go to next step in this check.

Is system voltage present?

NO: Open circuit in IGC machine harness (W21). Repair or replace harness. See Integrated Grade Control (IGC) Machine Harness (W21) Wiring Diagram—If Equipped. (Group 9015-10.)

Key switch OFF. Disconnect IGC power connector (X84). See Integrated Grade Control (IGC) Cab Harness (W22) Component Location—If Equipped. (Group 9015-10.) Check for continuity between circuit G15 BLK (X84 pin 3) on main cab/canopy harness YES: Go to Reprogram side of connector (X84) and machine ground. Controller. Is continuity indicated?

NO: Open circuit in main cab/canopy harness (W5). Repair or replace harness. See Main Cab/Canopy Harness (W5) Wiring Diagram. (Group 9015-10.) AA95137,000119A -19-21JAN08-6/7

• 5

Reprogram Controller

Reprogram electrohydraulic controller (EHC).

Check for active codes.

YES: Replace controller.

Is EHC code 000158.04 present?

NO: Checks complete. AA95137,000119A -19-21JAN08-7/7

000620.03 — Sensor Short to Power 5-volt supply to blade control joystick (BCJ) and pilot enable switch is short to power. Continued on next page

TM10721 (03SEP14)

9001-40-3

AA95137,0001221 -19-11JAN08-1/5

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=139

Electrohydraulic Controller (EHC) Diagnostic Trouble Codes Sensor 5-Volt Supply Short to Power Diagnostic Procedure Alarm Level: Check Service Code AA95137,0001221 -19-11JAN08-2/5

• 1

Code Check

Key switch ON.

Disconnect BCJ connector (X97). See Integrated Grade Control (IGC) Cab Harness (W22) Component Location—If Equipped. (Group 9015-10.) Check for active codes.

YES: Go to Short Circuit Check.

Is electrohydraulic controller (EHC) code 000620.03 still present?

NO: BCJ malfunction. Replace BCJ. AA95137,0001221 -19-11JAN08-3/5

• 2

Short Circuit Check

Key switch ON.

Disconnect BCJ connector (X97). See Integrated Grade Control (IGC) Cab Harness (W22) Component Location—If Equipped. (Group 9015-10.) Check voltage between circuit H22_CBL 2 (X97 pin 4) and circuit R41 BLK (X97 pin 6). YES: Short to power in IGC cab harness (W22). Repair or replace harness. See Integrated Grade Control (IGC) Cab Harness (W22) Wiring Diagram—If Equipped. (Group 9015-10.) Is voltage more than approximately 5 volts?

NO: Go to Reprogram Controller. AA95137,0001221 -19-11JAN08-4/5

• 3

Reprogram Controller

Reprogram electrohydraulic controller (EHC).

Check for active codes.

YES: Replace controller.

Is EHC code 000620.03 present?

NO: Checks complete. AA95137,0001221 -19-11JAN08-5/5

000620.04 — Sensor Short to GND 5-volt supply to blade control joystick (BCJ) and pilot enable switch is short to ground. AA95137,0001222 -19-11JAN08-1/6

5-Volt Sensor Supply Short to Ground Diagnostic Procedure Alarm Level: Check Service Code Continued on next page

TM10721 (03SEP14)

9001-40-4

AA95137,0001222 -19-11JAN08-2/6

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=140

Electrohydraulic Controller (EHC) Diagnostic Trouble Codes

• 1

Voltage Check

Key switch ON.

NO: Go to Reprogram Controller. AA95137,0001222 -19-11JAN08-3/6

• 2

Open Circuit Check

Key switch OFF.

Disconnect electrohydraulic controller (EHC) connector (X82) and BCJ connector (X97). See Integrated Grade Control (IGC) Cab Harness (W22) Component Location—If Equipped. (Group 9015-10.) Check continuity of the following circuits.

• H22 GRN (X97 pin 4 and X82 pin 3) • R41 BLK (X97 pin 6 and X82 pin 22)

YES: Go to Short Circuit Check.

Is continuity indicated in both circuits?

NO: Open circuit in IGC cab harness (W22). Repair or replace harness. See Integrated Grade Control (IGC) Cab Harness (W22) Wiring Diagram—If Equipped. (Group 9015-10.) AA95137,0001222 -19-11JAN08-4/6

• 3

Short Circuit Check

Key switch OFF.

Disconnect EHC connector (X82) and BCJ connector (X97). See Integrated Grade Control (IGC) Cab Harness (W22) Component Location—If Equipped. (Group 9015-10.) Check continuity between circuit H22 GRN (X82 pin 3) and machine ground.

YES: Short circuit in IGC cab harness (W22). Repair or replace harness. See Integrated Grade Control (IGC) Cab Harness (W22) Wiring Diagram—If Equipped. (Group 9015-10.)

Is continuity indicated?

NO: Replace BCJ (A9) and check active codes. If code 000620.04 is active, go to Reprogram Controller. AA95137,0001222 -19-11JAN08-5/6

• 4

Reprogram Controller

Reprogram electrohydraulic controller (EHC).

Check for active codes.

YES: Replace controller.

Is EHC code 00620.04 present?

NO: Checks complete. AA95137,0001222 -19-11JAN08-6/6

TM10721 (03SEP14)

9001-40-5

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=141

Electrohydraulic Controller (EHC) Diagnostic Trouble Codes

001903.00 — Aux 1 PVE Open Circuit There is an open present on the auxiliary 1 electrohydraulic actuator circuit. AA95137,0001223 -19-11JAN08-1/4

Auxiliary 1 Electrohydraulic Actuator Open Circuit Diagnostic Procedure Alarm Level: Check Service Code AA95137,0001223 -19-11JAN08-2/4

• 1

Open Circuit Check

Key switch OFF.

Disconnect auxiliary 1 actuator connector (X90) and electrohydraulic controller (EHC) connector (X83). See Integrated Grade Control (IGC) Machine Harness (W21) Component Location—If Equipped. (Group 9015-10.) Check continuity of the following circuits.

• P61 RED (X90 pin 4 and X83 pin 15) • H30 GRN (X90 pin 1 and X83 pin 14)

YES: Replace auxiliary 1 electrohydraulic actuator (if equipped) and check codes. If code 001903.00 is still active, go to Reprogram Controller.

• G30 BLK (X90 pin 3 and machine ground)

NO: If G30 BLK has no continuity, check for an open circuit in IGC machine harness (W21). See Integrated Grade Control (IGC) Machine Harness (W21) Wiring Diagram—If Equipped. (Group 9015-10.)

Is continuity indicated in all circuits?

NO: If P61 RED or H30 GRN have no continuity, go to next step in this check.

• P61 RED (X95 pin 13 and X83 pin 15) • H30 GRN (X95 pin 9 and X83 pin 14)

YES: Open circuit in IGC machine harness (W21). Repair or replace harness. See Integrated Grade Control (IGC) Machine Harness (W21) Wiring Diagram—If Equipped. (Group 9015-10.)

Is continuity indicated in both circuits?

NO: Open circuit in IGC cab harness (W22). Repair or replace harness. See Integrated Grade Control (IGC) Cab Harness (W22) Wiring Diagram—If Equipped. (Group 9015-10.) Continued on next page

TM10721 (03SEP14)

9001-40-6

AA95137,0001223 -19-11JAN08-3/4

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=142

Electrohydraulic Controller (EHC) Diagnostic Trouble Codes

• 2

Reprogram Controller

Reprogram electrohydraulic controller (EHC).

Check for active codes.

YES: Replace controller.

Is EHC code 001903.00 present?

NO: Checks complete. AA95137,0001223 -19-11JAN08-4/4

001903.01 — Aux 1 PVE Low or Open Circuit The auxiliary 1 electrohydraulic actuator circuit is open or short to 5 volts. AA95137,0001224 -19-24JAN08-1/5

Auxiliary 1 Electrohydraulic Actuator Open or Short to Ground Diagnostic Procedure Alarm Level: Check Service Code AA95137,0001224 -19-24JAN08-2/5

• 1

Short Circuit Check

Turn key switch OFF.

Disconnect electrohydraulic actuator connector (X90) and electrohydraulic controller (EHC) connector (X82). See Integrated Grade Control (IGC) Machine Harness (W21) Component Location—If Equipped. (Group 9015-10.) Check for continuity between (wire H30 GRN) pin 1 of connector (X90) and pin 3 (wire H22 GRN) of connector (X82). See Integrated Grade Control (IGC) Machine Harness (W21) Wiring Diagram—If Equipped. (Group 9015-10.)

YES: Short to power on circuit H30. Repair or replace harness.

Is continuity indicated?

NO: Go to next step in this check.

Turn key switch OFF. Disconnect electrohydraulic actuator connector (X90). See Integrated Grade Control (IGC) Machine Harness (W21) Component Location—If Equipped. (Group 9015-10.) YES: Short to ground on Check circuit P61 RED for ground at pin 4 of connector (X90). See Integrated Grade Control (IGC) Machine Harness (W21) Wiring Diagram—If Equipped. (Group 9015-10.) circuit P61 RED. Repair or replace harness. Is ground present?

NO: Go to Open Circuit Check. AA95137,0001224 -19-24JAN08-3/5

• 2

Open Circuit Check

Turn key switch OFF.

Disconnect auxiliary 1 actuator connector (X90) and EHC connector (X83). See Integrated Grade Control (IGC) Machine Harness (W21) Component Location—If Equipped. (Group 9015-10.) Check continuity (wire H30 GRN) between pin 1 of connector (X90) and pin 14 of connector (X83). See Integrated Grade Control (IGC) Machine Harness (W21) Wiring Diagram—If Equipped. (Group 9015-10.) Check continuity (wire P61 RED) between pin 4 of connector (X90) and pin 15 of connector (X83).

YES: Replace IGC auxiliary actuator. If code 001903.01 is still present after component is replaced, go to Reprogram Controller.

Is continuity indicated?

NO: Circuit without continuity indicated is open. Repair or replace harness. Continued on next page

TM10721 (03SEP14)

9001-40-7

AA95137,0001224 -19-24JAN08-4/5

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=143

Electrohydraulic Controller (EHC) Diagnostic Trouble Codes

• 3

Reprogram Controller

Reprogram electrohydraulic controller (EHC).

Check for active codes.

YES: Replace controller.

Is EHC code 001903.01 still present?

NO: Checks complete. AA95137,0001224 -19-24JAN08-5/5

001903.03 — Aux 1 PVE Short to Power There is a short to power present on the auxiliary 1 electrohydraulic actuator circuit. AA95137,000087C -19-05APR07-1/5

Auxiliary 1 Electrohydraulic Actuator Short to Power Diagnostic Procedure Alarm Level: Check Service Code AA95137,000087C -19-05APR07-2/5

• 1

Component Check

Look at LEDs on auxiliary electrohydraulic actuator (if equipped). See Integrated Grade Control (IGC) Machine Harness (W21) Component Location—If Equipped. (Group 9015-10.)

YES: Auxiliary actuator malfunction. Replace actuator.

Is LED constantly lit red?

NO: Go to Short Circuit Check. AA95137,000087C -19-05APR07-3/5

• 2

Short Circuit Check

Turn key switch OFF.

Check for a short to power on circuit (H30 GRN). See Integrated Grade Control (IGC) Cab Harness (W22) Wiring Diagram—If Equipped. (Group 9015-10.)

YES: Short to power on wire H30. Repair or replace harness.

Is a short to power present?

NO: Go to Reprogram Controller. AA95137,000087C -19-05APR07-4/5

• 3

Reprogram Controller

Reprogram electrohydraulic controller (EHC).

Check for active codes.

YES: Replace controller.

Is EHC code 001903.03 still present?

NO: Checks complete. AA95137,000087C -19-05APR07-5/5

001903.04 — Aux 1 PVE Short to GND There is a short to ground present on the auxiliary 1 electrohydraulic actuator circuit. AA95137,0001226 -19-24JAN08-1/5

Auxiliary 1 Electrohydraulic Actuator Short to Ground Diagnostic Procedure Alarm Level: Check Service Code Continued on next page

TM10721 (03SEP14)

9001-40-8

AA95137,0001226 -19-24JAN08-2/5

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=144

Electrohydraulic Controller (EHC) Diagnostic Trouble Codes

• 1

Component Check CAUTION: Prevent possible injury from unexpected machine movement. Blade functions will change when connectors are swapped; keep bystanders clear from area. Disconnect blade tilt actuator (Y31) and auxiliary 1 actuator connector (X90). See Integrated Grade Control (IGC) Machine Harness (W21) Component Location—If Equipped. (Group 9015-10.) Connect auxiliary 1 actuator connector (X90) to blade tilt actuator (Y31). Cycle key switch ON and OFF. Check for active codes.

YES: Go to Short Circuit Check.

Is electrohydraulic controller (EHC) code 001903.04 present?

NO: Replace auxiliary 1 electrohydraulic actuator. AA95137,0001226 -19-24JAN08-3/5

• 2

Short Circuit Check

Key switch OFF.

Disconnect auxiliary 1 actuator connector (X90) and EHC connector (X83). See Integrated Grade Control (IGC) Machine Harness (W21) Component Location—If Equipped and see Integrated Grade Control (IGC) Cab Harness (W22) Component Location—If Equipped. (Group 9015-10.) Check for continuity between circuit H30 GRN (X90 pin 1) and machine ground.

YES: Go to next step in this check.

Is continuity indicated?

NO: Go to Reprogram Controller.

Disconnect EHC connector (X83) and bulkhead connector (X95). See Integrated Grade Control (IGC) Cab Harness (W22) Component Location—If Equipped. (Group 9015-10.) Check for continuity between circuit H30 GRN (X83 pin 14) and machine ground.

YES: Short to ground in IGC cab harness (W22). Repair or replace harness. See Integrated Grade Control (IGC) Cab Harness (W22) Wiring Diagram—If Equipped. (Group 9015-10.)

Is continuity indicated?

NO: Short to ground in IGC machine harness (W21). Repair or replace harness. See Integrated Grade Control (IGC) Machine Harness (W21) Wiring Diagram—If Equipped. (Group 9015-10.) AA95137,0001226 -19-24JAN08-4/5

• 3

Reprogram Controller

Reprogram electrohydraulic controller (EHC).

Check for active codes.

YES: Replace controller.

Is EHC code 001903.04 present?

NO: Checks complete. AA95137,0001226 -19-24JAN08-5/5

001903.31 — Aux 1 PVE Spool Pos Error The auxiliary 1 electrohydraulic actuator indicates a spool position fault. Continued on next page

TM10721 (03SEP14)

9001-40-9

AA95137,0001227 -19-24JAN08-1/6

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=145

Electrohydraulic Controller (EHC) Diagnostic Trouble Codes Auxiliary 1 Electrohydraulic Actuator Spool Position Error Diagnostic Procedure Alarm Level: Check Service Code AA95137,0001227 -19-24JAN08-2/6

• 1

Component Check

Look at LEDs on auxiliary 1 electrohydraulic actuator (if equipped).

YES: Auxiliary 1 electrohydraulic actuator malfunction. Replace actuator.

Is LED constantly lit red?

NO: Go to Short Circuit Check. AA95137,0001227 -19-24JAN08-3/6

• 2

Short Circuit Check

Disconnect auxiliary 1 actuator connector (X90) (if equipped) and electrohydraulic controller (EHC) connector (X83). See Integrated Grade Control (IGC) Machine Harness (W21) Component Location—If Equipped and see Integrated Grade Control (IGC) Cab Harness (W22) Component Location—If Equipped. (Group 9015-10.) Turn key switch ON. Put hydraulic enable switch in enable position. Check for voltage at pin 1 (wire H30 GRN) on auxiliary actuator connector (X90).

YES: Go to next step in this check.

Is system voltage present?

NO: Go to Open Circuit Check.

Disconnect bulkhead connector (X95) and EHC connector (X83). Turn key switch ON. Put hydraulic enable switch in enable position. Check for voltage at pin 9 (wire H30 GRN) on IGC cab harness side of connector (X95). YES: Short to power in IGC See Integrated Grade Control (IGC) Cab Harness (W22) Component Location—If cab harness (W22). Repair Equipped. (Group 9015-10.) or replace. See Integrated Grade Control (IGC) Cab Harness (W22) Wiring Diagram—If Equipped. (Group 0915-10.) Is system voltage present?

NO: Short to power in IGC machine harness (W21). Repair or replace. See Integrated Grade Control (IGC) Machine Harness (W21) Wiring Diagram—If Equipped. (Group 0915-10.) Continued on next page

TM10721 (03SEP14)

9001-40-10

AA95137,0001227 -19-24JAN08-4/6

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=146

Electrohydraulic Controller (EHC) Diagnostic Trouble Codes

• 3

Open Circuit Check

Disconnect EHC connector (X83) and auxiliary actuator connector (X90). See Integrated Grade Control (IGC) Machine Harness (W21) Component Location—If Equipped and see Integrated Grade Control (IGC) Cab Harness (W22) Component Location—If Equipped. (Group 9015-10.) Check continuity of the following circuits.

• P61 RED (X83 pin 15 and X90 pin 4) • H30 GRN (X83 pin 14 and X90 pin 1) • H27 GRN (X83 pin 3 and X90 pin 2)

YES: Go to Reprogram Controller.

• G30 BLK (IGC ground (W20) and X90 pin 3)

NO: Go to next step in this check.

Is continuity indicated in all circuits?

NO: If G30 BLK does not have continuity with IGC ground (W20). Check circuit G30 BLK for a broken wire or loose connection in IGC machine harness. Repair or replace. See Integrated Grade Control (IGC) Machine Harness (W21) Wiring Diagram—If Equipped. (Group 0915-10.)

• P61 RED (X83 pin 15 and X95 pin 13) • H30 GRN (X83 pin 14 and X95 pin 9) • H27 GRN (X83 pin 3 and X95 pin 10)

YES: Open circuit in IGC cab harness (W22). Repair or replace wire with no continuity. See Integrated Grade Control (IGC) Cab Harness (W22) Wiring Diagram—If Equipped. (Group 0915-10.)

Is continuity indicated in all circuits?

NO: Open circuit in IGC machine harness (W21). Repair or replace wire with no continuity. See Integrated Grade Control (IGC) Machine Harness (W21) Wiring Diagram—If Equipped. (Group 0915-10.) AA95137,0001227 -19-24JAN08-5/6

• 4

Reprogram Controller

Reprogram electrohydraulic controller (EHC).

Check for active codes.

YES: Replace controller.

Is EHC code 001903.31 present?

NO: Checks complete. AA95137,0001227 -19-24JAN08-6/6

001915.00 — Aux 2 PVE Open Circuit Not Applicable AA95137,000087F -19-12MAR07-1/1

TM10721 (03SEP14)

9001-40-11

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=147

Electrohydraulic Controller (EHC) Diagnostic Trouble Codes

001915.01 — Aux 2 PVE Low or Open Circuit Not Applicable AA95137,0000880 -19-12MAR07-1/1

001915.03 — Aux 2 PVE Short to Power Not Applicable AA95137,0000881 -19-12MAR07-1/1

001915.04 — Aux 2 PVE Short to GND Not Applicable AA95137,0000882 -19-12MAR07-1/1

001915.31 — Aux 2 PVE Spool Pos Error Not Applicable AA95137,0000883 -19-12MAR07-1/1

002697.09 — CAN Joystick Pos Missing From BCJ

The controller area network (CAN) joystick position signal is missing from blade control joystick. AA95137,0001228 -19-11JAN08-1/3

CAN Joystick Position Signal Missing from Blade Control Joystick Diagnostic Procedure Alarm Level: Check Service Code AA95137,0001228 -19-11JAN08-2/3

• 1

Circuit Check

Perform CAN Circuit Test. (Group 9015-20.)

YES: Blade control joystick (BCJ) internal malfunction. Replace BCJ.

Is CAN circuit OK?

NO: Repair CAN circuit wires. See Integrated Grade Control (IGC) Machine Harness (W21) Wiring Diagram—If Equipped and see Integrated Grade Control (IGC) Cab Harness (W22) Wiring Diagram—If Equipped. (Group 9015-10.) AA95137,0001228 -19-11JAN08-3/3

002712.00 — Hyd Enable Sw Inputs Both On The electrohydraulic controller (EHC) detects both inputs from the pilot enable switch at the same time. AA95137,0001229 -19-14JAN08-1/5

Hydraulic Enable Switch Inputs Both On Diagnostic Procedure Alarm Level: Check Service Code Continued on next page

TM10721 (03SEP14)

9001-40-12

AA95137,0001229 -19-14JAN08-2/5

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=148

Electrohydraulic Controller (EHC) Diagnostic Trouble Codes

• 1

Component Check

Remove hydraulic enable switch (S30).

Check continuity between pins 1 and 2 with the switch in the enabled position. Check continuity between pins 2 and 3 with the switch in the disabled position.

YES: Internal short in switch. Replace hydraulic enable switch.

Is continuity indicated in either position?

NO: Go to Short Circuit Check. AA95137,0001229 -19-14JAN08-3/5

• 2

Short Circuit Check

Disconnect hydraulic enable switch (S30) and EHC connector (X82). See Integrated Grade Control (IGC) Cab Harness (W22) Component Location—If Equipped. (Group 9015-10.) Check for continuity between circuits H23 GRN (X82 pin 18) and H36 GRN (X82 pin 17). YES: Short circuit in IGC cab harness (W22). Repair or replace harness. See Integrated Grade Control (IGC) Cab Harness (W22) Wiring Diagram—If Equipped. (Group 9015-10.) Is continuity indicated?

NO: Go to Reprogram Controller. AA95137,0001229 -19-14JAN08-4/5

• 3

Reprogram Controller

Reprogram electrohydraulic controller (EHC).

Check for active codes.

YES: Replace controller.

Is EHC code 002712.00 present?

NO: Checks complete. AA95137,0001229 -19-14JAN08-5/5

002712.01 — Hyd Enable Sw Inputs Both Off The EHC detects both inputs from the pilot enable switch are off. AA95137,000119B -19-26MAR10-1/5

Hydraulic Enable Switch Inputs Both Off Diagnostic Procedure Alarm Level: Check Service Code Continued on next page

TM10721 (03SEP14)

9001-40-13

AA95137,000119B -19-26MAR10-2/5

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=149

Electrohydraulic Controller (EHC) Diagnostic Trouble Codes

• 1

Component Check

Key switch OFF.

Disconnect hydraulic enable switch (S30). See Integrated Grade Control (IGC) Cab Harness (W22) Component Location—If Equipped. (Group 9015-10.) Check continuity of hydraulic enable switch (S30). Hydraulic Enable Switch (S30) Continuity Table Switch Position

Continuity Between Pins

Hydraulics Enabled

Pins 3 and 2

Hydraulics Disabled

Pins 2 and 1

Is continuity indicated in the correct positions?

YES: Go to Open Circuit Check.

NO: Switch malfunction. Replace hydraulic enable switch (S30). See Integrated Grade Control (IGC) Cab Harness (W22) Component Location—If Equipped. (Group 9015-10.) AA95137,000119B -19-26MAR10-3/5

• 2

Open Circuit Check

Remove EHC connector (X82) and hydraulic enable switch (S30) connector. See Integrated Grade Control (IGC) Cab Harness (W22) Component Location—If Equipped. (Group 9015-10.) Check the following circuits for continuity.

• H22 GRN (X82 pin 3 and switch connector pin 2) • H23 GRN (X82 pin 18 and switch connector pin 3) • H36 GRN (X82 pin 17 and switch connector pin 1)

YES: Go to Reprogram Controller.

Is continuity indicated?

NO: Open circuit in IGC cab harness. Repair or replace harness. See Integrated Grade Control (IGC) Cab Harness (W22) Wiring Diagram—If Equipped. (Group 9015-10.) AA95137,000119B -19-26MAR10-4/5

• 3

Reprogram Controller

Reprogram electrohydraulic controller (EHC).

Check for active codes.

YES: Replace controller.

Is EHC code 002712.01 present?

NO: Checks complete. AA95137,000119B -19-26MAR10-5/5

003157.03 — Incr / Decr Buttons Short to Power

The blade height increment / decrement buttons circuit voltage is high or short to power. AA95137,000122A -19-24JAN08-1/5

Blade Height Increment / Decrement Buttons Short to Power Diagnostic Procedure Alarm Level: No Warning Lamp Continued on next page

TM10721 (03SEP14)

9001-40-14

AA95137,000122A -19-24JAN08-2/5

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=150

Electrohydraulic Controller (EHC) Diagnostic Trouble Codes

• 1

DTC Check

Disconnect blade control joystick (BCJ) connector (X97). See Integrated Grade Control (IGC) Cab Harness (W22) Component Location—If Equipped. (Group 9015-10.) Check for active codes.

YES: Go to Short Circuit Check.

Is electrohydraulic controller (EHC) code 003157.03 still present?

NO: BCJ malfunction. Replace joystick handle. AA95137,000122A -19-24JAN08-3/5

• 2

Short Circuit Check

Disconnect BCJ connector (X97). Check voltage of circuit H20 BLU (X97 pin 3). See YES: Short circuit in Integrated Grade Control (IGC) Cab Harness (W22) Component Location—If Equipped. IGC cab harness (W22). (Group 9015-10.) Repair or replace harness. See Integrated Grade Control (IGC) Cab Harness (W22) Wiring Diagram—If Equipped. (Group 9015-10.) Is voltage greater than 1 volt?

NO: Go to Reprogram Controller. AA95137,000122A -19-24JAN08-4/5

• 3

Reprogram Controller

Reprogram electrohydraulic controller (EHC).

Check for active codes.

YES: Replace controller.

Is EHC code 003157.03 present?

NO: Checks complete. AA95137,000122A -19-24JAN08-5/5

003157.04 — Incr / Decr Buttons Open or Short

The blade height increment/decrement buttons circuit is open or short to ground. AA95137,000122B -19-24JAN08-1/6

Blade Height Increment/Decrement Buttons Open or Short Diagnostic Procedure Alarm Level: No Warning Lamp AA95137,000122B -19-24JAN08-2/6

• 1

Component Check

Disconnect blade control joystick (BCJ) connector (X97). See Integrated Grade Control (IGC) Cab Harness (W22) Component Location—If Equipped. (Group 9015-10.) Verify increase/decrease buttons are not pushed. Check for continuity between pin 1 and pin 3 on BCJ.

YES: BCJ malfunction. Replace joystick.

Is continuity indicated?

NO: Go to next step in this check.

Disconnect blade control joystick (BCJ) connector (X97). Push and hold increase/decrease buttons. Check for continuity between pin 1 and pin 3 on BCJ.

YES: Go to Open Circuit Check.

Is continuity indicated?

NO: BCJ malfunction. Replace joystick. Continued on next page

TM10721 (03SEP14)

9001-40-15

AA95137,000122B -19-24JAN08-3/6

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=151

Electrohydraulic Controller (EHC) Diagnostic Trouble Codes

• 2

Open Circuit Check

Disconnect EHC connector (X82) and BCJ connector (X97). See Integrated Grade Control (IGC) Cab Harness (W22) Component Location—If Equipped. (Group 9015-10.) Check the following circuits for continuity.

• H20 BLU (X82 pin 21 and X97 pin 3) • H22 BRN (X82 pin 3 and X97 pin 1) • R41 PNK (X82 pin 22 and X97 pin 6)

YES: Go to Short Circuit Check.

Is continuity indicated in all circuits?

NO: Open circuit in IGC cab harness (W22). Repair or replace. See Integrated Grade Control (IGC) Cab Harness (W22) Wiring Diagram—If Equipped. (Group 9015-10.) AA95137,000122B -19-24JAN08-4/6

• 3

Short Circuit Check

• H20 BLU ( X97 pin 3) • H22 BRN (X97 pin 1)

YES: Short to ground in IGC cab harness (W22). Repair or replace. See Integrated Grade Control (IGC) Cab Harness (W22) Wiring Diagram—If Equipped. (Group 9015-10.)

Is ground present on either circuit?

NO: Go to Reprogram Controller. AA95137,000122B -19-24JAN08-5/6

• 4

Reprogram Controller

Reprogram electrohydraulic controller (EHC).

Check for active codes.

YES: Replace controller.

Is EHC code 003157.04 present?

NO: Checks complete. AA95137,000122B -19-24JAN08-6/6

003157.31 — Incr / Decr Buttons Invalid Output

The blade increment/decrement buttons circuit has an abnormal value. AA95137,000122C -19-24JAN08-1/6

Blade Increment/Decrement Buttons Abnormal Value Diagnostic Procedure Alarm Level: No Warning Light Continued on next page

TM10721 (03SEP14)

9001-40-16

AA95137,000122C -19-24JAN08-2/6

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=152

Electrohydraulic Controller (EHC) Diagnostic Trouble Codes

• 1

Code Check

Disconnect blade control joystick (BCJ) connector (X97). See Integrated Grade Control (IGC) Cab Harness (W22) Component Location—If Equipped. (Group 9015-10.) Check for active codes.

YES: BCJ malfunction. Replace joystick handle.

Is electrohyraulic controller (EHC) code 003157.04 present?

NO: Go to Voltage Check. AA95137,000122C -19-24JAN08-3/6

• 2

Voltage Check

Disconnect BCJ connector (X97). See Integrated Grade Control (IGC) Cab Harness (W22) Component Location—If Equipped. (Group 9015-10.) Check voltage of circuit H20_CBL2 BLU (X97 pins 3 and 6).

YES: Short circuit in harness. Repair or replace. See Integrated Grade Control (IGC) Cab Harness (W22) Wiring Diagram—If Equipped. (Group 9015-10.)

Is voltage more than 1 volt?

NO: Go to Component Check. AA95137,000122C -19-24JAN08-4/6

• 3

Component Check

YES: BCJ malfunction. Replace joystick handle.

Is continuity indicated?

NO: Go to next step in this check.

Disconnect blade control joystick (BCJ) connector (X97). Push and hold increase/decrease buttons. Check for continuity between pin 1 and pin 3 on BCJ.

YES: Go to Reprogram Controller.

Is continuity indicated?

NO: BCJ malfunction. Replace joystick handle. AA95137,000122C -19-24JAN08-5/6

• 4

Reprogram Controller

Reprogram electrohydraulic controller (EHC).

Check for active codes.

YES: Replace controller.

Is EHC code 003157.31 present?

NO: Checks complete. AA95137,000122C -19-24JAN08-6/6

522442.03 — Blade Buttons Short to Power Blade angle buttons circuit is short to power. AA95137,000124F -19-24JAN08-1/5

Blade Buttons Short to Power Diagnostic Procedure Continued on next page

TM10721 (03SEP14)

9001-40-17

AA95137,000124F -19-24JAN08-2/5

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=153

Electrohydraulic Controller (EHC) Diagnostic Trouble Codes

• 1

Code Check

Turn key switch OFF.

Disconnect blade control joystick (BCJ) connector (X97). See Integrated Grade Control (IGC) Cab Harness (W22) Component Location—If Equipped. (Group 9015-10.) Turn key switch ON. Check for active codes. See Standard Display Monitor (SDM) Menu Structure—Service YES: Replace BCJ. Mode. (Group 9015-16.) Is EHC code 522442.03 gone and 522442.04 active?

NO: Go to Short Circuit Check. AA95137,000124F -19-24JAN08-3/5

• 2

Short Circuit Check

Turn key switch OFF.

YES: Circuit H25 is short to power. Repair or replace harness. See Integrated Grade Control (IGC) Cab Harness (W22) Wiring Diagram—If Equipped. (Group 9015-10.)

Is system voltage present?

NO: Go to Reprogram Controller. AA95137,000124F -19-24JAN08-4/5

• 3

Reprogram Controller

Reprogram electrohydraulic controller (EHC).

Check for active codes.

YES: Replace EHC.

Is EHC code 522442.03 present?

NO: Checks complete. AA95137,000124F -19-24JAN08-5/5

522442.04 — Blade Buttons Open or Short to Ground

Blade angle buttons circuit is open or short to ground. AA95137,0001250 -19-24JAN08-1/5

Blade Buttons Open or Short to Ground Diagnostic Procedure Continued on next page

TM10721 (03SEP14)

9001-40-18

AA95137,0001250 -19-24JAN08-2/5

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=154

Electrohydraulic Controller (EHC) Diagnostic Trouble Codes

• 1

Open Circuit Check

Turn key switch OFF.

Disconnect blade control joystick (BCJ) connector (X97) and electrohydraulic controller (EHC) connector (X82). See Integrated Grade Control (IGC) Cab Harness (W22) Component Location—If Equipped. (Group 9015-10.) Check circuit H25 GRN for continuity between pin 2 on connector (X97) and pin 20 on connector (X82).

YES: Go to Short Circuit Check.

Is continuity indicated?

NO: Circuit H25 GRN is open. Repair or replace harness. See Integrated Grade Control (IGC) Cab Harness (W22) Wiring Diagram—If Equipped. (Group 9015-10.) AA95137,0001250 -19-24JAN08-3/5

• 2

Short Circuit Check

Turn key switch OFF.

YES: Circuit H25 GRN is short to ground. Repair circuit or replace harness. See Integrated Grade Control (IGC) Cab Harness (W22) Wiring Diagram—If Equipped. (Group 9015-10.)

Is ground present?

NO: Go to Reprogram Controller. AA95137,0001250 -19-24JAN08-4/5

• 3

Reprogram Controller

Reprogram electrohydraulic controller (EHC).

Check for active codes.

YES: Replace EHC.

Is EHC code 522442.04 present?

NO: Checks complete. AA95137,0001250 -19-24JAN08-5/5

522442.31 — Blade Buttons Invalid Output The blade angle buttons circuit has an abnormal value. AA95137,000122D -19-24JAN08-1/6

Blade Angle Buttons Invalid Output Diagnostic Procedure Continued on next page

TM10721 (03SEP14)

9001-40-19

AA95137,000122D -19-24JAN08-2/6

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=155

Electrohydraulic Controller (EHC) Diagnostic Trouble Codes

• 1

Code Check

Disconnect connector X97 on the blade control joystick (BCJ). See Integrated Grade Control (IGC) Cab Harness (W22) Component Location—If Equipped. (Group 9015-10.) Check for active codes.

YES: BCJ malfunction. Replace BCJ.

Is electrohydraulic controller (EHC) code 522442.31 gone and 522442.04 present?

NO: Go to Voltage Check. AA95137,000122D -19-24JAN08-3/6

• 2

Voltage Check

Disconnect BCJ connector (X97). See Integrated Grade Control (IGC) Cab Harness (W22) Component Location—If Equipped. (Group 9015-10.) Check voltage of circuit H25_CBL2 WHT (X97 pins 2 and 6).

YES: Short circuit in harness. Repair or replace. See Integrated Grade Control (IGC) Cab Harness (W22) Wiring Diagram—If Equipped. (Group 9015-10.)

Is voltage more than 1 volt?

NO: Go to Open Circuit Check. AA95137,000122D -19-24JAN08-4/6

• 3

Open Circuit Check

Disconnect EHC connector (X82) and BCJ connector (X97). See Integrated Grade Control (IGC) Cab Harness (W22) Component Location—If Equipped. (Group 9015-10.) Check continuity of circuit H25_CBL2 WHT (X82 pin 20 and X97 pin 2).

YES: Replace BCJ and check for active codes. If 522442.31 is still active, go to Reprogram Controller.

Is continuity indicated?

NO: Open circuit in harness. Repair or replace. See Integrated Grade Control (IGC) Cab Harness (W22) Wiring Diagram—If Equipped. (Group 9015-10.) AA95137,000122D -19-24JAN08-5/6

• 4

Reprogram Controller

Reprogram electrohydraulic controller (EHC).

Check for active codes.

YES: Replace controller.

Is EHC code 522442.31 active?

NO: Checks complete. AA95137,000122D -19-24JAN08-6/6

523779.00 — Blade Rotate Current Above Max

The blade angle electrohydraulic actuator current is more than maximum requirement. AA95137,000122E -19-24JAN08-1/4

Blade Angle Buttons Current Above Maximum Diagnostic Procedure Continued on next page

TM10721 (03SEP14)

9001-40-20

AA95137,000122E -19-24JAN08-2/4

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=156

Electrohydraulic Controller (EHC) Diagnostic Trouble Codes

• 1

Short Circuit Check

Disconnect connector X83 from EHC and disconnect actuator connector. See Integrated Grade Control (IGC) Cab Harness (W22) Component Location—If Equipped and see Integrated Grade Control (IGC) Machine Harness (W21) Component Location—If Equipped. (Group 9015-10.) Check continuity between circuit H31 RED (X83 pin 12) and ground. Check continuity between circuit H34 BLK (X83 pin 5) and ground.

YES: Go to next step in this check.

Is continuity indicated between circuit H31 RED or H34 RED and ground?

NO: Go to Reprogram Controller.

Disconnect EHC connector (X83) and disconnect bulkhead connector (X95). See Integrated Grade Control (IGC) Cab Harness (W22) Component Location—If Equipped and see Integrated Grade Control (IGC) Machine Harness (W21) Component Location—If Equipped. (Group 9015-10.) Check continuity between circuit H31 RED (X83 pin 12) and ground. Check continuity between circuit H34 BLK (X83 pin 5) and ground.

YES: Short to ground in IGC cab harness (W22). Repair or replace harness. See Integrated Grade Control (IGC) Cab Harness (W22) Wiring Diagram—If Equipped. (Group 9015-10.)

Is continuity indicated between circuit H31 RED or H34 BLK and ground?

• 2

Reprogram Controller

Reprogram electrohydraulic controller (EHC).

Check for active codes.

YES: Replace controller.

Is EHC code 523779.00 active?

NO: Checks complete. AA95137,000122E -19-24JAN08-4/4

523779.01 — Blade Rotate Current Below Min The blade angle electrohydraulic actuator current is below minimum value. AA95137,000122F -19-24JAN08-1/5

Blade Angle Actuator Current Below Minimum Diagnostic Procedure Alarm Level: Check Service Code Continued on next page

TM10721 (03SEP14)

9001-40-21

AA95137,000122F -19-24JAN08-2/5

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=157

Electrohydraulic Controller (EHC) Diagnostic Trouble Codes

• 1

Short Circuit Check

Turn key switch OFF.

Disconnect blade angle electrohydraulic actuator (Y30). See Integrated Grade Control (IGC) Machine Harness (W21) Component Location—If Equipped. (Group 9015-10.) Turn key switch ON. Move hydraulic enable switch into enable position. Check circuit H31 RED for voltage at pin 1 on actuator (Y30) connector. Check circuit H34 BLK for voltage at pin 4 on actuator (Y30) connector.

YES: Circuit with system voltage present is short to power. Repair circuit or replace harness. See Integrated Grade Control (IGC) Machine Harness (W21) Wiring Diagram—If Equipped. (Group 9015-10.) See Integrated Grade Control (IGC) Cab Harness (W22) Wiring Diagram—If Equipped. (Group 9015-10.)

Is system voltage present on either circuit?

NO: Go to Open Circuit Check.

Continued on next page

TM10721 (03SEP14)

9001-40-22

AA95137,000122F -19-24JAN08-3/5

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=158

Electrohydraulic Controller (EHC) Diagnostic Trouble Codes

• 2

Open Circuit Check

Key switch OFF.

Disconnect connector X83 from EHC and disconnect actuator connector. See Integrated Grade Control (IGC) Machine Harness (W21) Component Location—If Equipped and see Integrated Grade Control (IGC) Cab Harness (W22) Component Location—If Equipped. (Group 9015-10.) Check circuit H31 RED (X83 pin 12 and actuator connector pin 1) for continuity. Check circuit H34 BLK (X83 pin 5 and actuator connector pin 4) for continuity.

YES: Go to Reprogram Controller.

Is continuity indicated in both circuits?

NO: Go to next step in this check.

Disconnect EHC connector (X82) and bulkhead connector (X95). see Integrated Grade Control (IGC) Cab Harness (W22) Component Location—If Equipped. (Group 9015-10.) Check the following circuits for continuity on the IGC cab harness (W22).

• H31 RED (X83 pin 12 and X95 pin 1) • H34 BLK (X83 pin 5 and X95 pin 2)

YES: Open circuit in IGC machine harness (W21). Repair or replace harness. See Integrated Grade Control (IGC) Machine Harness (W21) Wiring Diagram—If Equipped. (Group 9015-10.)

Is continuity indicated in both circuits?

• 3

Reprogram Controller

Reprogram electrohydraulic controller (EHC).

Check for active codes.

YES: Replace controller.

Is EHC code 523779.01 active?

NO: Checks complete. AA95137,000122F -19-24JAN08-5/5

523780.00 — Tilt PVE Open Circuit The blade tilt electrohydraulic actuator circuit is open. AA95137,0001217 -19-25JAN08-1/6

Blade Tilt Actuator Open Circuit Alarm Level: Check Service Code AA95137,0001217 -19-25JAN08-2/6

• 1

Component Check

Look at LEDs on blade tilt actuator (Y31). See Integrated Grade Control (IGC) Machine YES: Blade tilt actuator Harness (W21) Component Location—If Equipped. (Group 9015-10.) (Y31) malfunction. Replace actuator. Is LED constantly lit red?

NO: Go to Voltage Check. Continued on next page

TM10721 (03SEP14)

9001-40-23

AA95137,0001217 -19-25JAN08-3/6

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=159

Electrohydraulic Controller (EHC) Diagnostic Trouble Codes

• 2

Voltage Check

Disconnect actuator (Y31) connector. See Integrated Grade Control (IGC) Machine Harness (W21) Component Location—If Equipped. (Group 9015-10.) Measure voltage of circuit P62 RED (pins 4 and 3).

YES: Go to Open Circuit Check.

Is system voltage present?

NO: Go to next step in this check.

Disconnect bulkhead connector (X95). See Integrated Grade Control (IGC) Cab Harness (W22) Component Location—If Equipped. (Group 9015-10.) Measure voltage between circuit P62 RED (X95 pin 4) and machine ground (W20) on IGC cab harness side of connector (X95).

YES: Open circuit in IGC machine harness (W21). Repair or replace harness. See Integrated Grade Control (IGC) Machine Harness (W21) Wiring Diagram—If Equipped. (Group 9015-10.)

Is system voltage present?

• 3

Open Circuit Check

Disconnect EHC connector (X83) and actuator connector. See Integrated Grade Control (IGC) Machine Harness (W21) Component Location—If Equipped and see Integrated Grade Control (IGC) Cab Harness (W22) Component Location—If Equipped. (Group 9015-10.) Check circuit H32 GRN (X83 pin 20 and actuator connector pin 1) for continuity.

YES: Go to Reprogram Controller.

Is continuity indicated?

NO: Go to next step in this check.

Disconnect EHC connector (X83) and bulkhead connector (X95). See Integrated Grade Control (IGC) Cab Harness (W22) Component Location—If Equipped. (Group 9015-10.) Check circuit H32 GRN (X83 pin 20 and X95 pin 3) for continuity.

YES: Open circuit in harness. Repair or replace harness. See Integrated Grade Control (IGC) Machine Harness (W21) Wiring Diagram—If Equipped. (Group 9015-10.)

Is continuity indicated?

NO: Open circuit in IGC cab harness (W22). Repair or replace harness. See Integrated Grade Control (IGC) Cab Harness (W22) Wiring Diagram—If Equipped. (Group 9015-10.) Continued on next page

TM10721 (03SEP14)

9001-40-24

AA95137,0001217 -19-25JAN08-5/6

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=160

Electrohydraulic Controller (EHC) Diagnostic Trouble Codes

• 4

Reprogram Controller

Reprogram electrohydraulic controller (EHC).

Check for active codes.

YES: Replace controller.

Is EHC code 523780.00 active?

NO: Checks complete. AA95137,0001217 -19-25JAN08-6/6

523780.01 — Tilt PVE Low or Open Circuit The blade tilt electrohydraulic actuator circuit is open or short. AA95137,0001230 -19-24JAN08-1/6

Blade Tilt Actuator Open Circuit Alarm Level: Check Service Code AA95137,0001230 -19-24JAN08-2/6

• 1

Component Check

NO: Go to Short Circuit Check. AA95137,0001230 -19-24JAN08-3/6

• 2

Short Circuit Check

Disconnect actuator (Y31) connector and electrohydraulic controller (EHC) connector (X83). See Integrated Grade Control (IGC) Machine Harness (W21) Component Location—If Equipped and see Integrated Grade Control (IGC) Cab Harness (W22) Component Location—If Equipped. (Group 9015-10.) Check for continuity between pin 1 (wire H32 GRN) and pin 4 (wire P62 RED) of actuator (Y31) connector.

YES: Go to next step in this check.

Is continuity indicated?

NO: Go to Open Circuit Check.

Disconnect bulkhead connector (X95) and EHC connector (X83). See Integrated Grade Control (IGC) Cab Harness (W22) Component Location—If Equipped. (Group 9015-10.) Check for continuity between pin 3 (wire H32 GRN) and pin 4 (wire P62 RED) on IGC cab harness side of connector (X95).

YES: Short circuit in IGC cab harness (W22). Repair or replace harness. See Integrated Grade Control (IGC) Cab Harness (W22) Wiring Diagram—If Equipped. (Group 9015-10.)

Is continuity indicated?

NO: Short circuit in IGC machine harness (W21). Repair or replace harness. See Integrated Grade Control (IGC) Machine Harness (W21) Wiring Diagram—If Equipped. (Group 9015-10.) Continued on next page

TM10721 (03SEP14)

9001-40-25

AA95137,0001230 -19-24JAN08-4/6

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=161

Electrohydraulic Controller (EHC) Diagnostic Trouble Codes

• 3

Open Circuit Check

Disconnect EHC connector (X83) and actuator connector. See Integrated Grade Control (IGC) Machine Harness (W21) Component Location—If Equipped and see Integrated Grade Control (IGC) Cab Harness (W22) Component Location—If Equipped. (Group 9015-10.) Check continuity between actuator (Y31) connector pin 1 (wire H32 GRN) and EHC connector (X83) pin 20. Check continuity between actuator (Y31) connector pin 4 (wire P62 RED) and EHC connector (X83) pin 19.

YES: Go to Reprogram Controller.

Is continuity indicated?

NO: Go to next step in this check.

Disconnect EHC connector (X83) and bulkhead connector (X95). See Integrated Grade Control (IGC) Cab Harness (W22) Component Location—If Equipped. (Group 9015-10.) Check continuity between EHC connector (X83) pin 20 (wire H32 GRN) and bulkhead connector (X95) pin 3 on the IGC cab harness side of connector (X95). Check continuity between EHC connector (X83) pin 19 (wire P62 RED) and bulkhead connector (X95) pin 5 on the IGC cab harness side of connector (X95).

YES: Open circuit in harness. Repair or replace harness. See Integrated Grade Control (IGC) Machine Harness (W21) Wiring Diagram—If Equipped. (Group 9015-10.)

Is continuity indicated?

• 4

Reprogram Controller

Reprogram electrohydraulic controller (EHC).

Check for active codes.

YES: Replace controller.

Is EHC code 523780.00 still present?

NO: Checks complete. AA95137,0001230 -19-24JAN08-6/6

523780.03 — Tilt PVE Short to Power The blade tilt electrohydraulic actuator circuit is short to power. AA95137,0001231 -19-14JAN08-1/5

Blade Tilt Actuator Short to Power Diagnostic Procedure Alarm Level: Check Service Code AA95137,0001231 -19-14JAN08-2/5

• 1

Component Check

NO: Go to Short Circuit Check. Continued on next page

TM10721 (03SEP14)

9001-40-26

AA95137,0001231 -19-14JAN08-3/5

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=162

Electrohydraulic Controller (EHC) Diagnostic Trouble Codes

• 2

Short Circuit Check

Check wire H32 GRN for short to power.

YES: Repair or replace harness. See Integrated Grade Control (IGC) Cab Harness (W22) Wiring Diagram—If Equipped and see Integrated Grade Control (IGC) Machine Harness (W21) Wiring Diagram—If Equipped. (Group 9015-10.)

Is wire H32 GRN shorted to power?

NO: Go to Reprogram Controller. AA95137,0001231 -19-14JAN08-4/5

• 3

Reprogram Controller

Reprogram electrohydraulic controller (EHC).

Check for active codes.

YES: Replace controller.

Is EHC code 523780.03 still present?

NO: Checks complete. AA95137,0001231 -19-14JAN08-5/5

523780.04 — Tilt PVE Short to GND The blade tilt electrohydraulic actuator circuit has low voltage or a short to ground. AA95137,0001232 -19-24JAN08-1/5

Blade Tilt Actuator Short to Ground Diagnostic Procedure Alarm Level: Check Service Code AA95137,0001232 -19-24JAN08-2/5

• 1

Component Check

NO: Go to Short Circuit Check. Continued on next page

TM10721 (03SEP14)

9001-40-27

AA95137,0001232 -19-24JAN08-3/5

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=163

Electrohydraulic Controller (EHC) Diagnostic Trouble Codes

• 2

Short Circuit Check

Disconnect electrohyraulic controller (EHC) connector (X83) and actuator (Y31) connector. See Integrated Grade Control (IGC) Machine Harness (W21) Component Location—If Equipped and see Integrated Grade Control (IGC) Cab Harness (W22) Component Location—If Equipped. (Group 9015-10.) Check continuity between circuit H32 GRN (X83 pin 20) and machine ground (W20).

YES: Go to next step in this check.

Is continuity indicated?

NO: Go to Reprogram Controller.

YES: Short circuit in IGC cab harness (W22). Repair or replace harness. See Integrated Grade Control (IGC) Cab Harness (W22) Wiring Diagram—If Equipped. (Group 9015-10.)

Is continuity indicated?

NO: Short circuit in harness IGC machine harness (W21). Repair or replace harness. See Integrated Grade Control (IGC) Machine Harness (W21) Wiring Diagram—If Equipped. (Group 9015-10.) AA95137,0001232 -19-24JAN08-4/5

• 3

Reprogram Controller

Reprogram electrohydraulic controller (EHC).

Check for active codes.

YES: Replace controller.

Is EHC code 523780.04 active?

NO: Checks complete. AA95137,0001232 -19-24JAN08-5/5

523780.31 — Tilt PVE Spool Pos Error The blade tilt electrohydraulic actuator has a spool position fault. AA95137,0001233 -19-24JAN08-1/6

Blade Tilt Actuator Spool Position Error Diagnostic Procedure Alarm Level: Check Service Code AA95137,0001233 -19-24JAN08-2/6

• 1

Component Check

NO: Go to Short Circuit Check. Continued on next page

TM10721 (03SEP14)

9001-40-28

AA95137,0001233 -19-24JAN08-3/6

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=164

Electrohydraulic Controller (EHC) Diagnostic Trouble Codes

• 2

Short Circuit Check

Remove EHC connector (X83) and actuator connector. See Integrated Grade Control (IGC) Machine Harness (W21) Component Location—If Equipped and see Integrated Grade Control (IGC) Cab Harness (W22) Component Location—If Equipped. (Group 9015-10.) Check voltage of circuit H32 GRN (actuator connector pin 1).

YES: Go to next step in this check.

Is voltage more than 1 volt?

NO: Go to Open Circuit Check.

Remove bulkhead connector (X95). See Integrated Grade Control (IGC) Cab Harness (W22) Component Location—If Equipped. (Group 9015-10.) Check voltage of circuit H32 GRN (X95 pin 3) on IGC cab harness side of connector (X95).

YES: Short circuit in IGC cab harness (W22). Repair or replace harness. See Integrated Grade Control (IGC) Cab Harness (W22) Wiring Diagram—If Equipped. (Group 9015-10.)

Is voltage more than 1 volt?

• 3

Open Circuit Check

Disconnect EHC connector (X83) and blade tilt actuator connector. See Integrated Grade Control (IGC) Machine Harness (W21) Component Location—If Equipped and see Integrated Grade Control (IGC) Cab Harness (W22) Component Location—If Equipped. (Group 9015-10.) Check continuity of the following circuits.

• H28 GRN (X83 pin 4 and actuator connector pin

YES: Go to Reprogram Controller.

Is continuity indicated in all circuits?

NO: Go to next step in this check.

• H28 GRN (X83 pin 4 and X95 pin 4)

YES: Open circuit in IGC cab harness (W22). Repair or replace wire with no continuity. See Integrated Grade Control (IGC) Cab Harness (W22) Wiring Diagram—If Equipped. (Group 0915-10.)

Is continuity indicated in all circuits?

TM10721 (03SEP14)

9001-40-29

AA95137,0001233 -19-24JAN08-5/6

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=165

Electrohydraulic Controller (EHC) Diagnostic Trouble Codes

• 4

Reprogram Controller

Reprogram electrohydraulic controller (EHC).

Check for active codes.

YES: Replace controller.

Is EHC code 523780.31 active?

NO: Checks complete. AA95137,0001233 -19-24JAN08-6/6

523781.00 — Height PVE Open Circuit The blade lift hydraulic actuator circuit is open. AA95137,0001234 -19-24JAN08-1/6

Blade Lift Hydraulic Actuator Open Circuit Diagnostic Procedure Alarm Level: Check Service Code AA95137,0001234 -19-24JAN08-2/6

• 1

Component Check

Look at LEDs on blade lift actuator (Y32). See Integrated Grade Control (IGC) Machine YES: Blade lift actuator Harness (W21) Component Location—If Equipped. (Group 9015-10.) (Y32) malfunction. Replace actuator. Is LED constantly lit red?

NO: Go to Voltage Check. AA95137,0001234 -19-24JAN08-3/6

• 2

Voltage Check

Disconnect actuator (Y32) connector. See Integrated Grade Control (IGC) Machine Harness (W21) Component Location—If Equipped. (Group 9015-10.) Measure voltage of circuit P62 RED (pins 4 and 3).

YES: Go to Open Circuit Check.

Is system voltage present?

NO: Go to next step in this check.

YES: Open circuit in IGC machine harness (W21). Repair or replace harness. See Integrated Grade Control (IGC) Machine Harness (W21) Wiring Diagram—If Equipped. (Group 9015-10.)

Is system voltage present?

NO: Open circuit in IGC cab harness (W22). Repair or replace harness. See Integrated Grade Control (IGC) Cab Harness (W22) Wiring Diagram—If Equipped. (Group 9015-10.) Continued on next page

TM10721 (03SEP14)

9001-40-30

AA95137,0001234 -19-24JAN08-4/6

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=166

Electrohydraulic Controller (EHC) Diagnostic Trouble Codes

• 3

Open Circuit Check

Disconnect electrohydraulic controller (EHC) connector (X83) and actuator connector. See Integrated Grade Control (IGC) Machine Harness (W21) Component Location—If Equipped and see Integrated Grade Control (IGC) Cab Harness (W22) Component Location—If Equipped. (Group 9015-10.) Check circuit H35 GRN (X83 pin 24 and actuator connector pin 1) for continuity.

YES: Go to Reprogram Controller.

Is continuity indicated?

NO: Go to next step in this check.

YES: Open circuit in harness. Repair or replace harness. See Integrated Grade Control (IGC) Machine Harness (W21) Wiring Diagram—If Equipped. (Group 9015-10.)

Is continuity indicated?

• 4

Reprogram Controller

Reprogram electrohydraulic controller (EHC).

Check for active codes.

YES: Replace controller.

Is EHC code 523781.00 active?

NO: Checks complete. AA95137,0001234 -19-24JAN08-6/6

523781.01 — Height PVE Low or Open Circuit The blade lift hydraulic actuator circuit has low voltage or an open circuit. AA95137,0001235 -19-24JAN08-1/7

Blade Lift Hydraulic Actuator Open Circuit Diagnostic Procedure Alarm Level: Check Service Code AA95137,0001235 -19-24JAN08-2/7

• 1

Component Check

Look at LEDs on blade lift actuator (Y32). See Integrated Grade Control (IGC) Machine YES: Blade tilt actuator Harness (W21) Component Location—If Equipped. (Group 9015-10.) (Y32) malfunction. Replace actuator. Is LED constantly lit red?

NO: Go to Voltage Check. Continued on next page

TM10721 (03SEP14)

9001-40-31

AA95137,0001235 -19-24JAN08-3/7

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=167

Electrohydraulic Controller (EHC) Diagnostic Trouble Codes

• 2

Voltage Check

Disconnect actuator (Y32) connector. See Integrated Grade Control (IGC) Machine Harness (W21) Component Location—If Equipped. (Group 9015-10.) Measure voltage of circuit P62 RED (pins 4 and 3).

YES: Go to Short Circuit Check.

Is system voltage present?

NO: Go to next step in this check.

YES: Open circuit in IGC machine harness (W21). Repair or replace harness. See Integrated Grade Control (IGC) Machine Harness (W21) Wiring Diagram—If Equipped. (Group 9015-10.)

Is system voltage present?

• 3

Short Circuit Check

Disconnect actuator (Y32) connector and electrohydraulic controller (EHC) connector (X83). See Integrated Grade Control (IGC) Machine Harness (W21) Component Location—If Equipped and see Integrated Grade Control (IGC) Cab Harness (W22) Component Location—If Equipped. (Group 9015-10.) Check for continuity between pin 1 (wire H35 GRN) and pin 4 (wire P62 RED) of actuator (Y31) connector.

YES: Go to next step in this check.

Is continuity indicated?

NO: Go to Open Circuit Check.

Disconnect bulkhead connector (X95) and EHC connector (X83). See Integrated Grade Control (IGC) Cab Harness (W22) Component Location—If Equipped. (Group 9015-10.) Check for continuity between pin 6 (wire H32 GRN) and pin 4 (wire P62 RED) on IGC cab harness side of connector (X95).

YES: Short circuit in IGC cab harness (W22). Repair or replace harness. See Integrated Grade Control (IGC) Cab Harness (W22) Wiring Diagram—If Equipped. (Group 9015-10.)

Is continuity indicated?

TM10721 (03SEP14)

9001-40-32

AA95137,0001235 -19-24JAN08-5/7

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=168

Electrohydraulic Controller (EHC) Diagnostic Trouble Codes

• 4

Open Circuit Check

Disconnect EHC connector (X83) and actuator connector. See Integrated Grade Control (IGC) Machine Harness (W21) Component Location—If Equipped and see Integrated Grade Control (IGC) Cab Harness (W22) Component Location—If Equipped. (Group 9015-10.) Check continuity between actuator (Y32) connector pin 1 (wire H35 GRN) and EHC connector (X83) pin 24.

YES: Go to Reprogram Controller.

Is continuity indicated?

NO: Go to next step in this check.

YES: Open circuit in harness. Repair or replace harness. See Integrated Grade Control (IGC) Machine Harness (W21) Wiring Diagram—If Equipped. (Group 9015-10.)

Is continuity indicated?

• 5

Reprogram Controller

Reprogram electrohydraulic controller (EHC).

Check for active codes.

YES: Replace controller.

Is EHC code 523781.01 active?

NO: Checks complete. AA95137,0001235 -19-24JAN08-7/7

523781.03 — Height PVE Short to Power The blade lift hydraulic actuator circuit is short to power. AA95137,0000894 -19-05APR07-1/5

Blade Lift Actuator Short to Power Diagnostic Procedure Alarm Level: Check Service Code AA95137,0000894 -19-05APR07-2/5

• 1

Component Check

NO: Go to Short Circuit Check. Continued on next page

TM10721 (03SEP14)

9001-40-33

AA95137,0000894 -19-05APR07-3/5

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=169

Electrohydraulic Controller (EHC) Diagnostic Trouble Codes

• 2

Short Circuit Check

Check wire H35 GRN for short to power.

Is wire H35 GRN shorted to power?

NO: Go to Reprogram Controller. AA95137,0000894 -19-05APR07-4/5

• 3

Reprogram Controller

Reprogram electrohydraulic controller (EHC).

Check for active codes.

YES: Replace controller.

Is EHC code 523781.03 active?

NO: Checks complete. AA95137,0000894 -19-05APR07-5/5

523781.04 — Height PVE Short to GND The blade lift hydraulic actuator circuit is short to ground. AA95137,0001236 -19-25JAN08-1/6

Blade Lift Actuator Short to Ground Diagnostic Procedure Alarm Level: Check Service Code AA95137,0001236 -19-25JAN08-2/6

• 1

Component Check

NO: Go to Voltage Check. Continued on next page

TM10721 (03SEP14)

9001-40-34

AA95137,0001236 -19-25JAN08-3/6

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=170

Electrohydraulic Controller (EHC) Diagnostic Trouble Codes

• 2

Voltage Check

Disconnect actuator (Y32) connector. See Integrated Grade Control (IGC) Machine Harness (W21) Component Location—If Equipped. (Group 9015-10.) Measure voltage of circuit P62 RED (actuator connector pins 4 and 3).

YES: Go to Short Circuit Check.

Is system voltage present?

NO: Go to next step in this check.

YES: Open circuit in IGC machine harness (W21). Repair or replace harness. See Integrated Grade Control (IGC) Machine Harness (W21) Wiring Diagram—If Equipped. (Group 9015-10.)

Is system voltage present?

• 3

Short Circuit Check

Disconnect electrohydraulic controller (EHC) connector (X83) and actuator (Y32) connector. See Integrated Grade Control (IGC) Machine Harness (W21) Component Location—If Equipped and see Integrated Grade Control (IGC) Cab Harness (W22) Component Location—If Equipped. (Group 9015-10.) Check continuity between circuit H35 GRN (X83 pin 24) and machine ground (W20).

YES: Go to next step in this check.

Is continuity indicated?

NO: Go to Reprogram Controller.

YES: Short circuit in IGC cab harness (W22). Repair or replace harness. See Integrated Grade Control (IGC) Cab Harness (W22) Wiring Diagram—If Equipped. (Group 9015-10.)

Is continuity indicated?

TM10721 (03SEP14)

9001-40-35

AA95137,0001236 -19-25JAN08-5/6

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=171

Electrohydraulic Controller (EHC) Diagnostic Trouble Codes

• 4

Reprogram Controller

Reprogram electrohydraulic controller (EHC).

Check for active codes.

YES: Replace controller.

Is EHC code 523781.04 active?

NO: Checks complete. AA95137,0001236 -19-25JAN08-6/6

523781.31 — Height PVE Spool Pos Error The EHC detects a blade lift electrohydraulic actuator spool position fault. AA95137,0001237 -19-24JAN08-1/7

Blade Lift Actuator Spool Position Error Diagnostic Procedure Alarm Level: Check Service Code AA95137,0001237 -19-24JAN08-2/7

• 1

Component Check

NO: Go to Short Circuit Check—Short to Ground. AA95137,0001237 -19-24JAN08-3/7

• 2

Short Circuit Check—Short to Ground

Remove electrohydraulic controller (EHC) connector (X83) and actuator connector. See Integrated Grade Control (IGC) Machine Harness (W21) Component Location—If Equipped and see Integrated Grade Control (IGC) Cab Harness (W22) Component Location—If Equipped. (Group 9015-10.) Check continuity between circuit H29 GRN (actuator connector pin 2) and machine ground.

YES: Go to next step in this check.

Is continuity indicated?

NO: Go to Short Circuit Check—Short to Power.

Remove EHC connector (X83) and bulkhead connector (X95). See Integrated Grade Control (IGC) Cab Harness (W22) Component Location—If Equipped. (Group 9015-10.) Check continuity between circuit H29 GRN (X95 pin 8) and machine ground (W20).

YES: Short circuit in IGC cab harness (W22). Repair or replace harness. See Integrated Grade Control (IGC) Cab Harness (W22) Wiring Diagram—If Equipped. (Group 9015-10.)

Is continuity indicated?

TM10721 (03SEP14)

9001-40-36

AA95137,0001237 -19-24JAN08-4/7

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=172

Electrohydraulic Controller (EHC) Diagnostic Trouble Codes

• 3

Short Circuit Check—Short to Power

YES: Go to next step in this check.

Is voltage more than 1 volt?

NO: Go to Open Circuit Check.

Remove bulkhead connector (X95). See Integrated Grade Control (IGC) Cab Harness (W22) Component Location—If Equipped. (Group 9015-10.) Check voltage of circuit H29 GRN (X95 pin 8) on IGC cab harness side of connector (X95).

YES: Short circuit in IGC cab harness (W22). Repair or replace harness. See Integrated Grade Control (IGC) Cab Harness (W22) Wiring Diagram—If Equipped. (Group 9015-10.)

Is voltage more than 1 volt?

• 4

Open Circuit Check

Disconnect EHC connector (X83) and blade lift actuator connector. See Integrated Grade Control (IGC) Machine Harness (W21) Component Location—If Equipped and see Integrated Grade Control (IGC) Cab Harness (W22) Component Location—If Equipped. (Group 9015-10.) Check continuity of the following circuits.

• H29 GRN (X83 pin 10 and actuator connector pin 2)

YES: Go to Reprogram Controller.

Is continuity indicated in all circuits?

NO: Go to next step in this check.

• H29 GRN (X83 pin 10 and X95 pin 8)

YES: Open circuit in IGC cab harness (W22). Repair or replace wire with no continuity. See Integrated Grade Control (IGC) Cab Harness (W22) Wiring Diagram—If Equipped. (Group 0915-10.)

Is continuity indicated in all circuits?

TM10721 (03SEP14)

9001-40-37

AA95137,0001237 -19-24JAN08-6/7

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=173

Electrohydraulic Controller (EHC) Diagnostic Trouble Codes

• 5

Reprogram Controller

Reprogram electrohydraulic controller (EHC).

Check for active codes.

YES: Replace controller.

Is EHC code 523781.31 active?

NO: Checks complete. AA95137,0001237 -19-24JAN08-7/7

524059.00 — Aux 2 Jstk Sensor 2 Volts High Not Applicable NM00125,0000862 -19-18MAY11-1/1

524059.01 — Aux 2 Jstk Sensor 2 Volts Low Not Applicable NM00125,0000863 -19-18MAY11-1/1

524059.03 — Aux 2 Jstk Sensor 2 Short to Power

Not Applicable AA95137,0000897 -19-12MAR07-1/1

524059.04 — Aux 2 Jstk Sensor 2 Short to GND

Not Applicable AA95137,0000898 -19-12MAR07-1/1

524059.31 — Aux 2 Jstk Sensor 2 Invalid Output

Not Applicable AA95137,0000899 -19-12MAR07-1/1

524062.00 — Aux 1 Jstk Sensor 2 Volts High Auxiliary joystick 1 sensor 2 circuit (wire H37 GRN) voltage is above normal operating range. NM00125,0000864 -19-10JUN11-1/5

Sensor 2 of Auxiliary Joystick 1 Diagnostic Procedure Alarm Level: Check Service Code Indicator NM00125,0000864 -19-10JUN11-2/5

• 1

Code Check

Disconnect connector (X85) from auxiliary joystick (if equipped). See Integrated Grade Control (IGC) Cab Harness (W22) Component Location—If Equipped. (Group 9015-10.) Check for electrohydraulic controller (EHC) code 524062.04.

YES: Auxiliary 1 joystick malfunction. Replace auxiliary 1 joystick.

Is EHC code 524062.04 active?

NO: Go to Short Circuit Check. Continued on next page

TM10721 (03SEP14)

9001-40-38

NM00125,0000864 -19-10JUN11-3/5

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=174

Electrohydraulic Controller (EHC) Diagnostic Trouble Codes

• 2

Short Circuit Check

Ignition OFF.

Disconnect auxiliary joystick connector (X85) and electrohydraulic control unit (EHC) connector (X82). See Integrated Grade Control (IGC) Cab Harness (W22) Component Location—If Equipped. (Group 9015-10.) Ignition ON. Check circuit H37 GRN for voltage at pin 4 of auxiliary joystick connector (X85).

YES: Circuit H37 GRN is short to power. Repair or replace harness. See Integrated Grade Control (IGC) Cab Harness (W22) Wiring Diagram—If Equipped and see Integrated Grade Control (IGC) Machine Harness (W21) Wiring Diagram—If Equipped. (Group 9015-10.)

Is voltage present?

NO: Go to Harness Check. NM00125,0000864 -19-10JUN11-4/5

• 3

Harness Check

Turn battery disconnect switch to the OFF position.

Disconnect electrohydraulic control unit (EHC) connectors (X82 and X83), auxiliary joystick connector (X85), and eloctrohydraulic control unit interface connector (X96). See Integrated Grade Control (IGC) Machine Harness (W21) Component Location—If Equipped and see Integrated Grade Control (IGC) Machine Harness (W21) Component Location—If Equipped. (Group 9015-10.) Check for continuity between pin 4 (circuit H37 GRN) of auxiliary joystick connector (X85) and remaining pins of EHC connectors (X82, X83, and X96).

YES: Circuit H37 GRN is short to circuit that indicated continuity. Repair circuit or replace harness. See Integrated Grade Control (IGC) Cab Harness (W22) Wiring Diagram—If Equipped and see Integrated Grade Control (IGC) Machine Harness (W21) Wiring Diagram—If Equipped. (Group 9015-10.)

Is continuity indicated?

NO: Auxiliary 1 joystick malfunction. Replace auxiliary 1 joystick. NM00125,0000864 -19-10JUN11-5/5

524062.01 — Aux 1 Jstk Sensor 2 Volts Low Auxiliary joystick 1 sensor 2 (circuit H37 GRN) voltage is below normal operating range. NM00125,000086A -19-21JUN11-1/6

Sensor 2 of Auxiliary Joystick 1 Diagnostic Procedure Alarm Level: Check Service Code Indicator Continued on next page

TM10721 (03SEP14)

9001-40-39

NM00125,000086A -19-21JUN11-2/6

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=175

Electrohydraulic Controller (EHC) Diagnostic Trouble Codes

• 1

Code Check

YES: Auxiliary 1 joystick malfunction. Replace auxiliary 1 joystick.

Is EHC code 524062.04 active?

NO: Go to Open Circuit Check. NM00125,000086A -19-21JUN11-3/6

• 2

Open Circuit Check

Ignition OFF.

Disconnect harness connector (X85) from auxiliary joystick and harness connector (X82) from electrohydraulic control unit (EHC). Check circuit H37 GRN for continuity between pin 4 of auxiliary joystick connector (X85) and pin 17 of EHC connector (X82).

YES: Go to Short Circuit Check.

Is continuity indicated?

NO: Circuit H37 GRN is open. Repair or replace harness. See Integrated Grade Control (IGC) Cab Harness (W22) Wiring Diagram—If Equipped and see Integrated Grade Control (IGC) Machine Harness (W21) Wiring Diagram—If Equipped. (Group 9015-10.) NM00125,000086A -19-21JUN11-4/6

• 3

Short Circuit Check

Ignition OFF.

Disconnect auxiliary joystick connector (X85) and electrohydraulic control unit (EHC) connector (X82). Check circuit H37 GRN for ground at pin 4 of auxiliary joystick connector (X85).

YES: Circuit H37 GRN is short to ground. Repair or replace harness. See Integrated Grade Control (IGC) Cab Harness (W22) Wiring Diagram—If Equipped and see Integrated Grade Control (IGC) Machine Harness (W21) Wiring Diagram—If Equipped. (Group 9015-10.)

Is ground indicated?

NO: Go to Harness Check. Continued on next page

TM10721 (03SEP14)

9001-40-40

NM00125,000086A -19-21JUN11-5/6

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=176

Electrohydraulic Controller (EHC) Diagnostic Trouble Codes

• 4

Harness Check

Turn battery disconnect switch to the OFF position.

Disconnect electrohydraulic control unit (EHC) connectors (X82 and X83), auxiliary joystick connector (X85), and eloctrohydraulic control unit interface connector (X96). See Integrated Grade Control (IGC) Machine Harness (W21) Component Location—If Equipped and see Integrated Grade Control (IGC) Cab Harness (W22) Component Location—If Equipped. (Group 9015-10.) Check for continuity between pin 4 (circuit H37 GRN) of auxiliary joystick connector (X85) and remaining pins of EHC connectors (X82, X83, and X96).

Is continuity indicated?

NO: Auxiliary 1 joystick malfunction. Replace auxiliary 1 joystick. NM00125,000086A -19-21JUN11-6/6

524062.03 — Aux 1 Jstk Sensor 2 Short to Power

The sensor 2 circuit of auxiliary joystick 1 is short to power. AA95137,0001238 -19-14JAN08-1/5

Sensor 2 of Auxiliary Joystick 1 Diagnostic Procedure Alarm Level: Check Service Code AA95137,0001238 -19-14JAN08-2/5

• 1

Code Check

Disconnect connector (X85) from auxiliary joystick (if equipped). See Integrated Grade Control (IGC) Cab Harness (W22) Component Location—If Equipped. (Group 9015-10.) Check for active codes.

YES: Go to Short Circuit Check.

Is electrohydraulic controller (EHC) code 524062.03 still active?

NO: Auxiliary 1 joystick malfunction. Replace auxiliary 1 joystick.

Continued on next page

TM10721 (03SEP14)

9001-40-41

AA95137,0001238 -19-14JAN08-3/5

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=177

Electrohydraulic Controller (EHC) Diagnostic Trouble Codes

• 2

Short Circuit Check

Disconnect auxiliary joystick (if equipped) connector (X85).

Check voltage of circuit H37 GRN (X85 pin 4)

YES: Short to power in IGC cab harness (W21). Repair or replace harness. See Integrated Grade Control (IGC) Cab Harness (W22) Wiring Diagram—If Equipped. (Group 9015-10.)

Is voltage present?

NO: Go to Reprogram Controller. AA95137,0001238 -19-14JAN08-4/5

• 3

Reprogram Controller

Reprogram electrohydraulic controller (EHC).

Check for active codes.

YES: Replace controller.

Is EHC code 524062.03 active?

NO: Checks complete. AA95137,0001238 -19-14JAN08-5/5

524062.04 — Aux 1 Jstk Sensor 2 Short to GND

The sensor 2 circuit of auxiliary joystick 1 is short to ground. AA95137,0001239 -19-14JAN08-1/6

Sensor 2 of Auxiliary Joystick 1 Diagnostic Procedure Alarm Level: Check Service Code AA95137,0001239 -19-14JAN08-2/6

• 1

Code Check

Disconnect connector (X85) from auxiliary joystick (if equipped). See Integrated Grade Control (IGC) Cab Harness (W22) Component Location—If Equipped. (Group 9015-10.) Check for active codes.

YES: Go to Open Circuit Check.

Is electrohydraulic controller (EHC) code 524062.04 active?

NO: Auxiliary 1 joystick malfunction. Replace auxiliary 1 joystick.

Continued on next page

TM10721 (03SEP14)

9001-40-42

AA95137,0001239 -19-14JAN08-3/6

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=178

Electrohydraulic Controller (EHC) Diagnostic Trouble Codes

• 2

Open Circuit Check

Disconnect EHC connector (X82) and connector (X85) from auxiliary joystick (if equipped). See Integrated Grade Control (IGC) Cab Harness (W22) Component Location—If Equipped. (Group 9015-10.) Check continuity of the following circuits.

• H37 GRN (X85 pin 4 and X82 pin 23) • H22 GRN (X85 pin 2 and X82 pin 3) • R41 BLK (X85 pin 1 and X82 pin 22)

YES: Go to Short Circuit Check.

Is continuity indicated for all circuits?

NO: Open circuit in IGC cab harness (W22). Repair or replace harness. see Integrated Grade Control (IGC) Cab Harness (W22) Wiring Diagram—If Equipped. (Group 9015-10.) AA95137,0001239 -19-14JAN08-4/6

• 3

Short Circuit Check

Disconnect connector (X85) from auxiliary joystick (if equipped). See Integrated Grade Control (IGC) Cab Harness (W22) Component Location—If Equipped. (Group 9015-10.) Check continuity of the following circuits to machine ground.

• H37 GRN (X85 pin 4) • H22 GRN (X85 pin 2)

YES: Short circuit in IGC cab harness (W22). Repair or replace harness. see Integrated Grade Control (IGC) Cab Harness (W22) Wiring Diagram—If Equipped. (Group 9015-10.)

Do either of the circuits have continuity with machine ground?

NO: Go to Reprogram Controller. AA95137,0001239 -19-14JAN08-5/6

• 4

Reprogram Controller

Reprogram electrohydraulic controller (EHC).

Check for active codes.

YES: Replace controller.

Is EHC code 524062.04 active?

NO: Checks complete. AA95137,0001239 -19-14JAN08-6/6

524062.31 — Aux 1 Jstk Sensor 2 Invalid Output

EHC detects an abnormal value from the sensor 2 circuit of auxiliary 1 joystick. AA95137,000123A -19-14JAN08-1/6

Sensor 2 of Auxiliary Joystick 1 Diagnostic Procedure Alarm Level: Check Service Code Continued on next page

TM10721 (03SEP14)

9001-40-43

AA95137,000123A -19-14JAN08-2/6

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=179

Electrohydraulic Controller (EHC) Diagnostic Trouble Codes

• 1

Code Check

Disconnect connector (X85) from auxiliary joystick (if equipped). See Integrated Grade Control (IGC) Cab Harness (W22) Component Location—If Equipped. (Group 9015-10.) Check for active codes.

YES: Go to Voltage Check.

Is electrohydraulic controller (EHC) code 524062.31 active?

NO: Auxiliary 1 joystick malfunction. Replace auxiliary 1 joystick. AA95137,000123A -19-14JAN08-3/6

• 2

Voltage Check

Disconnect connector X85 from auxiliary 1 joystick (if equipped). See Integrated Grade Control (IGC) Cab Harness (W22) Component Location—If Equipped. (Group 9015-10.) Check voltage across circuits H22 GRN (X85 pin 1) and R41 BLK (X85 pin 4).

YES: Go to Short Circuit Check.

Is voltage 4.75—5.25 volts?

NO: Open circuit in harness. Repair or replace harness. See Integrated Grade Control (IGC) Cab Harness (W22) Wiring Diagram—If Equipped. (Group 9015-10.) AA95137,000123A -19-14JAN08-4/6

• 3

Short Circuit Check

Disconnect EHC connector (X83) and auxiliary 1 joystick (if equipped) connector (X85).

Check continuity between circuits H37 GRN (X85 pin 3) and H26 GRN (X85 pin 2). Check continuity between circuit H37 GRN (X85 pin 3) machine ground.

YES: Short circuit in harness. Repair or replace harness. See Integrated Grade Control (IGC) Cab Harness (W22) Wiring Diagram—If Equipped. (Group 9015-10.)

Is continuity indicated between circuits H37 GRN and H26 GRN or ground?

NO: Replace auxiliary 1 joystick. If code 524062.31 remains active, go to Reprogram Controller. AA95137,000123A -19-14JAN08-5/6

• 4

Reprogram Controller

Reprogram electrohydraulic controller (EHC).

Check for active codes.

YES: Replace controller.

Is EHC code 524062.31 active?

NO: Checks complete. AA95137,000123A -19-14JAN08-6/6

524085.00 — Aux 2 Jstk Sensor 1 Volts High Not Applicable NM00125,0000866 -19-23MAY11-1/1

524085.01 — Aux 2 Jstk Sensor 1 Volts Low Not Applicable NM00125,0000867 -19-23MAY11-1/1

TM10721 (03SEP14)

9001-40-44

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=180

Electrohydraulic Controller (EHC) Diagnostic Trouble Codes

524085.03 — Aux 2 Jstk Sensor 1 Short to Power

Not Applicable AA95137,000089D -19-12MAR07-1/1

524085.04 — Aux 2 Jstk Sensor 1 Short to GND

Not Applicable AA95137,000089E -19-12MAR07-1/1

524085.14 — Aux 2 Jstk Sensor Mismatch Not Applicable AA95137,000089F -19-12MAR07-1/1

524085.31 — Aux 2 Jstk Sensor 1 Invalid Output

Not Applicable AA95137,00008A0 -19-12MAR07-1/1

524086.00 — Aux 1 Jstk Sensor 1 Volts High Auxiliary joystick 1 sensor 1 circuit (wire H26 GRN) voltage is above normal operating range. NM00125,0000868 -19-21JUN11-1/5

Sensor 1 of Auxiliary Joystick 1 Diagnostic Procedure Alarm Level: Check Service Code NM00125,0000868 -19-21JUN11-2/5

• 1

Code Check

Disconnect electrical connector (X85) from auxiliary joystick (if equipped). See Integrated Grade Control (IGC) Cab Harness (W22) Component Location—If Equipped. (Group 9015-10.) Check for electrohydraulic controller (EHC) code 524086.04.

YES: Auxiliary 1 joystick malfunction. Replace auxiliary 1 joystick.

Is EHC code 524086.04 active?

NO: Go to Short Circuit Check Continued on next page

TM10721 (03SEP14)

9001-40-45

NM00125,0000868 -19-21JUN11-3/5

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=181

Electrohydraulic Controller (EHC) Diagnostic Trouble Codes

• 2

Short Circuit Check

Ignition OFF.

Disconnect harness connector (X85) from auxiliary joystick and harness connector (X82) from electrohydraulic controller (EHC). See Integrated Grade Control (IGC) Cab Harness (W22) Component Location—If Equipped. (Group 9015-10.) Ignition ON. Check circuit H26 GRN for voltage at pin 3 of auxiliary joystick connector (X85).

YES: Circuit H36 GRN is short to power. Repair circuit or replace harness. See Integrated Grade Control (IGC) Cab Harness (W22) Wiring Diagram—If Equipped and see Integrated Grade Control (IGC) Machine Harness (W21) Wiring Diagram—If Equipped. (Group 9015-10.)

Is voltage present?

NO: Go to Harness Check NM00125,0000868 -19-21JUN11-4/5

• 3

Harness Check

Turn battery disconnect switch to the OFF position.

Disconnect electrohydraulic controller (EHC) connectors (X82 and X83), auxiliary joystick connector (X85), and eloctrohydraulic controller interface connector (X96). See Integrated Grade Control (IGC) Machine Harness (W21) Component Location—If Equipped and see Integrated Grade Control (IGC) Cab Harness (W22) Component Location—If Equipped. (Group 9015-10.) Check for continuity between pin 3 (circuit H26 GRN) of auxiliary joystick connector (X85) and remaining pins of EHC connectors (X82, X83, and X96).

YES: Circuit H26 GRN is short to circuit that indicated continuity. Repair circuit or replace harness. See Integrated Grade Control (IGC) Cab Harness (W22) Wiring Diagram—If Equipped and see Integrated Grade Control (IGC) Machine Harness (W21) Wiring Diagram—If Equipped. (Group 9015-10.)

Is continuity indicated?

NO: Auxiliary 1 joystick malfunction. Replace auxiliary 1 joystick. NM00125,0000868 -19-21JUN11-5/5

524086.01 — Aux 1 Jstk Sensor 1 Volts Low Auxiliary joystick 1 sensor 1 (circuit H26 GRN) voltage is below normal operating range. NM00125,0000869 -19-21JUN11-1/6

Sensor 1 of Auxiliary Joystick 1 Diagnostic Procedure Continued on next page

TM10721 (03SEP14)

9001-40-46

NM00125,0000869 -19-21JUN11-2/6

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=182

Electrohydraulic Controller (EHC) Diagnostic Trouble Codes

• 1

Code Check

YES: Auxiliary 1 joystick malfunction. Replace auxiliary 1 joystick.

Is EHC code 524086.04 active?

NO: Go to Open Circuit Check. NM00125,0000869 -19-21JUN11-3/6

• 2

Open Circuit Check

Ignition OFF.

Disconnect harness connector (X85) from auxiliary joystick and harness connector (X82) from electrohydraulic control unit (EHC). See Integrated Grade Control (IGC) Cab Harness (W22) Component Location—If Equipped. (Group 9015-10.) Check circuit H26 GRN for continuity between pin 3 of auxiliary joystick connector (X85) and pin 23 of EHC connector (X82).

YES: Go to Short Circuit Check.

Is continuity indicated?

NO: Circuit H26 GRN is open. Repair or replace harness. See Integrated Grade Control (IGC) Cab Harness (W22) Wiring Diagram—If Equipped and see Integrated Grade Control (IGC) Machine Harness (W21) Wiring Diagram—If Equipped. (Group 9015-10.) NM00125,0000869 -19-21JUN11-4/6

• 3

Short Circuit Check

Ignition OFF.

Disconnect harness connector (X85) from auxiliary joystick and harness connector (X82) from electrohydraulic control unit (EHC). See Integrated Grade Control (IGC) Cab Harness (W22) Component Location—If Equipped. (Group 9015-10.) Check circuit H26 GRN for ground at pin 3 of auxiliary joystick connector (X85).

YES: Circuit H26 GRN is short to ground. Repair or replace harness. See Integrated Grade Control (IGC) Cab Harness (W22) Wiring Diagram—If Equipped. (Group 9015-10.)

Is ground indicated?

NO: Go to Harness Check. Continued on next page

TM10721 (03SEP14)

9001-40-47

NM00125,0000869 -19-21JUN11-5/6

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=183

Electrohydraulic Controller (EHC) Diagnostic Trouble Codes

• 4

Harness Check

Turn battery disconnect switch to the OFF position.

Disconnect electrohydraulic control unit (EHC) connectors (X82 and X83), auxiliary joystick connector (X85), and eloctrohydraulic control unit interface connector (X96). See Integrated Grade Control (IGC) Machine Harness (W21) Component Location—If Equipped and see Integrated Grade Control (IGC) Cab Harness (W22) Component Location—If Equipped. (Group 9015-10.) Check for continuity between pin 3 (circuit H26 GRN) of auxiliary joystick connector (X85) and remaining pins of EHC connectors (X82, X83, and X96).

Is continuity indicated?

NO: Auxiliary 1 joystick malfunction. Replace auxiliary 1 joystick. NM00125,0000869 -19-21JUN11-6/6

524086.03 — Aux 1 Jstk Sensor 1 Short to Power

Sensor 1 circuit of the auxiliary joystick 1 is short to power. AA95137,000123B -19-14JAN08-1/5

Sensor 1 of Auxiliary Joystick 1 Diagnostic Procedure Alarm Level: Check Service Code AA95137,000123B -19-14JAN08-2/5

• 1

Code Check

Disconnect connector (X85) from auxiliary joystick (if equipped). See Integrated Grade Control (IGC) Cab Harness (W22) Component Location—If Equipped. (Group 9015-10.) Check for active codes.

YES: Go to Short Circuit Check.

Is electrohydraulic controller (EHC) code 524086.03 active?

NO: Auxiliary 1 joystick malfunction. Replace auxiliary 1 joystick.

Continued on next page

TM10721 (03SEP14)

9001-40-48

AA95137,000123B -19-14JAN08-3/5

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=184

Electrohydraulic Controller (EHC) Diagnostic Trouble Codes

• 2

Short Circuit Check

Disconnect auxiliary joystick (if equipped) connector (X85).

Check voltage of circuit H26 GRN (X85 pin 3)

YES: Short to power in IGC cab harness (W22). Repair or replace harness. See Integrated Grade Control (IGC) Cab Harness (W22) Wiring Diagram—If Equipped. (Group 9015-10.)

Is voltage present?

NO: Go to Reprogram Controller. AA95137,000123B -19-14JAN08-4/5

• 3

Reprogram Controller

Reprogram electrohydraulic controller (EHC).

Check for active codes.

YES: Replace controller.

Is EHC code 524086.03 active?

NO: Checks complete. AA95137,000123B -19-14JAN08-5/5

524086.04 — Aux 1 Jstk Sensor 1 Short to GND

Sensor 1 circuit of the auxiliary joystick 1 is short to ground. AA95137,000123C -19-14JAN08-1/6

Sensor 1 of Auxiliary Joystick 1 Diagnostic Procedure Alarm Level: Check Service Code AA95137,000123C -19-14JAN08-2/6

• 1

Code Check

Disconnect connector (X85) from auxiliary joystick (if equipped). See Integrated Grade Control (IGC) Cab Harness (W22) Component Location—If Equipped. (Group 9015-10.) Check for active codes.

YES: Go to Open Circuit Check.

Is electrohydraulic controller (EHC) code 524086.04 active?

NO: Auxiliary 1 joystick malfunction. Replace auxiliary 1 joystick.

Continued on next page

TM10721 (03SEP14)

9001-40-49

AA95137,000123C -19-14JAN08-3/6

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=185

Electrohydraulic Controller (EHC) Diagnostic Trouble Codes

• 2

Open Circuit Check

• H26 GRN (X85 pin 3 and X82 pin 23) • H22 GRN (X85 pin 2 and X82 pin 3) • R41 BLK (X85 pin 1 and X82 pin 22)

YES: Go to Short Circuit Check.

Is continuity indicated for all circuits?

• 3

Short Circuit Check

Disconnect connector (X85) from auxiliary joystick (if equipped). See Integrated Grade Control (IGC) Cab Harness (W22) Component Location—If Equipped. (Group 9015-10.) Check continuity of the following circuits to machine ground.

• H26 GRN (X85 pin 3) • H22 GRN (X85 pin 2)

YES: Short circuit in IGC cab harness (W22). Repair or replace harness. see Integrated Grade Control (IGC) Cab Harness (W22) Wiring Diagram—If Equipped. (Group 9015-10.)

Do either of the circuits have continuity with machine ground?

NO: Go to Reprogram Controller. AA95137,000123C -19-14JAN08-5/6

• 4

Reprogram Controller

Reprogram electrohydraulic controller (EHC).

Check for active codes.

YES: Replace controller.

Is EHC code 524086.04 active?

NO: Checks complete. AA95137,000123C -19-14JAN08-6/6

524086.14 — Aux 1 Jstk Sensor Mismatch Electrohydraulic controller (EHC) detects mismatched signals from sensors 1 and 2 of the auxiliary 1 joystick. AA95137,000123D -19-14JAN08-1/7

Auxiliary Joystick 1 Diagnostic Procedure Alarm Level: Check Service Code Continued on next page

TM10721 (03SEP14)

9001-40-50

AA95137,000123D -19-14JAN08-2/7

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=186

Electrohydraulic Controller (EHC) Diagnostic Trouble Codes

• 1

Code Check

Disconnect connector (X85) from auxiliary joystick (if equipped). See Integrated Grade Control (IGC) Cab Harness (W22) Component Location—If Equipped. (Group 9015-10.) Check for active codes.

YES: Go to Voltage Check.

Is EHC code 524086.14 active?

NO: Auxiliary 1 joystick malfunction. Replace auxiliary 1 joystick. AA95137,000123D -19-14JAN08-3/7

• 2

Voltage Check

Disconnect connector (X85) from auxiliary 1 joystick (if equipped). See Integrated Grade Control (IGC) Cab Harness (W22) Component Location—If Equipped. (Group 9015-10.) Check voltage across circuits H22 GRN (X85 pin 2) and R41 BLK (X85 pin 1).

YES: Go to Short Circuit Check—Sensor 1.

Is voltage 4.75—5.25 volts?

NO: Harness malfunction. Repair or replace harness. See Integrated Grade Control (IGC) Cab Harness (W22) Wiring Diagram—If Equipped. (Group 9015-10.) AA95137,000123D -19-14JAN08-4/7

• 3

Short Circuit Check—Sensor 1

Disconnect connectors X83 from EHC and X85 from auxiliary 1 joystick (if equipped). See Integrated Grade Control (IGC) Cab Harness (W22) Component Location—If Equipped. (Group 9015-10.) Check continuity between circuits H37 GRN (X85 pin 4) and H26 GRN (X85 pin 3). Check continuity between circuit H26 GRN (X85 pin 3) and system power and machine YES: Short circuit in ground. harness. Repair or replace harness. See Integrated Grade Control (IGC) Cab Harness (W22) Wiring Diagram—If Equipped. (Group 9015-10.) Is continuity indicated between circuits H26 GRN and H37 GRN or power and ground?

NO: Go to Short Circuit Check—Sensor 2. AA95137,000123D -19-14JAN08-5/7

• 4

Short Circuit Check—Sensor 2

Disconnect EHC connector (X83) and connector (X85) from auxiliary 1 joystick (if equipped). See Integrated Grade Control (IGC) Cab Harness (W22) Component Location—If Equipped. (Group 9015-10.) Check continuity between circuits H37 GRN (X85 pin 4) and H26 GRN (X85 pin 3). Check continuity between circuit H37 GRN (X85 pin 4) and system power and machine YES: Short circuit in ground. harness. Repair or replace harness. See Integrated Grade Control (IGC) Cab Harness (W22) Wiring Diagram—If Equipped. (Group 9015-10.) Is continuity indicated between circuits H37 GRN and H26 GRN or power and ground?

Continued on next page

TM10721 (03SEP14)

9001-40-51

NO: Go to Reprogram Controller. AA95137,000123D -19-14JAN08-6/7

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=187

Electrohydraulic Controller (EHC) Diagnostic Trouble Codes

• 5

Reprogram Controller

Reprogram electrohydraulic controller (EHC).

Check for active codes.

YES: Replace controller.

Is EHC code 524086.14 active?

NO: Checks complete. AA95137,000123D -19-14JAN08-7/7

524086.31 — Aux 1 Jstk Sensor 1 Invalid Output

Electrohydraulic controller (EHC) detects an abnormal value from the sensor 1 circuit of auxiliary 1 joystick. AA95137,000123E -19-14JAN08-1/6

Sensor 1 of Auxiliary Joystick 1 Diagnostic Procedure Alarm Level: Check Service Code AA95137,000123E -19-14JAN08-2/6

• 1

Code Check

Disconnect connector (X85) from auxiliary joystick (if equipped). See Integrated Grade Control (IGC) Cab Harness (W22) Component Location—If Equipped. (Group 9015-10.) Check for active codes.

YES: Go to Voltage Check.

Is EHC code 524086.31 still active?

NO: Auxiliary 1 joystick malfunction. Replace auxiliary 1 joystick. AA95137,000123E -19-14JAN08-3/6

• 2

Voltage Check

YES: Go to Short Circuit Check.

Is voltage 4.75—5.25 volts?

NO: Open circuit in harness. Repair or replace harness. See Integrated Grade Control (IGC) Cab Harness (W22) Wiring Diagram—If Equipped. (Group 9015-10.) Continued on next page

TM10721 (03SEP14)

9001-40-52

AA95137,000123E -19-14JAN08-4/6

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=188

Electrohydraulic Controller (EHC) Diagnostic Trouble Codes

• 3

Short Circuit Check

Disconnect EHC connector (X83) and auxiliary 1 joystick (if equipped) connector (X85).

Check continuity between circuits H37 GRN (X85 pin 3) and H26 GRN (X85 pin 2). Check continuity between circuit H37 GRN (X85 pin 3) machine ground.

YES: Short circuit in harness. Repair or replace harness. See Integrated Grade Control (IGC) Cab Harness (W22) Wiring Diagram—If Equipped. (Group 9015-10.)

Is continuity indicated between circuits H37 GRN and H26 GRN or ground?

NO: Replace auxiliary 1 joystick. Check codes. If code 524086.31 is active, go to Reprogram Controller. AA95137,000123E -19-14JAN08-5/6

• 4

Reprogram Controller

Reprogram electrohydraulic controller (EHC).

Check for active codes.

YES: Replace controller.

Is EHC code 524086.31 active?

NO: Checks complete. AA95137,000123E -19-14JAN08-6/6

TM10721 (03SEP14)

9001-40-53

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=189

Electrohydraulic Controller (EHC) Diagnostic Trouble Codes

TM10721 (03SEP14)

9001-40-54

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=190

Group 50

Blade Control Joystick (BCJ) Diagnostic Trouble Codes Blade Control Joystick (BCJ) Diagnostic Trouble Codes The diagnostic trouble code number is indicated by a suspect parameter number (SPN) and a failure mode indicator (FMI) number. In the example002697.03, 2697 is the SPN and 03 is the FMI number. To view diagnostic trouble codes, use one of the following methods:

• Service ADVISOR™ system. See Reading Diagnostic

Trouble Codes with service ADVISOR™ Diagnostic Application. (Group 9015-20.) • Standard Display Monitor (SDM). See Standard Display Monitor (SDM) Menu Structure—Service Mode. (Group 9015-16.)

NOTE: For in-depth diagnostics on all BCJ diagnostic trouble codes, see specific code diagnostic procedure. (Group 9001-50.)

service ADVISOR is a trademark of Deere & Company TW73308,000011B -19-07JAN08-1/1

002697.03 — X-Axis Sensor Out of Range High

The x-axis effect sensor is out of range high. AA95137,000123F -19-14JAN08-1/3

Joystick Diagnostic Procedure Alarm Level: Check Service Code AA95137,000123F -19-14JAN08-2/3

• 1

Code Check

Check for active codes.

YES: Joystick malfunction. Replace joystick. See Integrated Grade Control (IGC) Cab Harness (W22) Component Location—If Equipped. (Group 9015-10.)

Is blade control joystick (BCJ) code 002697.03 still present?

NO: Checks complete. AA95137,000123F -19-14JAN08-3/3

002697.04 — X-Axis Sensor Out of Range Low

The x-axis effect sensor is out of range low. AA95137,0001240 -19-14JAN08-1/3

Joystick Diagnostic Procedure Alarm Level: Check Service Code AA95137,0001240 -19-14JAN08-2/3

• 1

Code Check

Check for active codes.

YES: Joystick malfunction. Replace joystick. See Integrated Grade Control (IGC) Cab Harness (W22) Component Location—If Equipped. (Group 9015-10.)

Is blade control joystick (BCJ) code 002697.04 still present?

NO: Check complete. AA95137,0001240 -19-14JAN08-3/3

TM10721 (03SEP14)

9001-50-1

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=191

Blade Control Joystick (BCJ) Diagnostic Trouble Codes

002697.12 — X-Axis Joystick Internal Failure The x-axis joystick sensor has an internal malfunction. AA95137,0001241 -19-14JAN08-1/3

Joystick Diagnostic Procedure Alarm Level: Check Service Code AA95137,0001241 -19-14JAN08-2/3

• 1

Code Check

Check for active codes.

YES: Joystick malfunction. Replace joystick. See Integrated Grade Control (IGC) Cab Harness (W22) Component Location—If Equipped. (Group 9015-10.)

Is blade control joystick (BCJ) code 002697.12 still present?

NO: Check complete. AA95137,0001241 -19-14JAN08-3/3

002697.13 — X-Axis Joystick Setup Failure The x-axis joystick sensor has a setup failure. AA95137,0001242 -19-14JAN08-1/3

Joystick Diagnostic Procedure Alarm Level: Check Service Code AA95137,0001242 -19-14JAN08-2/3

• 1

Code Check

Check for active codes.

YES: Joystick malfunction. Replace joystick. See Integrated Grade Control (IGC) Cab Harness (W22) Component Location—If Equipped. (Group 9015-10.)

Is blade control joystick (BCJ) code 002697.13 still present?

NO: Check complete. AA95137,0001242 -19-14JAN08-3/3

002697.14 — X-Axis Joystick Sensor Failure The x-axis joystick sensor is malfunctioning. AA95137,0001243 -19-14JAN08-1/3

Joystick Diagnostic Procedure Alarm Level: Check Service Code Continued on next page

TM10721 (03SEP14)

9001-50-2

AA95137,0001243 -19-14JAN08-2/3

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=192

Blade Control Joystick (BCJ) Diagnostic Trouble Codes

• 1

Code Check

Check for active codes.

YES: Joystick malfunction. Replace joystick. See Integrated Grade Control (IGC) Cab Harness (W22) Component Location—If Equipped. (Group 9015-10.)

Is blade control joystick (BCJ) code 002697.14 still present?

NO: Check complete. AA95137,0001243 -19-14JAN08-3/3

002698.03 — Y-Axis Sensor Out of Range High

The y-axis effect sensor voltage is out of range high. AA95137,0001244 -19-14JAN08-1/3

Joystick Diagnostic Procedure Alarm Level: Check Service Code AA95137,0001244 -19-14JAN08-2/3

• 1

Code Check

Check for active codes.

YES: Joystick malfunction. Replace joystick. See Integrated Grade Control (IGC) Cab Harness (W22) Component Location—If Equipped. (Group 9015-10.)

Is blade control joystick (BCJ) code 002698.03 still preent?

NO: Check complete. AA95137,0001244 -19-14JAN08-3/3

002698.04 — Y-Axis Sensor Out of Range Low

The y-axis effect sensor voltage is out of range low. AA95137,0001245 -19-14JAN08-1/3

Joystick Diagnostic Procedure Alarm Level: Check Service Code AA95137,0001245 -19-14JAN08-2/3

• 1

Code Check

Check for active codes.

YES: Joystick malfunction. Replace joystick. See Integrated Grade Control (IGC) Cab Harness (W22) Component Location—If Equipped. (Group 9015-10.)

Is blade control joystick (BCJ) code 002698.04 still present?

NO: Check complete. AA95137,0001245 -19-14JAN08-3/3

002698.12 — Y-Axis Joystick Internal Failure The y-axis joystick sensor has an internal malfunction. Continued on next page

TM10721 (03SEP14)

9001-50-3

AA95137,0001246 -19-14JAN08-1/3

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=193

Blade Control Joystick (BCJ) Diagnostic Trouble Codes Joystick Diagnostic Procedure Alarm Level: Check Service Code AA95137,0001246 -19-14JAN08-2/3

• 1

Code Check

Check for active codes.

YES: Joystick malfunction. Replace joystick. See Integrated Grade Control (IGC) Cab Harness (W22) Component Location—If Equipped. (Group 9015-10.)

Is blade control joystick (BCJ) code 002698.12 still present?

NO: Check complete. AA95137,0001246 -19-14JAN08-3/3

002698.13 — Y-Axis Joystick Setup Failure The y-axis joystick sensor has a setup error. AA95137,0001247 -19-14JAN08-1/3

Joystick Diagnostic Procedure Alarm Level: Check Service Code AA95137,0001247 -19-14JAN08-2/3

• 1

Code Check

Check for active codes.

YES: Joystick malfunction. Replace joystick. See Integrated Grade Control (IGC) Cab Harness (W22) Component Location—If Equipped. (Group 9015-10.)

Is blade control joystick (BCJ) code 002698.13 still present?

NO: Check complete. AA95137,0001247 -19-14JAN08-3/3

002698.14 — Y-Axis Joystick Sensor Failure The y-axis joystick sensor is malfunctioning. AA95137,0001248 -19-14JAN08-1/3

Joystick Diagnostic Procedure Alarm Level: Check Service Code Continued on next page

TM10721 (03SEP14)

9001-50-4

AA95137,0001248 -19-14JAN08-2/3

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=194

Blade Control Joystick (BCJ) Diagnostic Trouble Codes

• 1

Code Check

Check for active codes.

YES: Joystick malfunction. Replace joystick. See Integrated Grade Control (IGC) Cab Harness (W22) Component Location—If Equipped. (Group 9015-10.)

Is blade control joystick (BCJ) code 002698.14 still present?

NO: Check complete. AA95137,0001248 -19-14JAN08-3/3

TM10721 (03SEP14)

9001-50-5

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=195

Blade Control Joystick (BCJ) Diagnostic Trouble Codes

TM10721 (03SEP14)

9001-50-6

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=196

Contents

Section 9005 Operational Checkout Procedure

Page

Group 10—System Operational Checks Operational Checkout................................ 9005-10-1 Diagnostic Trouble Code Check................9005-10-1 Operational Checks—Key Switch OFF, Engine OFF...........................................9005-10-1 Operational Checks—Key Switch ON, Engine OFF ..........................................9005-10-2 Operational Checks—Key Switch ON, Engine ON ............................................9005-10-6

TM10721 (03SEP14)

9005-1

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=1

Contents

TM10721 (03SEP14)

9005-2

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=2

Group 10

System Operational Checks Operational Checkout Use this procedure to make a quick check of machine operation by doing a walk-around inspection and performing specific checks from the operator seat.

space to operate machine. Some checks may require varied surfaces. No special tools are necessary to perform the checkout.

Complete visual checks (oil levels, oil condition, external leaks, loose hardware, linkage, wiring, etc.) before performing the checkout.

If no problem is found, go to next check. If a problem is indicated, an additional check or repair procedure will be suggested.

Most checks will require machine systems to be at normal operating temperatures and a level area with adequate TW73308,000011C -19-23MAY12-1/28

Diagnostic Trouble Code Check TW73308,000011C -19-23MAY12-2/28

Display and Clear Trouble Always check for diagnostic trouble codes and correct them before performing Codes the operational checkout. Check for active and stored diagnostic trouble codes (DTCs). Diagnostic trouble codes can be displayed by using one of the following methods.

• Standard Display Monitor (SDM)

- To access DTCs using the SDM, see Standard Display Monitor (SDM) Menu Structure—Service Mode. (Group 9015-16.)

• Service ADVISOR™ Diagnostic Application

- To access DTCs using Service ADVISOR™ diagnostic application, see Reading Diagnostic Trouble Codes with Service ADVISOR™ Diagnostic Application. (Group 9015-20.) YES: Correct all diagnostic trouble codes before proceeding. See Reading Diagnostic Trouble Codes with Service ADVISOR™ Diagnostic Application and Service ADVISOR™ Connection Procedure. (Group 9015-20.)

LOOK: Are diagnostic trouble codes present?

NO: Continue with operational checks.

Service ADVISOR is a trademark of Deere & Company TW73308,000011C -19-23MAY12-3/28

Operational Checks—Key Switch OFF, Engine OFF Continued on next page

TM10721 (03SEP14)

9005-10-1

TW73308,000011C -19-23MAY12-4/28

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=199

System Operational Checks Battery Check

TX1014412A —UN—03NOV06

Hour Meter and Battery Meter Push SELECT button and hold until battery volts are displayed.

YES: Check complete.

LOOK: Do battery volts read a minimum of 12 volts?

NO: Check and recharge batteries. See Check Battery Electrolyte Level and Terminals. (Operator's Manual.) Check voltage on each battery before recharging. NOTE: If one battery will not hold a charge, replace both batteries. TW73308,000011C -19-23MAY12-5/28

Horn Check

Push horn button.

YES: Check complete.

LISTEN: Does horn activate?

NO: Check horn circuit. See System Functional Schematic and Section Legend. (Group 9015-10.) TW73308,000011C -19-23MAY12-6/28

Seat Control Checks

NOTE: For seat adjustment procedures, see Adjust Non-Suspension Seat or see Adjust Suspension Seat—If Equipped. (Operator's Manual.) If machine is equipped with air seat, key switch must be ON to raise seat. Does seat raise and lower easily? Does seat angle change easily? Does lever move easily to unlock seat support? Does seat move forward and rearward easily? Does lever lock seat support in position when released? Does seat back tilt forward and rearward easily?

YES: Check complete.

Does lever unlock and lock easily to hold seat back in position?

NO: Inspect linkage and repair. TW73308,000011C -19-23MAY12-7/28

Operational Checks—Key Switch ON, Engine OFF Continued on next page

TM10721 (03SEP14)

9005-10-2

TW73308,000011C -19-23MAY12-8/28

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=200

System Operational Checks Battery Disconnect Switch Check

T118722B —UN—01DEC98

Battery Disconnect Switch NOTE: Battery disconnect switch is located inside the left rear service door. Turn battery disconnect switch OFF. Turn key switch ON.

YES: Switch is malfunctioning. Check battery disconnect switch. See System Functional Schematic and Section Legend. (Group 9015-10.)

LOOK: Do monitor indicator lights come on?

NO: Continue check.

Turn battery disconnect switch ON. Turn key switch ON. Do not start engine.

YES: Check complete.

LOOK: Do monitor indicator lights come on?

NO: Check battery disconnect switch. See System Functional Schematic and Section Legend. (Group 9015-10.) TW73308,000011C -19-23MAY12-9/28

Monitor Check

Turn key switch OFF then back to ON. Observe monitor and note changes for first 3 seconds (bulbs, indicators and gauges). LOOK/LISTEN: Do all lights come on and is the audible alarm activated? LOOK: Does the display show “John Deere” and the model number? LOOK: Do all the gauge indicators point to approximately 12 o’clock position? LOOK: Is backlighting of gauges on? After 4 seconds observe changes in monitor.

YES: Check complete.

LOOK: Do gauge indicators change from 12 o’clock to normal readings?

NO: Check SDM Switched Power 5A Fuse (F23). See Fuse and Relay Specifications. (Group 9015-10.) TW73308,000011C -19-23MAY12-10/28

Backup Alarm Check

Key switch ON. Move park lock lever to the UNLOCK (down) position. Move TCL to reverse position.

YES: Check complete.

LISTEN: Does backup alarm activate?

NO: Check for voltage at backup alarm. If no voltage is present, calibrate TCU. See Transmission Harness (W7) Wiring Diagram. (Group 9015-10.) See Transmission Control Unit (TCU) Calibration. (Group 9015-20.) Continued on next page

TM10721 (03SEP14)

9005-10-3

TW73308,000011C -19-23MAY12-11/28

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=201

System Operational Checks Front/Rear Wiper and Washer Motor Check—If Equipped

T199302A —UN—15APR04

Wiper Switches (S.N. —210219)

TX1114380A —UN—21MAY12

Wiper Switches (S.N. 210220— ) 1— Left/Right Door Wiper Switch 2— Front/Rear Wiper Switch Key switch ON. Push front/rear wiper switch (2) to first detent (middle) position (S.N. —210219) or turn front/rear wiper switch (2) to the number three (end) position (S.N. 210220— ). LOOK: Do front and rear wipers operate? Push wiper switch fully to momentary position and hold. LOOK: Do both front and rear washer pumps operate?

YES: Check complete.

LOOK: Do front and rear wipers continue to operate?

NO: Washer fluid reservoir may be empty. Check Front/Rear Wiper 15A Fuse (F14). See Fuse and Relay Specifications. (Group 9015-10.)

Continued on next page

TM10721 (03SEP14)

9005-10-4

TW73308,000011C -19-23MAY12-12/28

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=202

System Operational Checks Left/Right Wiper and Washer Motor Check—If Equipped

T199302A —UN—15APR04

Wiper Switches (S.N. —210219)

TX1114380A —UN—21MAY12

Wiper Switches (S.N. 210220— ) 1— Left/Right Door Wiper Switch 2— Front/Rear Wiper Switch Key switch ON. Push left/right wiper switch (1) to first detent (middle) position (S.N. —210219) or turn left/right door wiper switch (1) to the number three (end) position (S.N. 210220— ). LOOK: Do left and right wipers operate? Push wiper switch fully to momentary position and hold. LOOK: Do both left and right washer pumps operate?

YES: Check complete.

LOOK: Do left and right wipers continue to operate?

NO: Washer fluid reservoir may be empty. Check Left/Right Wiper 15A Fuse (F16). See Fuse and Relay Specifications. (Group 9015-10.)

Continued on next page

TM10721 (03SEP14)

9005-10-5

TW73308,000011C -19-23MAY12-13/28

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=203

System Operational Checks Heater Blower Motor Check—If Equipped

TX1114381A —UN—21MAY12

Air Conditioning Controls 1— Air Conditioning Switch 2— Blower Switch 3— Temperature Control 4— Air Duct (8 used) Key switch ON.

YES: Check complete.

Turn blower switch (2) to 1st, 2nd, 3rd, and 4th positions.

NO: Check Heater/Blower 15A Fuse (F8). Replace if necessary. See Fuse and Relay Specifications. (Group 9015-10.)

FEEL: Does air exit all ducts from roof?

NO: Check wiring harness. See Cab Roof Harness (W4) Wiring Diagram. (Group 9015-10.) TW73308,000011C -19-23MAY12-14/28

Operational Checks—Key Switch ON, Engine ON TW73308,000011C -19-23MAY12-15/28

Alternator Check

Start engine and operate at slow idle.

YES: Check and recharge batteries. See Check Battery Electrolyte Level and Terminals. (Operator's Manual.) Check voltage on each battery before recharging. NOTE: If one battery will not hold a charge, replace both batteries. Test alternator. See Alternator Test. (Group 9015-20.)

LOOK: Is BATTERY CHARGING VOLTS indicator light on? Continued on next page

TM10721 (03SEP14)

9005-10-6

NO: Check complete. TW73308,000011C -19-23MAY12-16/28

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=204

System Operational Checks Air Restriction Indicator Check

T117820 —UN—25NOV98

Air Restriction Indicator Operated engine at slow idle and fast idle. YES: Clean or replace air cleaner elements. See Replace Air Cleaner Elements. (Operator's Manual.) LOOK: Does air restriction indicator light come on?

NO: Check complete. TW73308,000011C -19-23MAY12-17/28

Slow and Fast Idle Check

Operate engine at slow and fast idle. Record rpm readings displayed on monitor.

YES: Check complete.

LOOK: Are correct slow and fast idle speeds displayed on monitor?

NO: Check monitor inputs. See Engine Control Unit (ECU) Circuit Theory of Operation. (Group 9015-15.)

Specification Engine Slow Idle—Speed................................................................................... 900 rpm Engine Fast Idle—Speed.................................................................................. 2350 rpm

Check crankshaft position sensor circuit connections. TW73308,000011C -19-23MAY12-18/28

Park Brake Valve Leakage Hydraulic oil must be at operating temperature 66°C (150°F). Check Adjust engine speed control to slow idle with park lock lever in the LOCK (up) position. Observe charge pressure reading on the SDM. The charge pressure can be accessed as a live value in the SDM menu structure. See Standard Display Monitor (SDM) Menu Structure—Service Mode. (Group 9015-16.) Move park lock lever to the UNLOCK (down) position. LOOK: Does pressure drop as park lock lever is moved down, then returned to original value? Fully depress decel/brake pedal, then release. LOOK: Does pressure drop as decel/brake pedal is released, then returned to original value?

YES: Isolate park brakes, brake valve to locate leakage. If tracks move in neutral. Inspect park brake valve. See Park Brake Operation. (Group 9026-05.)

LOOK: Do tracks creep or move?

NO: Check complete. Continued on next page

TM10721 (03SEP14)

9005-10-7

TW73308,000011C -19-23MAY12-19/28

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=205

System Operational Checks Decelerator/Brake Pedal and Park Brake Check

CAUTION: Pushing on decel/brake pedal will stop machine abruptly. Operate engine at slow idle. Move park lock lever to the UNLOCK (down) position. Operate machine slowly in forward. Fully depress decel/brake pedal and then release. LOOK: Does machine stop when decel/brake pedal is depressed and move when pedal is released? Depress decel/brake pedal until spring resistance is felt. Adjust engine speed to fast idle and transmission speed to 3.0. Move TCL to forward position. Release decel/brake pedal. LOOK: Does machine accelerate smoothly to maximum speed?

YES: Check complete.

NOTE: Decel/brake response time can be set to operator preference. See Standard Display Monitor (SDM) Menu Structure—Service Mode. (Group 9015-16.)

NO: Inspect park brake valve. See Park Brake Operation. (Group 9026-05.) Perform Transmission Control Unit (TCU) Calibration. (Group 9015-20.) TW73308,000011C -19-23MAY12-20/28

Transmission Control Lever (TCL) Check

CAUTION: Prevent possible injury from machine movement. Make sure there is adequate room and be aware of bystanders. Operate engine at 1500 rpm. Specification Engine—Speed................................................................................................. 1500 rpm Put transmission speed to 2.0. Make several shifts from neutral to forward, neutral to reverse, and then forward to reverse. LOOK: Does machine shift smoothly? LOOK: Does machine operate in forward and reverse?

YES: Check complete.

NOTE: Transmission shift rate can be set to operator preference. Low has a slower reaction time, and high has a quicker reaction time. See Standard Display Monitor (SDM) Menu Structure—Service Mode to change transmission rates. (Group 9015-16.)

NO: Test TCL sensor. See Main Cab/Canopy Harness (W5) Wiring Diagram. (Group 9015-10.) TW73308,000011C -19-23MAY12-21/28

Transmission Speed Check

Operate engine at slow idle. Check transmission speed. Transmission speed should default to 1.6. LOOK: Does transmission speed default to 1.6? Increase transmission speed to 3.0.

YES: Check complete.

LOOK: Does transmission speed increase to 3.0?

NO: Calibrate TCU. See Transmission Control Unit (TCU) Calibration. (Group 9015-20.)

Continued on next page

TM10721 (03SEP14)

9005-10-8

TW73308,000011C -19-23MAY12-22/28

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=206

System Operational Checks Tracking and Maximum Speed Check

IMPORTANT: Track sag must be at specification and machine must be driven on a level surface for all tracking checks. Push decelerator mode switch to ENGINE MODE position. Operate engine at fast idle. Put transmission speed to 3.0. Move park lock lever to the UNLOCK (down) position. Push decelerator pedal fully to stop. Move TCL to FORWARD position. Slowly increase engine speed from slow to fast idle by slowly raising the decelerator pedal. LOOK: Does machine speed increase as engine rpm increases? Is tracking straight at all speeds?

YES: Check complete.

Repeat check for reverse travel.

NO: Perform Transmission Control Unit (TCU) Calibration. (Group 9015-20.) See Mistrack/Index Malfunctions and Machine Full Speed Malfunctions. (Group 9026-15.) TW73308,000011C -19-23MAY12-23/28

Hydraulic Controls Check

T8404AC —UN—14FEB95

Hydraulic Control Lever Positions A—Blade Tilt Right B—Blade Raise C—Blade Tilt Left D—Blade Lower E—Blade Float Operate engine at slow idle. Slowly move hydraulic control lever to all positions except blade float (E) and release. NOTE: Hydraulic control lever will not return to neutral when moved to blade float position (E). Lever must be manually pulled from float position. LOOK/FEEL: Does lever move to all positions easily and return to neutral when released?

YES: Check complete.

LOOK/FEEL: Does each hydraulic function operate smoothly without hesitation?

NO: If hydraulic control lever does not move easily or return to neutral, remove and inspect hydraulic control lever. If functions hesitate or do not operate smoothly, see Hydraulic System Diagnose Malfunctions. (Group 9025-15.)

Continued on next page

TM10721 (03SEP14)

9005-10-9

TW73308,000011C -19-23MAY12-24/28

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=207

System Operational Checks Control Valve Lift Check Test

T6583AE —UN—23AUG93

Dozer Position Operate engine at slow idle. Raise dozer blade approximately 305 mm (1.0 ft) above ground. Stop engine. Move hydraulic control lever to full raise position. LOOK: Does blade lower? Start engine Fully lower and tilt blade to the right to raise front of machine. Stop engine. Push hydraulic control lever to the power-down and tilt-right positions. LOOK: Does machine lower? Start engine and tilt blade fully to the left. Stop engine. Push hydraulic control lever to the tilt-left position.

YES: Inspect lift check in valve.

LOOK: Does machine lower?

NO: Check complete. TW73308,000011C -19-23MAY12-25/28

Blade Float Check

Operate engine at slow idle. Raise front of machine off ground by fully lowering and tilting blade. Push hydraulic control lever into float detent. LOOK: Does front of crawler lower to ground?

YES: Check complete.

FEEL: Does hydraulic control lever stay in float detent position?

NO: Check blade float detent coil. See System Functional Schematic and Section Legend. (Group 9015-10.) TW73308,000011C -19-23MAY12-26/28

Cycle Time Check

Use the standard display monitor (SDM) or Service ADVISOR™ Diagnostic Application YES: Check complete. to read engine rpm and hydraulic oil temperature. Specification Hydraulic Oil—Temperature............................................................................. 60—72°C 140—160°F Engine Fast Idle—Speed.................................................................................. 2350 rpm Blade Raise—Cycle Time.............................................................................2.3 seconds Blade Lower in Float Detent—Cycle Time..............................................................................................................1.7 seconds Blade Power Down—Cycle Time..................................................................1.3 seconds Blade Angle (left and right)—Cycle Time.......................................................3.2 seconds Blade Tilt (left)—Cycle Time.........................................................................0.8 seconds Blade Tilt (right)—Cycle Time.......................................................................0.9 seconds Do cycle times meet or exceed specification?

NO: Check hydraulic pump. See Hydraulic Pump Flow Test. (Group 9025-25.)

Service ADVISOR is a trademark of Deere & Company Continued on next page

TM10721 (03SEP14)

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TW73308,000011C -19-23MAY12-27/28

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=208

System Operational Checks Air Conditioning Check—If Equipped

TX1114381A —UN—21MAY12

Air Conditioning Controls 1— Air Conditioning Switch 2— Blower Switch 3— Temperature Control 4— Air Duct (8 used) Operate engine at fast idle. Push air conditioning switch (1) to ON position. NOTE: On position is up (snowflake). Down position is not used for this test. Turn blower switch (2) to 4th position. Wait several seconds for warm air in duct system to dissipate.

YES: Check complete.

FEEL: Is air from ducts cool?

NO: See Air Conditioning System Diagnose Malfunctions. (Group 9031-15.) TW73308,000011C -19-23MAY12-28/28

TM10721 (03SEP14)

9005-10-11

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=209

System Operational Checks

TM10721 (03SEP14)

9005-10-12

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=210

Section 9010 Engine Contents Page

Group 05—Theory Of Operation PowerTech E™ 4.5 L John Deere Engine ................................................... 9010-05-1 Cold Weather Starting Aid Operation............................................... 9010-05-1 Group 15—Diagnostic Information PowerTech E™ 4.5 L John Deere Engine ................................................... 9010-15-1 Engine Cooling System Component Location ............................. 9010-15-2 Engine Fuel System Component Location ................................................. 9010-15-3 Engine Intake and Exhaust Component Location ............................. 9010-15-9 Group 25—Tests Fluid Sampling Procedure—If Equipped ............................................... 9010-25-1 Engine Speed Check................................. 9010-25-5 Fuel System Test ....................................... 9010-25-6 Intake Manifold Pressure Test—Turbocharger Boost..................... 9010-25-7

TM10721 (03SEP14)

9010-1

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=1

Contents

TM10721 (03SEP14)

9010-2

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=2

Group 05

Theory Of Operation For additional information on John Deere PowerTech E™ engines and components, see the following component technical manuals (CTM): • PowerTech™ 4.5L & 6.8L Diesel Engines—Base Engine. (CTM104.) • POWERTECH E™ 4.5 and 6.8 L Diesel Engines—Level 16 Electronic Fuel System with Denso HPCR. (CTM502.)

M44215 —UN—07SEP88

PowerTech E™ 4.5 L John Deere Engine

PowerTech E is a trademark of Deere & Company CS33148,0002822 -19-03APR08-1/1

Cold Weather Starting Aid Operation Cold weather starting aid is activated by pushing control button on dash. Pushing control button energizes coil (C) which moves plunger (B) down, opening valve in starting fluid canister, and releasing starting fluid to the engine. Releasing control button on dash stops current flow to coil (C) allowing spring (A) to pull plunger up, closing the valve in the starting fluid canister. If engine is operated without starting fluid canister, the dust seal must be properly installed to prevent engine damage. C—Coil

T6543AB —UN—18NOV89

A—Spring B—Plunger

901005,BB11 -19-15AUG90-1/1

TM10721 (03SEP14)

9010-05-1

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=213

Theory Of Operation

TM10721 (03SEP14)

9010-05-2

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=214

Group 15

Diagnostic Information For additional information on John Deere PowerTech E™ engines and components, see the following component technical manuals (CTM): • PowerTech™ 4.5L & 6.8L Diesel Engines—Base Engine. (CTM104.) • POWERTECH E™ 4.5 and 6.8 L Diesel Engines—Level 16 Electronic Fuel System with Denso HPCR. (CTM502.)

M44215 —UN—07SEP88

PowerTech E™ 4.5 L John Deere Engine

PowerTech E is a trademark of Deere & Company CS33148,0002824 -19-03APR08-1/1

TM10721 (03SEP14)

9010-15-1

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=215

Diagnostic Information

Engine Cooling System Component Location

TX1032759 —UN—03DEC07

TX1032759 Engine Cooling System Component Location 1— Surge Tank

2— Radiator 3— Fan Shroud

4— Cooling Fan AA95137,000118A -19-03DEC07-1/1

TM10721 (03SEP14)

9010-15-2

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=216

Diagnostic Information

Engine Fuel System Component Location TX1032557 —UN—03JAN08

TX1032557 Engine Fuel System Component Location (S.N. —243763) Continued on next page

TM10721 (03SEP14)

9010-15-3

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=217

AA95137,0001189 -19-16JUL13-1/4

Diagnostic Information

TM10721 (03SEP14)

9010-15-4

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=218

Diagnostic Information 4— Fuel Tank 1— Fuel Leak-Off Line 5— Fuel Rail 2— High-Pressure Fuel Pump 3— Fuel Injection Nozzle (4 used) 6— Fuel Supply Pump 7— Final Fuel Filter

8— Fuel Supply Line 9— Primary Fuel Filter (water separator) Continued on next page

TM10721 (03SEP14)

9010-15-5

AA95137,0001189 -19-16JUL13-2/4

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=219

Diagnostic Information

TM10721 (03SEP14)

9010-15-6

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=220

Diagnostic Information

TX1138973 —UN—16JUL13

3 2 9 4

TX1138973 Engine Fuel System Component Location (S.N. 243764— ) Continued on next page

TM10721 (03SEP14)

9010-15-7

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=221

AA95137,0001189 -19-16JUL13-3/4

Diagnostic Information

TM10721 (03SEP14)

9010-15-8

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=222

Diagnostic Information 4— Fuel Tank 1— Fuel Leak-Off Line 5— Fuel Rail 2— High Pressure Fuel Pump 3— Fuel Injection Nozzle (4 used) 6— Fuel Supply Pump 7— Final Fuel Filter

8— Fuel Supply Line 9— Primary Fuel Filter (water separator) 10— Auxiliary Fuel Filter and Water Separator (If equipped) AA95137,0001189 -19-16JUL13-4/4

Engine Intake and Exhaust Component Location

1 2

6 4

TX1032760 —UN—03JAN08

TX1032760 Engine Intake and Exhaust Component Location 1— Charge Air Cooler 2— Air Filter Housing

3— Exhaust Manifold 4— Turbocharger Compressor

5— Turbocharger Turbine 6— Muffler AA95137,0001188 -19-21DEC07-1/1

TM10721 (03SEP14)

9010-15-9

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=223

Diagnostic Information

TM10721 (03SEP14)

9010-15-10

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=224

Group 25

Tests Fluid Sampling Procedure—If Equipped SPECIFICATIONS Engine Speed

Slow Idle

System Fluid Purge Volume (approximate)

100 mL 3.4 oz

Fluid Sample Volume (approximate)

75 mL 2.5 oz

TX1024519A —UN—01JUN07

This is the recommended procedure for obtaining oil samples using the John Deere sampling valve. A cap probe, plastic bag, and oil sampling kit for the appropriate system are needed for this procedure. Part numbers for the required items can be found at the end of this procedure. Fluid systems should be sampled at the following intervals:

• Each system at every oil change prior to changing oil • Engine oil: 250 hours • Engine coolant: 500 hours • Hydraulic oil: 500 hours • Transmission oil: 500 hours • Power train (axles, gearboxes): 500 hours

System Fluid Purge (excavator shown)

Machine Preparation 1. Start the machine and warm system to normal operating temperature. Operate machine functions so that the fluid is agitated throughout the system. 2. Once the system has reached operating temperature, operate engine at slow idle. Specification Engine—Speed..........................................................................Slow Idle

Specification System Fluid Purge—Volume (approximate)............................................................................... 100 mL 3.4 oz

3. Properly dispose of collected waste fluid. 4. If oil flow needs to be increased to obtain a representative sample, accelerate the flow of the system by increasing the engine speed to high idle while taking the sample.

3. Locate sample valve on unit and clean the area around the valve prior to removing dust cap. This will reduce additional fluid sample contamination. See Fluid Sampling Test Ports—If Equipped. (Operator's Manual.) 4.

Once the area has been cleaned, remove the dust cap from the valve.

Priming Sample Valve Oil must be purged from the system to ensure a representative sample is collected in the test collection bottle. The appropriate amount of waste oil is determined by the distance of the sampling valve from the flow of the system. It is recommended one full sample bottle, equal to 100 mL (3.4 oz), be purged from a remotely mounted valve prior to collecting the sample. 1. Connect probe to sample valve by placing the probe end into the valve port. 2. Press and hold the probe to release an appropriate amount of fluid into a waste container. Continued on next page

TM10721 (03SEP14)

9010-25-1

KK70125,0000C2E -19-05OCT09-1/6

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=225

Tests Obtaining Fluid Sample NOTE: This step is best done in a clean environment, rather than at the sample site.

TX1024509A —UN—31MAY07

1. Place the sample bottle from the sample kit into plastic bag. Seal plastic bag.

Place Sample Bottle in Plastic Bag KK70125,0000C2E -19-05OCT09-2/6

2. Remove the lid from the sample container, while keeping bottle inside plastic bag. Move the lid aside within the plastic bag, so that the bottle opening is accessible.

TX1024510A —UN—31MAY07

When collecting hydraulic or power train samples, be careful to hold the sheet of plastic (located under the lid) to the top of the bottle. This will ensure that the protective plastic is not removed when the lid is taken off.

Remove Lid of Sample Bottle (in plastic bag) Continued on next page

TM10721 (03SEP14)

9010-25-2

KK70125,0000C2E -19-05OCT09-3/6

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=226

Tests

NOTE: The plastic bag creates a protective covering for the sample so that external contaminants are not introduced into the fluid sample.

TX1024514A —UN—01JUN07

3. Holding bag tight across bottle, puncture hole in bag with cap probe line and insert line about 13 mm (0.5 in.) into the sample bottle.

Puncture Plastic Bag with Cap Probe Line Continued on next page

TM10721 (03SEP14)

9010-25-3

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450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=227

Tests

4. While holding cap probe line inside the bottle, press and hold the cap probe to the valve to release the sample fluid into the bottle that is still secured within the plastic bag. 5. Fill the sample bottle about 3/4 full of fluid.

TX1024515A —UN—01JUN07

Specification Fluid Sample—Volume (approximate)................................................................................. 75 mL 2.5 oz

6. Once a representative sample has been obtained, remove the tube and return the lid to the container, leaving the lid and bottle inside the plastic bag and the protective plastic sheet attached underneath the lid (if applicable). When properly performed, sample oil will be warm, indicating that all stagnant fluid was removed during the purge process and not sent to the lab.

Collect Sample Fluid (excavator shown)

NOTE: Cap probes are to be used for only one sampling procedure. 7. Install the dust cap to the sample valve, and properly dispose of the cap probe. 8. Fill out the sample information form completely, and submit the form and sample to the designated regional lab for testing. Fluid Analysis Sampling Materials Summary Part Number

Description

AT317904

Engine Test Kit

AT303189

Hydraulic and Power Train Test Kit

AT180344

Diesel Fuel Test Kit

AT183016

Coolant Test Kit

TY26349

1/4" Suction Pump Tubing, 100ft.

AT308579

120 mL Sample Bottle

AT315231

Poly Cap Probe

AT321211

Probe Style Sample Valve with Attached Cap, -4 SAE O-Ring

AT306111

Probe Style Sample Valve with Attached Cap, -6 SAE O-Ring

TY26363

Probe Style Sample Valve with Attached Cap, 1/4"-20 NPT

AT306133

Probe Style Sample Valve with Attached Cap, 1/8"-27 NPT

AT320593

Probe Style Sample Valve with Attached Cap, -6 ORFS Female

AT312932

Probe Style Sample Valve with Attached Cap, -8 ORFS Female

TY26364

90° Push Button Sample Valve with attached Cap, 1/8"-27 NPT

TY26365

Sample Valve Actuator Tubing Adaptor Fitting, KST Series Probe

N/A

Plastic Bag Continued on next page

TM10721 (03SEP14)

9010-25-4

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450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=228

Tests

Engine Speed Check

4. Move engine speed control switch to fast idle position and verify that fast idle is to specification.

SPECIFICATIONS Slow Idle Speed

900 rpm

Fast Idle Speed

2350 rpm

Specification Fast Idle—Speed....................................................................... 2350 rpm

CAUTION: Prevent possible injury from unexpected machine movement. Machine must be in neutral when performing this test.

IMPORTANT: Engine rpm can not be adjusted. 5. If slow or fast idle is not within specifications, check the following:

1. Run engine until it is at normal operating temperature. 2. Cycle engine speed control switch from slow to fast idle position. NOTE: Use standard display monitor (SDM) to observe engine speed by accessing the SDM menu structure. See Standard Display Monitor (SDM) Menu Structure—Service Mode. (Group 9015-16.)

• Check for diagnostic trouble codes (DTCs). See

Reading Diagnostic Trouble Codes with Service ADVISOR™ Diagnostic Application. (Group 9015-20.) • Check fuel filter and fuel system. • Check air cleaner elements. • Check engine control unit (ECU). See Engine Control Unit (ECU) Circuit Theory of Operation. (Group 9015-15.)

3. Move engine speed control switch to slow idle position and verify that slow idle is to specification. Specification Slow Idle—Speed........................................................................ 900 rpm TW73308,000011D -19-02JAN08-1/1

TM10721 (03SEP14)

9010-25-5

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=229

Tests

Fuel System Test

SPECIFICATIONS Loaded Transfer Pump Rated Pressure (minimum)

6.9 kPa 0.069 bar 1.0 psi

SERVICE EQUIPMENT AND TOOLS JT02161 Pressure Transducer 3500 kPa (35 bar) (500 psi) JT02156A Digital Pressure and Temperature Analyzer Clear Hose

This procedure is used to test for a suction leak in the fuel system. 1. Remove plug in left rear port (1) on fuel filter. Install appropriate size adapter fitting and JT02161 Pressure Transducer. 2. Connect JT02156A Digital Pressure and Temperature Analyzer.

TX1033840 —UN—02JAN08

3. Disconnect fuel return line connection at upper left rear of engine near exhaust manifold. IMPORTANT: Prevent possible damage to clear hose. Exhaust manifold may be hot. Keep clear hose away from exhaust manifold. 4. Install appropriate size clear hose (4) onto end of return fuel line (2). 5. Install other end of clear hose (4) to fuel line (3).

1— Left Rear Port 2— Fuel Return Line

6. Position excess clear hose above system in a loop. 7. Start machine. Reading at fuel pressure inlet should be at or above specification. Specification

3— Fuel Line 4— Clear Hose

8. If air flows through fuel in clear hose, there is a suction leak in fuel system.

Loaded Transfer Pump—Rated Pressure (minimum).................................................................................... 6.9 kPa 0.069 bar 1.0 psi SJ25320,00006F1 -19-02JAN08-1/1

TM10721 (03SEP14)

9010-25-6

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=230

Tests

Intake Manifold Pressure Test—Turbocharger Boost 70—90°C 160—200°F

Engine Fast Idle Speed

2350 rpm

Engine Rated Speed

2200 rpm

Transmission Speed Position

1.6

450J LT Turbocharger Boost Pressure (minimum)

34.5 kPa 0.3 bar 5.0 psi

450J LGP Turbocharger Boost Pressure (minimum)

41.4 kPa 0.4 bar 6.0 psi

550J LT Turbocharger Boost Pressure (minimum)

41.4 kPa 0.4 bar 6.0 psi

550J LGP Turbocharger Boost Pressure (minimum)

48.3 kPa 0.5 bar 7.0 psi

650J LT and LGP Turbocharger Boost Pressure (minimum)

55.2 kPa 0.5 bar 8.0 psi

TX1033258A —UN—12DEC07

SPECIFICATIONS Engine Coolant Temperature

1— Test Fitting

a. On display monitor (SDM), enter service mode by pushing and holding MENU for approximately 5 seconds until three beeps are heard and SERVICE MODE is temporarily displayed on the screen. b. Select MACHINE SETTINGS from the SDM main menu.

SERVICE EQUIPMENT AND TOOLS

c. Select BRAKE MODE from the submenu and set the brake mode to test. See Standard Display Monitor (SDM) Menu Structure—Service Mode. (Group 9015-16.)

JT02161 Transducer 3500 kPa (35 bar) (500 psi) JT02156A Digital Pressure and Temperature Analyzer

This procedure is used only as a guide to determine engine condition. Test must be done in area that allows driving the machine back and forth to circulate hydrostatic (HST) oil between test runs. If test is done in confined area, machine must be supported on stands so track can turn to circulate HST oil. NOTE: New engines may not develop specified boost pressure. Do not test before engine has completed 50 hours of operation. Turbocharger Boost Pressure Test should only be used as a general indicator of engine performance.

NOTE: The BRAKE menu selection will default to normal operation if key is cycled off to on. 5. Disable the decelerator mode with switch on instrument panel. See Main Cab/Canopy Harness (W5) Component Location. (Group 9015-10.) 6. Access engine RPM from the main menu screen on the standard display monitor (SDM). a. Select DIAGNOSTICS from SDM main menu screen.

NOTE: Reduce boost pressure specifications by 7% if No. 1 fuel is used.

b. Select LIVE VALUES from the machine settings submenu screen.

Machines are shipped from the factory with No. 1 fuel. 1.

2— JT02161 Transducer

c. Select SPEEDS from the live values submenu screen. Engine Speed then appears on the screen.

Install test fitting (1) in intake manifold at location shown.

7. Run engine at fast idle and compare fast idle speed to specifications. Test must be done at fast idle.

2. Connect JT02161 Transducer (2) to test fitting (1) and connect JT02156A Digital Pressure and Temperature Analyzer.

Specification Engine Fast Idle—Speed............................................................................... 2350 rpm

3. Warm engine to operating temperature. Specification Engine Coolant—Temperature.....................................................................................70—90°C 160—200°F

CAUTION: Unexpected movement of tracks can cause personal injury. Park lock lever must be in up position for this test. Doing this test with park lever down will cause tracks to turn.

4. Enable brake control using SDM menu as follows: Continued on next page

TM10721 (03SEP14)

9010-25-7

TW73308,000011E -19-10JAN08-1/2

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=231

Tests 8. Pull park lock lever to up position and set transmission speed to specification. Specification Transmission Speed—Position.................................................................................. 1.6

IMPORTANT: To prevent damage to multi-function valves, the test software limits the test function to 20 seconds before returning TCU to neutral. The TCL must be manually returned to neutral to reset test program. The tracks must be operated between test function to prevent localized overheating of multi-function valves. Rotating the tracks will circulate some hot oil out of closed loop circuit to the hydrostatic oil reservoir for cooling. a. Depress foot pedal to lower stop and hold in that position. b. Push transmission control lever (TCL) to forward detent. c. Slowly release foot pedal and pull engine down to rated speed. Record highest pressure reading.

550J LT—Turbocharger Boost Pressure (minimum).................................................................................. 41.4 kPa 0.4 bar 6.0 psi 550J LGP—Turbocharger Boost Pressure (minimum).......................................................................... 48.3 kPa 0.5 bar 7.0 psi 650J LT and LGP—Turbocharger Boost Pressure (minimum).................................................................................. 55.2 kPa 0.5 bar 8.0 psi

9. Return TCL to neutral for approximately 15 seconds before repeating test procedure. 10. Repeat test procedure at least four times and use the highest reading to compare to specification. 11. If boost pressure is too low, check and repair as required the following:

• Restricted air filter elements • Restricted fuel filter elements • Exhaust manifold leaks • Intake manifold leaks • Malfunctioning fuel transfer pump • Low compression pressure • Malfunctioning fuel injection nozzles • Carbon buildup in turbocharger • Turbocharger compressor or turbine wheel rubbing

Specification Engine Rated—Speed............................................................... 2200 rpm

IMPORTANT: Engine must be pulled down to rated speed of 2200 rpm. If rated speed is not achieved, it may be necessary to move TCL lever to right or left steering position to obtain 2200 rpm. Specification 450J LT—Turbocharger Boost Pressure (minimum).................................................................................. 34.5 kPa 0.3 bar 5.0 psi 450J LGP—Turbocharger Boost Pressure (minimum).......................................................................... 41.4 kPa 0.4 bar 6.0 psi

housing

• Low fuel delivery from high fuel pressure pump 12. Return machine settings to operator's preference. Review TCU Display Structure and see Transmission Control Unit (TCU) Circuit Theory of Operation. (Group 9015-15.) Also see Standard Display Monitor (SDM) Menu Structure—Service Mode. (Group 9015-16.)

TW73308,000011E -19-10JAN08-2/2

TM10721 (03SEP14)

9010-25-8

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=232

Section 9015 Electrical System Contents Page Page

Group 05—System Information Electrical Diagram Information .................. 9015-05-1 Group 10—System Diagrams Fuse and Relay Specifications .................. 9015-10-1 System Functional Schematic, Wiring Diagram, and Component Location Legend .................................... 9015-10-5 System Functional Schematic and Section Legend...................................... 9015-10-9 Power and Ground Cables (W1) Component Location ........................... 9015-10-54 Cab Roof Harness (W4) Component Location ........................... 9015-10-55 Cab Roof Harness (W4) Wiring Diagram ............................................... 9015-10-57 Main Cab/Canopy Harness (W5) Component Location ........................... 9015-10-67 Main Cab/Canopy Harness (W5) Wiring Diagram.................................... 9015-10-75 Engine Harness (W6) Component Location ............................................. 9015-10-123 Engine Harness (W6) Wiring Diagram ............................................. 9015-10-131 Transmission Harness (W7) Component Location ......................... 9015-10-146 Transmission Harness (W7) Wiring Diagram ............................................. 9015-10-151 A/C Harness (W8) Component Location ............................................. 9015-10-162 A/C Harness (W8) Wiring Diagram ............................................. 9015-10-165 Radio Harness (W9) Component Location ............................................. 9015-10-168 Radio Harness (W9) Wiring Diagram ............................................. 9015-10-170 Canopy Auxiliary Light Harness (W11) Component Location ............... 9015-10-172 Canopy Auxiliary Light Harness (W11) Wiring Diagram ....................... 9015-10-175 Grill Harness (W13) Component Location ............................................. 9015-10-177 Grill Harness (W13) Wiring Diagram ............................................. 9015-10-179 Integrated Grade Control (IGC) Machine Harness (W21) Component Location—If Equipped ........................................... 9015-10-182 Integrated Grade Control (IGC) Machine Harness (W21) Wiring Diagram—If Equipped ....................... 9015-10-185

Integrated Grade Control (IGC) Cab Harness (W22) Component Location—If Equipped ....................... 9015-10-188 Integrated Grade Control (IGC) Cab Harness (W22) Wiring Diagram—If Equipped ....................... 9015-10-190 Charge Pressure Sensor Harness (W25) Wiring Diagram (S.N. 173345— )......................................... 9015-10-194 JDLink™ System Harnesses Component Location—MIG/GTT .............. 9015-10-194 JDLink™ System Harnesses Component Location—MTG/SAT.............. 9015-10-198 JDLink™ System Wiring Diagrams—MIG/GTT......................... 9015-10-200 JDLink™ Ground Harness (W32) Wiring Diagram—If Equipped ............ 9015-10-212 JDLink™ System Wiring Diagrams—MTG/SAT ........................ 9015-10-213 Group 15—Sub-System Diagnostics Starting and Charging Circuit Theory of Operation............................... 9015-15-1 Controller Area Network (CAN) Circuit Theory of Operation ................... 9015-15-3 Engine Control Unit (ECU) Circuit Theory of Operation............................... 9015-15-5 Standard Display Monitor (SDM) Circuit Theory of Operation ................. 9015-15-15 Transmission Control Unit (TCU) Circuit Theory of Operation ................. 9015-15-19 Integrated Grade Control (IGC) Circuit Theory of Operation—If Equipped ............................................. 9015-15-22 JDLink™ Circuit Theory of Operation—If Equipped ....................... 9015-15-25 Group 16—Monitor Operation Standard Display Monitor (SDM) Menu Structure—Service Mode...................................................... 9015-16-1 Standard Display Monitor (SDM)—Change Units........................... 9015-16-4 Standard Display Monitor (SDM)—Hide/Unhide Main Menu...................................................... 9015-16-4 Standard Display Monitor (SDM)—Setting Hour Meter .................. 9015-16-5

Continued on next page

TM10721 (03SEP14)

9015-1

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=1

Contents

Page

Group 20—References Service ADVISOR™ Diagnostic Application ............................................. 9015-20-1 Service ADVISOR™ Connection Procedure .............................................. 9015-20-1 Reading Diagnostic Trouble Codes with Service ADVISOR™ Diagnostic Application ........................... 9015-20-3 JDLink™ System Identification.................. 9015-20-5 JDLink™ Connection Procedure—If Equipped ........................ 9015-20-8 Alternator Test ........................................... 9015-20-9 CAN Circuit Test ...................................... 9015-20-10 Controller Area Network (CAN) Diagnostics .........................................9015-20-10 Electrical Component Specifications ...................................... 9015-20-16 Transmission Control Unit (TCU) Calibration ........................................... 9015-20-19 Integrated Grade Control (IGC) Checks—If Equipped ..........................9015-20-19 IGC System Checks ................................9015-20-19 Integrated Grade Control (IGC) Diagnose Malfunctions—If Equipped .............................................9015-20-24 All Blade Functions Do Not Operate in Manual or Auto Modes ........................9015-20-24 All Blade Functions Operate Normally in Manual Mode, But Not in Auto Mode ...................................................9015-20-28 All Blade Functions Operate Normally in Auto Mode, But Not in Manual Mode ...................................................9015-20-31 Blade Lift and Tilt Operate Normally in Auto Mode, But Not in Manual Mode ...................................................9015-20-33 Blade Lift and Tilt Operate Normally, But Blade Angle Does Not ..................9015-20-34 Blade Lift and Angle Operate Normally, But Blade Incr/Decr Does Not.......................................................9015-20-36 Blade Response Is Not Smooth ..............9015-20-37 All Blade Functions Are Slow or Sluggish ..............................................9015-20-39 Blade Response Is Too Fast....................9015-20-39 Blade Moves Quickly (Jumps) to One Side, Then Slowly Comes Back on Grade ..................................................9015-20-40 Waves in Graded Surface .......................9015-20-41 Decelerator/Brake Pedal Adjustment........................................... 9015-20-42 Engine Speed Control Remove and Install ............................................ 9015-20-43 Rotary Sensor Remove and Install ................................................... 9015-20-44 Transmission Control Lever (TCL) Adjustment........................................... 9015-20-45 Replace WEATHER PACK™ Connector ............................................ 9015-20-47 TM10721 (03SEP14)

Install WEATHER PACK™ Contact ................................................ 9015-20-48 Replace DEUTSCH™ Connectors .......................................... 9015-20-49 Replace DEUTSCH™ Rectangular or Triangular Connectors ..................... 9015-20-50 Install DEUTSCH™ Contact.................... 9015-20-51 Repair 32 and 48 Way CINCH™ Connectors .......................................... 9015-20-52 Replace (Pull Type) Metri-Pack™ Connectors .......................................... 9015-20-55 Replace (Push Type) Metri-Pack™ Connectors .......................................... 9015-20-56

9015-2

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=2

Group 05

System Information Electrical Diagram Information NOTE: All System Functional Schematics, Circuit Schematics, and Wiring Diagrams are shown with key switch in the OFF position.

Continued on next page

TM10721 (03SEP14)

9015-05-1

KK70125,00005B4 -19-16FEB11-1/4

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=235

System Information

System Functional Schematic Diagram 1

BLOWER POSITION OFF (0) LOW (1) MOTOR MED (2) SPEED HIGH (3) SWITCH PURGE (4)

B 1 2 3 4

ORG

0 1 2 3

ORG

S7 BLOWER MOTOR SPEED SWITCH

ORG

RED

BLK

ORG

TO B:27 X3 (PIN 26)

F16 BLOWER MOTOR 15A FUSE

RED CABLE

9 1

G1 BATTERIES

K1 STARTER RELAY

BLK

W2 GROUND AT STARTER MOTOR

BLK

BLK BLK

TX1087288

W2 GROUND AT STARTER MOTOR

TX1087288 —UN—24JUN11

4 BLK

System Functional Schematic Diagram

Continued on next page

TM10721 (03SEP14)

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450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=236

System Information 1— Continuity Chart 4— Wire Identification 2— Wire Bundle 5— Wire Splice 3— Routing Location Information 6— Coordinate Letter

7— Coordinate Number 8— Component Name 9— Component Identification Number

The System Functional Schematic is made up of sections which contain one harness. The harnesses are separated by dashed lines and are laid out to match their relative position on the machine. Components can easily be found by using the coordinate system. The coordinate letter (6) is located on the left and right sides of the schematic while the coordinate number (7) is located on the top and bottom. Each electrical component is shown by a schematic symbol (10), the component name (8), and a component identification number (9). A component identification number and name will remain the same throughout the Operation and Test Technical Manual. This will allow for easy cross-referencing of all electrical drawings (Schematics, Wiring Diagrams, and Component Location). A continuity chart (1) is included for each multi-terminal switch.

When two or more wires converge to form a single dark line, it is a wire bundle (2). A wire bundle represents a group of wires that can be easily followed but are not joined together. Routing location information (3) is presented to let the reader know when a wire is connected to a component in another section. TO and FROM statements identify when power is going “To” or coming “From” a component in a different location. Both the coordinate letter and number will be called out separated by a colon. The component number and pin number are given at the bottom of the statement. In the example, power is coming from component X3 ECU connector 3, in coordinate B:27. A wire splice (5) is represented by two or more wires connected by a dot.

Continued on next page

TM10721 (03SEP14)

10— Component Schematic Symbol

9015-05-3

KK70125,00005B4 -19-16FEB11-3/4

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=237

System Information Wiring Diagram

END #1 V11 Y16 X4 G3/G4 X49 X49 X49 X49 X49 X49 X38 Y35 Y36 X4 G3/G4 W27 V11 Y16 X145 X37 G3/G4 B4 B3 B19 B23

NUMBER A06 A06A A06B B01 E05 E06 E07 E08 E09 E10 E13 E15 E15A E15B G03 G03A G03B G03C G03D H13 J08 M03 M04 M06 N02

COLOR ORG ORG ORG RED WHT GRY GRN ORG BLU BRN WHT RED RED RED BLK BLK BLK BLK BLK GRN TAN PUR PUR PUR YEL

10 END #2 X144 X144 X144 M1 X4 X4 X4 X4 X4 X4 X4 X147 X147 X147 W27 X148 X148 X148 W27 X4 X4 X4 X4 X4 X4

R02

Y02

B17 A

5 2

4 B A

A B

P11

B19

M06

Y35

E15

1 R17

Y36 6 X147 E15A

SIDE A

E15B E15 E15A

R04

M04

TX1088140

R16

TX1088140 —UN—18FEB11

SIDE B

Wiring Diagram Example

KK70125,00005B4 -19-16FEB11-4/4

TM10721 (03SEP14)

9015-05-4

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=238

System Information 1— Component Identification Number 2— Connector 3— Connector Face View

4— Wire Harness 5— Wire Number 6— Wire Splice 7— Wire End #1 Termination Location

Each harness on the machine is drawn showing connectors, wires, and splices. A “W” component identification number identifies harnesses. (W6, etc.) The harness is drawn showing spatial arrangement of components and branches. A component identification or connector number (1) identifies each component. The wire harness (4) is terminated by a top or side view of the connector (2). If more than one wire is supplied to the connector, a harness side connector face view (3) is provided. Each wire number is labeled for the appropriate pin. If only one wire is supplied to the connector, the wire number (5) is indicated. An “X” component identification number of 100 or higher identifies splices (6). Each splice lists side A wires and side B wires to differentiate the side of the harness that the wires come from.

8— Wire Number 9— Wire Color 10— Wire End #2 Termination Location

A wire legend is provided for each harness. A component identification number is listed in the “END #1” column (7) to indicate the termination location of one end of a wire. In the center, the wire number (8) and wire color (9) are listed. A component identification number in the “END #2” column (10) identifies the opposite end of the wire. Component Location Diagram The Component Location Diagram is a pictorial view by harness showing location of all electrical components, connectors, harness main ground locations and harness band and clamp location. Each component will be identified by the same identification letter/number and description used in the System Functional Schematic Diagram. KK70125,00005B4 -19-16FEB11-5/4

TM10721 (03SEP14)

9015-05-5

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=239

System Information

TM10721 (03SEP14)

9015-05-6

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=240

Group 10

System Diagrams Fuse and Relay Specifications IMPORTANT: Install fuse with correct amperage rating to prevent electrical system damage from overload.

NOTE: Load center 1 (A4) and load center 2 (A5) are located in the cab under the right console. See Main Cab/Canopy Harness (W5) Component Location. (Group 9015-10.)

F10

Engine Control Unit (ECU) and Standard Display Monitor (SDM) Unswitched Power In-Line 10-Amp Fuse (F7). See Engine Harness (W6) Component Location. (9015-10.)

F11

F12

F13

JDLink™ ground 5-Amp fuse (F31) is located in the battery compartment. See JDLink™ System Harnesses (W30, W31, and W32) Component Location—If Equipped. (Group 9015-10.)

F14

F17 F18

Accessory relay (K2) is located in the cab under the right console. See Main Cab/Canopy Harness (W5) Component Location. (Group 9015-10.) F18— Auxiliary Lights 25-Amp Circuit Breaker (marked as CB2) F21— Start Relay 10-Amp Fuse F22— Transmission Control Unit (TCU) Switched Power 10-Amp Fuse F23— Standard Display Monitor (SDM) Switched Power 5-Amp Fuse F24— Engine Control Unit (ECU) Switched Power 5-Amp Fuse F25— Start Aid/Alternator Excitation 15-Amp Fuse F26— JDLink™ Switched Power 5-Amp Fuse F27— Under-Seat Heater 20-Amp Fuse (marked as ROPS Heater) F28— Switch Backlights 5-Amp Fuse F29— Integrated Grade Control (IGC) 5-Amp Fuse K3—Horn Relay K4—Transmission Control Unit (TCU) and Standard Display Monitor (SDM) Relay K5—A/C Relay #1 K6—A/C Relay #2 V1— Alternator Excitation Diode

Load Center 1 (A4) (S.N. —210219)

F21 K3

F22 F23

F24 F25

F26 F27

F28 F29 V1

TX1032900 —UN—03DEC07

F1— Horn 10-Amp Fuse F2— Service ADVISOR™ 10-Amp Fuse F3— Radio Unswitched Power 10-Amp Fuse F4— A/C 15-Amp Fuse 1 F5— A/C 15-Amp Fuse 2 F6— JDLink™ Unswitched Power 10-Amp Fuse F8— Heater Blower 15-Amp Fuse F9— Power Outlet 10-Amp Fuse F10— Radio and Dome Light Switched Power 10-Amp Fuse F11— Air Seat 15-Amp Fuse F12— Heater Valve 5-Amp Fuse F13— Spare 5-Amp Fuse F14— Front and Rear Wipers 15-Amp Fuse F16— Left and Right Wipers 15-Amp Fuse F17— Lights 20-Amp Circuit Breaker (marked as CB1)

TX1032898 —UN—03DEC07

F16

Start relay (K1) is located in the engine compartment near the starter motor. See Engine Harness (W6) Component Location. (Group 9015-10.)

Load Center 2 (A5) (S.N. —210219) Service ADVISOR is a trademark of Deere & Company JDLink is a trademark of Deere & Company Continued on next page

TM10721 (03SEP14)

9015-10-1

CS33148,0002826 -19-11AUG14-1/4

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=241

System Diagrams

F10

F11

F12

F13

F21 F22

F23 F24

F25 F26

F14 F16

F27

F17

F29

F18

TX1142076 —UN—09AUG13

F28

TX1142076 Load Center 1 (A4) and Load Center 2 (A5) (S.N. 210220—243763) F1— Horn 10-Amp Fuse F9— Power Outlet 10-Amp Fuse F2— Service ADVISOR™ 10-Amp F10— Radio and Dome Light Fuse Switched Power 10-Amp F3— Radio Unswitched Power Fuse 10-Amp Fuse F11— Air Seat 15-Amp Fuse F4— A/C 15-Amp Fuse 1 F12— Heater Valve 5-Amp Fuse F5— A/C 15-Amp Fuse 2 F13— Spare 5-Amp Fuse F6— JDLink™ Unswitched Power F14— Front and Rear Wipers 10-Amp Fuse 15-Amp Fuse F8— Heater Blower 15-Amp Fuse F16— Left and Right Wipers 15-Amp Fuse F17— Lights 20-Amp Fuse F18— Auxiliary Lights 25-Amp Fuse F21— Start Relay 10-Amp Fuse

F22— Transmission Control Unit F28— Switch Backlights 5-Amp (TCU) Switched Power Fuse 10-Amp Fuse F29— Integrated Grade Control F23— Standard Display Monitor (IGC) 5-Amp Fuse (SDM) Switched Power K3—Horn Relay 5-Amp Fuse K4—Transmission Control Unit F24— Engine Control Unit (ECU) (TCU) and Standard Display Switched Power 5-Amp Monitor (SDM) Relay Fuse K5—A/C Relay #1 F25— Start Aid/Alternator K6—A/C Relay #2 Excitation 15-Amp Fuse V1— Alternator Excitation Diode F26— JDLink™ Switched Power 5-Amp Fuse F27— Under-Seat Heater 20-Amp Fuse (marked as ROPS Heater)

Service ADVISOR is a trademark of Deere & Company JDLink is a trademark of Deere & Company Continued on next page

TM10721 (03SEP14)

9015-10-2

CS33148,0002826 -19-11AUG14-2/4

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=242

System Diagrams

F10

F11

F12

F13

F21 F22

F23 F24

F25 F26

F14 F16

F27 F28

F17 F17

F29

F18

TX1142077 —UN—09AUG13

TX1142077 Load Center 1 (A4) and Load Center 2 (A5) (S.N. 243764— ) F1— Horn 10-Amp Fuse F10— Radio and Dome Light F2— Service ADVISOR™ 10-Amp Switched Power 10-Amp Fuse Fuse F3— Radio Unswitched Power F11— Air Seat 15-Amp Fuse 10-Amp Fuse F12— Heater Valve 5-Amp Fuse F4— A/C 15-Amp Fuse 1 F13— Spare 5-Amp Fuse F5— A/C 15-Amp Fuse 2 F14— Front and Rear Wipers F6— JDLink™ Unswitched Power 15-Amp Fuse 10-Amp Fuse F16— Left and Right Wipers F8— Heater Blower 15-Amp Fuse 15-Amp Fuse F9— Power Outlet 10-Amp Fuse F17— Fuel Filter Heater 20-Amp Fuse (A4) F17— Lights 20-Amp Fuse (A5) F18— Auxiliary Lights 25-Amp Fuse

F21— Start Relay 10-Amp Fuse F28— Switch Backlights 5-Amp F22— Transmission Control Unit Fuse (TCU) Switched Power F29— Integrated Grade Control 10-Amp Fuse (IGC) 5-Amp Fuse F23— Standard Display Monitor K3—Horn Relay (SDM) Switched Power K4—Transmission Control Unit 5-Amp Fuse (TCU) and Standard Display F24— Engine Control Unit (ECU) Monitor (SDM) Relay Switched Power 5-Amp K5—A/C Relay #1 Fuse K6—A/C Relay #2 F25— Start Aid/Alternator V1— Alternator Excitation Diode Excitation 15-Amp Fuse F26— JDLink™ Switched Power 5-Amp Fuse F27— Under-Seat Heater 20-Amp Fuse (marked as ROPS Heater)

Service ADVISOR is a trademark of Deere & Company JDLink is a trademark of Deere & Company Continued on next page

TM10721 (03SEP14)

9015-10-3

CS33148,0002826 -19-11AUG14-3/4

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=243

System Diagrams

For IGC load center location, see Integrated Grade Control (IGC) Machine Harness (W21) Component Location—If Equipped. (Group 9015-10.) F105— Integrated Grade Control (IGC) Unswitched Power 10-Amp Fuse F106— Integrated Grade Control (IGC) Unswitched Power 10-Amp Fuse K101— Integrated Grade Control (IGC) Switched Power Relay K102— Blade Control Joystick (BCJ) and Electrohydraulic Controller Relay

K101

F101 F102

K102

F103 F104 F105 F106

TX1017715 —UN—17JAN07

F101— Integrated Grade Control (IGC) Switched Power 15-Amp Fuse F102— Blade Control Joystick (BCJ) 5-Amp Fuse F103— Electrohydraulic Controller 10-Amp Fuse F104— Integrated Grade Control (IGC) Unswitched Power 10-Amp Fuse

Integrated Grade Control (IGC) Load Center (A8)—If Equipped CS33148,0002826 -19-11AUG14-4/4

TM10721 (03SEP14)

9015-10-4

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=244

System Diagrams

System Functional Schematic, Wiring Diagram, and Component Location Legend NOTE: A1—Transmission Control Unit (TCU) (SE5, W5)

• B31—Manifold Air Temperature Sensor (MAT) (SE9,

A1 indicates component identification number.

• B33—Charge Pressure Sensor (S.N. —173344) (SE6,

W6) W7)

Transmission Control Unit (TCU) indicates component name.

• B35—Fuel Level Sensor (SE13, W7) • B40—Transmission Oil Temperature Sensor (SE12, W6) • B41—Charge Pressure Sensor (S.N. 173345— ) (SE6,

SE5 indicates the section number of the System Functional Schematic where the component is located.

W7)

• B50—A/C (High/Low) Binary Pressure Switch (SE15,

W5 is the identification number of the harness the component is located on. This would indicate that the TCU is connected to W5 Main Cab/Canopy Harness.

• A1—Transmission Control Unit (TCU) (SE5, W5) • A2—Radio (12-Volt) (SE18, W9) • A3—Engine Control Unit (ECU) (SE9, SE10, W6) • A4—Load Center 1 (W5) • A5—Load Center 2 (W5) • A8—IGC Load Center—If Equipped (SE28, W21) • A9—Blade Control Joystick (BCJ)—If Equipped (SE30, W22)

• A11—Electrohydraulic Controller (EHC)—If Equipped (SE30, W22)

W8)

• B60—Water In Fuel (WIF) Sensor (SE8, W6, or W7) • B70—Camshaft Position Sensor (SE9, W6) • E1—Dome Light (SE18, W4) • E2—Rear Light (SE20, W5) • E3—Front Light Left (SE20, W13) • E4—Front Light Right (SE20, W13) • E5—Rear Auxiliary Light Right (SE21, W4, W11) • E6—Rear Auxiliary Light Left (SE21, W4, W11) • E7—Front Auxiliary Light Left (SE21, W4, W11) • E8—Front Auxiliary Light Right (SE21, W4, W11) • F1—Horn 10-Amp Fuse (SE3, W5) • F2—Service ADVISOR™ 10-Amp Fuse (SE7, W5) • F3—Radio Unswitched Power 10-Amp Fuse (SE18, W5)

• A12—Machine Information Gateway (MIG)

• A13—GlobalTRACS® Terminal (GTT) Controller—If Equipped (SE23, W31)

• F4—A/C 15-Amp Fuse #1 (SE15, W5) • F5—A/C 15-Amp Fuse #2 (SE15, W5) • F6—JDLink™ Unswitched Power 10-Amp Fuse (SE22,

• A6000—JDLink™ Modular Telematics Gateway (MTG) Control Unit (SE27, W6002)

• F7—Engine Control Unit (ECU) and Standard Display

Controller—If Equipped (SE24, SE25, W30)

• A6001—GPS/Cellular Antenna (SE27, W6002) • A6002—Satellite (SAT) Control Unit (if equipped) (SE27, W6002)

• A6003—Satellite Antenna (if equipped) (SE27, W6002) • B1—Decelerator Sensor (SE4, W5) • B2—TCL Sensor (SE4, W5) • B3—Motor Speed Sensor Right (SE6, W7) • B4—Transmission Speed Control Sensor (SE4, W5) • B5—Steer Sensor (SE4, W5) • B6—Crankshaft Position Sensor (SE9, W6) • B7—Motor Speed Sensor Left (SE6, W7) • B8—Pump Pressure Control Pilot (PCP) Rear (SE4, W6)

• B9—Pump Pressure Control Pilot (PCP) Front (SE4, W6)

• B10—Fuel Rail Pressure Sensor (SE8, W6) • B12—Engine Coolant Temperature Sensor (SE8, W6) • B13—Winch Pressure Switch (SE14, W5) • B14—Engine Oil Pressure Sensor (SE9, W6) • B15—Transmission Oil Filter Restriction Switch (SE13, W7)

• B16—Hydraulic Oil Filter Restriction Switch (SE13, W7) • B18—Engine Air Filter Restriction Switch (SE12, W6) • B20—Right Speaker (SE18, W9) • B21—Left Speaker (SE18, W9) • B22—A/C Freeze Switch (SE15, W8) • B25—Hydraulic Oil Temperature Sensor (SE13, W7) • B26—Heater Temperature Control (SE14, W4) • B28—Horn (SE3, W13) • B29—Fuel Temperature Sensor (SE8, W6)

SE26, W5)

Monitor (SDM) Unswitched Power Inline 10-Amp Fuse (SE10, W6) • F8—Heater Blower 15-Amp Fuse (SE14, W5) • F9—12V Power Outlet 10-Amp Fuse (SE18, W5) • F10—Radio and Dome Light Switched Power 10-Amp Fuse (SE18, W5) • F11—Air Seat 15-Amp Fuse (SE19, W5) • F12—Heater Valve 5-Amp Fuse (SE14, W5) • F13—Spare 5-Amp Fuse (SE7, W5) • F14—Front and Rear Wipers 15-Amp Fuse (SE16 or SE31, W5) • F16—Left and Right Wipers 15-Amp Fuse (SE17 or SE32, W5) • F17—Lights 20-Amp Circuit Breaker (marked as CB1) (X8) (SE20, W5) • F17—Fuel Filter Heater 20-Amp Fuse (X7) (S.N. 243764— ) (SE7, W7) • F18—Auxiliary Lights 25-Amp Circuit Breaker (marked as CB2) (SE21, W5) • F21—Start Relay 10-Amp Fuse (SE1, W5) • F22—Transmission Control Unit (TCU) Switched Power 10-Amp Fuse (SE4, W5) • F23—Standard Display Monitor (SDM) Switched Power 5-Amp Fuse (SE13, W5) • F24—Engine Control Unit (ECU) Switched Power 5-Amp Fuse (SE10, W5) • F25—Start Aid/Alternator Excitation 15-Amp Fuse (SE3, W5) • F26—JDLink™ Switched Power 5-Amp Fuse (SE22, SE26, W5)

Continued on next page

TM10721 (03SEP14)

9015-10-5

WS68074,00037BA -19-11AUG14-1/4

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=245

System Diagrams

• F27—Under-Seat Heater 20-Amp Fuse (marked as

ROPS Heater) (SE19, W5) • F28—Switch Backlights 5-Amp Fuse (SE20, W5) • F29—Integrated Grade Control (IGC) 5-Amp Fuse (SE28, W5) • F31—JDLink™ Ground 5-Amp Fuse—If Equipped (SE22, W32) • F36—JDLink™ Ground 5-Amp Fuse—If Equipped (SE26, W32) • F101—IGC Switched Power 15-Amp Fuse (SE28, W21) • F102—BCJ 5-Amp Fuse (SE28, W21) • F103—Electrohydraulic Controller 10-Amp Fuse (SE28, W21) • F104—IGC Unswitched Power 10-Amp Fuse (SE28, W21) • F105—IGC Unswitched Power 10-Amp Fuse (SE28, W21) • F106—IGC Unswitched Power 10-Amp Fuse (SE28, W21) • G1—Batteries (SE1, W1) • G3—Alternator (SE2, W6) • G4—12V Power Outlet (SE18, W5) • H1—Standard Display Monitor (SDM) (SE12, SE13, W5) • H4—Engine Warmup Indicator (SE10, W5) • H5—Monitor Alarm (SE12, W5) • H6—Backup Alarm (SE6, W5) • H7—Winch Pressure Warning Light (SE14, W5) • K1—Start Relay (SE2, W6) • K2—Accessory Relay (SE1, W5) • K3—Horn Relay (SE3, W5) • K4—Transmission Control Unit (TCU) and Standard Display Monitor (SDM) Relay (SE3, W5) • K5—A/C Relay 1 (SE15, W5) • K6—A/C Relay 2 (SE15, W5) • K101—IGC Switched Power Relay—If Equipped (SE28, W21) • K102—BCJ and Electrohydraulic Controller (EHC) Switched Power Relay—If Equipped (SE28, W21) • M1—Starter Motor (SE1, W6) • M2—Heater Blower Motor (SE14, W8) • M4—A/C Condenser Fan Motor 1 (SE15, W8) • M5—A/C Condenser Fan Motor 2 (SE15, W8) • M6—Left Door Wiper Motor (SE17 or SE32, W4) • M7—Front Wiper Motor (SE16 or SE31, W4) • M8—Rear Wiper Motor (SE16 or SE31, W5) • M9—Right Door Wiper Motor (SE17 or SE32, W4) • M10—Under-Seat Blower Motor (SE19, W5) • M11—Left/Right Washer Motor (SE17 or SE32, W7) • M12—Heater Valve Motor (SE14, W5) • M13—Front/Rear Washer Motor (SE16 or SE31, W7) • M14—Air Seat Motor (SE19, W5) • R2—Cab Heater Blower Resistor (SE4, W8) • R3—Under-Seat Heater Blower Resistor (SE19, W5) • R4—CAN Termination Resistor (SE11, W6) • R5—CAN Termination Resistor (SE12, W5) • R6—IGC CAN Termination Resistor (SE30, W22) • R7—IGC CAN Termination Resistor (SE30, W22) • R8—Fuel Filter Heater (S.N. 243764— ) (if equipped) (SE7, W7) • R10—Engine Speed Control (SE4, W5) • S1—Key Switch (SE1, W5)

• S2—Battery Disconnect Switch (SE1, W1) • S3—Neutral Switch (SE4, W5) • S5—Start Aid Switch (SE3, W5) • S6—Horn Switch (SE3, W5) • S7—Heater Blower Switch (SE14, W4) • S8—Decelerator Mode Switch (SE4, W5) • S9—Left/Right Door Wiper Switch (SE17 or SE32, W4) • S10—Front/Rear Wiper Switch (SE16 or SE31, W4) • S11—Auxiliary Light Switch (SE21, W5) • S13—Under-Seat Heater Blower Switch (SE19, W5) • S14—Light Switch (SE20, W5) • S15—Dome Light Switch (SE18, W4) • S19—A/C On/Off Switch (SE15, W4) • S20—Park Lock Lever Switch (SE2, W5) • S22—Air Seat Switch (SE19, W5) • S30—Hydraulic Enable Switch—If Equipped (SE30, W22)

• V1—Alternator 5-Amp Excitation Diode (SE2, W5) • V2—Start Relay 1-Amp Diode (SE2, W6) • V4—Starter Solenoid 5-Amp Diode (SE2, W6) • V6—A/C Compressor Clutch 5-Amp Diode (SE15, W6) • V7—Front Wiper Diode (SE16 or SE31, W4) • V8—Door Wiper Diode (S.N. —210219) (SE17, W4) • V8—Left Door Wiper Diode (S.N. 210220— ) (SE32, W4)

• V9—Rear Wiper Diode (SE16 or SE31, W4) • V10—Right Door Wiper Diode (S.N. 210220— ) (SE32, W4)

• V11—Front/Rear Wiper Diode (S.N. 210220— ) (SE31, W4)

• W1—Power and Ground Cables • W2—Cab/Canopy Harness Ground at Cab/Canopy Right Front (SE31, SE32, W5)

• W3—Ground at Starter Motor (W6) • W4—Cab Roof Harness • W5—Main Cab/Canopy Harness • W6—Engine Harness • W7—Transmission Harness • W8—A/C Harness • W9—Radio Harness • W10—Radio Antenna (SE18, W9) • W11—Canopy Auxiliary Light Harness • W13—Grill Harness • W14—A/C Condenser Harness (W8) • W15—Main Frame Ground (SE1, W1) • W16—Frame Ground at Cab/Canopy Right Front (W5) • W20—IGC Ground (SE28, SE29, W21) • W21—Integrated Grade Control (IGC) Machine Harness • W22—Integrated Grade Control (IGC) Cab Harness • W25—Charge Pressure Sensor Harness (S.N. 173345— ) (W7, W25)

• W30—Machine Information Gateway (MIG) Harness—If Equipped (S.N. 159987—161691 )

• W30—Machine Information Gateway (MIG) Harness—If Equipped (S.N. 161692— )

• W31—GlobalTRACS® Terminal (GTT) Harness—If Equipped

• W32—JDLink™ Ground Harness—If Equipped • W33—GlobalTRACS® Terminal (GTT) Antenna—If Equipped (SE23, W31)

• W34—GlobalTRACS® Terminal (GTT) Chassis Ground—If Equipped (SE23, W31)

Continued on next page

TM10721 (03SEP14)

9015-10-6

WS68074,00037BA -19-11AUG14-2/4

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=246

System Diagrams

• W6002—JDLink™ Modular Telematics Gateway (MTG)

Harness—If Equipped (S.N. 196418— ) • W6003—JDLink™ Satellite (SAT) Harness—If Equipped (S.N. 196418— ) • X1—TCU 30-Pin Connector (SE5, W5) • X2—TCU 18-Pin Connector (SE5, W5) • X3—Service ADVISOR™ Connector (SE7, W5) • X5—SDM 14-Pin Connector (SE12, SE13, W5) • X6—SDM 16-Pin Connector (SE12, SE13, W5) • X7—Load Center 1 (A4) Connector (W5) • X8—Load Center 2 (A5) Connector (W5) • X9—Main Cab/Canopy Harness-to-Engine Harness 1-Pin Connector (W5, W6) • X10—Main Cab/Canopy Harness-to-Engine Harness 31-Pin Connector (W5, W6) • X11—Main Cab/Canopy Harness-to-Transmission Harness Connector (SE31, SE32, W5, W7) • X12—Cab Roof Harness-to-A/C Harness Connector (W4, W8) • X13—Cab Roof Harness-to-Radio Harness Connector (W4, W9) • X19—Main Cab/Canopy Harness-to-Cab Roof Harness Connector 1 (SE31, SE32, W4, W5) • X20—Main Cab/Canopy Harness-to-Cab Roof Harness Connector 2 (W4, W5) • X23—Engine Harness-to-Fuel Injection Harness Connector (SE11, W6) • X26—Engine Control Unit (ECU) 48-Pin Connector (SE9, SE10, W6) • X27—Engine Control Unit (ECU) 32-Pin Connector (SE9, SE10, W6) • X28—Air Seat Connector (SE19, W5) • X29—Spare 2-Pin Connector (SE7, W5) • X32—Main Cab/Canopy Harness-to-Rear Wiper (M8) Connector (W5) • X36—Transmission Harness-to-JDLink™ Ground Harness 1-Pin Connector—If Equipped (W7, W32 • X38—JDLink™ MMS Direct 4-Pin Connector (Ethernet)—If Equipped (SE22, SE26, W30) • X39—GT Config Tool Adapter 6-Pin Connector (RS-232)—If Equipped (SE22, SE26, W31) • X44—Engine Harness-to-Grille Harness Connector (W6, W13) • X48—Main Cab/Canopy Harness-to-Canopy Auxiliary Light Harness Connector (SE21, W5, W11) • X49—Engine Control Unit (ECU) Inline Fuse Connector (SE1, W6) • X51—A/C Harness-to-Condenser Harness Connector (W8) • X53—Switched Power Terminal Connector (W5) • X54—Unswitched Power Terminal Connector (W5) • X55—Unswitched Power Terminal Connector (W5) • X62—Main Cab/Canopy Harness-to-GlobalTRACS® Terminal (GTT) Harness 12-Pin Connector—If Equipped (SE22, W5, W31) • X63—Main Cab/Canopy Harness-to-Machine Information Gateway (MIG) Harness 12-Pin Connector—If Equipped (SE22, SE27, W5, W30) • X64—GlobalTRACS® Terminal (GTT) 70-Pin Connector—If Equipped (SE23, W31)

• X65—Machine Information Gateway (MIG)

Harness-to-GlobalTRACS® Terminal (GTT) Harness—If Equipped (SE23, W30, W31) • X66—Machine Information Gateway (MIG) 30-Pin (L1—Y3) Connector—If Equipped (SE24, SE25, W30) • X67—Machine Information Gateway (MIG) 30-Pin (A1—K3) Connector—If Equipped (SE24, SE25, W30) • X70—Charge Pressure Sensor Harness Connector (S.N. 173345— ) (W25, W7) • X81—RS232 3-Pin Connector—If Equipped (SE30, W22) • X82—Electrohydraulic Controller (EHC) Connector—If Equipped (SE30, W22) • X83—Electrohydraulic Controller (EHC) Connector—If Equipped (SE30, W22) • X84—Main Cab/Canopy Harness-to-IGC Cab Harness 4-Pin Connector (SE28, W5, W22) • X85—Auxiliary Joystick Connector—If Equipped (SE30, W22) • X86—Machine CAN Connector—If Equipped (SE30, W22) • X87—IGC Power 1-Pin Connector (SE28, W21) • X90—IGC Auxiliary Actuator 4-Pin Connector—If Equipped (SE29, W21) • X95—IGC Machine Harness-to-IGC Cab Harness 35-Pin Connector—If Equipped (SE29, W21, W22) • X96—IGC Interface 23-Pin Connector—If Equipped (SE29, W21) • X97—BCJ Switch Module Connector—If Equipped (SE30, W22) • X98—BCJ Four-Way Axis Module Connector—If Equipped (SE30, W22) • X106—R04 BLK Splice (W7) • X108—G01 BLK Splice (W7) • X110—G09F BLK Splice (W4) • X111—L03 BRN Splice (W4) • X112—P15 RED Splice (W4) • X113—G10 BLK Splice (W4) • X114—G20 BLK Splice (W4) • X115—P27 RED Splice (W4) • X116—L02 BRN Splice (W4) • X117—G09G BLK Splice (W4) • X118—P26 RED Splice (W4) • X125—L04 BRN Splice (W13) • X126—G03 BLK Splice (W13) • X127—R01 BLK Splice (W6) • X128—G05 BLK Splice (W6) • X129—G01 BLK Splice (W6) • X130—R02 BLK Splice (W6) • X131—M13 LGRN Splice (W6) • X132—M12 YEL Splice (W6) • X133—P06 RED Splice (W6) • X134—R11 Shield Splice (W6) • X154—G30 BLK Splice (W21) • X155—G30 BLK Splice 2 (W21) • X156—P50 RED Splice (W21) • X157—P62 RED Splice (W21) • X158—P14 RED Splice (W21) • X159—P51 RED Splice (W21) • X160—G30 BLK Splice 3 (W21) • X161—M17 YEL Splice (W22) • X162—M18 LGRN Splice (W22)

Continued on next page

TM10721 (03SEP14)

9015-10-7

WS68074,00037BA -19-11AUG14-3/4

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=247

System Diagrams

• X163—R40 BLK Splice (W22) • X164—H20 BLU Splice (W22) • X165—H22 GRN Splice (W22) • X166—H24 GRN Splice (W22) • X167—H25 GRN Splice (W22) • X168—H33 GRN Splice (W22) • X169—R41 BLK Splice (W22) • X170—R13 BLK Splice 1 (W22) • X171—M13 LGRN Splice 1 (W22) • X172—M12 YEL Splice 1 (W22) • X173—P58 RED Splice (W22) • X174—G15 BLK Splice (W22) • X175—M12 YEL Splice 2 (W22) • X176—M13 LGRN Splice 2 (W22) • X177—R13 BLK Splice 2 (W22) • X178—E07 WHT Splice (W5) • X179—P01 RED Splice (W5) • X180—P07 RED Splice (W5) • X181—B03 RED Splice (W5) • X182—G09 BLK Splice (W5) • X183—P05 RED Splice (W5) • X184—L02 BRN Splice (W5) • X185—G04 BLK Splice (W5) • X186—R02 BLK Splice (W5) • X187—M13 LGRN Splice (W5) • X188—M12 YEL Splice (W5) • X189—R04 BLK Splice (W5) • X190—P10 RED Splice (W5) • X191—P70 RED Splice (W5) • X192—G71 BLK Splice (W5) • X193—G70 BLK Splice (W5) • X194—M12 YEL Splice (W5) • X195—M13 LGRN Splice (W5) • X196—R02 BLK Splice (W5) • X197—G01 BLK Splice (W5) • X198—M12 YEL Splice (W5) • X199—M13 LGRN Splice (W5) • X200—R02 BLK Splice (W5) • X201—M12 YEL Splice (W5) • X202—M13 LGRN Splice (W5) • X203—R02 BLK Splice (W5) • X204—B07 RED Splice (W5) • X205—G04 BLK Splice (W5)

• X206—L03 BRN Splice (W5) • X207—P09 RED Splice (W5) • X208—P17 RED Splice (W5) • X209—G02 BLK Splice (W5) • X210—P26 RED Splice (W5) • X211—A28 ORG Splice (W5) • X212—G10 BLK Splice (W5) • X213—B10 RED Splice (W5) • X214—E25 WHT Splice (W6) • X215—R70 BLK Splice (W31) • X5000—G70 BLK Splice (W6002) • X5001—P70 RED Splice (W6002) • X6001—Cellular Antenna Connector • X6002—GPS Antenna Connector • X6005—Satellite Antenna Connector • X6014—Modular Telematics Gateway (MTG) Control Unit 48-Pin Connector (SE27, W6002)

• X6015—Satellite (SAT) Module Control Unit 48-Pin Connector (SE27, W6002, W6003)

• X6016—Satellite Adapter Harness-to-Universal

JDLink™ Harness 6-Pin Connector (SE27, W6002, W6003) • X6020—Not Used • X6021—Not Used • X6022—Not Used • X6023––Not Used • Y1—Fuel Pump Control Valve Solenoid (SE10, W6) • Y2—Start Aid Solenoid (SE3, W6) • Y3—Motor Shift Solenoid Right (SE6, W7) • Y4—Motor Shift Solenoid Left (SE6, W7) • Y5—A/C Compressor Clutch (SE15, W6) • Y11—Park Brake Solenoid (SE6, W7) • Y12—Electronic Injector Solenoid (Cylinder 1) (SE11, W6) • Y13—Electronic Injector Solenoid (Cylinder 2) (SE11, W6) • Y14—Electronic Injector Solenoid (Cylinder 3) (SE11, W6) • Y15—Electronic Injector Solenoid (Cylinder 4) (SE11, W6) • Y30—Blade Angle Actuator—If Equipped (SE29, W21) • Y31—Blade Tilt Actuator—If Equipped (SE29, W21) • Y32—Blade Lift Actuator—If Equipped (SE29, W21)

GlobalTRACS is a trademark of Qualcomm Corporate JDLink is a trademark of Deere & Company Service ADVISOR is a trademark of Deere & Company WS68074,00037BA -19-11AUG14-4/4

TM10721 (03SEP14)

9015-10-8

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=248

System Diagrams

System Functional Schematic and Section Legend

• SE1—Battery and Ignition Power Circuits (12-volt system)

• SE2—Starting and Charging Circuits • SE3—Start Aid and Horn Circuits • SE4—Transmission Control Unit (TCU) Circuit • SE5—Transmission Control Unit (TCU) Circuit • SE6—Transmission Control Unit (TCU) Circuit • SE7—Service ADVISOR™ and Spare Circuits • SE8—Engine Control Unit (ECU) Input Circuits • SE9—Engine Control Unit (ECU) Input Circuits • SE10—Engine Control Unit (ECU) Output Circuits • SE11—Engine Control Unit (ECU) Output Circuits • SE12—Standard Display Monitor (SDM) Circuits • SE13—Standard Display Monitor (SDM) Circuits • SE14—Winch and Heater Circuits • SE15—Air Conditioner Circuit • SE16—Front and Rear Wiper Circuit (S.N. —210219)

• SE17—Left and Right Wiper Circuit (S.N. —210219) • SE18—Dome Light, Radio, and 12-Volt Outlet Circuits • SE19—Under-Seat Heater and Air Seat Circuits • SE20—Standard Lighting Circuit • SE21—Optional Lighting Circuit • SE22—Machine Information Power Circuit (optional) • SE23—GlobalTRACS® Terminal (GTT) Circuit (optional) (S.N. —196417)

• SE24—Machine Information Gateway (MIG) Circuit (otional), (earlier MIG harness) (S.N. —196417)

• SE25—Machine Information Gateway (MIG) Circuit (optional), (later MIG harness) (S.N. —196417)

• SE26—JDLink™ Information Power Circuit (optional) • SE27—JDLink™ Satellite (SAT) and Modular Telematics Gateway (MTG) Circuit (optional) (S.N. 196418— )

• SE28—Integrated Grade Control (IGC) Circuit (optional) • SE29—Integrated Grade Control (IGC) Circuit (optional) • SE30—Integrated Grade Control (IGC) Circuit (optional) • SE31—Front and Rear Wiper Circuit (S.N. 210220— ) • SE32—Left and Right Wiper Circuit (S.N. 210220— )

Service ADVISOR is a trademark of Deere & Company GlobalTRACS is a trademark of Qualcomm Incorporated Continued on next page

TM10721 (03SEP14)

9015-10-9

WS68074,00037BB -19-11AUG14-1/23

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=249

System Diagrams

TM10721 (03SEP14)

9015-10-10

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=250

System Diagrams

TX1102932 —UN—07JAN12

System Functional Schematic (SE1, SE2, and SE3) (1 of 11) Continued on next page

TM10721 (03SEP14)

9015-10-11

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=251

WS68074,00037BB -19-11AUG14-2/23

System Diagrams

TM10721 (03SEP14)

9015-10-12

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=252

System Diagrams B28— Horn F1— Horn 10-Amp Fuse F21— Start Relay 10-Amp Fuse F25— Start Aid/Alternator Excitation 15-Amp Fuse G1—Batteries G3—Alternator K1—Start Relay K2—Accessory Relay K3—Horn Relay K4—Transmission Control Unit (TCU) and Standard Display Monitor (SDM) Relay

M1—Starter Motor S1— Key Switch S2— Battery Disconnect Switch S5— Start Aid Switch S6— Horn Switch S20— Park Lock Lever Switch V1— Alternator 5-Amp Excitation Diode V2— Start Relay 1-Amp Diode V4— Starter Solenoid 5-Amp Diode

W2—Cab/Canopy Harness X44— Engine Harness-to-Grille Ground at Cab/Canopy Harness Connector Right Front X49— Engine Control Unit (ECU) W3—Ground at Starter Motor Inline Fuse Connector W15—Main Frame Ground Y2— Start Aid Solenoid X9— Main Cab/Canopy Harness-to-Engine Harness 1-Pin Connector X10— Main Cab/Canopy Harness-to-Engine Harness 31-Pin Connector

Continued on next page

TM10721 (03SEP14)

9015-10-13

WS68074,00037BB -19-11AUG14-3/23

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=253

System Diagrams

TM10721 (03SEP14)

9015-10-14

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=254

System Diagrams

TX1102934 —UN—07JAN12

System Functional Schematic (SE4, SE5, and SE6) (2 of 11) Continued on next page

TM10721 (03SEP14)

9015-10-15

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=255

WS68074,00037BB -19-11AUG14-4/23

System Diagrams

TM10721 (03SEP14)

9015-10-16

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=256

System Diagrams

A1—Transmission Control Unit B9—Pump Pressure Control Pilot S3— Neutral Switch (TCU) (PCP) Front S8— Decelerator Mode Switch B1—Decelerator Sensor B33— Charge Pressure Sensor W2—Cab/Canopy Harness B2—TCL Sensor (S.N. —173344) Ground at Cab/Canopy B3—Motor Speed Sensor Right B41— Charge Pressure Sensor Right Front B4—Transmission Speed Control (S.N. 173345— ) W3—Ground at Starter Motor Sensor F22— Transmission Control Unit X1— TCU 30-Pin Connector B5—Steer Sensor (TCU) Switched Power X2— TCU 18-Pin Connector B7—Motor Speed Sensor Left 10-Amp Fuse X10— Main Cab/Canopy B8—Pump Pressure Control Pilot H6—Backup Alarm Harness-to-Engine (PCP) Rear R10— Engine Speed Control Harness 31-Pin Connector Continued on next page

TM10721 (03SEP14)

9015-10-17

X11— Main Cab/Canopy Harness-to-Transmission Harness Connector Y3— Motor Shift Solenoid Right Y4— Motor Shift Solenoid Left Y11— Park Brake Solenoid

WS68074,00037BB -19-11AUG14-5/23

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=257

System Diagrams

TM10721 (03SEP14)

9015-10-18

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=258

System Diagrams

TX1140662 —UN—07AUG13

B01 RED (UNSWITCHED) B07 RED (SWITCHED) B03 RED (SWITCHED) CAN DATA LINE

B07 RED

B01 RED

B07 RED

B01 RED (UNSWITCHED) B07 RED (SWITCHED) B03 RED (SWITCHED) CAN DATA LINE

F2 SERVICE ADVISOR 10-AMP FUSE

M12 YEL M13 LGRN

E25 WHT

X07 YEL

P31 RED

X09 YEL

P04 RED

B60 WATER IN FUEL (WIF) SENSOR

B12 ENGINE COOLANT TEMPERATURE SENSOR

B29 FUEL TEMPERATURE SENSOR

B31 MANIFOLD AIR TEMPERATURE (MAT) SENSOR

M12 YEL M13 LGRN R02 BLK

X3 SERVICE ADVISOR CONNECTOR

R01 BLK

A3 D2

R01 BLK

R10 BLK

R8 FUEL FILTER HEATER

R10 BLK

E2 A3 ENGINE CONTROL UNIT (ECU)

B6 CRANKSHAFT POSITION SENSOR

B70 CAMSHAFT POSITION SENSOR

A G01 BLK

S.N. 243764-

G04 BLK

G01 BLK

R01 BLK

B14 ENGINE OIL PRESSURE SENSOR

N01 YEL

X29 SPARE CONNECTOR

X11 A

C4 F4

X08 YEL

R01 BLK X09 YEL

P40 RED

P02 RED

R02 BLK

E25 WHT

X10

F13 SPARE 5-AMP FUSE (SWITCHED)

F17 FUEL FILTER HEATER 20-AMP FUSE (X7)

TO SE22 X63

X11

B01 RED (UNSWITCHED) B07 RED (SWITCHED) B03 RED (SWITCHED) CAN DATA LINE

= X26

B10 RAIL PRESSURE SENSOR

= X27

X11 R15 BLK

G06 BLK

D4 B4

M20 PUR

S.N. 243764(IF EQUIPPED)

W3 GROUND AT STARTER MOTOR

M22 PUR

R16 BLK

W2 FRAME GOUND AT CAB/CANOPY RIGHT FRONT SE7

SE8

E21 WHT

E20 WHT

D3 E3

SE9

450J/550J/650J SYSTEM FUNCTIONAL SCHEMATIC

TX1140662

System Functional Schematic (SE7, SE8, and SE9) (3 of 11) Continued on next page

TM10721 (03SEP14)

9015-10-19

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=259

WS68074,00037BB -19-11AUG14-6/23

System Diagrams

TM10721 (03SEP14)

9015-10-20

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=260

System Diagrams 1— Primary Fuel Filter Mounted by Hydraulic Reservoir 2— Primary Fuel Filter Mounted by Engine (S.N. 243764— ) A3—Engine Control Unit (ECU) B6—Crankshaft Position Sensor B10— Fuel Rail Pressure Sensor B12— Engine Coolant Temperature Sensor

B14— Engine Oil Pressure F13— Spare 5-Amp Fuse Sensor F17— Fuel Filter Heater 20-Amp B29— Fuel Temperature Sensor Circuit Breaker (X7) B31— Manifold Air Temperature R8—Fuel Filter Heater Sensor (MAT) W2—Cab/Canopy Harness B60— Water In Fuel (WIF) Sensor Ground at Cab/Canopy B70— Camshaft Position Sensor Right Front F2— Service ADVISOR™ 10-Amp W3—Ground at Starter Motor Fuse X3— Service ADVISOR™ Connector X10— Main Cab/Canopy Harness-to-Engine Harness 31-Pin Connector

X11— Main Cab/Canopy Harness-to-Transmission Harness Connector X26— Engine Control Unit (ECU) 48-Pin Connector X27— Engine Control Unit (ECU) 32-Pin Connector X29— Spare 2-Pin Connector

Service ADVISOR is a trademark of Deere & Company Continued on next page

TM10721 (03SEP14)

9015-10-21

WS68074,00037BB -19-11AUG14-7/23

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=261

System Diagrams

TM10721 (03SEP14)

9015-10-22

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=262

System Diagrams

TX1168702 —UN—14AUG14

System Functional Schematic (SE10, SE11, and SE12) (4 of 11) Continued on next page

TM10721 (03SEP14)

9015-10-23

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=263

WS68074,00037BB -19-11AUG14-8/23

System Diagrams

TM10721 (03SEP14)

9015-10-24

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=264

System Diagrams

A3—Engine Control Unit (ECU) B18— Engine Air Filter Restriction Switch B40— Transmission Oil Temperature Sensor F7— Engine Control Unit (ECU) and Standard Display Monitor (SDM) Unswitched Power Inline 10-Amp Fuse F24— Engine Control Unit (ECU) Switched Power 5-Amp Fuse

H1—Standard Display Monitor (SDM) H4—Engine Warmup Indicator H5—Monitor Alarm R4—CAN Termination Resistor R5—CAN Termination Resistor W3—Ground at Starter Motor X5— SDM 14-Pin Connector X6— SDM 16-Pin Connector X10— Main Cab/Canopy Harness-to-Engine Harness 31-Pin Connector

X23— Engine Harness-to-Fuel Y13— Electronic Injector Injection Harness Solenoid (cylinder 2) Connector Y14— Electronic Injector X26— Engine Control Unit (ECU) Solenoid (cylinder 3) 48-Pin Connector Y15— Electronic Injector X27— Engine Control Unit (ECU) Solenoid (cylinder 4) 32-Pin Connector Y1— Fuel Pump Control Valve Solenoid Y12— Electronic Injector Solenoid (cylinder 1)

Continued on next page

TM10721 (03SEP14)

9015-10-25

WS68074,00037BB -19-11AUG14-9/23

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=265

System Diagrams

TM10721 (03SEP14)

9015-10-26

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=266

System Diagrams

TX1102937 —UN—07JAN12

System Functional Schematic (SE13, SE14, and SE15) (5 of 11) Continued on next page

TM10721 (03SEP14)

9015-10-27

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=267

WS68074,00037BB -19-11AUG14-10/23

System Diagrams

TM10721 (03SEP14)

9015-10-28

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=268

System Diagrams

B13— Winch Pressure Switch B15— Transmission Oil Filter Restriction Switch B16— Hydraulic Oil Filter Restriction Switch B22— A/C Freeze Switch B25— Hydraulic Oil Temperature Sensor B26— Heater Temperature Control B35— Fuel Level Sensor B50— A/C (high/low) Binary Pressure Switch F4— A/C 15-Amp Fuse #1 F5— A/C 15-Amp Fuse #2

F8— Heater Blower 15-Amp Fuse F12— Heater Valve 5-Amp Fuse F23— Standard Display Monitor (SDM) Switched Power 5-Amp Fuse H1—Standard Display Monitor (SDM) H7—Winch Pressure Warning Light K5—A/C Relay 1 K6—A/C Relay 2 M2—Heater Blower Motor M4—A/C Condenser Fan Motor 1 M5—A/C Condenser Fan Motor 2 M12— Heater Valve Motor

R2—Cab Heater Blower Resistor S7— Heater Blower Switch S19— A/C On/Off Switch V6— A/C Compressor Clutch 5-Amp Diode W2—Cab/Canopy Harness Ground at Cab/Canopy Right Front W3—Ground at Starter Motor X5— SDM 14-Pin Connector X6— SDM 16-Pin Connector X10— Main Cab/Canopy Harness-to-Engine Harness 31-Pin Connector

Continued on next page

TM10721 (03SEP14)

9015-10-29

X11— Main Cab/Canopy Harness-to-Transmission Harness Connector X12— Cab Roof Harness-to-A/C Harness Connector X19— Main Cab/Canopy Harness-to-Cab Roof Harness Connector 1 X20— Main Cab/Canopy Harness-to-Cab Roof Harness Connector 2 Y5— A/C Compressor Clutch

WS68074,00037BB -19-11AUG14-11/23

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=269

System Diagrams

TM10721 (03SEP14)

9015-10-30

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=270

System Diagrams

TX1102938 —UN—20JAN12

System Functional Schematic (SE16, SE17, and SE18) (6 of 11) Continued on next page

TM10721 (03SEP14)

9015-10-31

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=271

WS68074,00037BB -19-11AUG14-12/23

System Diagrams

TM10721 (03SEP14)

9015-10-32

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=272

System Diagrams

A2—Radio (12-Volt) B20— Right Speaker B21— Left Speaker E1— Dome Light F3— Radio Unswitched Power 10-Amp Fuse F9— 12V Power Outlet 10-Amp Fuse F10— Radio and Dome Light Switched Power 10-Amp Fuse F14— Front and Rear Wipers 15-Amp Fuse

F16— Left and Right Wipers 15-Amp Fuse G4—12V Power Outlet M6—Left Door Wiper Motor M7—Front Wiper Motor M8—Rear Wiper Motor M9—Right Door Wiper Motor M11— Left/Right Washer Motor M13— Front/Rear Washer Motor S9— Left/Right Door Wiper Switch

S10— Front/Rear Wiper Switch S15— Dome Light Switch V7— Front Wiper Diode V8— Door Wiper Diode V9— Rear Wiper Diode W2—Cab/Canopy Harness Ground at Cab/Canopy Right Front W10—Radio Antenna X11— Main Cab/Canopy Harness-to-Transmission Harness Connector

Continued on next page

TM10721 (03SEP14)

9015-10-33

X13— Cab Roof Harness-toRadio Harness Connector X19— Main Cab/Canopy Harness-to-Cab Roof Harness Connector 1 X20— Main Cab/Canopy Harness-to-Cab Roof Harness Connector 2

WS68074,00037BB -19-11AUG14-13/23

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=273

System Diagrams

TM10721 (03SEP14)

9015-10-34

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=274

System Diagrams

TX1140907 —UN—29JUL13

BO1 RED (UNSWITCHED) B07 RED (SWITCHED) B03 RED (SWITCHED)

P23 RED

E2 REAR LIGHT

M10 UNDER-SEAT BLOWER MOTOR

G09 BLK

G04 BLK

L03 BRN

X19

L04 BRN

E3 FRONT LIGHT LEFT

E4 FRONT LIGHT RIGHT

E6 REAR AUX. LIGHT LEFT

E5 REAR AUX. LIGHT RIGHT

E7 FRONT AUX. LIGHT LEFT

G09 BLK

X19 G03 BLK

G02 BLK

G03 BLK

G09 BLK

L02 BRN

L05 BRN

L04 BRN

L02 BRN

TO SE4 S8

G07 BLK

L01 BRN

G04 BLK

L05 BRN

L02 BRN

E8 FRONT AUX. LIGHT RIGHT

G09 BLK 7

G09 BLK

X44 W2 FRAME GROUND AT CAB/CANOPY RIGHT FRONT

SE19

W2 FRAME GROUND AT CAB/CANOPY RIGHT FRONT SE20

W3 GROUND AT STARTER MOTOR

W2 FRAME GROUND AT CAB/CANOPY RIGHT FRONT SE21

450J/550J/650J SYSTEM FUNCTIONAL SCHEMATIC

TX1140907

System Functional Schematic (SE19, SE20, and SE21) (7 of 11) Continued on next page

TM10721 (03SEP14)

P23 RED

X44 L04 BRN

G07 BLK

W2 FRAME GROUND AT CAB/CANOPY RIGHT FRONT

L05 BRN

L04 BRN

G07 BLK

G04 BLK

P20 RED

R3 UNDER-SEAT BLOWER RESISTOR

M14 AIR SEAT MOTOR

3 1

C B A D

X10 A01 ORG G04 BLK

S14 ON LIGHT OFF SWITC 2

A02 ORG

S22 AIR SEAT SWITCH

X28

L05 BRN

A15 ORG

G07 BLK

A15 ORG

P20 RED

4 8

S11 AUXILIARY OFF LIGHT SWITCH ON

L03 BRN

L05 BRN

G09 BLK

A01 ORG

L03 BRN

P22 RED

G09 BLK

L03 BRN

A02 ORG

X48

G07 BLK

F17 LIGHT 20-AMP CIRCUIT BREAKER (MARKED AS CB1) (X8)

P23 RED

F18 AUX. LIGHT 25-AMP CIRCUIT BREAKER (MARKED AS CB2)

F28 SWITCH BACKLIGHTS 5-AMP FUSE L05 BRN

S13 UNDER-SEAT HEATER BLOWER SWITCH

B07 RED

L05 BRN

B07 RED

OFF

F27 UNDER-SEAT HEATER 20-AMP FUSE

A16 ORG

B07 RED

L05 BRN (BACKLIGHTS)

F11 AIR SEAT 15-AMP FUSE

BO1 RED (UNSWITCHED) B07 RED (SWITCHED) B03 RED (SWITCHED)

L02 BRN

BO1 RED (UNSWITCHED) B07 RED (SWITCHED) B03 RED (SWITCHED)

9015-10-35

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=275

WS68074,00037BB -19-11AUG14-14/23

System Diagrams

TM10721 (03SEP14)

9015-10-36

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=276

System Diagrams E2— Rear Light E3— Front Light Left E4— Front Light Right E5— Rear Auxiliary Light Right E6— Rear Auxiliary Light Left E7— Front Auxiliary Light Left E8— Front Auxiliary Light Right F11— Air Seat 15-Amp Fuse F17— Lights 20-Amp Circuit Breaker (marked as CB1) (X8)

F18— Auxiliary Lights 25-Amp S13— Under-Seat Heater Blower X28— Air Seat Connector Circuit Breaker (marked as Switch X44— Engine Harness-to-Grille CB2) S14— Light Switch Harness Connector F27— Under-Seat Heater 20-Amp S22— Air Seat Switch X48— Main Cab/Canopy Fuse (marked as ROPS W2—Cab/Canopy Harness Harness-to-Canopy Heater) Ground at Cab/Canopy Auxiliary Light Harness F28— Switch Backlights 5-Amp Right Front Connector Fuse W3—Ground at Starter Motor M10— Under-Seat Blower Motor X10— Main Cab/Canopy M14— Air Seat Motor Harness-to-Engine R3—Under-Seat Heater Blower Harness 31-Pin Connector Resistor X19— Main Cab/Canopy S11— Auxiliary Light Switch Harness-to-Cab Roof Harness Connector 1 Continued on next page

TM10721 (03SEP14)

9015-10-37

WS68074,00037BB -19-11AUG14-15/23

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=277

System Diagrams

TM10721 (03SEP14)

9015-10-38

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=278

System Diagrams

TX1102941 —UN—09JAN12

B01 RED (UNSWITCHED) B07 RED (SWITCHED) B03 RED

B01 RED (UNSWITCHED) B07 RED (SWITCHED)

OPTION (S.N. —196417) F26 JDLINK SWITCHED POWER 5-AMP FUSE

X63

F6 JDLINK UNSWITCHED POWER 10-AMP FUSE

P71 RED

ANA1

P70 RED

P70B RED

UNSWITCHED POWER

P71A RED

P71 RED

SWITCHED POWER

M50A PUR

M50 PUR

10BT_TX1+

M51A PUR

M51 PUR

10BT_TX1-

M52A PUR

M52 PUR

10BT_RX1+

M53A PUR

M53 PUR

10BT_RX1-

M12 YEL

M12AA YEL

CAN1_HIGH

M13 LGRN

M13AA LGRN

CAN1_LOW

R02 BLK

R02AA BLK

G71C BLK

G71D BLK

G70H BLK

G70 BLK

P70 RED

FROM SE7 CAN BUS

P70F RED

X38 JDLINK MMS DIRECT CONNECTOR (ETHERNET)

P70 RED

P70A RED

A13 GLOBALTRACS® TERMINAL (GTT) CONTROLLER

G71A BLK

W33 GTT ANTENNA = X64

EARLIER MIG HARNESS

A12 MACHINE INFORMATION GATEWAY (MIG) CONTROLLER

= X66 = X67

X65

MIG_WAKEUP

M62A PUR

M62 PUR

COM2_CTS

GTT_RXD+

M60A PUR

M60 PUR

MIG_COM1_TXD+

GTT_RXD-

M61A PUR

M61 PUR

MIG_COM1_TXD-

M63 PUR

MIG_COM1_RXD-

M64 PUR

MIG_COM1_RXD+

M65 PUR

MIG_COM2_RXD+ (CTS+)

M66 PUR

MIG_COM2_RXD- (CTS-)

M68 PUR

MIG_COM2_TXD- (RTS-)

M69 PUR

MIG_COM2_TXD+ (RTS+)

M67 PUR

CONTRL_OUT

G70A BLK

GND_1

G70B BLK

GND_2

G70C BLK

GND_3

G70D BLK

GND_4

CELL (BLK) GPS (RED)

X62 FROM SE2 G3 (X10 PIN 25)

P70E RED

P70C RED

BAT+

M06 PUR

M54 PUR

RUN_TERMINAL

G70F BLK

G70G BLK

G70E BLK

BAT_RTN

M55A PUR

M55 PUR

DIAG_TX

M56A PUR

M56 PUR

DIAG_RX

M57A PUR

M57 PUR

DIAG_GND

M58A PUR

M58 PUR

DIAG_DCD

M59A PUR

M59 PUR

DIAG_DTR

G71B BLK

G71 BLK

R71 BLK

CHASSIS GND

G70J BLK

X11

X36

X39 GT TOOL ADAPTER CONNECTOR (RS232)

F31 JDLINK GROUND 5A FUSE TO SE1 S2 (PIN 1)

W2 FRAME GROUND AT CAB/CANOPY RIGHT FRONT

BLK

W34 GTT CHASSIS GROUND

SE22

R70A BLK GTT_TXD-

M63A PUR

GTT_TXD+

M64A PUR

M63 PUR

M64 PUR

R70B BLK GW_RTS+

M65A PUR

GW_RTS-

M66A PUR

G71F BLK 8

M65 PUR

M66 PUR

R70C BLK GW_CTS-

M68A PUR

GW_CTS+

M69A PUR

G71G BLK 11

M68 PUR

M69 PUR

R70C BLK GTT_WAKEUP

M67A PUR

SHIELD

R70 BLK

M70 PUR

M71 PUR

M72 PUR

M73 PUR

SE23

G71H BLK 10

M67 PUR

G70A BLK

SE24

450J/550J/650J SYSTEM FUNCTIONAL SCHEMATIC

TX1102941

System Functional Schematic (SE22, SE23, and SE24) (8 of 11) Continued on next page

TM10721 (03SEP14)

G71E BLK

9015-10-39

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=279

WS68074,00037BB -19-11AUG14-16/23

System Diagrams

TM10721 (03SEP14)

9015-10-40

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=280

System Diagrams

1— Earlier MIG Harness W33—GlobalTRACS® Terminal X39— GT Config Tool Adapter X66— Machine Information A12— Machine Information (GTT) Antenna (if 6-Pin Connector (RS-232) Gateway (MIG) 30-Pin Gateway (MIG) Controller equipped) (if equipped) (L1—Y3) Connector (if (if equipped) W34—GlobalTRACS® Terminal X62— Main Cab/Canopy Harequipped) A13— GlobalTRACS® Terminal (GTT) Chassis Ground (if ness-to-GlobalTRACS® X67— Machine Information (GTT) Controller (if equipped) Terminal (GTT) Harness Gateway (MIG) 30-Pin equipped) X11— Main Cab/Canopy 12-Pin Connector (if (A1—K3) Connector (if F6— JDLink™ Unswitched Power Harness-to-Transmission equipped) equipped) 10-Amp Fuse Harness Connector X63— Main Cab/Canopy F26— JDLink™ Switched Power X36— Transmission Harness-to-Machine 5-Amp Fuse Harness-to-JDLink™ Information Gateway (MIG) F31— JDLink™ Ground 5-Amp Ground Harness 1-Pin Harness 12-Pin Connector Fuse (if equipped) Connector (if equipped) (if equipped) W2—Cab/Canopy Harness X38— JDLink™ MMS Direct 4-Pin X64— GlobalTRACS® Terminal Ground at Cab/Canopy Connector (Ethernet) (if (GTT) 70-Pin Connector (if Right Front equipped) equipped) X65— Machine Information Gateway (MIG) Harnessto-GlobalTRACS® Terminal (GTT) Harness (if equipped) JDLink is a trademark of Deere & Company GlobalTRACS is a trademark of Qualcomm Incorporated Continued on next page

TM10721 (03SEP14)

9015-10-41

WS68074,00037BB -19-11AUG14-17/23

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=281

System Diagrams

TM10721 (03SEP14)

9015-10-42

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=282

System Diagrams

TX1102942 —UN—09JAN12

B01 RED (UNSWITCHED) B07 RED (SWITCHED) B03 RED

OPTION (S.N. 196418— )

M60 PUR

MIG_COM1_TXD+

M61 PUR

MIG_COM1_TXD-

M63 PUR

MIG_COM1_RXD-

M64 PUR

MIG_COM1_RXD+

M65 PUR

MIG_COM2_RXD+ (CTS+)

M66 PUR

MIG_COM2_RXD- (CTS-)

M67 PUR

MIG_COM2_TXD- (RTS-)

M68 PUR

MIG_COM2_TXD+ (RTS+)

M69 PUR

CONTRL_OUT

M65 PUR M66 PUR

G70C BLK M67 PUR M68 PUR G70D BLK

M69 PUR

P71 RED

M50 PUR

M51 PUR

M17 YEL

M52 PUR

M18 LT GRN

M53 PUR

R40 BLK

M12 YEL

FROM SE7 CAN BUS

M13 LT GRN

R02 BLK

R13 BLK

G71 BLK

G70 BLK

M74 PUR

= X6014

M06 PUR

M76 PUR

= X6001

G70 BLK

M75 PUR

M55 PUR

M56 PUR

M57 PUR

M58 PUR

M59 PUR

G71 BLK

X11

GND_2

G71G BLK

GND_3

G71H BLK

GND_4

BLK

X36

TO SE1 S2 (PIN 1)

SE25

F36 JDLINK GROUND 5A FUSE

X39

G71 BLK

G71F BLK

BLK

= X6002

A6002 SATELLITE (SAT) CONTROL UNIT

X6016 J1003 TAN

M1005 PUR

M1004 PUR

P1002 PUR

= X6015

G1001 PUR

= X6005

OPTION A6003 SATELLITE ANTENNA

X62 W2 FRAME GROUND AT CAB/CANOPY RIGHT FRONT

SE26

SE27

450J/550J/650J SYSTEM FUNCTIONAL SCHEMATIC

TX1102942

System Functional Schematic (SE25, SE26, SE27) (9 of 11) Continued on next page

TM10721 (03SEP14)

M06 PUR

G70 BLK

G71D BLK

GND_1

P70 RED

G70 BLK N2

FROM SE2 G3 (X10 PIN 25)

G71E BLK

M73 PUR

COM2_CTS

G70B BLK

P71 RED

X38

M75 PUR

M64 PUR

M76 PUR

M62 PUR

M63 PUR

P70 RED

= X67

M62 PUR

G70A BLK

M74 PUR

G70 BLK

P70 RED

= X66

P70 RED

G71D BLK

X63

G70 BLK

A12 MACHINE INFORMATION GATEWAY (MIG) CONTROLLER

A6000 MODULAR TELEMATICS GATEWAY (MTG) CONTROL UNIT

M72 PUR

LATER MIG HARNESS

A6001 GPS/CELL ANTENNA

M71 PUR

P71 RED

OPTION (S.N. —196417)

F6 JDLINK UNSWITCHED POWER 5A FUSE P70 RED

F26 JDLINK SWITCHED POWER 5A FUSE 2

B01 RED (UNSWITCHED) B07 RED (SWITCHED)

M70 PUR

B01 RED (UNSWITCHED) B07 RED (SWITCHED) B03 RED

9015-10-43

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=283

WS68074,00037BB -19-11AUG14-18/23

System Diagrams

TM10721 (03SEP14)

9015-10-44

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=284

System Diagrams

2— Later MIG Harness F36— JDLink™ Ground 5-Amp X63— Main Cab/Canopy X6015—Satellite (SAT) Module A12— Machine Information Fuse Harness-to-Machine Control Unit 48-Pin Gateway (MIG) Controller W2—Cab/Canopy Harness Information Gateway (MIG) Connector (if equipped) Ground at Cab/Canopy Harness 12-Pin Connector X6016—Satellite Adapter A6000— Modular Telematics Right Front (if equipped) Harness-to-Universal Gateway (MTG) Control X11— Main Cab/Canopy X66— Machine Information JDLink™ Harness 6-Pin Unit Harness-to-Transmission Gateway (MIG) 30-Pin Connector A6001—GPS/Cellular Antenna Harness Connector (L1—Y3) Connector (if A6002—Satellite (SAT) Control X36— Transmission equipped) Unit (if equipped) Harness-to-JDLink™ X67— Machine Information A6003— Satellite Antenna (if Ground Harness 1-Pin Gateway (MIG) 30-Pin equipped) Connector (if equipped) (A1—K3) Connector (if F6— JDLink™ Unswitched Power X38— JDLink™ MMS Direct 4-Pin equipped) 10-Amp Fuse Connector (ethernet) (if X6001—Cellular Antenna F26— JDLink™ Switched Power equipped) Connector 5-Amp Fuse X39— GT Config Tool Adapter X6002—GPS Antenna Connector 6-Pin Connector (RS-232) X6005—Satellite Antenna (if equipped) Connector X62— Main Cab/Canopy HarX6014—Modular Telematics ness-to-GlobalTRACS® Gateway (MTG) Control Terminal (GTT) Harness Unit 48-Pin Connector 12-Pin Connector (if equipped) JDLink is a trademark of Deere & Company GlobalTRACS is a trademark of Qualcomm Incorporated Continued on next page

TM10721 (03SEP14)

9015-10-45

WS68074,00037BB -19-11AUG14-19/23

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=285

System Diagrams

TM10721 (03SEP14)

9015-10-46

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=286

System Diagrams

TX1102943 —UN—09JAN12

P50 RED

P59 RED

P51 RED 2

X84 X95

P58 RED

P14 RED

Y32 BLADE LIFT ACTUATOR

P50 RED

K102 BCJ AND EHC SWITCHED POWER RELAY

87A

G30 BLK

P58 RED

P58 RED P58 RED

H36 GRN H23 GRN

17 18

A-PORT GND GND B-PORT

1 2 3 4

H31 RED G30 BLK G30 BLK H34 BLK

H34 BLK

SIG STATUS GND PWR

1 2 3 4

H32 GRN H28 RED G30 BLK P62 RED

3 4

H32 GRN H28 GRN

P62 RED

SIG STATUS GND PWR

1 2 3 4

H35 GRN H29 GRN G30 BLK P62 RED

6 8

H35 GRN H29 GRN

H31 RED

12 3

H22 GRN

= X83

P62 RED

X90 IGC AUXILIARY ACTUATOR CONNECTOR

F104 10-AMP FUSE

1 2 3 4

23 16 22

9 10

H30 GRN H27 GRN

P61 RED

H20 GRN H33 GRN H24 GRN H25 GRN

M13 LGRN R13 BLK M12 YEL

22 3 7

F105 10-AMP FUSE

R43 BLK M26 BLU M25 ORG

24 22 23

R42 BLK M24 BLU M23 ORG

27 25 26

5 6

M17 YEL R40 BLK M18 LGRN

11 4

M18 LGRN R40 BLK M17 YEL

P56 RED P57 RED

M18 LGRN R40 BLK M17 YEL

16 15

R40 BLK G30 BLK

R40 BLK

M17 YEL

G30 BLK

C D B

G H

U W

P60 RED

SE28

X96 IGC INTERFACE CONNECTOR

X95

W20 IGC GROUND

SE29

X85 AUXILIARY JOYSTICK CONNECTOR

R41 PNK H22 BRN H20 BLU H33 BLK H24 GRY H25 WHT

6 1 3 4 1

5 2

R7 IGC CAN TERMINATION HI RESISTOR +

120

= X97 = X98

LO B C A M13 LGRN

M22 PUR

M21 PUR

M20 PUR

X81 RS232 A B C CONNECTOR

M18 LGRN R40 BLK M17 YEL G14 BLK

X10

A9 BLADE CONTROL JOYSTICK (BCJ)

M13 LGRN R13 BLK M12 YEL

R6 IGC CAN TERMINATION RESISTOR

W3 GROUND AT STARTER MOTOR

B C A

M18 LGRN R40 BLK M17 YEL

M13 LGRN R13 BLK M12 YEL

B C A

X86 MACHINE CAN CONNECTOR

G30 BLK

SE30

450J/550J/650J SYSTEM FUNCTIONAL SCHEMATIC

TX1102943

System Functional Schematic (SE28, SE29, and SE30) (10 of 11) Continued on next page

TM10721 (03SEP14)

G14 BLK

M18 LGRN

R40 BLK G30 BLK

M23 ORG

G30 BLK

M24 BLU

G30 BLK

R42 BLK

F101 15-AMP FUSE

M25 ORG

M26 BLU

R T

P60 RED

R43 BLK

P55 RED

87A

P56 RED

K101 IGC SWITCHED POWER RELAY P57 RED

G30 BLK

21 19 20

P50 RED

G30 BLK P54 RED

W20 IGC GROUND

X84

120

P55 RED

2 3 4 1

S30 HYDRAULIC ENABLE SWITCH

F106 10-AMP FUSE

H23 GRN H36 GRN

H22 GRN H26 GRN H37 GRN R41 BLK

P50 RED

P14 RED

P50 RED

H26 GRN H37 GRN R41 BLK

H30 GRN H27 GRN G30 BLK P61 RED

H22 GRN

A11 ELECTROHYDRAULIC CONTROLLER (EHC)

21 P50 RED

P51 RED

P58 RED

= X82

Y31 BLADE TILT ACTUATOR

F103 10-AMP FUSE

P59 RED

9015-10-47

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=287

WS68074,00037BB -19-11AUG14-20/23

G30 BLK

P14 RED

P51 RED

ENABLED DISABLED

Y30 BLADE ANGLE ACTUATOR

F102 5-AMP FUSE

P59 RED

M12 YEL

F29 IGC SWITCHED POWER 5-AMP FUSE

A8 IGC LOAD CENTER

R13 BLK

B07 RED

G15 BLK

B07 RED

G15 BLK

B01 RED B07 RED

B07 RED

P59 RED

B07 RED

X87

System Diagrams

TM10721 (03SEP14)

9015-10-48

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=288

System Diagrams

A8—IGC Load Center (if equipped) A9—Blade Control Joystick (BCJ) (if equipped) A11— Electrohydraulic Controller (EHC) (if equipped) F29— Integrated Grade Control (IGC) 5-Amp Fuse F101— IGC Switched Power 15-Amp Fuse F102— BCJ 5-Amp Fuse F103— Electrohydraulic Controller 10-Amp Fuse F104— IGC Unswitched Power 10-Amp Fuse F105— IGC Unswitched Power 10-Amp Fuse F106— IGC Unswitched Power 10-Amp Fuse

X82— Electrohydraulic K101— IGC Switched Power Controller (EHC) Relay (if equipped) Connector (if equipped) K102— BCJ and Electrohydraulic X83— Electrohydraulic Controller (EHC) Controller (EHC) Switched Power Relay (if Connector (if equipped) equipped) X84— Main Cab/Canopy R6—IGC CAN Termination Harness-to-IGC Cab Resistor Harness 4-Pin Connector R7—IGC CAN Termination X85— Auxiliary Joystick Resistor Connector (if equipped) S30— Hydraulic Enable Switch (if X86— Machine CAN Connector equipped) (if equipped) W3—Ground at Starter Motor X87— IGC Power 1-Pin W20—IGC Ground Connector X10— Main Cab/Canopy X90— IGC Auxiliary Actuator Harness-to-Engine 4-Pin Connector (if Harness 31-Pin Connector equipped) X81— RS232 3-Pin Connector (if X95— IGC Machine equipped) Harness-to-IGC Cab Harness 35-Pin Connector (if equipped) Continued on next page

TM10721 (03SEP14)

9015-10-49

X96— IGC Interface 23-Pin Connector (if equipped) X97— BCJ Switch Module Connector (if equipped) X98— BCJ Four-Way Axis Module Connector (if equipped) Y30— Blade Angle Actuator (if equipped) Y31— Blade Tilt Actuator (if equipped) Y32— Blade Lift Actuator (if equipped)

WS68074,00037BB -19-11AUG14-21/23

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=289

System Diagrams

TM10721 (03SEP14)

9015-10-50

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=290

System Diagrams

TX1102944 —UN—20JAN12

System Functional Schematic (SE31 and SE32) (11 of 11) Continued on next page

TM10721 (03SEP14)

9015-10-51

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=291

WS68074,00037BB -19-11AUG14-22/23

System Diagrams

TM10721 (03SEP14)

9015-10-52

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=292

System Diagrams F14— Front and Rear Wipers 15-Amp Fuse F16— Left and Right Wipers 15-Amp Fuse M6—Left Door Wiper Motor M7—Front Wiper Motor M8—Rear Wiper Motor M9—Right Door Wiper Motor

M11— Left/Right Washer Motor M13— Front/Rear Washer Motor S9— Left/Right Door Wiper Switch S10— Front/Rear Wiper Switch V7— Front Wiper Diode V8— Left Door Wiper Diode

V9— Rear Wiper Diode V10— Right Door Wiper Diode V11— Front/Rear Wiper Diode W2—Cab/Canopy Harness Ground at Cab/Canopy Right Front X11— Main Cab/Canopy Harness-to-Transmission Harness Connector

X19— Main Cab/Canopy Harness-to-Cab Roof Harness Connector 1 X20— Main Cab/Canopy Harness-to-Cab Roof Harness Connector 2

WS68074,00037BB -19-11AUG14-23/23

TM10721 (03SEP14)

9015-10-53

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=293

System Diagrams

Power and Ground Cables (W1) Component Location

M1 G1

TX1032990 —UN—05DEC07

W15

TX1032990 Power and Ground Cables (W1) Component Location G1—Batteries M1—Starter Motor

S2— Battery Disconnect Switch

W3—Ground at Starter Motor W15—Main Frame Ground AA95137,0001194 -19-04DEC07-1/1

TM10721 (03SEP14)

9015-10-54

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=294

System Diagrams

Cab Roof Harness (W4) Component Location M7

S9 X13

S10 V8 V9

B26 V7

S19

S7 E8

X12

M9 E5

X19

TX1033213 —UN—23JAN08

X20

TX1033213 Cab Roof Harness (W4) Component Location (S.N. —210219) B26— Heater Temperature Control E1— Dome Light E5— Rear Auxiliary Light Right E6— Rear Auxiliary Light Left E7— Front Auxiliary Light Left E8— Front Auxiliary Light Right

M6—Left Door Wiper Motor M7—Front Wiper Motor M9— Right Door Wiper Motor S7— Heater Blower Switch S9— Left/Right Door Wiper Switch S10— Front/Rear Wiper Switch

S19— Air Conditioner On/Off Switch V7— Front Wiper Diode V8— Door Wiper Diode V9— Rear Wiper Diode X12— Cab Roof Harness-to-A/C Harness Connector X13— Cab Roof Harness-toRadio Harness Connector Continued on next page

TM10721 (03SEP14)

9015-10-55

X19— Main Cab/Canopy Harness-to-Cab Roof Harness Connector 1 X20— Main Cab/Canopy Harness-to-Cab Roof Harness Connector 2

AA95137,000118C -19-05DEC11-1/2

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=295

System Diagrams

S10 V10

S9 X13 V8

V11

B26 V7

S19

S7 E8

M6 X12

M9 E5

X19

TX1102702 —UN—15DEC11

X20

TX1102702 Cab Roof Harness (W4) Component Location (S.N. 210220— ) B26— Heater Temperature Control E1— Dome Light E5— Rear Auxiliary Light Right E6— Rear Auxiliary Light Left E7— Front Auxiliary Light Left E8— Front Auxiliary Light Right M6—Left Door Wiper Motor

M7—Front Wiper Motor M9— Right Door Wiper Motor S7— Heater Blower Switch S9— Left/Right Door Wiper Switch S10— Front/Rear Wiper Switch S19— Air Conditioner On/Off Switch V7— Front Wiper Diode

V8— Left Door Wiper Diode V9— Rear Wiper Diode V10— Right Door Wiper Diode V11— Front/Rear Wiper Diode X12— Cab Roof Harness-to-A/C Harness Connector X13— Cab Roof Harness-toRadio Harness Connector

X19— Main Cab/Canopy Harness-to-Cab Roof Harness Connector 1 X20— Main Cab/Canopy Harness-to-Cab Roof Harness Connector 2

AA95137,000118C -19-05DEC11-2/2

TM10721 (03SEP14)

9015-10-56

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=296

System Diagrams

Cab Roof Harness (W4) Wiring Diagram END #1 NUMBER COLOR X19 P26 RED X118 P26A RED X118 P26B RED X118 P26D RED X20 P27A RED M9 P27B RED X115 P27C RED X115 P27D RED S9 P27E RED S7 P28B RED

END #2 X118 S10 S10 M7 X115 X115 M6 S9 S9 X20

TX1033277 —UN—23JAN08

TX1033277

END #1 NUMBER COLOR END #2 S9 A03C ORG X19 B26 A04A ORG X20 S10 A05C ORG X19 S19 A21 ORG X12 S19 A21A ORG S19 S7 A22 ORG X12 S7 A23 ORG X12 S7 A24 ORG X12 X20 A28A ORG X12 S19 A30 ORG S7 S7 A30A ORG X12 S10 A31A ORG V9 X19 A31B ORG S10 V9 A32A ORG V7 M7 A32C ORG V7 M7 A33A ORG V7 V8 A34A ORG S9 M9 A34B ORG S9 M6 A35 ORG V8 X12 G08 BLK X20 X12 G08B BLK X20 X110 G09F BLK X19 X19 G09G BLK X117 X110 G09H BLK E5 X110 G09J BLK E6 X117 G09K BLK E7 X117 G09L BLK E8 X113 G10A BLK M6 M9 G10B BLK X113 X113 G10D BLK M7 X19 G10H BLK X113 X114 G20B BLK X19 X13 G20C BLK X114 E1 G20D BLK X114 S19 G20E BLK X114 B26 G20F BLK X114 S19 G20G BLK S10 S9 G20H BLK S10 X19 L02E BRN X116 X116 L02F BRN E8 X116 L02G BRN E7 X111 L03E BRN X19 E5 L03F BRN X111 E6 L03G BRN X111 X20 L05H BRN S19 S19 L05K BRN S10 S9 L05L BRN S10 B26 P09D RED X20A X19 P15C RED X112 X13 P15D RED X112 X13 P15E RED X112 E1 P15F RED X112 X20 P16B RED X12 X20 P17B RED X12 X13 P25B RED X19

Cab Roof Harness (W4) Wire Table (S.N. —210219) Continued on next page

TM10721 (03SEP14)

9015-10-57

CS33148,0002828 -19-05DEC11-1/6

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=297

System Diagrams

TM10721 (03SEP14)

9015-10-58

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=298

System Diagrams

TX1033278 —UN—25JAN08

E5 2

1 2

L03F G09H

E6 1 2

PIN_ANODE A34A SOC_CATHODE A35

L03G L09J

E8 1 2

L03G G09L

1 2

PIN_ANODE A33A SOC_CATHODE A35 A32C

X114

X115

X116

X117

SIDE A G20B SIDE B G02C G20D G20E G20F

SIDE A P27S SIDE B P27B P27C P27D

SIDE A L02F L02G SIDE B L02E

SIDE A G09K

X12 1 2 3 4 5 6 7 8 9 10 11 12

X113

G08 A30A A23 A21 A22 A24 A28A G08B

SIDE A G10H SIDE B G10A G10B G10D

P17B

X111 SIDE A L03E SIDE B L03F L03G

P16B

SIDE B

A B C

P09D A04A G20F

P26A P26B P26D

S10

X13 A B C D

S7 1

X110

X20

1 2 3 4 5 6 7 8 9 10 11 12

G09F G09G G10H P26 A03C G20B

P15F G20D

P26

7 8 9 10 11 12

B26

PIN_ANODE A31A SOC_CATHODE A32A

L02E L03E A05C A31B P15C P25B

A B

1 2 3 4 5 6

SIDE A

G09L SIDE B G09G

SIDE A P15C SIDE B P15D P15E P15F

X19

X118 C B A

X112

SIDE A G09H G09J SIDE B G09F

2 3 4 B

A30 A30A A22 A23 A24 P28B

P15D P25B G20C P15E

L05H P09D A04A P17B P16B

4 3

1 2 3 4

P27B A34B G10B

S19 1 2 3 8

4 5 6 7 8 9 10

1 2

D C B A

P27A

A28A G08 G08B P28B

L02G G09K

E1 A

A21A A30 A21 A21A

G20E G20G L05H L05K

4 5 6 7 8 9 10

1 2 3 4 5 6 7 8

P27D P27E A34A A34B

P26A A31A A13B P26A A05C G20G G20H L05K L05L

9 10

P27E A03C G20H L05L

1 2 3 4 5 6

M6 A32C P26D G10D A33A

1 2 3 4

P27C A35 G10A

TX1033278 Cab Roof Harness (W4) Wiring Diagram (S.N. —210219) Continued on next page

TM10721 (03SEP14)

9015-10-59

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=299

CS33148,0002828 -19-05DEC11-2/6

System Diagrams

TM10721 (03SEP14)

9015-10-60

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=300

System Diagrams B26— Heater Temperature Control E1— Dome Light E5— Rear Auxiliary Light Right E6— Rear Auxiliary Light Left E7— Front Auxiliary Light Left E8— Front Auxiliary Light Right M6—Left Door Wiper Motor M7—Front Wiper Motor

M9—Right Door Wiper Motor S7— Heater Blower Switch S9— Left/Right Door Wiper Switch S10— Front/Rear Wiper Switch S15— Dome Light Switch S19— A/C On/Off Switch V7— Front Wiper Diode V8— Door Wiper Diode V9— Rear Wiper Diode

X12— Cab Roof Harness-to-A/C Harness Connector X13— Cab Roof Harness-toRadio Harness Connector X19— Main Cab/Canopy Harness-to-Cab Roof Harness Connector 1 X20— Main Cab/Canopy Harness-to-Cab Roof Harness Connector 2 Continued on next page

TM10721 (03SEP14)

9015-10-61

X110— G09F BLK Splice X111— L03 BRN Splice X112— P15 RED Splice X113— G10 BLK Splice X114— G20 BLK Splice X115— P27 RED Splice X116— L02 BRN Splice X117— G09G BLK Splice X118— P26 RED Splice CS33148,0002828 -19-05DEC11-3/6

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=301

System Diagrams

END #1 NUMBER COLOR X20 P17B RED X13 P25B RED X19 P26 RED X118 P26A RED X118 P26D RED X20 P27A RED M9 P27B RED X115 P27C RED X115 P27D RED S9 P27E RED S7 P28B RED

END #2 X12 X19 X118 S10 M7 X115 X115 M6 S9 S9 X20

TX1096911 —UN—31AUG11

TX1096911

END #1 NUMBER COLOR END #2 S9 A03C ORG X19 B26 A04A ORG X20 S10 A05C ORG X19 S19 A21 ORG X12 S19 A21A ORG S19 S7 A22 ORG X12 S7 A23 ORG X12 S7 A24 ORG X12 X20 A28A ORG X12 S19 A30 ORG S7 S7 A30A ORG X12 S10 A31A ORG V9 V11 A31B ORG S10 V9 A32A ORG S10 V9 A32B ORG V7 M7 A32C ORG V7 M7 A33A ORG V7 V8 A34A ORG S9 V10 A34B ORG S9 M6 A35A ORG V8 V8 A35B ORG S9 M9 A36A ORG V10 V10 A36B ORG S9 V11 A37A ORG S10 X19 A37B ORG V11 X12 G08 BLK X20 X12 G08B BLK X20 X110 G09F BLK X19 X19 G09G BLK X117 X110 G09H BLK E5 X110 G09J BLK E6 X117 G09K BLK E7 X117 G09L BLK E8 X113 G10A BLK M6 M9 G10B BLK X113 X113 G10D BLK M7 X19 G10H BLK X113 X114 G20B BLK X19 X13 G20C BLK X114 E1 G20D BLK X114 S19 G20E BLK X114 B26 G20F BLK X114 X19 L02E BRN X116 X116 L02F BRN E8 X116 L02G BRN E7 X111 L03E BRN X19 E5 L03F BRN X111 E6 L03G BRN X111 X20 L05H BRN S19 B26 P09D RED X20A X19 P15C RED X112 X13 P15D RED X112 X13 P15E RED X112 S15 P15F RED X112 X20 P16B RED X12

Cab Roof Harness (W4) Wire Table (S.N. 210220— ) Continued on next page

TM10721 (03SEP14)

9015-10-62

CS33148,0002828 -19-05DEC11-4/6

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=302

System Diagrams

TX1096912 —UN—06SEP11

E5 2

1 2

L03F G09H

E6 1 2

L03G G09J

V11

PIN_ANODE A34A SOC_CATHODE A35A A35B

PIN_ANODE A31B CATHODE_SOC A37A A37B

1 2

L02F G09L

A B

P15F G20D A

1 2

L02G G09K

X114

X115

X116

X117

SIDE A G20B SIDE B G20C G20D G20E G20F

SIDE A P27A SIDE B P27B P27C P27D

SIDE A L02F L02G SIDE B L02E

SIDE A G09K

X12 1 2 3 4 5 6 7 8 9 10 11 12

PIN_ANODE A34B SOC_CATHODE A36A A36B

PIN_ANODE A33A SOC_CATHODE A32B A32C

V10

X113

G08 A30A A23 A21 A22 A24 A28A G08B

SIDE A G10H SIDE B G10A G10B G10D

P17B

X111 SIDE A L03E SIDE B L03F L03G

P16B

SIDE B

P26

SIDE A P15C SIDE B P15D P15E P15F

A B C

P09D A04A G20F

P26A P26D

V9 PIN_ANODE A31A SOC_CATHODE A32A A32B

S9 I

B 3

X110 SIDE A G09H G09J SIDE B G09F

X20

1 2 3 4 5 6 7 8 9 10 11 12

X19 G09F G09G G10H P26 A03C G20B

1 2 3

X13 A B C D

7 8 9 10 11 12

B26

X112

L02E L03E A05C A37B P15C P25B

SIDE A

G09L SIDE B G09G

1 2 3 4 5 6

X118 C B A

2 3 4 B

A30 A30A A22 A23 A24 P28B

P15D P25B G20C P15E

4 B L P

D C B A

A28A G08 G08B P28B

4 3

1 2 3 7

1 2 3 4

B 1

— 2

P27B A36A G10B

1 2 3 4 B L P

A32A A37A A31A A31B A05C P26A — —

S19

P27A L05H P09D A04A P17B P16B

S10 A35B A36B A34A A34B A03C P27D —

4 5 6 7 8 9 10

A21A A30 A21 A21A

M7 G20E L05H 6

1 2 3 4 5 6

M6 A32C P26D G10D A33A

1 2 3 4

P27C A35A G10A

TX1096912 Cab Roof Harness (W4) Wiring Diagram (S.N. 210220— ) Continued on next page

TM10721 (03SEP14)

9015-10-63

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=303

CS33148,0002828 -19-05DEC11-5/6

System Diagrams

TM10721 (03SEP14)

9015-10-64

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=304

S7— Heater Blower Switch S9— Left/Right Door Wiper Switch S10— Front/Rear Wiper Switch S15— Dome Light Switch S19— A/C On/Off Switch V7— Front Wiper Diode V8— Left Door Wiper Diode V9— Rear Wiper Diode V10— Right Door Wiper Diode

V11— Front/Rear Wiper Diode X12— Cab Roof Harness-to-A/C Harness Connector X13— Cab Roof Harness-toRadio Harness Connector X19— Main Cab/Canopy Harness-to-Cab Roof Harness Connector 1 X20— Main Cab/Canopy Harness-to-Cab Roof Harness Connector 2

CS33148,0002828 -19-05DEC11-6/6

TM10721 (03SEP14)

9015-10-65

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=305

System Diagrams

TM10721 (03SEP14)

9015-10-66

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=306

System Diagrams

Main Cab/Canopy Harness (W5) Component Location TX1065932 —UN—12OCT09

A4 B4 R10 H4

F10

F11

F12

F13

F21 K3

F22 F23

F24 F25

F26 F27

F14

F16

X5 H1

F29

F18

S20

S11

F28

F17

S13 B2

S14 R5

X63 A1 X62

X28

X11

X19

X10

X29 E2

X84

X39

X38 X29

W16

X9 X87 M12

H6 B13

TX1065932 Main Cab/Canopy Harness (W5) Component Location (S.N. —210219) Continued on next page

TM10721 (03SEP14)

9015-10-67

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=307

AA95137,000118F -19-08AUG13-1/4

System Diagrams

TM10721 (03SEP14)

9015-10-68

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=308

System Diagrams

A1—Transmission Control Unit R3—Under-Seat Heater Blower (TCU) Resistor A4—Load Center 1 R5—CAN Termination Resistor A5—Load Center 2 R10— Engine Speed Control B1—Decelerator Sensor S1— Key Switch B2—TCL Sensor S3— Neutral Switch B4—Transmission Speed Control S5— Start Aid Switch Sensor S6— Horn Switch B5—Steer Sensor S8— Decelerator Mode Switch B13— Winch Pressure Switch S11— Auxiliary Light Switch E2— Rear Light S13— Under-Seat Heater Blower G4—Power Outlet (12 volt) Switch H1—Standard Display Monitor S14— Light Switch (SDM) S20— Park Lock Lever Switch H4—Warmup Indicator W2—Cab/Canopy Harness H5—Monitor Alarm Ground H6—Backup Alarm W16—Frame Ground at H7—Winch Pressure Warning Cab/Canopy Right Front Light X1— TCU 30-Pin Connector K2—Accessory Relay X2— TCU 18-Pin Connector M8—Rear Wiper Motor M12— Heater Valve Motor

X3— Service ADVISOR™ X39— GT Config Tool Adapter Connector 6-Pin Connector (RS-232) X5— SDM 14-Pin Connector X62— Cab Harness-toX6— SDM 16-Pin Connector GlobalTRACS® Terminal X9— Cab/Canopy Harness-to(GTT) Harness 12-Pin Engine Harness Connector Connector X10— Cab/Canopy Harness-toX63— Cab Harness-to-Machine Engine Harness Connector Information Gateway (MIG) X11— Cab/Canopy Harness-toHarness 12-Pin Connector Transmission Harness X84— IGC Cab Harness-to-Cab Connector Harness 4-Pin Connector X19— Main Cab/Canopy X87— IGC Power 1-Pin Harness-to-Cab Roof Connector Harness Connector X28— Air Seat Connector X29— Spare X38— JDLink™ MMS Direct 4-Pin Connector (ethernet)

JDLink is a trademark of Deere & Company GlobalTRACS is a trademark of Qualcomm Corporate Continued on next page

TM10721 (03SEP14)

9015-10-69

AA95137,000118F -19-08AUG13-2/4

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=309

System Diagrams

TM10721 (03SEP14)

9015-10-70

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=310

System Diagrams

TX1142074 —UN—09AUG13

B4 R10 H4

F10

F11

F5 F6

F12

F13

F14

F21

F23

F12

F25

F13

F16

S20

F23 F24

F25 F26

F28

X5 S5

F26 F27

F21 F22

F24

F17

F22

F14

F16

F27 F28

F17

F29

F17

F29

F18

S11

(S.N. 243764— )

(S.N. 210220—243763)

(S.N. 243764— )

B5 S13

S14

R5 X1

B1 A1 X63

X28

X11

X19

X10

X29 E2

X84 X48 X29

W16

X9 X87

M12

H6 B13

TX1142074 Main Cab/Canopy Harness (W5) Component Location (S.N. 210220— ) Continued on next page

TM10721 (03SEP14)

9015-10-71

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=311

AA95137,000118F -19-08AUG13-3/4

System Diagrams

TM10721 (03SEP14)

9015-10-72

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=312

System Diagrams A1—Transmission Control Unit K2—Accessory Relay M8—Rear Wiper Motor (TCU) M12— Heater Valve Motor A4—Load Center 1 R3—Under-Seat Heater Blower A5—Load Center 2 Resistor B1—Decelerator Sensor R5—CAN Termination Resistor B2—TCL Sensor B4—Transmission Speed Control R10— Engine Speed Control S1— Key Switch Sensor S3— Neutral Switch B5—Steer Sensor S5— Start Aid Switch B13— Winch Pressure Switch S6— Horn Switch E2— Rear Light S8— Decelerator Mode Switch G4—Power Outlet (12 volt) S11— Auxiliary Light Switch H1—Standard Display Monitor S13— Under-Seat Heater Blower (SDM) Switch H4—Warmup Indicator S14— Light Switch H5—Monitor Alarm S20— Park Lock Lever Switch H6—Backup Alarm H7—Winch Pressure Warning Light

W2—Cab/Canopy Harness X19— Main Cab/Canopy Ground Harness-to-Cab Roof W16—Frame Ground at Harness Connector Cab/Canopy Right Front X28— Air Seat Connector X1— TCU 30-Pin Connector X29— Spare X2— TCU 18-Pin Connector X48— Main Cab/Canopy X3— Service ADVISOR™ Harness-to-Canopy Connector Auxiliary Light Harness X5— SDM 14-Pin Connector Connector X6— SDM 16-Pin Connector X63— Cab Harness-to-Machine X9— Cab/Canopy Harness-toInformation Gateway (MIG) Engine Harness Connector Harness 12-Pin Connector X10— Cab/Canopy Harness-toX84— IGC Cab Harness-to-Cab Engine Harness Connector Harness 4-Pin Connector X11— Cab/Canopy Harness-toX87— IGC Power 1-Pin Transmission Harness Connector Connector

AA95137,000118F -19-08AUG13-4/4

TM10721 (03SEP14)

9015-10-73

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=313

System Diagrams

TM10721 (03SEP14)

9015-10-74

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=314

System Diagrams

Main Cab/Canopy Harness (W5) Wiring Diagram TX1033529 —UN—18DEC07

TX1033529

END #1 NUMBER A5 A00 R3 A01 R3 A02A X19 A03B X20 A04B X19 A05B A5 A06B A15A S13 A4 A16 X20 A28B A5 A28C A5 A28D X19 A31C X54 B01A X54 B01B X55 B01C X55 B01F B03A S1 A5 B03B A5 B03C A5 B03D A5 B03E K2 B06A X53 B07A X53 B07B A5 B07C A5 B07D A5 B07E A5 B07F A5 B10A A5 B10B A5 B10C A5 E01A X2 E03A X2 E06A X178 E07 X178 E07C X178 E07D A5 E09 X10 E10 X10 E25B X10 G01 X10 G01A X197 G01B X197 G01D X6 G01E H6 G01K X197 G01N X209 G02A X209 G02B E2 G02C B13 G02D X185 G04 X205 G04A

COLOR END #2 X10 ORG S13 ORG S13 ORG X11 ORG M12 ORG X11 ORG ORG S6 S13 ORG X28 ORG X211 ORG X211 ORG X211 ORG M8 ORG RED X9 RED S1 RED K2 RED A57 RED X181 RED X181 RED X181 RED X181 RED X181 RED S1 RED K2 RED X204 RED X204 RED X204 RED X204 RED X204 RED X213 RED X213 RED X213 WHT S1 WHT S3 WHT S8 WHT S20 WHT X10 WHT X2 WHT X10 WHT S5 WHT X11 X11 BLK BLK X197 BLK X3 BLK X2 BLK X197 BLK X197 BLK S3 BLK W2 BLK G4 BLK X209 BLK X209 BLK W2 BLK W2

END #1 X205 X185 X185 R3 X185 X185 X205 A5 A5 A5 M12 S11 S13 S13 W2 X20 X20 X182 X182 X182 X19 X19 X212 X19 X212 M8 X10 X19 X11 X193 X193 W2 X192 X192 A5 E2 X184 X184 X184 X206 X19 X206 X10 A5 S13 S13 S11 X20 H5 H6 X10 X10 X201 X198

NUMBER G04B G04C G04D G04E G04F G04G G04H G04J G04K G04L G04M G07A G07G G07H G07R G08A G08C G09A G09B G09C G09D G09E G10C G10E G10J G10AA G14B G20A G70F G70G G70H G71A G71B G71C J01B L01 L02A L02B L02D L03A L03B L03D L04A L05 L05A L05B L05D L05F M01A M02A M03B M06B M12 M12A

COLOR END #2 BLK K2 BLK X28 BLK S20 BLK X185 BLK S8 BLK S6 BLK X29 BLK X205 BLK X205 BLK X205 BLK X185 BLK S8 BLK S14 BLK S11 BLK S14 BLK W2 BLK W2 BLK W2 BLK X48 BLK X48 BLK X182 BLK X182 BLK W2 BLK X212 BLK X11 BLK X212 BLK A54 BLK W2 BLK X193 BLK X62 BLK X63 BLK X192 BLK X62 BLK X63 TAN X10 BRN S14 BRN S11 BLK X19 BRN X48 BRN S11 BLK X206 BRN X48 BRN S14 BRN S14 BRN S14 BRN S11 BRN S8 BRN S8 PUR X6 PUR X2 PUR H4 PUR X62 YEL X3 YEL X2

END #1 NUMBER X188 M12C X188 M12F X6 M12G X10 M12K X194 M12L M12AB X194 X198 M12TJ X202 M13 X199 M13A X187 M13C X187 M13F X187 M13G X10 M13K X195 M13L X195 M13AB X199 M13TJ X63 M50A X63 M51A X63 M52A X63 M53A M55A X62 X62 M56A M57A X62 X62 M58A X62 M59A X11 N03B X11 N04B H7 N05A X10 N06 A5 P01A X179 P01B A5 P01C A4 P02A X183 P05A X183 P05B X183 P05C X10 P06B X10 P07B X180 P07C A5 P07D A4 P09A X20 P09B M12 P09C A5 P10A X190 P10B H7 P10C A5 P12A A5 P14A A4 P15A A5 P16 A5 P17A X20 P17C X10 P17D A4 P20A

COLOR END #2 YEL X201 YEL R5 YEL X188 YEL X194 YEL X198 YEL X63 YEL X201 X3 LGRN X2 LGRN X202 LGRN R5 LGRN X6 LGRN X195 LGRN X199 LGRN X63 LGRN X202 LGRN PUR X38 PUR X38 PUR X38 PUR X38 PUR X39 PUR X39 PUR X39 PUR X39 PUR X39 YEL X5 YEL X5 YEL B13 YEL X5 RED X179 RED S5 RED X179 RED X3 RED A4 RED A5 RED A5 RED X6 RED X180 RED H4 RED X180 RED X207 RED X207 RED X207 RED X190 RED X6 RED X190 RED X2 RED A54 RED X19 RED X20 RED X208 RED X208 RED X208 RED S14

Main Cab/Canopy Harness (W5) Wire Legend (S.N. —210219) Continued on next page

TM10721 (03SEP14)

9015-10-75

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=315

END #1 NUMBER P20B S14 A5 P22A A4 P23E P23F S11 X19 P25A X19 P26C M8 P26E A4 P26F X20 P27 X20 P28A A4 P29A A4 P31A A4 P32A A4 P33A A4 P70D X191 P70E X191 P70F A5 P71A X10 R01F X203 R02 X200 R02A X186 R02C X186 R02F X186 R02G X10 R02K R02L X196 R02M X196 X200 R02TJ X189 R04 X10 R04F X11 R04G H5 R11A X1 T01 X1 T02 X11 T03 X1 T04 B1 T05 B1 T06 X1 T07 X1 T08 X1 T09 X1 T10 X1 T11 X11 T17 X11 T18 X11 T19 X11 T20 X11 T21 X1 T33A X10 T38 X10 T41 X10 T42 T45 X10 X11 T50

COLOR END #2 RED S14 RED S13 RED S11 RED S11 RED A4 RED X210 RED X210 RED X210 RED A4 RED A4 RED G4 RED X29 RED A5 RED A5 RED X191 RED X62 RED X63 RED X63 BLK X11 BLK X3 BLK BLK X203 BLK R5 BLK BLK X196 BLK X200 BLK X63 BLK X203 BLK X5 BLK X189 BLK X189 BLK X6 BLU B2 BLU B2 BLU X1 BLU B4 BLU X1 BLU X1 BLU B4 BLU S21 BLU S21 BLU B5 BLU B5 BLU X1 BLU X1 BLU X1 BLU X1 BLU X1 BLU S20 BLU X1 BLU X1 BLU X1 BLU X1 BLU X2

END #1 NUMBER X11 T51 X11 T52A X11 X12A X10 X38 X11 Y33 X1 Z01 X11 Z02 B1 Z03 X1 Z04 X1 Z05 X1 Z07 X11 Z08 X11 Z09

COLOR END #2 BLU X2 BLU X2 YEL X5 YEL X5 YEL X6 B2 GRY X1 GRY X1 GRY B4 GRY B5 GRY GRY S21 X1 GRY X1 GRY

AA95137,000118E -19-22JUL13-1/27

System Diagrams

TX1033530 —UN—19DEC07

X29 X184

X183

SIDE A L02A L02D SIDE B L02B

SIDE A P05A SIDE B P05B P05C

A B

P31A G04H

1 X11

X11

SOC 31

20 21

X184

X183

7 1 15

SIDE A E07 E07D SIDE B E07C

1 2 3 4

L02D L03D G09C G09B

M12 A B C D E F

X48

14 25

X178

28 16

5 13

29 17

4 12

2 3

11 23

P09C G04M A04B

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16

17 18 19 20 21 22 23 24 25 26 27 28 29 30 31

G01 T03 T19 Z02 T50 A03B T51 G70F T18 T17 Z08 T52A

T20 T21 Z09 E25B G10J A05B N04B N03B X12A R01F Y33 R04G

SOC

X182 SIDE A G09A SIDE B G09B G09C G09D G09E

X7 (A4) P05A P02A P25A P32A P33A P70D

SIDE A B03B B03C B03D B03E SIDE B B03A

A B

A B C D

15 27

14 26

X10

X87 X179 SIDE A P01A P01C SIDE B P01B

R3 A16 G04C

5 25

4 24

29 17

X28

7 1

X9 B

X180 SIDE A P07D SIDE B P07B P07C

3 11

10 22

X181

C1 C2 C3 C4 C5 C6 C7 C8 C9 C10

P28A P29A P15A A16 P09A P31A P26F P27 P20A P23E

21 9

1 B0

A1 A2 A3 A4 A5 A6 A7 A8 A9 A10

X10

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16

A00 T42 E07C T38 G01A L04A G01 P07B N06 J01B E09 T41 T45 P06B X38

17 18 19 20 21 22 23 24 25 26 27 28 29 30 31

R04F P17D M03B M12K M13K R02K E10 M06B G14B E25B R01F

A01 A02A G04E

SHT 1 OF 4

TX1033530 Main Cab/Canopy Harness (W5) Wiring Diagram (S.N. —210219) (SHT 1 of 4)

AA95137,000118E -19-22JUL13-2/27

Continued on next page

TM10721 (03SEP14)

9015-10-76

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=316

System Diagrams

1— Continued on SHT 2 3— Continued on SHT 4 A4—Load Center 1 M12— Heater Valve Motor R3—Under-Seat Heater Blower Resistor X7— Load Center 1 (A4) Connector X9— Main Cab/Canopy Harness-to-Engine Harness 1-Pin Connector

X10— Main Cab/Canopy Harness-to-Engine Harness 31-Pin Connector X11— Main Cab/Canopy Harness-to-Transmission Harness Connector X28— Air Seat Connector X29— Spare 2-Pin Connector

X48— Main Cab/Canopy Harness-to-Canopy Auxiliary Light Harness Connector X87— IGC Power 1-Pin Connector X178— E07 WHT Splice X179— P01 RED Splice X180— P07 RED Splice

Continued on next page

TM10721 (03SEP14)

9015-10-77

X181— B03 RED Splice X182— G09 BLK Splice X183— P05 RED Splice X184— L02 BRN Splice

AA95137,000118E -19-22JUL13-3/27

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=317

System Diagrams

TM10721 (03SEP14)

9015-10-78

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=318

System Diagrams

TX1033531 —UN—18DEC07

S11 1 2

SIDE A G04F SIDE B G04 G04C G04D G04E G04G G04M

SIDE A R02C SIDE B R02F R02G

SIDE A M13F M13G SIDE B M13C

SIDE A M12F M12G SIDE B M12C

9 10

B1 A B C

T05 T06 Z03

A B

— E06A G04F — —

6 7 8 9 10

L05D L05F — —

A B C

10 3 2 1 8

X189

S13

SIDE A R04F R04G SIDE B R04

1 2 3 4 5 6 7

A02A A15A P22A A01 G07G G07H L05A L05B — —

M12F M13F R02F

9 6 5 4 7

R5 A

9 10

SIDE A P10A SIDE B P10B P10C

9 10

— A15A

— G07A

L05 L05A — —

X190

S8 1 2 3 4 5

P20B L04A — P20B L01

3 4 5 6

BAT IGN1

BO6A — B01B B03A — E01A

IGN2

ACC1 ACC2 BAT IGN1 IGN2 ST

G07G G07R

ACC2

9 6 5 4 7

— — —

R11A M01A

ACC1

10 3 2 1 8

A B

— —

— P20A

9 6 5 4 7

E10 — —

6 7 8 9 10

1 2

10 3 2 1 8

— P01B

P23F L02A — P23F L03A G07A G07H L05B L05D — —

S14

C B A

S5 1 2 3 4 5

9 6 5 4 7

X188

10 3 2 1 8

G02A G04 G04A G07R G08A G08C G09A G10C G20A G71A

X187

9 6 5 4 7

X186

10 3 2 1 8

X185

3 4 5 6 7

— P23E

S8 H7

S R P N M L K J H G F E D C B A

N05A

A B C D E F G

X38 R04 — — N06 N03B —

R02G

P N M L K J H G F E D C B A

X5 (H1) H J K L M N P

A B C D E F G H

— N04B X12A — — —

—

TX1033531

P06B —

J K M12G L R11A M — N — P R — — S

— M13G P10B M01A Y33 G01E — — SHT 2 OF 4

Main Cab/Canopy Harness (W5) Wiring Diagram (S.N. —210219) (SHT 2 of 4) Continued on next page

TM10721 (03SEP14)

X6 (H1)

9015-10-79

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=319

AA95137,000118E -19-22JUL13-4/27

System Diagrams

TM10721 (03SEP14)

9015-10-80

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=320

System Diagrams

1— Continued on SHT 1 2— Continued on SHT 3 B1—Decelerator Sensor H1—Standard Display Monitor (SDM) H5—Monitor Alarm H7—Winch Pressure Warning Indicator

R5—CAN Termination Resistor S1— Key Switch S5— Start Aid Switch S8— Decelerator Mode Switch S11— Auxiliary Light Switch S13— Under-Seat Heater Blower Switch

S14— Light Switch W2—Cab/Canopy Harness Ground at Cab/Canopy Right Front X5— SDM 14-Pin Connector X6— SDM 16-Pin Connector X185— G04 BLK Splice

Continued on next page

TM10721 (03SEP14)

9015-10-81

X186— R02 BLK Splice X187— M13 LGRN Splice X188— M12 YEL Splice X189— R04 BLK Splice X190— P10 RED Splice

AA95137,000118E -19-22JUL13-5/27

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=321

System Diagrams

TM10721 (03SEP14)

9015-10-82

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=322

System Diagrams

TX1033533 —UN—18DEC07

X2 (A1) — —

A1 A2 A3 B1 B2 B3 C1 C2 C3

M12A — — E07D E06A — M13A

— T50

D1 D2 D3 E1 E2 E3 F1 F2 F3

B5 A B C

— G01D E03A T52A

B A

A B C

A B

S20

E03A G01N

A B C

G04D T33 E07

A B

A06A G04G

1A 1B 2A 2B

B2 C2

B1 C1

A B C

B2 B4 A B C

A B C

T07 T04 Z04

T01 T02 Z01

X197

SIDE A M13A M13TJ SIDE B M13L

SIDE A G01A G01B G01E G01K SIDE B G01D G01N

X199

X197

X199 X1

A2 A1

11 12

R10 1A

R02A

B3 C3 D3

P07B M03B — —

B3 C3

A B C B A

P12A T51 M02A

G3 H3

B2 C2 D2

G2 H2

B1 C1 D1

G1 H1

C B A

A B C

T08 T09 Z07

A1 A2 A3 B1 B2 B3 C1 C2 C3 D1 D2 D3 E1 E2 E3

T01 T02 Z01 T03 — Z02 T07 T04 Z04 T10 T11 Z05 T20 T33A Z09

F1 F2 F3 G1 G2 G3 H1 H2 H3 J1 J2 J3 K1 K2 K3

T05 T06 Z03 T08 T09 Z07

X201

X200

X198

SIDE B M13 M13C M13TJ

SIDE B M12 M12C M12TJ

SIDE A R02A R02TJ SIDE B R02L

SIDE A M12A M12TJ SIDE B M12L

2B G0

X202

SIDE B R02 R02C R02TJ

D C B

G70H M12AB M13AB R02M M50A M51A M52A M53A G71C —

11 12

X62 1 2 3 4 5 6 7 8 9 10 11 12

X191 SIDE A P70D SIDE B P70E P70F

P70F M06A G70G M55A M56A M57A

X192 SIDE A G71A SIDE B G71B G71C

M58A M59A G71B — — —

X193

J H

T18 T17 Z08 T38 T19 T41 T42

X196

X195

SIDE A R02K SIDE B R02L R02M

SIDE A M13K SIDE B M13AB M13L

SIDE A M12K SIDE B M12AB M12L

E F G

X3 A B C D E

G01B P02 M12 M13 R02

F G H J

— — — —

T21 T45

SHT 3 OF 4

TX1033533 Main Cab/Canopy Harness (W5) Wiring Diagram (S.N. —210219) (SHT 3 of 4) Continued on next page

TM10721 (03SEP14)

P70F P71A

X194

X203

1 2 3 4 5 6 7 8 9 10 11 12

SIDE A G70F SIDE B G70G G70H

9 P2

X1 (A1)

X63

S3 T10 T11 Z05

9015-10-83

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=323

AA95137,000118E -19-22JUL13-6/27

System Diagrams

TM10721 (03SEP14)

9015-10-84

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=324

System Diagrams

2— Continued on SHT 2 S6— Horn Switch A1—Transmission Control Unit S20— Park Lock Lever Switch (TCU) X1— TCU 30-Pin Connector B2—TCL Sensor X2— TCU 18-Pin Connector B4—Transmission Speed Control X3— Service ADVISOR™ Sensor Connector B5—Steer Sensor X62— Main Cab/Canopy HarG4—Power Outlet (12-Volt) ness-to-GlobalTRACS® H4—Warmup Indicator Terminal (GTT) Harness R10— Engine Speed Control 12-Pin Connector S3— Neutral Start Switch

X63— Main Cab/Canopy X197— G01 BLK Splice Harness-to-Machine X198— M12 YEL Splice Information Gateway (MIG) X199— M13 LGRN Splice Harness 12-Pin Connector X200— R02 BLK Splice X191— P70 RED Splice X201— M12 YEL Splice X192— G71 BLK Splice X202— M13 LGRN Splice X193— G70 BLK Splice X203— R02 BLK Splice X194— M12 YEL Splice X195— M13 LGRN Splice X196— R02 BLK Splice

Service ADVISOR is a trademark of Deere & Company Continued on next page

TM10721 (03SEP14)

9015-10-85

AA95137,000118E -19-22JUL13-7/27

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=325

System Diagrams

TM10721 (03SEP14)

9015-10-86

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=326

System Diagrams

TX1033534 —UN—18DEC07

X19 1

E2 2

L01 G02C

A B

L02B L03B A05B A31C P15A P25A G09E G09D G10E P26C A03B G20A

1 2 3 4 5 6 7 8 9 10 11 12

G01K

K2 A B

X209

X211

M02A

X39

X38

SIDE A A28B SIDE B A28C A28D

SIDE A G02C G02D SIDE B G02A G02B

X211

X209

X84

1 2 3 4

P14A G14B

B06A G04B

X207

SIDE A P09A P09C SIDE B P09B

B07A

X207

X205 B13 A B

M55A M56A M57A M58A M59A

1 2 3 4 5 6

M50A M51A M52A M53A

1 2 3 4

N05A G02D

SIDE A G10AA G10E SIDE B G10C G10J

SIDE A P26F SIDE B P26C P26E

SIDE A P17A P17D SIDE B P17C

SIDE A L03A L03D SIDE B L03B

X213 SIDE A B10B B10C SIDE B B10A

SIDE A G04J G04K G04L SIDE B G04A G04B G04H

X205

X213 X20 M8 1 2 3 4

P26E A31C G10AA

4 3

1 2

1 2 3 4 5 6 7 8 9 10 11 12

B07

X53 (A4)

X204 SIDE A B07B SIDE B B07C B07D B07E B07F

X206

X208

X210

X212

X55 (A4)

X54 (A4)

P27 L05F P09B A04B P17C P16 A28B G08C G08A P28A

X8 (A5)

A1 A2 A3 A4 A5 A6 A7 A8 A9 A10

E01A B10C B10B B03D B03C B03E B07E B07D B07F P01C

AA1 AA2 AA3 AA4 AA5 AA6 AA7 AA8 AA9 AA10

E09 P12A P10A P07D P01A P71A P22A L05 P14A J01B

B1 B2 B3 B4 B5 B6 B7 B8 B9 B10

P06C A06A B03B G04J P32A G04K P33A G04L

C1 C2 C3 C4 C5 C6 C7 C8 C9 C10

D1 D2 D3 D4 D5 D6 D7 D8 D9 D10

P05B A00 B07C B10A A28D P17A A28C P16 SHT 4 OF 4

TX1033534 Main Cab/Canopy Harness (W5) Wiring Diagram (S.N. —210219) (SHT 4 of 4) Continued on next page

TM10721 (03SEP14)

9015-10-87

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=327

AA95137,000118E -19-22JUL13-8/27

System Diagrams

TM10721 (03SEP14)

9015-10-88

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=328

System Diagrams

3— Continued on SHT 1 A4—Load Center 1 A5—Load Center 2 B13— Winch Pressure Switch E2— Rear Light H6—Backup Alarm K2—Accessory Relay M8—Rear Wiper Motor X8— Load Center 2 (A5) Connector X19— Main Cab/Canopy Harness-to-Cab Roof Harness Connector 1

X55— Unswitched Power X20— Main Cab/Canopy Terminal Connector Harness-to-Cab Roof X84— Main Cab/Canopy Harness Connector 2 Harness-to-IGC Cab X38— JDLink™ MMS Direct 4-Pin Harness 4-Pin Connector Connector (Ethernet) X204— B07 RED Splice X39— GT Config Tool Adapter 6-Pin Connector (RS-232) X205— G04 BLK Splice X53— Switched Power Terminal X206— L03 BRN Splice X207— P09 RED Splice Connector X208— P17 RED Splice X54— Unswitched Power Terminal Connector

Continued on next page

TM10721 (03SEP14)

9015-10-89

X209— G02 BLK Splice X210— P26 RED Splice X211— A28 ORG Splice X212— G10 BLK Splice X213— B10 RED Splice

AA95137,000118E -19-22JUL13-9/27

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=329

System Diagrams

TM10721 (03SEP14)

9015-10-90

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=330

System Diagrams

TX1097000 —UN—01SEP11

TX1097000

END #1 NUMBER A5 A00 R3 A01 R3 A02A X19 A03B X20 A04B X19 A05B A5 A06A A15A S13 A4 A16 X20 A28B A5 A28C A5 A28D X19 A37D X54 B01A X54 B01B X55 B01C X55 B01F B03A S1 A5 B03B A5 B03C A5 B03D A5 B03E K2 B06A X53 B07A X53 B07B A5 B07C A5 B07D A5 B07E A5 B07F A5 B07G A5 B07H A5 B10A A5 B10B A5 B10C A5 E01A X2 E03A X2 E06A X178 E07 X178 E07C X178 E07D A5 E09 X10 E10 X10 E25B X10 G01 X10 G01A X197 G01B X197 G01D X6 G01E H6 G01K X197 G01N X209 G02A X209 G02B E2 G02C B13 G02D

COLOR END #2 X10 ORG S13 ORG S13 ORG X11 ORG M12 ORG X11 ORG ORG S6 S13 ORG X28 ORG X211 ORG X211 ORG X211 ORG M8 ORG RED X9 RED S1 RED K2 RED X87 RED X181 RED X181 RED X181 RED X181 RED X181 RED S1 RED K2 RED X204 RED X204 RED X204 RED X204 RED X204 RED X204 RED X204 RED X213 RED X213 RED X213 WHT S1 WHT S3 WHT S8 WHT S20 WHT X10 WHT X2 WHT X10 WHT S5 WHT X11 X11 BLK BLK X197 BLK X3 BLK X2 BLK X197 BLK X197 BLK S3 BLK W2 BLK G4 BLK X209 BLK X209

END #1 X185 X205 X205 X185 X185 R3 X185 X185 X205 A5 A5 A5 M12 S11 S13 S13 W2 X20 X20 X182 X182 X182 X19 X19 X212 X19 X212 M8 X10 X19 X11 W2 A5 E2 X184 X184 X184 X206 X19 X206 X10 A5 S13 S13 S11 X20 H5 H6 X10 X201 X198 X188 X188 X6

NUMBER G04 G04A G04B G04C G04D G04E G04F G04G G04H G04J G04K G04L G04M G07A G07G G07H G07R G08A G08C G09A G09B G09C G09D G09E G10C G10E G10J G10AA G14B G20A G70F G71A J01B L01 L02A L02B L02D L03A L03B L03D L04A L05 L05A L05B L05D L05F M01A M02A M03B M12 M12A M12C M12F M12G

COLOR END #2 BLK W2 BLK W2 BLK K2 BLK X28 BLK S20 BLK X185 BLK S8 BLK S6 BLK X29 BLK X205 BLK X205 BLK X205 BLK X185 BLK S8 BLK S14 BLK S11 BLK S14 BLK W2 BLK W2 BLK W2 BLK X48 BLK X48 BLK X182 BLK X182 BLK W2 BLK X212 BLK X11 BLK X212 BLK X84 BLK W2 BLK X41 BLK X41 TAN X10 BRN S14 BRN S11 BLK X19 BRN X48 BRN S11 BLK X206 BRN X48 BRN S14 BRN S14 BRN S14 BRN S11 BRN S8 BRN S8 PUR X6 PUR X2 PUR H4 YEL X3 YEL X2 YEL X201 YEL R5 YEL X188

END #1 NUMBER X10 M12K X194 M12L M12AB X194 X198 M12TJ X202 M13 X199 M13A X187 M13C X187 M13F X187 M13G X10 M13K X195 M13L X195 M13AB X199 M13TJ X11 N03B X11 N04B H7 N05A X10 N06 A5 P01A X179 P01B A5 P01C A4 P02A X183 P05A X183 P05B X183 P05C X10 P06B X10 P07B X180 P07C A5 P07D A4 P09A X20 P09B M12 P09C A5 P10A X190 P10B H7 P10C A5 P12A A5 P14A A4 P15A A5 P16 A5 P17A X20 P17C X10 P17D A4 P20A P20B S14 A5 P22A A4 P23E P23F S11 X19 P25A X19 P26C M8 P26E A4 P26F X20 P27 X20 P28A A4 P29A A4 P31A

COLOR END #2 YEL X194 YEL X198 YEL X41 YEL X201 X3 LGRN X2 LGRN X202 LGRN R5 LGRN X6 LGRN X195 LGRN X199 LGRN X41 LGRN X202 LGRN YEL X5 YEL X5 YEL B13 YEL X5 RED X179 RED S5 RED X179 RED X3 RED A4 RED A5 RED A5 RED X6 RED X180 RED H4 RED X180 RED X207 RED X207 RED X207 RED X190 RED X6 RED X190 RED X2 RED X84 RED X19 RED X20 RED X208 RED X208 RED X208 RED S14 RED S14 RED S13 RED S11 RED S11 RED A4 RED X210 RED X210 RED X210 RED A4 RED A4 RED G4 RED X29

Main Cab/Canopy Harness (W5) Wiring Diagram (S.N. 210220—243763) (1 of 5) Continued on next page

TM10721 (03SEP14)

9015-10-91

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=331

END #1 NUMBER A4 P32A A4 P33A A4 P70D A5 P71A X10 R01F X203 R02 X200 R02A X186 R02C X186 R02F X186 R02G X10 R02K R02L X196 R02M X196 X200 R02TJ X189 R04 X10 R04F X11 R04G H5 R11A X1 T01 X1 T02 X11 T03 X1 T04 B1 T05 B1 T06 X1 T07 X1 T08 X1 T09 X1 T10 X1 T11 X11 T17 X11 T18 X11 T19 X11 T20 X11 T21 X1 T33A X10 T38 X10 T41 X10 T42 T45 X10 X11 T50 X11 T51 X11 T52A X11 X12A X10 X38 X11 Y33 X1 Z01 X11 Z02 B1 Z03 X1 Z04 X1 Z05 X1 Z07 X11 Z08 X11 Z09

COLOR END #2 RED A5 RED A5 RED X41 RED X41 BLK X11 BLK X3 BLK BLK X203 BLK R5 BLK BLK X196 BLK X200 BLK X41 BLK X203 BLK X5 BLK X189 BLK X189 BLK X6 BLU B2 BLU B2 BLU X1 BLU B4 BLU X1 BLU X1 BLU B4 BLU S21 BLU S21 BLU B5 BLU B5 BLU X1 BLU X1 BLU X1 BLU X1 BLU X1 BLU S20 BLU X1 BLU X1 BLU X1 BLU X1 BLU X2 BLU X2 BLU X2 YEL X5 YEL X5 YEL X6 B2 GRY X1 GRY X1 GRY B4 GRY B5 GRY GRY S21 X1 GRY X1 GRY

AA95137,000118E -19-22JUL13-10/27

System Diagrams

TX1097001 —UN—06DEC11

X184

X183

SIDE A L02A L02D SIDE B L02B

SIDE A P05A SIDE B P05B P05C

X184

X183

X29 B

A B

P31A G04H

1 X11

X11

SOC 31

20 21 10

12 24

L02D L03D G09C G09B

SIDE A E07 E07D SIDE B E07C

X204 X205

SIDE A B10B B10C SIDE B B10A

SIDE A G04J G04K G04L SIDE B G04A G04B G04H

SIDE A B07B SIDE B B07C B07D B07E B07F B07G B07H

X213

X205

X204

X213

X8 (A5) B1 B2 B3 B4 B5 B6 B7 B8 B9 B10

P05C A06A B03B G04J P32A G04K P33A G04L

C1 C2 C3 C4 C5 C6 C7 C8 C9 C10

P05B A00 B07C B10A A28D P17A A28C P16 P20A P23E

D1 D2 D3 D4 D5 D6 D7 D8 D9 D10

B07G B07H

14 26

M12 A B C D E F

P09C G04M A04B

X182

A B

SIDE A G09A SIDE B G09B G09C G09D G09E

A B C D

T20 T21 Z09 E25B G10J A05B N04B N03B X12A R01F Y33 R04G

SIDE A B03B B03C B03D B03E SIDE B B03A

19 18

2 3

7 1

11 12

15 27

14 25

28 16

5 13

29 17

10 22

X10

X80 SIDE A P07D SIDE B P07B P07C

20 21

X181

X87 X179 SIDE A P01A P01C SIDE B P01B

R3 A16 G04C

T50 A03B T51 G70F T18 T17 Z08 T52A

X28

17 18 19 20 21 22 23 24 25 26 27 28 29 30 31

G01 T03 T19 Z02

SOC

X9 B

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16

X10

E09 P12A P10A P07D P01A P71A P22A L05 P14A J01B

1 B0

AA1 AA2 AA3 AA4 AA5 AA6 AA7 AA8 AA9 AA10

E01A B10C B10B B03D B03C B03E B07E B07D B07F P01C

6 15

X178

29 17

5 13

X48

A1 A2 A3 A4 A5 A6 A7 A8 A9 A10

7 1

2 3

1 2 3 4

9 22

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16

A00 T42 E07C T38 G01A L04A G01 P07B N06 J01B E09 T41 T45 P06B X38

17 18 19 20 21 22 23 24 25 26 27 28 29 30 31

R04F P17D M03B M12K M13K R02K E10 G14B E25B R01F

A01 A02A G04E

TX1097001 Main Cab/Canopy Harness (W5) Wiring Diagram (S.N. 210220—243763) (2 of 5)

AA95137,000118E -19-22JUL13-11/27

Continued on next page

TM10721 (03SEP14)

9015-10-92

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=332

System Diagrams

1— Continued on Page 3 3— Continued on Page 5 A5—Load Center 1 M12— Heater Valve Motor R3—Under-Seat Heater Blower Resistor X8— Load Center 2 (A5) Connector X9— Main Cab/Canopy Harness-to-Engine Harness 1-Pin Connector

X10— Main Cab/Canopy Harness-to-Engine Harness 31-Pin Connector X11— Main Cab/Canopy Harness-to-Transmission Harness Connector X28— Air Seat Connector X29— Spare 2-Pin Connector

X48— Main Cab/Canopy Harness-to-Canopy Auxiliary Light Harness Connector X87— IGC Power 1-Pin Connector X178— E07 WHT Splice X179— P01 RED Splice X180— P07 RED Splice X181— B03 RED Splice

Continued on next page

TM10721 (03SEP14)

9015-10-93

X182— G09 BLK Splice X183— P05 RED Splice X184— L02 BRN Splice X205— G04 BLK Splice X213— B10 RED Splice

AA95137,000118E -19-22JUL13-12/27

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=333

System Diagrams

TM10721 (03SEP14)

9015-10-94

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=334

System Diagrams

TX1097002 —UN—01SEP11

S11 X187

X188

SIDE A R02C SIDE B R02F R02G

SIDE A M13F M13G SIDE B M13C

SIDE A M12F M12G SIDE B M12C

G02A G04 G04A G07R G08A G08C G09A G10C G20A G71A

9 6 5 4 7

X186

SIDE A G04F SIDE B G04 G04C G04D G04E G04G G04M

8 9 10

B1 9 6 5 4 7

T05 T06 Z03

C B A

10 3 2 1 8

A B C

A B

R11A M01A

A B

E10 — —

— — — — —

IGN1 IGN2

6 7 8 9 10

X38 R04 — — N06 N03B —

H J K L M N P

M12F M13F R02F

9 6 5 4 7

P20B L04A — P20B L01

3 4 5 6

L05 L05A — —

X189

S13

SIDE A R04F R04G SIDE B R04

1 2 3 4 5 6 7

— A15A A02A A15A P22A A01 G07G G07H L05A L05B — —

R5 A

9 10

SIDE A P10A SIDE B P10B P10C

9 10

S8 H7

— N04B X12A — — —

A B C

10 3 2 1 8

P N M L K J H G F E D C B A

X5 (H1) A B C D E F G

L05D L05F — —

1A 1B 2A 2B

P10C N05A — —

9 10

— G07A

G04F — —

6 7 8

G07G G07R

X190

9 6 5 4 7

— E06A

10 3 2 1 8

1 2 3 4 5

— P20A

9 6 5 4 7

— P01B

ACC2

1 2 3 4 5

BAT

P23F L02A — P23F L03A G07A G07H L05B L05D — —

1 2

10 3 2 1 8

BO6A — B01B B03A — E01A

ACC1

ACC1 ACC2 BAT IGN1 IGN2 ST

— P23E

S14

3 4 5 6 7

10 3 2 1 8

X185 2

1 2

—

S R P N M L K J H G F E D C B A

R02G

X6 (H1) A B C D E F G H

P06B —

J K M12G L R11A M — N — P R — — S

— M13G P10B M01A Y33 G01E — —

TX1097002 Main Cab/Canopy Harness (W5) Wiring Diagram (S.N. 210220—243763) (3 of 5) Continued on next page

TM10721 (03SEP14)

9015-10-95

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=335

AA95137,000118E -19-22JUL13-13/27

System Diagrams

TM10721 (03SEP14)

9015-10-96

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=336

System Diagrams

1— Continued on Page 2 2— Continued on Page 4 B1—Decelerator Sensor H1—Standard Display Monitor (SDM) H5—Monitor Alarm H7—Winch Pressure Warning Indicator

R5—CAN Termination Resistor S1— Key Switch S5— Start Aid Switch S8— Decelerator Mode Switch S11— Auxiliary Light Switch S13— Under-Seat Heater Blower Switch

S14— Light Switch W2—Cab/Canopy Harness Ground at Cab/Canopy Right Front X5— SDM 14-Pin Connector X6— SDM 16-Pin Connector X185— G04 BLK Splice

Continued on next page

TM10721 (03SEP14)

9015-10-97

X186— R02 BLK Splice X187— M13 LGRN Splice X188— M12 YEL Splice X189— R04 BLK Splice X190— P10 RED Splice

AA95137,000118E -19-22JUL13-14/27

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=337

System Diagrams

TM10721 (03SEP14)

9015-10-98

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=338

System Diagrams

TX1097003 —UN—01SEP11

X2 (A1) — —

A1 A2 A3 B1 B2 B3 C1 C2 C3

M12A — — E07D E06A — M13A

— T50

D1 D2 D3 E1 E2 E3 F1 F2 F3

B5 A B C

— G01D E03A T52A

X63

S3 T10 T11 Z05

B A

A B C

A B

S20

E03A G01N

A B C

G04D T33 E07

A B

A06A G04G

B2 C2

B1 C1

A B C

11 12

A B

1A 1B 2A 2B

C B A

B3 C3

P12A T51 M02A

B2 B4 A B C

A B C

T07 T04 Z04

T01 T02 Z01

P07B M03B — —

X197

SIDE A M13A M13TJ SIDE B M13L

SIDE A G01A G01B G01E G01K SIDE B G01D G01N

X199

X197

X199 X1

B3 C3 D3

G3 H3

B2 C2 D2

G2 H2

B1 C1 D1

G1 H1

C B A

A B C

A1 A2 A3 B1 B2 B3 C1 C2 C3 D1 D2 D3 E1 E2 E3

T01 T02 Z01 T03 — Z02 T07 T04 Z04 T10 T11 Z05 T20 T33A Z09

F1 F2 F3 G1 G2 G3 H1 H2 H3 J1 J2 J3 K1 K2 K3

T05 T06 Z03 T08 T09 Z07

SIDE A M12K SIDE B M12AB M12L

X201

X200

X198

SIDE B M13 M13C M13TJ

SIDE B M12 M12C M12TJ

SIDE A R02A R02TJ SIDE B R02L

SIDE A M12A M12TJ SIDE B M12L

2B G0

X202

SIDE B R02 R02C R02TJ

G70F M12AB M13AB R02M — — — — G71A —

T08 T09 Z07

X203

P70F P71A

X194

9 P2

X1 (A1)

1 2 3 4 5 6 7 8 9 10 11 12

R10 1A

R02A

D C B

A J H

T18 T17 Z08 T38 T19 T41 T42

X196

X195

SIDE A R02K SIDE B R02L R02M

SIDE A M13K SIDE B M13AB M13L

E F G

X3 A B C D E

G01B P02A M12 M13 R02

F G H J

— — — —

T21 T45

TX1097003 Main Cab/Canopy Harness (W5) Wiring Diagram (S.N. 210220—243763) (4 of 5) Continued on next page

TM10721 (03SEP14)

9015-10-99

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=339

AA95137,000118E -19-22JUL13-15/27

System Diagrams

TM10721 (03SEP14)

9015-10-100

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=340

System Diagrams

2— Continued on Page 3 R10— Engine Speed Control A1—Transmission Control Unit S3— Neutral Start Switch (TCU) S6— Horn Switch B2—TCL Sensor S20— Park Lock Lever Switch B4—Transmission Speed Control X1— TCU 30-Pin Connector Sensor X2— TCU 18-Pin Connector B5—Steer Sensor X3— Service ADVISOR™ G4—Power Outlet (12-Volt) Connector H4—Warmup Indicator

X63— Main Cab/Canopy X199— M13 LGRN Splice Harness-to-Machine X200— R02 BLK Splice Information Gateway (MIG) X201— M12 YEL Splice Harness 12-Pin Connector X202— M13 LGRN Splice X194— M12 YEL Splice X203— R02 BLK Splice X195— M13 LGRN Splice X196— R02 BLK Splice X197— G01 BLK Splice X198— M12 YEL Splice

Service ADVISOR is a trademark of Deere & Company Continued on next page

TM10721 (03SEP14)

9015-10-101

AA95137,000118E -19-22JUL13-16/27

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=341

System Diagrams

TM10721 (03SEP14)

9015-10-102

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=342

System Diagrams

TX1097004 —UN—01SEP11

X19 1

E2 2

L01 G02C

A B

X84

G01K

L02B L03B A05B A37D P15A P25A G09E G09D G10E P26C A03B G20A

1 2 3 4 5 6 7 8 9 10 11 12

A B

X209

X211

M02A

SIDE A A28B SIDE B A28C A28D

SIDE A G02C G02D SIDE B G02A G02B

X211

X209

1 2 3 4

P14A G14B

B06A G04B

X207

SIDE A P09A P09C SIDE B P09B

B07A

X207

B B07

B13 A B

N05A G02D

SIDE A G10AA G10E SIDE B G10C G10J

SIDE A P26F SIDE B P26C P26E

SIDE A P17A P17D SIDE B P17C

SIDE A L03A L03D SIDE B L03B

B07

X53 (A4)

X206

X208

X210

X212

X55 (A4) X7 (A4) X20 M8 1 2 3 4

P26E A37D G10AA

1 2 3 4 5 6 7 8 9 10 11 12

P27 L05F P09B A04B P17C P16 A28B G08C G08A P28A

A1 A2 A3 A4 A5 A6 A7 A8 A9 A10

P28A P29A P15A A16 P09A P31A P26F P27 — —

C1 C2 C3 C4 C5 C6 C7 C8 C9 C10

P05A P02A P25A P32A P33A P70D

X54 (A4)

TX1097004 Main Cab/Canopy Harness (W5) Wiring Diagram (S.N. 210220—243763) (5 of 5) Continued on next page

TM10721 (03SEP14)

9015-10-103

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=343

AA95137,000118E -19-22JUL13-17/27

System Diagrams

TM10721 (03SEP14)

9015-10-104

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=344

System Diagrams

3— Continued on Page 2 A4—Load Center 1 A5—Load Center 2 B13— Winch Pressure Switch E2— Rear Light H6—Backup Alarm K2—Accessory Relay M8—Rear Wiper Motor X7— Load Center 1 (A4) Connector

X19— Main Cab/Canopy Harness-to-Cab Roof Harness Connector 1 X20— Main Cab/Canopy Harness-to-Cab Roof Harness Connector 2 X53— Switched Power Terminal Connector X54— Unswitched Power Terminal Connector

X55— Unswitched Power Terminal Connector X84— Main Cab/Canopy Harness-to-IGC Cab Harness 4-Pin Connector X204— B07 RED Splice X206— L03 BRN Splice X207— P09 RED Splice

Continued on next page

TM10721 (03SEP14)

9015-10-105

X208— P17 RED Splice X209— G02 BLK Splice X210— P26 RED Splice X211— A28 ORG Splice X212— G10 BLK Splice

AA95137,000118E -19-22JUL13-18/27

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=345

System Diagrams

TM10721 (03SEP14)

9015-10-106

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=346

System Diagrams

TX1136732 —UN—12JUL13

END #1 NUMBER A5 A00 R3 A01 R3 A02A X19 A03B X20 A04B X19 A05B A5 A06A S13 A15A A4 A16 X20 A28B A5 A28C A5 A28D X19 A37D X54 B01A X54 B01B X55 B01C X55 B01F S1 B03A A5 B03B A5 B03C A5 B03D A5 B03E K2 B06A X53 B07A X53 B07B A5 B07C A5 B07D A5 B07E A5 B07F A5 B07G A5 B07H A5 B10A A5 B10B A5 B10C A5 E01A X2 E03A X2 E06A X178 E07 X178 E07C X178 E07D A5 E09 X10 E10 X10 E25B X10 G01

COLOR END #2 X10 ORG S13 ORG S13 ORG X11 ORG M12 ORG X11 ORG S6 ORG S13 ORG X28 ORG X211 ORG X211 ORG X211 ORG M8 ORG X9 RED S1 RED K2 RED X87 RED X181 RED X181 RED X181 RED X181 RED X181 RED S1 RED K2 RED X204 RED X204 RED X204 RED X204 RED X204 RED X204 RED X204 RED X213 RED X213 RED X213 RED S1 WHT S3 WHT S8 WHT S20 WHT X10 WHT X2 WHT X10 WHT S5 WHT X11 WHT X11 BLK

END #1 X10 X197 X197 X6 H6 X197 X209 X209 E2 B13 X185 X205 X205 X185 X185 R3 X185 X185 X205 A5 A5 A5 M12 X11 S11 S13 S13 W2 X20 X20 X182 X182 X182 X19 X19 X212 X19 X212 M8 X10 X19 X11 W2 A5

NUMBER G01A G01B G01D G01E G01K G01N G02A G02B G02C G02D G04 G04A G04B G04C G04D G04E G04F G04G G04H G04J G04K G04L G04M G06B G07A G07G G07H G07R G08A G08C G09A G09B G09C G09D G09E G10C G10E G10J G10AA G14B G20A G70F G71A J01B

COLOR END #2 BLK X197 BLK X3 BLK X2 BLK X197 BLK X197 BLK S3 BLK W2 BLK G4 BLK X209 BLK X209 BLK W2 BLK W2 BLK K2 BLK X28 BLK S20 BLK X185 BLK S8 BLK S6 BLK X29 BLK X205 BLK X205 BLK X205 BLK X185 BLK W2 BLK S8 BLK S14 BLK S11 BLK S14 BLK W2 BLK W2 BLK W2 BLK X48 BLK X48 BLK X182 BLK X182 BLK W2 BLK X212 BLK X11 BLK X212 BLK X84 BLK W2 BLK X41 BLK X41 TAN X10

END #1 NUMBER E2 L01 X184 L02A X184 L02B X184 L02D X206 L03A X19 L03B X206 L03D X10 L04A A5 L05 S13 L05A S13 L05B S11 L05D X20 L05F H5 M01A H6 M02A X10 M03B X201 M12 X198 M12A X188 M12C X188 M12F X6 M12G X10 M12K X194 M12L X194 M12AB X198 M12TJ X202 M13 X199 M13A X187 M13C X187 M13F X187 M13G X10 M13K X195 M13L X195 M13AB X199 M13TJ X11 N03B X11 N04B H7 N05A X10 N06 A5 P01A X179 P01B A5 P01C A4 P02A X183 P05A X183 P05B

COLOR END #2 BRN S14 BRN S11 BLK X19 BRN X48 BRN S11 BLK X206 BRN X48 BRN S14 BRN S14 BRN S14 BRN S11 BRN S8 BRN S8 PUR X6 PUR X2 PUR H4 YEL X3 YEL X2 YEL X201 YEL R5 YEL X188 YEL X194 YEL X198 YEL X41 YEL X201 LGRN X3 LGRN X2 LGRN X202 LGRN R5 LGRN X6 LGRN X195 LGRN X199 LGRN X41 LGRN X202 YEL X5 YEL X5 YEL B13 YEL X5 RED X179 RED S5 RED X179 RED X3 RED A4 RED A5

END #1 NUMBER X11 Z08 X11 Z09 X183 P05C X10 P06B X10 P07B X180 P07C A5 P07D A4 P09A X20 P09B M12 P09C A5 P10A X190 P10B H7 P10C A5 P12A A5 P14A A4 P15A A5 P16 A5 P17A X20 P17C X10 P17D A4 P20A S14 P20B A5 P22A A4 P23E S11 P23F X19 P25A X19 P26C M8 P26E A4 P26F X20 P27 X20 P28A A4 P29A A4 P31A A4 P32A A4 P33A X7 P40A A4 P70D A5 P71A X10 R01F X203 R02 X200 R02A X186 R02C X186 R02F X186 R02G

COLOR END #2 X1 GRY X1 GRY A5 RED X6 RED X180 RED H4 RED X180 RED RED X207 RED X207 RED X207 RED X190 RED X6 RED X190 RED X2 RED X84 RED X19 RED X20 RED X208 RED X208 RED X208 RED S14 RED S14 RED S13 RED S11 RED S11 RED A4 RED X210 RED X210 RED X210 RED A4 RED A4 RED G4 RED X29 RED A5 RED A5 RED X11 RED X41 RED X41 BLK X11 BLK X3 BLK BLK X203 BLK R5 BLK

END #1 NUMBER X10 R02K X196 R02L X196 R02M X200 R02TJ X189 R04 X10 R04F X11 R04G H5 R11A X1 T01 X1 T02 X11 T03 X1 T04 B1 T05 B1 T06 X1 T07 X1 T08 X1 T09 X1 T10 X1 T11 X11 T17 X11 T18 X11 T19 X11 T20 X11 T21 X1 T33A X10 T38 X10 T41 X10 T42 X10 T45 X11 T50 X11 T51 X11 T52A X11 X12A X10 X38 X11 Y33 X1 Z01 X11 Z02 B1 Z03 X1 Z04 X1 Z05 X1 Z07

COLOR END #2 BLK X196 BLK X200 BLK X41 BLK X203 BLK X5 BLK X189 BLK X189 BLK X6 BLU B2 BLU B2 BLU X1 BLU B4 BLU X1 BLU X1 BLU B4 BLU S21 BLU S21 BLU B5 BLU B5 BLU X1 BLU X1 BLU X1 BLU X1 BLU X1 BLU S20 BLU X1 BLU X1 BLU X1 BLU X1 BLU X2 BLU X2 BLU X2 YEL X5 YEL X5 YEL X6 GRY B2 GRY X1 GRY X1 GRY B4 GRY B5 GRY S21

TX1136732 Main Cab/Canopy Harness (W5) Wiring Diagram (S.N. 243764— ) (1 of 5) Continued on next page

TM10721 (03SEP14)

9015-10-107

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=347

AA95137,000118E -19-22JUL13-19/27

System Diagrams

TX1136733 —UN—12JUL13

X184

X183

SIDE A L02A L02D SIDE B L02B

SIDE A P05A SIDE B P05B P05C

X184

X183

X29 B

A B

P31A G04H

1 X11

X11

SOC 31

20 21

12 24

L02D L03D G09C G09B

SIDE A E07 E07D SIDE B E07C

X204 X205

SIDE A B10B B10C SIDE B B10A

SIDE A G04J G04K G04L SIDE B G04A G04B G04H

SIDE A B07B SIDE B B07C B07D B07E B07F B07G B07H

X213

X205

X204

X213

X8 (A5) B1 B2 B3 B4 B5 B6 B7 B8 B9 B10

P05C A06A B03B G04J P32A G04K P33A G04L

C1 C2 C3 C4 C5 C6 C7 C8 C9 C10

P05B A00 B07C B10A A28D P17A A28C P16 P20A P23E

D1 D2 D3 D4 D5 D6 D7 D8 D9 D10

B07G B07H

14 26

M12 A B C D E F

P09C G04M A04B

X182

A B

SIDE A G09A SIDE B G09B G09C G09D G09E

A B C D

G06B T20 T21 Z09 E25B G10J A05B N04B N03B X12A R01F Y33 R04G

P40A

SIDE A B03B B03C B03D B03E SIDE B B03A

19 18

2 3

7 1

11 12

15 27

14 25

28 16

5 13

29 17

10 22

X10

X180 SIDE A P07D SIDE B P07B P07C

20 21

X181

X87 X179 SIDE A P01A P01C SIDE B P01B

R3 A16 G04C

T50 A03B T51 G70F T18 T17 Z08 T52A

X28

17 18 19 20 21 22 23 24 25 26 27 28 29 30 31

G01 T03 T19 Z02

SOC

X9 B

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16

X10

E09 P12A P10A P07D P01A P71A P22A L05 P14A J01B

1 B0

AA1 AA2 AA3 AA4 AA5 AA6 AA7 AA8 AA9 AA10

E01A B10C B10B B03D B03C B03E B07E B07D B07F P01C

6 15

X178

29 17

5 13

X48

A1 A2 A3 A4 A5 A6 A7 A8 A9 A10

7 1

2 3

1 2 3 4

9 10 22

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16

A00 T42 E07C T38 G01A L04A G01 P07B N06 J01B E09 T41 T45 P06B X38

17 18 19 20 21 22 23 24 25 26 27 28 29 30 31

R04F P17D M03B M12K M13K R02K E10 G14B E25B R01F

A01 A02A G04E

TX1136733 Main Cab/Canopy Harness (W5) Wiring Diagram (S.N. 243764— ) (2 of 5)

AA95137,000118E -19-22JUL13-20/27

Continued on next page

TM10721 (03SEP14)

9015-10-108

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=348

System Diagrams

X10— Main Cab/Canopy Harness-to-Engine Harness 31-Pin Connector X11— Main Cab/Canopy Harness-to-Transmission Harness Connector X28— Air Seat Connector X29— Spare 2-Pin Connector X48— Main Cab/Canopy Harness-to-Canopy Auxiliary Light Harness Connector

X87— IGC Power 1-Pin Connector X178— E07 WHT Splice X179— P01 RED Splice X180— P07 RED Splice X181— B03 RED Splice X182— G09 BLK Splice X183— P05 RED Splice X184— L02 BRN Splice

Continued on next page

TM10721 (03SEP14)

9015-10-109

X204— B07 RED Splice X205— G04 BLK Splice X213— B10 RED Splice

AA95137,000118E -19-22JUL13-21/27

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=349

System Diagrams

TM10721 (03SEP14)

9015-10-110

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=350

System Diagrams

TX1140372 —UN—12JUL13

S11 X187

X188

SIDE A R02C SIDE B R02F R02G

SIDE A M13F M13G SIDE B M13C

SIDE A M12F M12G SIDE B M12C

W2 G02A G04 G04A G06B W2

G07R G08A G08C G09A G10C G20A G71A

9 6 5 4 7

X186

SIDE A G04F SIDE B G04 G04C G04D G04E G04G G04M

8 9 10

B1 9 6 5 4 7

T05 T06 Z03

C B A

10 3 2 1 8

A B C

A B

R11A M01A

A B

E10 — —

— — — — —

IGN1 IGN2

6 7 8 9 10

X38 R04 — — N06 N03B —

H J K L M N P

M12F M13F R02F

9 6 5 4 7

P20B L04A — P20B L01

3 4 5 6

L05 L05A — —

X189

S13

SIDE A R04F R04G SIDE B R04

1 2 3 4 5 6 7

— A15A A02A A15A P22A A01 G07G G07H L05A L05B — —

R5 A

9 10

SIDE A P10A SIDE B P10B P10C

9 10

S8 H7

— N04B X12A — — —

A B C

10 3 2 1 8

P N M L K J H G F E D C B A

X5 (H1) A B C D E F G

L05D L05F — —

1A 1B 2A 2B

P10C N05A — —

9 10

— G07A

G04F — —

6 7 8

G07G G07R

X190

9 6 5 4 7

— E06A

10 3 2 1 8

1 2 3 4 5

— P20A

9 6 5 4 7

— P01B

ACC2

1 2 3 4 5

BAT

P23F L02A — P23F L03A G07A G07H L05B L05D — —

1 2

10 3 2 1 8

BO6A — B01B B03A — E01A

ACC1

ACC1 ACC2 BAT IGN1 IGN2 ST

— P23E

S14

3 4 5 6 7

10 3 2 1 8

X185 2

1 2

—

S R P N M L K J H G F E D C B A

R02G

X6 (H1) A B C D E F G H

P06B —

J K M12G L R11A M — N — P R — — S

— M13G P10B M01A Y33 G01E — —

TX1140372 Main Cab/Canopy Harness (W5) Wiring Diagram (S.N. 243764— ) (3 of 5) Continued on next page

TM10721 (03SEP14)

9015-10-111

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=351

AA95137,000118E -19-22JUL13-22/27

System Diagrams

TM10721 (03SEP14)

9015-10-112

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=352

System Diagrams

1— Continued on Page 2 2— Continued on Page 4 B1—Decelerator Sensor H1—Standard Display Monitor (SDM) H5—Monitor Alarm H7—Winch Pressure Warning Indicator

R5—CAN Termination Resistor S1— Key Switch S5— Start Aid Switch S8— Decelerator Mode Switch S11— Auxiliary Light Switch S13— Under-Seat Heater Blower Switch

S14— Light Switch W2—Cab/Canopy Harness Ground at Cab/Canopy Right Front X5— SDM 14-Pin Connector X6— SDM 16-Pin Connector X185— G04 BLK Splice

Continued on next page

TM10721 (03SEP14)

9015-10-113

X186— R02 BLK Splice X187— M13 LGRN Splice X188— M12 YEL Splice X189— R04 BLK Splice X190— P10 RED Splice

AA95137,000118E -19-22JUL13-23/27

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=353

System Diagrams

TM10721 (03SEP14)

9015-10-114

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=354

System Diagrams

TX1097003 —UN—01SEP11

X2 (A1) — —

A1 A2 A3 B1 B2 B3 C1 C2 C3

M12A — — E07D E06A — M13A

— T50

D1 D2 D3 E1 E2 E3 F1 F2 F3

B5 A B C

— G01D E03A T52A

X63

S3 T10 T11 Z05

B A

A B C

A B

S20

E03A G01N

A B C

G04D T33 E07

A B

A06A G04G

B2 C2

B1 C1

A B C

11 12

A B

1A 1B 2A 2B

C B A

B3 C3

P12A T51 M02A

B2 B4 A B C

A B C

T07 T04 Z04

T01 T02 Z01

P07B M03B — —

X197

SIDE A M13A M13TJ SIDE B M13L

SIDE A G01A G01B G01E G01K SIDE B G01D G01N

X199

X197

X199 X1

B3 C3 D3

G3 H3

B2 C2 D2

G2 H2

B1 C1 D1

G1 H1

C B A

A B C

A1 A2 A3 B1 B2 B3 C1 C2 C3 D1 D2 D3 E1 E2 E3

T01 T02 Z01 T03 — Z02 T07 T04 Z04 T10 T11 Z05 T20 T33A Z09

F1 F2 F3 G1 G2 G3 H1 H2 H3 J1 J2 J3 K1 K2 K3

T05 T06 Z03 T08 T09 Z07

SIDE A M12K SIDE B M12AB M12L

X201

X200

X198

SIDE B M13 M13C M13TJ

SIDE B M12 M12C M12TJ

SIDE A R02A R02TJ SIDE B R02L

SIDE A M12A M12TJ SIDE B M12L

2B G0

X202

SIDE B R02 R02C R02TJ

G70F M12AB M13AB R02M — — — — G71A —

T08 T09 Z07

X203

P70F P71A

X194

9 P2

X1 (A1)

1 2 3 4 5 6 7 8 9 10 11 12

R10 1A

R02A

D C B

A J H

T18 T17 Z08 T38 T19 T41 T42

X196

X195

SIDE A R02K SIDE B R02L R02M

SIDE A M13K SIDE B M13AB M13L

E F G

X3 A B C D E

G01B P02A M12 M13 R02

F G H J

— — — —

T21 T45

TX1097003 Main Cab/Canopy Harness (W5) Wiring Diagram (S.N. 243764— ) (4 of 5) Continued on next page

TM10721 (03SEP14)

9015-10-115

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=355

AA95137,000118E -19-22JUL13-24/27

System Diagrams

TM10721 (03SEP14)

9015-10-116

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=356

System Diagrams

Service ADVISOR is a trademark of Deere & Company Continued on next page

TM10721 (03SEP14)

9015-10-117

AA95137,000118E -19-22JUL13-25/27

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=357

System Diagrams

TM10721 (03SEP14)

9015-10-118

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=358

System Diagrams

TX1136734 —UN—01JUL13

X19 1

E2 2

L01 G02C

A B

L02B L03B A05B A37D P15A P25A G09E G09D G10E P26C A03B G20A

X84

G01K

1 2 3 4 5 6 7 8 9 10 11 12

A B

X209

X211

M02A

SIDE A A28B SIDE B A28C A28D

SIDE A G02C G02D SIDE B G02A G02B

X211

X209

1 2 3 4

P14A G14B

B06A G04B

X207

SIDE A P09A P09C SIDE B P09B

B07A

X207

B B07

B13 A B

N05A G02D

SIDE A G10AA G10E SIDE B G10C G10J

SIDE A P26F SIDE B P26C P26E

SIDE A P17A P17D SIDE B P17C

SIDE A L03A L03D SIDE B L03B

B07

X53 (A4)

X206

X208

X210

X212

X55 (A4) X7 (A4) X20 M8 1 2 3 4

P26E A37D G10AA

1 2 3 4 5 6 7 8 9 10 11 12

P27 L05F P09B A04B P17C P16 A28B G08C G08A P28A

A1 A2 A3 A4 A5 A6 A7 A8 A9 A10

P28A P29A P15A A16 P09A P31A P26F P27 P40A —

C1 C2 C3 C4 C5 C6 C7 C8 C9 C10

P05A P02A P25A P32A P33A P70D

X54 (A4)

TX1136734 Main Cab/Canopy Harness (W5) Wiring Diagram (S.N. 243764— ) (5 of 5) Continued on next page

TM10721 (03SEP14)

9015-10-119

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=359

AA95137,000118E -19-22JUL13-26/27

System Diagrams

TM10721 (03SEP14)

9015-10-120

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=360

System Diagrams

3— Continued on Page 2 A4—Load Center 1 B13— Winch Pressure Switch E2— Rear Light H6—Backup Alarm K2—Accessory Relay M8—Rear Wiper Motor X7— Load Center 1 (A4) Connector

X19— Main Cab/Canopy Harness-to-Cab Roof Harness Connector 1 X20— Main Cab/Canopy Harness-to-Cab Roof Harness Connector 2 X53— Switched Power Terminal Connector

X54— Unswitched Power Terminal Connector X55— Unswitched Power Terminal Connector X84— Main Cab/Canopy Harness-to-IGC Cab Harness 4-Pin Connector X206— L03 BRN Splice

X207— P09 RED Splice X208— P17 RED Splice X209— G02 BLK Splice X210— P26 RED Splice X211— A28 ORG Splice X212— G10 BLK Splice

AA95137,000118E -19-22JUL13-27/27

TM10721 (03SEP14)

9015-10-121

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=361

System Diagrams

TM10721 (03SEP14)

9015-10-122

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=362

System Diagrams

Engine Harness (W6) Component Location TX1033672 —UN—03JAN08

X44

B18

X27 X26

F7 B12

X23 V4

B31 B70 Y5

B29

Y2 R4

X10 V4 V2 V2

B6 X10 X9

B9 M1

B14 B10

B40

X49

B40 TX1033672 Engine Harness (W6) Component Location (S.N. —243763) Continued on next page

TM10721 (03SEP14)

9015-10-123

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=363

AA95137,0001199 -19-11AUG14-1/4

System Diagrams

TM10721 (03SEP14)

9015-10-124

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=364

System Diagrams

A3—Engine Control Unit (ECU) B29— Fuel Temperature Sensor B6—Crankshaft Position Sensor B31— Manifold Air Temperature B8—Pump Pressure Control Pilot Sensor (PCP) Rear B40— Transmission Oil B9—Pump Pressure Control Pilot Temperature Sensor (PCP) Front B70— Camshaft Position Sensor B10— Fuel Rail Pressure Sensor F7— Engine Control Unit (ECU) B12— Engine Coolant and Standard Display Temperature Sensor Monitor (SDM) Unswitched B14— Engine Oil Pressure Power Inline 10-Amp Fuse Sensor G3—Alternator B18— Engine Air Filter K1—Start Relay Restriction Switch M1—Starter Motor R4—CAN Termination Resistor

V2— Start Relay 1-Amp Diode V4— Starter Solenoid Diode V6— A/C Compressor Clutch 5-Amp Diode X9— Main Cab/Canopy Harness-to-Engine Harness 1-Pin Connector X10— Main Cab/Canopy Harness-to-Engine Harness 31-Pin Connector X23— Engine Harness-to-Fuel Injection Harness Connector X26— Engine Control Unit (ECU) 48-Pin Connector

Continued on next page

TM10721 (03SEP14)

9015-10-125

X27— Engine Control Unit (ECU) 32-Pin Connector X44— Engine Harness-to-Grille Harness Connector X49— Inline Fuse Power Connector Y1— Fuel Pump Control Valve Solenoid Y2— Start Aid Solenoid Y5— A/C Compressor Clutch Solenoid

AA95137,0001199 -19-11AUG14-2/4

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=365

System Diagrams

TM10721 (03SEP14)

9015-10-126

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=366

System Diagrams

TX1138952 —UN—01JUL13

X44

B18 B18 A3 X27 A3 X26

K1 V6 R4 B12

B70

B31

B60

X23

B60

X10

B29

B14 B6

X10

V2 X9 B10

M1 X49

B40 X9

B9 B8

B40

TX1138952 Engine Harness (W6) Component Location (S.N. 243764— ) Continued on next page

TM10721 (03SEP14)

9015-10-127

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=367

AA95137,0001199 -19-11AUG14-3/4

System Diagrams

TM10721 (03SEP14)

9015-10-128

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=368

System Diagrams

A3—Engine Control Unit (ECU) B31— Manifold Air Temperature V2— Start Relay 1-Amp Diode B6—Crankshaft Position Sensor Sensor V4— Starter Solenoid Diode B8—Pump Pressure Control Pilot B40— Transmission Oil V6— A/C Compressor Clutch (PCP) Rear Temperature Sensor 5-Amp Diode B9—Pump Pressure Control Pilot B60— Water-in-Fuel (WIF) Sensor X9— Main Cab/Canopy (PCP) Front B70— Camshaft Position Sensor Harness-to-Engine Harness B10— Fuel Rail Pressure Sensor F7— Engine Control Unit (ECU) 1-Pin Connector B12— Engine Coolant and Standard Display X10— Main Cab/Canopy Temperature Sensor Monitor (SDM) Unswitched Harness-to-Engine B14— Engine Oil Pressure Power Inline 10-Amp Fuse Harness 31-Pin Connector Sensor G3—Alternator X23— Engine Harness-to-Fuel B18— Engine Air Filter K1—Start Relay Injection Harness Restriction Switch M1—Starter Motor Connector B29— Fuel Temperature Sensor R4—CAN Termination Resistor X26— Engine Control Unit (ECU) 48-Pin Connector

AA95137,0001199 -19-11AUG14-4/4

TM10721 (03SEP14)

9015-10-129

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=369

System Diagrams

TM10721 (03SEP14)

9015-10-130

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=370

System Diagrams

Engine Harness (W6) Wiring Diagram TX1033771 —UN—04JAN08

B18 B29

A B

X09A R01C

B10 1

N06A G05E

1 2 3

1 R10A E20A E21A

X49

X128

E0 9A E0 9B

SIDE A G05A SIDE B G05B G05D G05E G05G G05H

E07A

E07B E B01 5A 0 E

1 2

END #2 X27 X133 X133 X133 X133 X133 X133 X26 X10 V6 X127 X127 X127 X127 X127 X27 X130

5B E0

SOC 20 31 21 8 19 9 18 10 2 22 3 29 7 1 11 17 6 4 28 23 16 5 12 13 15 14 24 27 25 26 30

X128

3A G0 4A G1 2 R0

X127 SIDE A R01A R01C R01E SIDE B R01D R01G R01H

G05A

G05

X130 X130 B40 X27 X27 X27 X27 X27 B8 B8 B9 B9 X27 X27 X27 B40

G0 G0 1H G0 1J 1M

NUMBER COLOR P04A RED P06 RED P06C RED P06D RED P06E RED P06F RED P06G RED P07A RED P17E RED P17F RED R01A BLK R01C BLK R01D BLK R01E BLK R01G BLK R01H BLK R02GND BLK R02D BLK R02E BLK R02H BLK R04A BLK R05A BLK R10A BLK R11 BLK R15 BLK R16 BLK T38A BLU T41A BLU T42A BLU T45A BLU X07A YEL X08A YEL X09A YEL X38A YEL

W3 W3 X129 X26 X26 X26 W3 G3 X128 V4 V6 X128 B18 X128 Y2 W3 X10 X10 X26 X10 X132 X132 X132 X26 X131 X131 X27 X27 X27 B18

END #1 B14 F7 X10 X26 X26 X26 X26 X10 V6 Y5 B12 B29 B31 B14 X10 X127 W3 X130 R4 X10 X10 Y1 B10 X134 B6 B70 X10 X10 X10 X10 B12 B31 B29 X10

B1 1A

END #2 X10 M1 M1 M1 X49 Y1 K1 K1 K1 K1 K1 K1 Y2 X27 X27 X27 X27 X27 X27 X27 X27 X27

B01

COLOR ORG RED RED RED RED RED WHT WHT WHT WHT WHT WHT WHT RED ORG WHT GRN YEL BLU WHT WHT WHT CLR CLR BLK BLK BLK BLK BLK BLK BLK BLK BLK BLK BLK BLK BLK BLK BLK BLK TAN BRN PUR PUR YEL YEL YEL LGRN LGRN LGRN PUR PUR YEL YEL

B01D

NUMBER A00A B01 B01D B01E B11A E02A E05A E05B E07A E07B E09A E09B E10A E11A E12A E13A E15A E17A E18A E20A E21A E25A SHIELD_1 SHIELD_2 G01H G01J G01M G01R G01T G01U G03A G05 G05A G05B G05C G05D G05E G05G G05H G14A J01A L04E M03A M06 M12D M12E M12H M13D M13E M13H M20 M22 N01A N06A

B01E

END #1 X44 X9 G3 K1 F7 X27 M1 V4 X10 V2 X10 V2 X10 X23 X23 X23 X23 X23 X23 B10 B10 X10 X134 X134 X10 X10 W3 X129 X129 X129 X44 W3 W3 X128 Y5 X44 X128 V6 X128 X10 G3 X44 X10 G3 X26 R4 X10 X131 R4 X10 B6 B70 B14 X10

W3 M1 M1

X10 1 2 3 4 5 6 7 8 9 10 11 12

V4 ANODE_PIN G05B CATHODE_SOC E05B

A00A T42A E07A T38A G01J L04E G01H P07A N06A J01A E09A

13 14 15 16 17 18 19 20 21 22 23 24

T41A T45A P06C X38A R04A P17E M03A M12H M13H R02H

25 26 27 28 29 30 31

M06 G14A E25A R01G

E10A

B14 A B C

R01E P04A N01A

B14

V2 ANODE_PIN E07B CATHODE_SOC E09B

B40 B

B6 A B A

B70 A B

2 1

R16 M22

1 2

A B

X38A R04A

B12 E02A R05A

A B

N20 R15

2 1

X07A R01A

1 2

B8 T45A T42A

1 2

T41A T38A

TX1033771 Engine Harness (W6) Wiring Diagram (S.N. —243763) (1 of 2) Continued on next page

TM10721 (03SEP14)

9015-10-131

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=371

AA95137,0001198 -19-11AUG14-1/8

System Diagrams

TM10721 (03SEP14)

9015-10-132

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=372

System Diagrams

1— Continued on Sheet 2 B14— Engine Oil Pressure B6—Crankshaft Position Sensor Sensor B8—Pump Pressure Control Pilot B18— Engine Air Filter (PCP) Rear Restriction Switch B9—Pump Pressure Control Pilot B29— Fuel Temperature Sensor (PCP) Front B40— Transmission Oil B10— Fuel Rail Pressure Sensor Temperature Sensor B12— Engine Coolant B70— Camshaft Position Sensor Temperature Sensor K1—Start Relay M1—Starter Motor

V2— Start Relay 1-Amp Diode V4— Starter Solenoid 5-Amp Diode W3—Ground at Starter Motor X9— Main Cab/Canopy Harness-to-Engine Harness 1-Pin Connector X10— Main Cab/Canopy Harness-to-Engine Harness 31-Pin Connector

Continued on next page

TM10721 (03SEP14)

9015-10-133

X49— Engine Control Unit (ECU) Inline Fuse Unswitched Power Connector X127— R01 BLK Splice X128— G05 BLK Splice Y1— Fuel Pump Control Valve Solenoid

AA95137,0001198 -19-11AUG14-2/8

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=373

System Diagrams

TM10721 (03SEP14)

9015-10-134

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=374

System Diagrams

TX1033772 —UN—23JAN08

M4 M3 M2 M1 L4 L3

L2 L1

K4 K3 K2 K1 J4

X27 (A3)

X26

H4 H3 H2 H1 G4 G3 G2 G1 F4 F3

F2 F1

E4 E3

E2 E1

D4 D3 D2 D1 C4 C3 C2 C1 B4 B3 B2 B1 A4 A3 A2 A1

X27

X26 (A3) A1 A2 A3 A4 B1 B2 B3 B4 C1 C2 C3 C4 D1 D2 D3 D4

M12D

M13D P07A

N03A

E1 E2 E3 E4 F1 F2 F3 F4 G1 G2 G3 G4 H1 H2 H3 H4

J1 J2 J3 J4 K1 K2 K3 K4 L1 L2 L3 L4 M1 M2 M3 M4

H4 H3 H2 H1 G4 G3 G2 G1 F4 F3

F2 F1

E4 E3

E2 E1

A1 A2 A3 A4 B1 B2 B3 B4 C1 C2 C3 C4 D1 D2 D3 D4

N01A M22 E25A M20 E18A X08A X07A E15A R01H E21A R15

E1 E2 E3 E4 F1 F2 F3 F4 G1 G2 G3 G4 H1 H2 H3 H4

E13A R10A E20A R16 E17A R11 P04A X09A E12A E11A

X134

X133

SIDE A R11 SIDE B SHIELD_1 SHIELD_2

SIDE A P06C SIDE B P06 P06D P06E P06F P06G

X132 SIDE A M12D SIDE B M12E M12H

F7 E02A R05A

A B

B11A P06

Y2 A B

D4 D3 D2 D1

E10A G05H

X131

SIDE A M13D SIDE B M13E M13H

C4 C3 C2 C1 B4 B3 B2 B1

P06F G01U G01T P06E P06D G01R

A4 A3 A2 A1

Y5 R4 A B C

P06G

G05C

8 7

1 2

6 5

3 4

X130 M12E M13E R02E

SIDE A R02D SIDE B R02E R02GND R02H

B C

X23

M06

B01D

A00A G05D L04E G03A

G05

1 2 3 4

ANODE_PIN G05C G05G CATHODE_SOC P17E P17F

J01A

X44

P17F

X44 1

1 2 3 4 5 6 7 8

E13A

E15A

B31 E17A E18A E12A E11A

A B

X08A R01D

X129 SIDE A G01M SIDE B G01R G01T G01U

1 TX1033772 Engine Harness (W6) Wiring Diagram (S.N. —243763) (2 of 2) Continued on next page

TM10721 (03SEP14)

9015-10-135

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=375

AA95137,0001198 -19-11AUG14-3/8

System Diagrams

TM10721 (03SEP14)

9015-10-136

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=376

System Diagrams

1— Continued on Sheet 1 A3—Engine Control Unit (ECU) B31— Manifold Air Temperature Sensor F7— Engine Control Unit (ECU) and Standard Display Monitor (SDM) Unswitched Power Inline 10-Amp Fuse

G3—Alternator R4—CAN Termination Resistor V6— A/C Compressor Clutch 5-Amp Diode X23— Engine Harness-to-Fuel Injection Harness Connector X26— Engine Control Unit (ECU) 48-Pin Connector

X27— Engine Control Unit (ECU) 32-Pin Connector X44— Engine Harness-to-Grille Harness Connector X129— G01 BLK Splice X130— R02 BLK Splice X131— M13 LGRN Splice X132— M12 YEL Splice

Continued on next page

TM10721 (03SEP14)

9015-10-137

X133— P06 RED Splice X134— R11 Shield Splice Y2— Start Aid Solenoid Y5— A/C Compressor Clutch Solenoid

AA95137,0001198 -19-11AUG14-4/8

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=377

System Diagrams

TM10721 (03SEP14)

9015-10-138

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=378

System Diagrams

TX1136736 —UN—01JUL13

TX1136736

W3 W3 X129 X26 X26 X26 W3 G3 X128 V4 V6 X128 B18 X128 Y2 W3 X10 X10 X26 X10 X132 X132 X132 X26 X131 X131 X27 X27

B18 B29

A B

X09A R01C

B10 1

N06A G05E

1 2 3

1 R10A E20A E21A

X49

X128

E0 9A E0 9B

SIDE A G05A SIDE B G05B G05D G05E G05G G05H

E07A

E07B E B01 5A 0 E 5B E0

SOC 20 31 21 8 30 19 9 18 10 2 22 3 29 7 1 11 17 6 4 28 23 16 5 12 13 15 14 24 27 25 26

X128

3A G0 4A G1 2 R0

X127 SIDE A R01A R01C R01E SIDE B R01D R01G R01H R01K

G05A

X130 X130 B40 X27 X27 X27 X27 X27 B8 B8 B9 B9 X27 X27 X27 B40

W3 M1 M1

X10 1 2 3 4 5 6 7 8 9 10 11 12

V4 ANODE_PIN G05B CATHODE_SOC E05B

A00A T42A E07A T38A G01J L04E G01H P07A N06A J01A E09A

13 14 15 16 17 18 19 20 21 22 23 24

T41A T45A P06C X38A R04A P17E M03A M12H M13H R02H

25 26 27 28 29 30 31

M06 G14A E25F R01G

E10A

V2 ANODE_PIN E07B CATHODE_SOC E09B

B14 A B C

R01E P04A N01A

B C

B40

B6 A B A

B70 A B

2 1

Y1 R16 M22

1 2

E02A R05A

A B

B9 2 1

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=379

A B

X38A R04A

1 2

B8 T45A T42A

1 2

T41A T38A

X07A R01A Engine Harness (W6) Wiring Diagram (S.N. 243764— ) (1 of 2)

9015-10-139

N20 R15

B12

Continued on next page

TM10721 (03SEP14)

1 2

END #2 X27 B18 X27 X133 X133 X133 X133 X133 X133 X26 X10 V6 X127 X127 X127 X127 X127 X27 B60 X130

G05

NUMBER COLOR N01A YEL N06A YEL P04A RED P06 RED P06C RED P06D RED P06E RED P06F RED P06G RED P07A RED P17E RED P17F RED R01A BLK R01C BLK R01D BLK R01E BLK R01G BLK R01H BLK R01K BLK R02GND BLK R02D BLK R02E BLK R02H BLK R04A BLK R05A BLK R10A BLK R11 BLK R15 BLK R16 BLK T38A BLU T41A BLU T42A BLU T45A BLU X07A YEL X08A YEL X09A YEL X38A YEL

G0 G0 1H G0 1J 1M

END #1 B14 X10 B14 F7 X10 X26 X26 X26 X26 X10 V6 Y5 B12 B29 B31 B14 X10 X127 X127 W3 X130 R4 X10 X10 Y1 B10 X134 B6 B70 X10 X10 X10 X10 B12 B31 B29 X10

B1 1A

END #2 X10 M1 M1 M1 X49 Y1 K1 K1 K1 K1 K1 K1 Y2 X27 X27 X27 X27 X27 X27 X27 X27 X27 X214 X214

B01

COLOR ORG RED RED RED RED RED WHT WHT WHT WHT WHT WHT WHT RED ORG WHT GRN YEL BLU WHT WHT WHT WHT WHT CLR CLR BLK BLK BLK BLK BLK BLK BLK BLK BLK BLK BLK BLK BLK BLK BLK BLK TAN BRN PUR PUR YEL YEL YEL LGRN LGRN LGRN PUR PUR

B01D

NUMBER A00A B01 B01D B01E B11A E02A E05A E05B E07A E07B E09A E09B E10A E11A E12A E13A E15A E17A E18A E20A E21A E25A E25D E25F SHIELD_1 SHIELD_2 G01H G01J G01M G01R G01T G01U G03A G05 G05A G05B G05C G05D G05E G05G G05H G14A J01A L04E M03A M06 M12D M12E M12H M13D M13E M13H M20 M22

B01E

END #1 X44 X9 G3 K1 F7 X27 M1 V4 X10 V2 X10 V2 X10 X23 X23 X23 X23 X23 X23 B10 B10 X214 B60 X10 X134 X134 X10 X10 W3 X129 X129 X129 X44 W3 W3 X128 Y5 X44 X128 V6 X128 X10 G3 X44 X10 G3 X26 R4 X10 X131 R4 X10 B6 B70

AA95137,0001198 -19-11AUG14-5/8

System Diagrams

TM10721 (03SEP14)

9015-10-140

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=380

System Diagrams

Continued on next page

TM10721 (03SEP14)

9015-10-141

X49— Engine Control Unit (ECU) Inline Fuse Unswitched Power Connector X127— R01 BLK Splice X128— G05 BLK Splice Y1— Fuel Pump Control Valve Solenoid

AA95137,0001198 -19-11AUG14-6/8

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=381

System Diagrams

TM10721 (03SEP14)

9015-10-142

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=382

System Diagrams

TX1136737 —UN—02JUL13

M4 M3 M2 M1 L4 L3

L2 L1

K4 K3 K2 K1 J3

X214

X26

H4 H3 H2 H1 G4 G3 G2 G1 F4 F3

F2 F1

E4 E3

E2 E1

X27 (A3)

SIDE A E25F E25D SIDE B E25A

D4 D3 D2 D1 C4 C3 C2 C1 B4 B3 B2 B1 A4 A3 A2 A1

X27

X26 (A3) A1 A2 A3 A4 B1 B2 B3 B4 C1 C2 C3 C4 D1 D2 D3 D4

M12D

M13D P07A

M03A

E1 E2 E3 E4 F1 F2 F3 F4 G1 G2 G3 G4 H1 H2 H3 H4

J1 J2 J3 J4 K1 K2 K3 K4 L1 L2 L3 L4 M1 M2 M3 M4

H4 H3 H2 H1 G4 G3 G2 G1 F4 F3

F2 F1

E4 E3

E2 E1

A1 A2 A3 A4 B1 B2 B3 B4 C1 C2 C3 C4 D1 D2 D3 D4

N01A M22 E25A M20 E18A X08A X07A E15A R01H E21A R15

E1 E2 E3 E4 F1 F2 F3 F4 G1 G2 G3 G4 H1 H2 H3 H4

E13A R10A E20A R16 E17A R11 P04A X09A E12A E11A

X134

X133

SIDE A R11 SIDE B SHIELD_1 SHIELD_2

SIDE A P06C SIDE B P06 P06D P06E P06F P06G

X132 SIDE A M12D SIDE B M12E M12H

F7 E02A R05A

A B

B11A P06

Y2 A B

D4 D3 D2 D1

E10A G05H

X131

SIDE A M13D SIDE B M13E M13H

C4 C3 C2 C1 B4 B3 B2 B1

P06F G01U G01T P06E P06D G01R

A4 A3 A2 A1

Y5 R4

X130

A B C

P06G

G05C

8 7

1 2

6 5

3 4

M12E M13E R02E

B60 A B

SIDE A R02D SIDE B R02E R02GND R02H

E25D R01K

B A

X23

M06

ANODE_PIN G05C G05G CATHODE_SOC P17E P17F

B01D

A00A G05D L04E G03A

G05

1 2 3 4

J01A

X44

P17F

1 2 3 4 5 6 7 8

E13A E15A E17A E18A E12A E11A

X129

B31 A B

SIDE A G01M SIDE B G01R G01T G01U

X08A R01D

1 TX1136737 Engine Harness (W6) Wiring Diagram (S.N. 243764— ) (2 of 2) Continued on next page

TM10721 (03SEP14)

9015-10-143

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=383

AA95137,0001198 -19-11AUG14-7/8

System Diagrams

TM10721 (03SEP14)

9015-10-144

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=384

System Diagrams

1— Continued on Sheet 1 G3—Alternator A3—Engine Control Unit (ECU) R4—CAN Termination Resistor B31— Manifold Air Temperature V6— A/C Compressor Clutch Sensor 5-Amp Diode B60— Water In Fuel (WIF) Sensor X23— Engine Harness-to-Fuel F7— Engine Control Unit (ECU) Injection Harness and Standard Display Connector Monitor (SDM) Unswitched X26— Engine Control Unit (ECU) Power Inline 10-Amp Fuse 48-Pin Connector

X27— Engine Control Unit (ECU) 32-Pin Connector X44— Engine Harness-to-Grille Harness Connector X129— G01 BLK Splice X130— R02 BLK Splice X131— M13 LGRN Splice X132— M12 YEL Splice

X133— P06 RED Splice X134— R11 Shield Splice X214— E25 WHT Splice Y2— Start Aid Solenoid Y5— A/C Compressor Clutch Solenoid

AA95137,0001198 -19-11AUG14-8/8

TM10721 (03SEP14)

9015-10-145

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=385

System Diagrams

Transmission Harness (W7) Component Location

B15

X36

B16

X11

M11 B25 B35

B7 B33 Y11 Y4

B60 Y3

M13

TX1033019 —UN—11JAN08

TX1033019 Transmission Harness (W7) Component Location (S.N. —173344)

Continued on next page

TM10721 (03SEP14)

9015-10-146

AA95137,0001196 -19-06AUG13-1/5

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=386

System Diagrams B3—Motor Speed Sensor Right B7—Motor Speed Sensor Left B15— Transmission Oil Filter Restriction Switch B16— Hydraulic Oil Filter Restriction Switch

B25— Hydraulic Oil Temperature M13— Front/Rear Washer Motor Sensor X11— Main Cab/Canopy B33— Charge Pressure Sensor Harness-to-Transmission B35— Fuel Level Sensor Harness Connector B60— Water-in-Fuel (WIF) Sensor X36— Transmission M11— Left/Right Washer Motor Harness-to-JDLink™ Ground Harness 1-Pin Connector

Y3— Motor Shift Solenoid Right Y4— Motor Shift Solenoid Left Y11— Park Brake Solenoid

JDLink is a trademark of Deere & Company Continued on next page

TM10721 (03SEP14)

9015-10-147

AA95137,0001196 -19-06AUG13-2/5

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=387

System Diagrams

B15 X36

X11

B16

M11 B35

B25

Y11 B60

W25 W25 Y4

X70

M13

B41 Y3

TX1063230 —UN—31AUG09

TX1063230 Transmission Harness (W7) Component Location (S.N. 173345—243763)

Continued on next page

TM10721 (03SEP14)

9015-10-148

AA95137,0001196 -19-06AUG13-3/5

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=388

System Diagrams B3—Motor Speed Sensor Right B7—Motor Speed Sensor Left B15— Transmission Oil Filter Restriction Switch B16— Hydraulic Oil Filter Restriction Switch B25— Hydraulic Oil Temperature Sensor

B35— Fuel Level Sensor X11— Main Cab/Canopy B41— Charge Pressure Sensor Harness-to-Transmission B60— Water-in-Fuel (WIF) Sensor Harness Connector M11— Left/Right Washer Motor X36— Transmission M13— Front/Rear Washer Motor Harness-to-JDLink™ W25—Charge Pressure Sensor Ground Harness 1-Pin Harness Connector

X70— Charge Pressure Sensor Harness Connector Y3— Motor Shift Solenoid Right Y4— Motor Shift Solenoid Left Y11— Park Brake Solenoid

JDLink is a trademark of Deere & Company Continued on next page

TM10721 (03SEP14)

9015-10-149

AA95137,0001196 -19-06AUG13-4/5

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=389

System Diagrams

B15 X36

B16

M11

X11

B25 B7

B35

Y11

M13 B60 B41

W25

Y4 Y3

X70

TX1138944 —UN—06AUG13

R8 B3

TX1138944 Transmission Harness (W7) Component Location (S.N. 243764— ) B3—Motor Speed Sensor Right B7—Motor Speed Sensor Left B15— Transmission Oil Filter Restriction Switch B16— Hydraulic Oil Filter Restriction Switch B25— Hydraulic Oil Temperature Sensor

B35— Fuel Level Sensor W25—Charge Pressure Sensor B41— Charge Pressure Sensor Harness B60— Water-in-Fuel (WIF) Sensor X11— Main Cab/Canopy Connector (if equipped) Harness-to-Transmission M11— Left/Right Washer Motor Harness Connector M13— Front/Rear Washer Motor X36— Transmission R8—Fuel Filter Heater (if Harness-to-JDLink™ equipped) Ground Harness 1-Pin Connector

X70— Charge Pressure Sensor Harness Connector Y3— Motor Shift Solenoid Right Y4— Motor Shift Solenoid Left Y11— Park Brake Solenoid

JDLink is a trademark of Deere & Company AA95137,0001196 -19-06AUG13-5/5

TM10721 (03SEP14)

9015-10-150

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=390

System Diagrams

Transmission Harness (W7) Wiring Diagram TX1032996 —UN—11JAN08

NUMBER A03A A05A E25C G01C G01F G01G G01L G10F G10G G70J N03A N04A R01J R04B R04C R04D T03D T17A T18A T19A T20A T21A T50A T51A T52 X12 Y33A Z02A Z08A Z09A

COLOR ORG ORG WHT BLK BLK BLK BLK BLK BLK BLK YEL YEL BLK BLK BLK BLK BLU BLU BLU BLU BLU BLU BLU BLU BLU YEL YEL GRY GRY GRY

END #2 M11 M13 B60 X108 X108 Y4 Y11 M11 M13 X36 B16 B15 B60 X106 X106 X106 B3 B7 B7 B3 B33 B33 Y4 Y3 Y11 B25 B35 B3 B7 B33

X36 A

G70J

B15

N04A

A B

B60 A B

Z08A

E25C R01J

B A

X12 R04C

Y33A

M11

A C

A B

Z09A T20A

T21A

1 2

A03A G10F G10G

T52 G01L

X108

1 2

X106

SIDE A G01C G01F SIDE B G01G G01L

Y4 1

B35

T50A G01G

SIDE A R04B R04C SIDE B R04D

X108

X106

G01C T03A

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31

A B

B33

X11

B25

Y11

A05A G10G

N03A

B7 T18A T17A

1 2

B16

A B

M13

B A

END #1 X11 X11 X11 X11 Y3 X108 X108 X11 M11 X11 X11 X11 X11 B35 B25 X11 X11 X11 X11 X11 X11 X11 X11 X11 X11 X11 X11 X11 X11 X11

T19A Z02A — T50A A03A T51A G70J T18A T17A Z08A T52 — — — — T20A T21A Z09A E25C G10F A05A — N04A N03A X12 R01J Y33A R04D —

X11

20 8

19 29 28

7 17

1 2

12 13

14 26

T51A G01F

11 4

6 27

15 1

21 9

24 25

B3 A

B C

A B

T03A T19A

Z02A

TX1032996 Transmission Harness (W7) Wiring Diagram (S.N. —173344) Continued on next page

TM10721 (03SEP14)

9015-10-151

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=391

AA95137,0001197 -19-07AUG13-1/6

System Diagrams

TM10721 (03SEP14)

9015-10-152

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=392

System Diagrams

B3—Motor Speed Sensor Right B7—Motor Speed Sensor Left B15— Transmission Oil Filter Restriction Switch B16— Hydraulic Oil Filter Restriction Switch B25— Hydraulic Oil Temperature Sensor

X36— Transmission B33— Charge Pressure Sensor Harness-to-JDLink™ B35— Fuel Level Sensor Ground Harness 1-Pin B60— Water-in-Fuel (WIF) Sensor Connector M11— Left/Right Washer Motor M13— Front/Rear Washer Motor X106— R04 BLK Splice X108— G01 BLK Splice X11— Main Cab/Canopy Harness-to-Transmission Y3— Motor Shift Solenoid Right Harness Connector

Y4— Motor Shift Solenoid Left Y11— Park Brake Solenoid

JDLink is a trademark of Deere & Company Continued on next page

TM10721 (03SEP14)

9015-10-153

AA95137,0001197 -19-07AUG13-2/6

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=393

System Diagrams

TM10721 (03SEP14)

9015-10-154

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=394

System Diagrams

TX1063232 —UN—26AUG09

NUMBER A03A A05A E25C G01C G01F G01G G01L G10F G10G G70J N03A N04A R01J R04B R04C R04D T03D T17A T18A T19A T20A T21A T50A T51A T52 X12 Y33A Z02A Z08A Z09A

COLOR ORG ORG WHT BLK BLK BLK BLK BLK BLK BLK YEL YEL BLK BLK BLK BLK BLU BLU BLU BLU BLU BLU BLU BLU BLU YEL YEL GRY GRY GRY

END #2 M11 M13 B60 X108 X108 Y4 Y11 M11 M13 X36 B16 B15 B60 X106 X106 X106 B3 B7 B7 B3 X70 X70 Y4 Y3 Y11 B25 B35 B3 B7 X70

X36 A

G70J

B15

N04A

A B

B60 A B

M11 1

A B

Z09A T20A

T21A

1 2

A03A G10F G10G

T52 G01L

X108

1 2

X106

SIDE A G01C G01F SIDE B G01G G01L

Y4 2

B35

Y33A

B A

X12 R04C

E25C R01J

T50A G01G

SIDE A R04B R04C SIDE B R04D

X108

X106

G01C T03A

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31

A B

X70

Z08A

X11

B25

A05A G10G

N03A

Y11 T18A T17A

1 2

B16

A B

M13

B A

END #1 X11 X11 X11 X11 Y3 X108 X108 X11 M11 X11 X11 X11 X11 B35 B25 X11 X11 X11 X11 X11 X11 X11 X11 X11 X11 X11 X11 X11 X11 X11

T19A Z02A — T50A A03A T51A G70J T18A T17A Z08A T52 — — — — T20A T21A Z09A E25C G10F A05A — N04A N03A X12 R01J Y33A R04D —

X11

20 8

19 29 28

7 17

1 2

12 13

14 26

T51A G01F

11 4

15 1

1 6

21 9

24 25

B3 A

B C

A B

T03A T19A

Z02A

TX1063232 Transmission Harness (W7) Wiring Diagram (S.N. 173345—243763 ) Continued on next page

TM10721 (03SEP14)

9015-10-155

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=395

AA95137,0001197 -19-07AUG13-3/6

System Diagrams

TM10721 (03SEP14)

9015-10-156

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=396

System Diagrams

B3—Motor Speed Sensor Right B7—Motor Speed Sensor Left B15— Transmission Oil Filter Restriction Switch B16— Hydraulic Oil Filter Restriction Switch B25— Hydraulic Oil Temperature Sensor

X36— Transmission B35— Fuel Level Sensor Harness-to-JDLink™ B60— Water-in-Fuel (WIF) Sensor Ground Harness 1-Pin M11— Left/Right Washer Motor Connector M13— Front/Rear Washer Motor X70— Charge Pressure Sensor X11— Main Cab/Canopy Harness Connector Harness-to-Transmission X106— R04 BLK Splice Harness Connector

X108— G01 BLK Splice Y3— Motor Shift Solenoid Right Y4— Motor Shift Solenoid Left Y11— Park Brake Solenoid

JDLink is a trademark of Deere & Company Continued on next page

TM10721 (03SEP14)

9015-10-157

AA95137,0001197 -19-07AUG13-4/6

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=397

System Diagrams

TM10721 (03SEP14)

9015-10-158

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=398

System Diagrams

TX1136740 —UN—06AUG13

NUMBER A03A A05A E25C G01C G01F G01G G01L G06B G10F G10G G70J N03A N04A P40D R01J R04B R04C R04D T03D T17A T18A T19A T20A T21A T50A T51A T52 X12 Y33A Z02A Z08A Z09A

COLOR ORG ORG WHT BLK BLK BLK BLK BLK BLK BLK BLK YEL YEL RED BLK BLK BLK BLK BLU BLU BLU BLU BLU BLU BLU BLU BLU YEL YEL GRY GRY GRY

END #2 M11 M13 B60 X108 X108 Y4 Y11 R8 M11 M13 X36 B16 B15 R8 B60 X106 X106 X106 B3 B7 B7 B3 X70 X70 Y4 Y3 Y11 B25 B35 B3 B7 X70

X36 A

G70J

B15 N04A

Z08A

A05A G10G

X11

A B A B

E25C R01J

1 2

B A

R8 A B

G06B P40D

B35

Y33A

M11 2 1

A B

Z09A T20A

T21A

1 2

A03A G10F G10G

T52 G01L

X108

X106

SIDE A G01C G01F SIDE B G01G G01L

Y4 2

A B

B60

X12 R04C

T50A G01G

SIDE A R04B R04C SIDE B R04D

X108

X106

G01C T03A

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31

B25

X70

1 2

N03A

B7 T18A T17A

M13

B16

Y11 A B

B A

END #1 X11 X11 X11 X11 Y3 X108 X108 X11 X11 M11 X11 X11 X11 X11 X11 B35 B25 X11 X11 X11 X11 X11 X11 X11 X11 X11 X11 X11 X11 X11 X11 X11

T19A Z02A — T50A A03A T51A G70J T18A T17A Z08A T52 — — P40D G06B T20A T21A Z09A E25C G10F A05A — N04A N03A X12 R01J Y33A R04D —

X11

20 8

19 29 28

7 17

1 2

12 13

14 26

T51A G01F

11 4

15 1

1 6

21 9

24 25

B3 A

B C

A B

T03A T19A

Z02A

TX1136740 Transmission Harness (W7) Wiring Diagram (S.N. 243764— ) Continued on next page

TM10721 (03SEP14)

9015-10-159

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=399

AA95137,0001197 -19-07AUG13-5/6

System Diagrams

TM10721 (03SEP14)

9015-10-160

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=400

System Diagrams

B3—Motor Speed Sensor Right B7—Motor Speed Sensor Left B15— Transmission Oil Filter Restriction Switch B16— Hydraulic Oil Filter Restriction Switch B25— Hydraulic Oil Temperature Sensor

X36— Transmission B35— Fuel Level Sensor Harness-to-JDLink™ B60— Water-in-Fuel (WIF) Sensor Ground Harness 1-Pin Connector (if equipped) Connector M11— Left/Right Washer Motor M13— Front/Rear Washer Motor X70— Charge Pressure Sensor Harness Connector R8—Fuel Filter Heater (if X106— R04 BLK Splice equipped) X108— G01 BLK Splice X11— Main Cab/Canopy Harness-to-Transmission Harness Connector

Y3— Motor Shift Solenoid Right Y4— Motor Shift Solenoid Left Y11— Park Brake Solenoid

JDLink is a trademark of Deere & Company AA95137,0001197 -19-07AUG13-6/6

TM10721 (03SEP14)

9015-10-161

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=401

System Diagrams

A/C Harness (W8) Component Location

B22 R2 B50

M5 X12

X51

TX1016301

TX1016301 —UN—08DEC06

W14

A/C Harness (W8) Component Location

Continued on next page

TM10721 (03SEP14)

9015-10-162

WS68074,000094B -19-15JAN07-1/2

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=402

System Diagrams B22— A/C Freeze Switch B50— A/C High/Low Pressure (Binary) Switch M2—Heater Blower Motor

M4—Condenser Fan Motor W14—Condenser Harness M5—Condenser Fan Motor X12— Cab/Canopy-to-A/C R2—Cab Heater Blower Resistor Harness Connector X51— A/C Harness-to-Condenser Harness Connector WS68074,000094B -19-15JAN07-2/2

TM10721 (03SEP14)

9015-10-163

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=403

System Diagrams

TM10721 (03SEP14)

9015-10-164

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=404

System Diagrams

A/C Harness (W8) Wiring Diagram TX1074339 —UN—05APR10

Air Conditioning Harness (W8) Wiring Diagram Continued on next page

TM10721 (03SEP14)

9015-10-165

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=405

WS68074,000094C -19-24MAR10-1/2

System Diagrams

TM10721 (03SEP14)

9015-10-166

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=406

System Diagrams

B22— A/C Freeze Switch B50— A/C High/Low Pressure (Binary) Switch M2—Heater Blower Motor

TM10721 (03SEP14)

9015-10-167

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=407

System Diagrams

Radio Harness (W9) Component Location

W10 B21

B20 A2

TX1018537 —UN—06FEB07

X13

TX1018537 Radio Harness (W9) Component Location A2—Radio (12 V) B20— Right Speaker

B21— Left Speaker W10—Radio Antenna

X13— Cab/Canopy Harness-toRadio Harness Connector AA95137,0000785 -19-05FEB07-1/1

TM10721 (03SEP14)

9015-10-168

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=408

System Diagrams

TM10721 (03SEP14)

9015-10-169

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=409

System Diagrams

TX1011976 —UN—13SEP06

Radio Harness (W9) Wiring Diagram

Continued on next page

TM10721 (03SEP14)

9015-10-170

CED,TX14826,10546 -19-08SEP06-1/2

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=410

System Diagrams A2—Radio (12 V) B20— Right Speaker

B21— Left Speaker X13— Cab/Canopy Harness-toRadio Harness Connector CED,TX14826,10546 -19-08SEP06-2/2

TM10721 (03SEP14)

9015-10-171

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=411

System Diagrams

Canopy Auxiliary Light Harness (W11) Component Location

E6 E8

T199446 —UN—22APR04

X48

T199446 Canopy Auxiliary Light Harness (W11) Component Location

Continued on next page

TM10721 (03SEP14)

9015-10-172

AA95137,0000779 -19-01FEB07-1/2

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=412

System Diagrams E5— Rear Auxiliary Light Right E6— Rear Auxiliary Light Left

E7— Front Auxiliary Light Right E8— Front Auxiliary Light Left

X48— Canopy Harness-toCanopy Auxiliary Light Harness Connector AA95137,0000779 -19-01FEB07-2/2

TM10721 (03SEP14)

9015-10-173

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=413

System Diagrams

TM10721 (03SEP14)

9015-10-174

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=414

System Diagrams

Canopy Auxiliary Light Harness (W11) Wiring Diagram T198579 —UN—22APR04

Canopy Auxiliary Light Harness (W11) Wiring Diagram Continued on next page

TM10721 (03SEP14)

9015-10-175

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=415

AA95137,000077A -19-01FEB07-1/2

System Diagrams

TM10721 (03SEP14)

9015-10-176

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=416

System Diagrams E5— Rear Auxiliary Light Right E6— Rear Auxiliary Light Left

E7— Front Auxiliary Light Right E8— Front Auxiliary Light Left

X48— Canopy Harness-toCanopy Auxiliary Light Harness Connector

X115— L02 BRN Splice X117— L03 BRN Splice AA95137,000077A -19-01FEB07-2/2

Grill Harness (W13) Component Location

X44

E4 B28

T198510 —UN—13APR04

T198510 Grill Harness (W13) Component Location B28— Horn E3— Front Light Left

E4— Front Light Right X44— Engine Harness-to-Grill Harness Connector MF82180,00001C6 -19-15MAR04-1/1

TM10721 (03SEP14)

9015-10-177

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=417

System Diagrams

TM10721 (03SEP14)

9015-10-178

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=418

System Diagrams

Grill Harness (W13) Wiring Diagram T198569 —UN—22APR04

Grill Harness (W13) Wiring Diagram Continued on next page

TM10721 (03SEP14)

9015-10-179

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=419

MF82180,00001C7 -19-15MAR04-1/2

System Diagrams

TM10721 (03SEP14)

9015-10-180

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=420

System Diagrams B28— Horn E3— Front Light Left E4— Front Light Right

X44— Engine Harness-to-Grill Harness Connector

X125— L04 Brn Splice X126— G03 Blk Splice MF82180,00001C7 -19-15MAR04-2/2

TM10721 (03SEP14)

9015-10-181

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=421

System Diagrams

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

A8 X95

X87 Y31

Y32

W20 Y30 X90

TX1017558 —UN—06FEB07

X96

TX1017558 Integrated Grade Control (IGC) Machine Harness (W21) Component Location

Continued on next page

TM10721 (03SEP14)

9015-10-182

AA95137,000073F -19-02FEB07-1/2

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=422

System Diagrams A8—IGC Load Center W20—IGC Ground X87— IGC Power 1-Pin Connector X90— IGC Auxiliary Actuator 4-Pin Connector

Y30— Blade Angle Actuator X95— IGC Machine Y31— Blade Tilt Actuator Harness-to-IGC Cab Harness 35-Pin Connector Y32— Blade Lift Actuator X96— IGC Interface 23-Pin Connector AA95137,000073F -19-02FEB07-2/2

TM10721 (03SEP14)

9015-10-183

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=423

System Diagrams

TM10721 (03SEP14)

9015-10-184

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=424

System Diagrams

Integrated Grade Control (IGC) Machine Harness (W21) Wiring Diagram—If Equipped TX1017537 —UN—06FEB07

AA95137,0000740 -19-02FEB07-1/2

Continued on next page

TM10721 (03SEP14)

9015-10-185

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=425

System Diagrams

TM10721 (03SEP14)

9015-10-186

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=426

System Diagrams

A8—IGC Load Center W20—IGC Ground X87— IGC Power 1-Pin Connector X90— IGC Auxiliary Actuator 4-Pin Connector X95— IGC Machine Harness-to-IGC Cab Harness 35-Pin Connector

X96— IGC Interface 23-Pin Connector (IGC option) X154— G30 BLK Splice X155— G30 BLK Splice 2 X156— P50 RED Splice X157— P62 RED Splice

X158— P14 RED Splice Y32— Blade Lift Actuator (IGC X159— P51 RED Splice option) X160— G30 BLK Splice 3 Y30— Blade Angle Actuator (IGC option) Y31— Blade Tilt Actuator (IGC option)

AA95137,0000740 -19-02FEB07-2/2

TM10721 (03SEP14)

9015-10-187

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=427

System Diagrams

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

X82 A11

X83 X86

X81 R6 A9

S30

X97 X98

R7 X84 X85

TX1142464 —UN—16AUG13

X95

TX1142464 Integrated Grade Control (IGC) Cab Harness (W22) Component Location

Continued on next page

TM10721 (03SEP14)

9015-10-188

AA95137,0000741 -19-15AUG13-1/2

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=428

System Diagrams A9—Blade Control Joystick (BCJ) A11— Electrohydraulic Controller R6—IGC CAN Termination Resistor R7—IGC CAN Termination Resistor S30— Hydraulic Enable Switch

X85— Auxiliary Joystick X81— RS232 3-Pin Connector X98— BCJ Four-Way Axis Module Connector X82— Electrohydraulic Connector X86— Machine CAN 3-Pin Controller (EHC) Connector Connector X95— IGC Machine X83— Electrohydraulic Harness-to-IGC Cab Controller (EHC) Harness 35-Pin Connector Connector X97— BCJ Switch Module X84— IGC Cab Harness-toConnector Cab/Canopy Harness 4-Pin Connector AA95137,0000741 -19-15AUG13-2/2

TM10721 (03SEP14)

9015-10-189

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=429

System Diagrams

TX1017859 —UN—24JAN07

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

Integrated Grade Control (IGC) Cab Harness (W22) Wire Table Continued on next page

TM10721 (03SEP14)

9015-10-190

AA95137,0000742 -19-24JAN07-1/3

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=430

System Diagrams

TX1017709 —UN—18JAN07

Integrated Grade Control (IGC) Cab Harness (W22) Wiring Diagram Continued on next page

TM10721 (03SEP14)

9015-10-191

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=431

AA95137,0000742 -19-24JAN07-2/3

System Diagrams

TM10721 (03SEP14)

9015-10-192

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=432

System Diagrams X85— Auxiliary Joystick 4-Pin R6—IGC CAN Termination X162— M18 LGRN Splice Connector Resistor X163— R40 BLK Splice X86— Machine CAN 3-Pin R7—IGC CAN Termination X164— H20 BLU Splice Connector Resistor X165— H22 GRN Splice X95— IGC Machine S30— Hydraulic Enable Switch X166— H24 GRN Splice Harness-to-IGC Cab X81— RS232 3-Pin Connector X167— H25 GRN Splice Harness 35-Pin Connector X168— H33 GRN Splice X82— Electrohydraulic X97— BCJ Switch Module Controller (EHC) X169— R41 BLK Splice Connector X83— Electrohydraulic X170— R13 BLK Splice 1 X98— BCJ Four-Way Axis Module X171— M13 LGRN Splice 1 Controller (EHC) Connector X84— IGC Cab Harness-toCab/Canopy Harness 4-Pin X161— M17 YEL Splice Connector

X172— M12 YEL Splice 1 X173— P58 RED Splice X174— G15 BLK Splice X175— M12 YEL Splice 2 X176— M13 LGRN Splice 2 X177— R13 BLK Splice 2

AA95137,0000742 -19-24JAN07-3/3

TM10721 (03SEP14)

9015-10-193

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=433

System Diagrams

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

COLOR BLK RED WHT

END #1 X70 X70 X70

END #2 B41 B41 B41

B41

X70 BLK RED WHT

A B C

BLK RED WHT

TX1063211 —UN—28AUG09

A B C

TX1063211 Charge Pressure Sensor Harness (W25) Wiring Diagram (S.N. 173345— ) B41— Charge Pressure Sensor

X70— Charge Pressure Sensor Connector JW40272,00004E4 -19-23SEP09-1/1

JDLink™ System Harnesses Component Location—MIG/GTT Machine may be equipped with one of two different JDLink™ systems. See JDLink™ System Identification. (Group 9015-20.) Continued on next page

TM10721 (03SEP14)

9015-10-194

DP27668,00007A0 -19-21NOV13-1/3

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=434

System Diagrams

JDLink™ Harnesses (W30, W31, and W32) Component Location—If Equipped (S.N. —196417) TX1025831 —UN—27JUL07

W33

A12

A13

W34

X36 X67 X66 X63 X64

X65 X62

F31 W30

W32

W31

TX1025831

JDLink™ Harnesses (W30, W31, and W32) Component Location Continued on next page

TM10721 (03SEP14)

9015-10-195

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=435

DP27668,00007A0 -19-21NOV13-2/3

System Diagrams

TM10721 (03SEP14)

9015-10-196

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=436

System Diagrams

A12— Machine Information Gateway (MIG) Controller A13— GlobalTRACS® Terminal (GTT) Controller F31— JDLink™ Ground 5 Amp Fuse S2— Battery Disconnect Switch

W30—Machine Information Gateway (MIG) Harness W31—GlobalTRACS® Terminal (GTT) Harness W32—JDLink™ Ground Harness W33—GlobalTRACS® Terminal (GTT) Antenna W34—GlobalTRACS® Terminal (GTT) Chassis Ground X36— Transmission Harness-to-JDLink™ Ground Harness 1-Pin Connector

X62— Cab Harness-toX66— Machine Information GlobalTRACS® Terminal Gateway (MIG) 30-Pin (GTT) Harness 12-Pin (L1—Y3) Connector Connector X67— Machine Information X63— Cab Harness-to-Machine Gateway (MIG) 30-Pin Information Gateway (MIG) (A1—K3) Connector Harness 12-Pin Connector X64— GlobalTRACS® Terminal (GTT) 70-Pin Connector X65— Machine Information Gateway (MIG) Harness-toGlobalTRACS® Terminal (GTT) Harness 12-Pin Connector

GlobalTRACS is a trademark of Qualcomm Incorporated JDLink is a trademark of Deere & Company DP27668,00007A0 -19-21NOV13-3/3

TM10721 (03SEP14)

9015-10-197

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=437

System Diagrams

JDLink™ System Harnesses Component Location—MTG/SAT Machine may be equipped with one of two different JDLink™ systems. See JDLink™ System Identification. (Group 9015-20.)

Continued on next page

TM10721 (03SEP14)

9015-10-198

WS68074,00037C1 -19-21NOV13-1/2

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=438

System Diagrams

JDLink™ Harnesses (W6002 and W6003) Component Location—If Equipped (S.N. 196418— )

A6001

A6003

A6000

X6016 X63

A6002

X6015

X6016

X6014

W6003

X63 A6000 A6002 TX1086785

TX1086785 —UN—17JAN11

W6002

JDLink™ Harnesses (W6002 and W6003) Component Location (S.N. 196418— ) WS68074,00037C1 -19-21NOV13-2/2

TM10721 (03SEP14)

9015-10-199

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=439

System Diagrams A6000—JDLink™ Modular X6014—Modular Telematics A6003—Satellite Antenna (if Telematics Gateway Gateway (MTG) Control equipped) (MTG) Control Unit Unit 48-Pin Connector W6002—Universal JDLink™ A6001—GPS/Cellular Antenna X6015—Satellite (SAT) Module Harness A6002—Satellite (SAT) Module Control Unit 48-Pin W6003—Satellite Adapter Control Unit (if equipped) Connector Harness X6016—Satellite Adapter X63— Main Cab/Canopy Harness-to-Universal Harness-to-JDLink JDLink™ Harness 6-Pin Harness 12-Pin Connector Connector JDLink is a trademark of Deere & Company WS68074,00037C1 -19-21NOV13-3/2

JDLink™ System Wiring Diagrams—MIG/GTT Machine may be equipped with one of two different JDLink™ systems. See JDLink™ System Identification. (Group 9015-20.) Continued on next page

TM10721 (03SEP14)

9015-10-200

DP27668,00007A1 -19-21NOV13-1/7

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=440

System Diagrams

Machine Information Gateway (MIG) Harness (W30) Wiring Diagram—If Equipped (S.N. 159987—161691) TX1026202 —UN—25JUL07

X65 1 2 3 4 5 6 7 8 9 10 11 12

M60 M61 M62 — M63 M64 — M65 M66 M67 M68 M69

X66 L1 L2 L3 M1 M2 M3 N1 N2 N3 P1 P2 P3 R1 R2 R3

1 2 3 4 5 6 7 8 9 10 11 12

X65

X63

P70A — M12AA — — M13AA — G70C — M67 P71 — — P70B G70D

X67 P70 P71 G70 M12AA M13AA R02AA M50 M51 M52 M53 G71D —

1 2 3 4 5 6 7 8 9 10 11 12

X63

S1 S2 S3 T1 T2 T3 W1 W2 W3 X1 X2 X3 Y1 Y2 Y3

Y X W T S

R P N M L

A1 A2 A3 B1 B2 B3 C1 C2 C3 D1 D2 D3 E1 E2 E3

X188

X66

X186 SIDE A G70 SIDE B G70A G70B G70C G70D

X186

X188 X187 SIDE A P70 SIDE B P70A P70B

SIDE A G71D G71E G71F G71G G71H

F1 F2 F3 G1 G2 G3 H1 H2 H3 J1 J2 J3 K1 K2 K3

— — — — — — — — — — — — — — —

X67 G71E

X187

M53 M64 M60 M52 M63 M61 M50 — — M51 — — — — —

K J H G F

E D C B A

1 2 3

1 2 3 4 5 6 7 8 9 10 11 12

— M65 M66 — M69 M68 — G70A — — M62 — G07B — —

R02AA

END #2 X63 X66 X66 X66 X66 X188 — — — — X66 X66 X67 X67 X67 X67 X65 X65 X65 X65 X65 X65 X65 X65 X65 X65 X187 X66 X66 X66 —

G71H

COLOR BLK BLK BLK BLK BLK BLK BLK BLK BLK BLK YEL YEL PUR PUR PUR PUR PUR PUR PUR PUR PUR PUR PUR PUR PUR PUR RED RED RED RED BLK

G71G

NUMBER G70 G70A G70B G70C G70D G71D G71E G71F G71G G71H M12AA M13AA M50 M51 M52 M53 M60 M61 M62 M63 M64 M65 M66 M67 M68 M69 P70 P70A P70B P71 R02AA

1 2 3

END #1 X186 X186 X186 X186 X186 X63 X188 X188 X188 X188 X63 X63 X63 X63 X63 X63 X67 X67 X66 X67 X67 X66 X66 X66 X66 X66 X63 X187 X187 X63 X63

G71F

TX1026202 Machine Information Gateway (MIG) Wiring Harness (W30) Diagram (S.N. 159987—161691) Continued on next page

TM10721 (03SEP14)

9015-10-201

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=441

DP27668,00007A1 -19-21NOV13-2/7

System Diagrams

TM10721 (03SEP14)

9015-10-202

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=442

System Diagrams

X63— Cab Harness-to-Machine X66— Machine Information Information Gateway (MIG) Gateway (MIG) 30-Pin Harness 12-Pin Connector (L1—Y3) Connector X65— Machine Information X67— Machine Information Gateway (MIG) Harness-toGateway (MIG) 30-Pin GlobalTRACS® Terminal (A1—K3) Connector (GTT) Harness 12-Pin Connector

X186— G70 BLK Splice X187— P70 RED Splice X188— G71 BLK Splice

GlobalTRACS is a trademark of Qualcomm Incorporated Continued on next page

TM10721 (03SEP14)

9015-10-203

DP27668,00007A1 -19-21NOV13-3/7

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=443

System Diagrams

TM10721 (03SEP14)

9015-10-204

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=444

System Diagrams

Machine Information Gateway (MIG) Harness (W30) Wiring Diagram—If Equipped (S.N. 161692—196417) TX1041205 —UN—02JUN08

X65 1 2 3 4 5 6 7 8 9 10 11 12

END #2 X63 — — — — X188 X66 X66 X66 X66 X66 X66 X67 X67 X67 X67 X65 X65 X65 X65 X65 X65 X65 X65 X65 X65 X187 X66 X66 X66 —

M60 M61 M62 — M63 M64 — M65 M66 M67 M68 M69

X67 A1 A2 A3 B1 B2 B3 C1 C2 C3 D1 D2 D3 E1 E2 E3

1 2 3 4 5 6 7 8 9 10 11 12

X65

X63 P70 P71 G70 M12AA M13AA R02AA M50 M51 M52 M53 G71D —

1 2 3 4 5 6 7 8 9 10 11 12

X63

F1 F2 F3 G1 G2 G3 H1 H2 H3 J1 J2 J3 K1 K2 K3

— — — — — — — — — — — — — — —

X66 K J H G F

L1 L2 L3 M1 M2 M3 N1 N2 N3 P1 P2 P3 R1 R2 R3

E D C B A

X186

X67

X188 SIDE A G71D SIDE B G71E G71F G71G G71H

X188

X186 X187 SIDE A P70 SIDE B P70A P70B

SIDE A G70 G70A G70B G70C G70D

S1 S2 S3 T1 T2 T3 W1 W2 W3 X1 X2 X3 Y1 Y2 Y3

P70A — M12AA — — M13AA — G71G — M67 P71 — — P70B G71H

X66 G70C

X187

— M65 M66 — M69 M68 — G71E — — M62 — G71F — —

Y X W T S

R P N M L

1 2 3

1 2 3 4 5 6 7 8 9 10 11 12

M53 M64 M60 M52 M63 M61 M50 — — M51 — — — — —

G70B

COLOR BLK BLK BLK BLK BLK BLK BLK BLK BLK BLK YEL YEL PUR PUR PUR PUR PUR PUR PUR PUR PUR PUR PUR PUR PUR PUR RED RED RED RED BLK

G70A

NUMBER G70 G70A G70B G70C G70D G71D G71E G71F G71G G71H M12AA M13AA M50 M51 M52 M53 M60 M61 M62 M63 M64 M65 M66 M67 M68 M69 P70 P70A P70B P71 R02AA

1 2 3

END #1 X186 X186 X186 X186 X186 X63 X188 X188 X188 X188 X63 X63 X63 X63 X63 X63 X67 X67 X66 X67 X67 X66 X66 X66 X66 X66 X63 X187 X187 X63 X63

G70D R02AA

TX1041205 Machine Information Gateway (MIG) Wiring Harness (W30) Diagram (S.N. 161692—196417) Continued on next page

TM10721 (03SEP14)

9015-10-205

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=445

DP27668,00007A1 -19-21NOV13-4/7

System Diagrams

TM10721 (03SEP14)

9015-10-206

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=446

System Diagrams

X186— G70 BLK Splice X187— P70 RED Splice X188— G71 BLK Splice

Continued on next page

TM10721 (03SEP14)

9015-10-207

DP27668,00007A1 -19-21NOV13-5/7

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=447

System Diagrams

TM10721 (03SEP14)

9015-10-208

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=448

System Diagrams

GlobalTRACS® Terminal (GTT) Harness (W31) Wiring Diagram—If Equipped (S.N. —196417) TX1148033 —UN—21NOV13

X64

57 58 59 60 61 62 63

5 4 3 2 1

M70 M71 M72 M73

M60A M61A M62A — M63A M64A — M65A M66A M67A M68A M69A

X64

R70C R70D

1 2 3 4 5 6 7 8 9 10 11 12

R70A R70B

X65

— — — — — — — — — —

65 66 67 68 69 70

X215

X62

61 62 63 64 65 66 67 68 69 70

7 8 9 10 11 12

SIDE A R70 SIDE B R70A R70B R70C R70D

M63A M60A M61A — — — R71 M69A M68A — — — — — — — — — — —

1 2 3 4 5 6

X215

41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60

W34

— — G70E M59 M66A — — — — M72 M73 M62A M67A — — — — M70 M71 M64A

P70C M54 G70E M55 M56 M57 M58 M59 G71 — — —

21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40

1 2 3 4 5 6 7 8 9 10 11 12

M55 M56 M58 — — — — — — — — M54 P70C M57 M65A R70 — — — —

X62

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20

9 10 11 12 13

END #2 X64 W34 X64 X64 X64 X64 X64 X64 X64 X64 X64 X64 X64 X64 X64 X64 X64 X64 — — — — X64 X64 — — — — X64

COLOR BLK BLK PUR PUR PUR PUR PUR PUR PUR PUR PUR PUR PUR PUR PUR PUR PUR PUR PUR PUR PUR PUR RED BLK BLK BLK BLK BLK BLK

NUMBER G70E G71 M54 M55 M56 M57 M58 M59 M60A M61A M62A M63A M64A M65A M66A M67A M68A M69A M70 M71 M72 M73 P70C R70 R70A R70B R70C R70D R71

G71 R71

END #1 X62 X62 X62 X62 X62 X62 X62 X62 X65 X65 X65 X65 X65 X65 X65 X65 X65 X65 X64 X64 X64 X64 X62 X215 X215 X215 X215 X215 W34

X65 1 2 3 4 5 6 7 8 9 10 11 12

TX1148033 GlobalTRACS® Terminal (GTT) Harness (W31) Wiring Diagram (S.N. —196417) Continued on next page

TM10721 (03SEP14)

9015-10-209

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=449

DP27668,00007A1 -19-21NOV13-6/7

System Diagrams

TM10721 (03SEP14)

9015-10-210

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=450

System Diagrams

W34—Frame Ground at Cab/Canopy Right Front X62— Cab Harness-toGlobalTRACS® Terminal (GTT) Harness 12-Pin Connector

X64— GlobalTRACS® Terminal X215— R70 BLK Splice (GTT) 70-Pin Connector X65— Machine Information Gateway (MIG) Harness-toGlobalTRACS® Terminal (GTT) Harness 12-Pin Connector DP27668,00007A1 -19-21NOV13-7/7

TM10721 (03SEP14)

9015-10-211

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=451

System Diagrams

JDLink™ Ground Harness (W32) Wiring Diagram—If Equipped END #1 S2 X36

NUMBER — —

COLOR BLK BLK

END #2 F31 F31

X36 F31 BLK

TX1026235 —UN—27JUL07

BLK

TX1026235 S2— Battery Disconnect Switch X36— Transmission Harness-to-JDLink™ Ground Harness 1-Pin Connector

F31— JDLink™ Ground 5-Amp Fuse

JDLink is a trademark of Deere & Company KK70125,0000C61 -19-30NOV07-1/1

TM10721 (03SEP14)

9015-10-212

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=452

System Diagrams

JDLink™ System Wiring Diagrams—MTG/SAT Machine may be equipped with one of two different JDLink™ systems. See JDLink™ System Identification. (Group 9015-20.)

Continued on next page

TM10721 (03SEP14)

9015-10-213

WS68074,00037C2 -19-22NOV13-1/3

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=453

System Diagrams

JDLink™ Modular Telematics Gateway (MTG) Harness (W6002) Wiring Diagram—If Equipped (S.N. 196418— )

END #1 X5000 X6014 X6016 X6014 X63 X63 X63 X6014 X6014 X6014 X6014 X6014 X6016 X6016 X6014 X5001 X6014 X6016 X63 X63 X63

NUMBER G70 G70A G70B G71D M12AA M13AA M17L M18L M70 M71 M72 M73 M74B M74A M76A P70 P70A P70B P71 R13AA R40L

COLOR BLK BLK BLK BLK YEL LT GRN YEL LT GRN PUR PUR PUR PUR PUR PUR PUR RED RED RED RED BLK BLK

END #2 X63 X5000 X5000 X63 X6014 X6014 X6014 X63 X6020 X6021 X6022 X6023 X6014 X6014 X6016 X63 X5001 X5001 X6014 SHLD SHLD

X6016 1 2 3 4 5 6

G70B P70B M74B M76A M75A —

X63 1 2 3 4 5 6 7 8 9 10 11 12

P70 P71 G70 M12AA M13AA R12AA — M17L M18L R40L G71D —

7 8

9 10 11 12

5 4

2 1

X6014 (A6000)

X6021 1

A B C D E F G H J K L M

X6022

X6020

X6023

X5000

X5001

SIDE A G70 SIDE B G70A G70B

SIDE A P70 SIDE B P70A P70B

TX1086381 —UN—03JAN11

M73

M17L M18L — M73 M12AA M13AA — M72 — — — M71 — — — M70 P71 — — — G70A P70A M74B —

M72

G1 G2 G3 G4 H1 H2 H3 H4 J1 J2 J3 J4 K1 K2 K3 K4 L1 L2 L3 L4 M1 M2 M3 M4

M71

M76A M75A — — — — — — — — — — — — — — — — — — — — G71D —

M70

A1 A2 A3 A4 B1 B2 B3 B4 C1 C2 C3 C4 D1 D2 D3 D4 E1 E2 E3 E4 F1 F2 F3 F4

TX1086381 JDLink™ Modular Telematics Gateway (MTG) Harness (W6002) Wiring Diagram (S.N. 196418— ) Continued on next page

TM10721 (03SEP14)

9015-10-214

WS68074,00037C2 -19-22NOV13-2/3

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=454

System Diagrams A6000—JDLink™ Modular X5000—G70 BLK Splice Telematics Gateway X5001—P70 RED Splice (MTG) Control Unit X6014—Modular Telematics X63— JDLink™ 12-Pin Connector Gateway (MTG) 48-Pin Connector

X6016—Satellite Adapter Harness-to-Universal JDLink™ Harness Connector X6020—Not Used X6021—Not Used

X6022—Not Used X6023—Not Used

JDLink is a trademark of Deere & Company WS68074,00037C2 -19-22NOV13-3/3

TM10721 (03SEP14)

9015-10-215

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=455

System Diagrams JDLink™ Satellite (SAT) Harness (W6003) Wiring Diagram—If Equipped (S.N. 196418— )

END #1 X6016 X6016 X6016 X6016 X6016

NUMBER G1001 J1003 M1004 M1005 P1002

COLOR END #2 BLK X6015 TAN X6015 PUR X6015 PUR X6015 RED X6015

X6015 (A6002)

2 3 4

K L M

M1005 M1004

G1 G2 G3 G4 H1 H2 H3 H4 J1 J2 J3 J4 K1 K2 K3 K4 L1 L2 L3 L4 M1 M2 M3 M4

J1003

X6016 1 2 3 4 5 6

G1001 P1002

1 2 3

6 5 4

TX1083072

G1001 P1002 J1003 M1004 M1005

TX1083072 —UN—07JAN11

A B C D E F G H J 1

A1 A2 A3 A4 B1 B2 B3 B4 C1 C2 C3 C4 D1 D2 D3 D4 E1 E2 E3 E4 F1 F2 F3 F4

JDLink™ Satellite (SAT) Harness (W6003) Wiring Diagram—If Equipped (S.N. 196418— ) A6002—Satellite (SAT) Control Unit X6015—JDLink™ Satellite Module Connector

X6016—Satellite Adapter Harness-to-Universal JDLink™ Harness Connector WS68074,00037C2 -19-22NOV13-4/3

TM10721 (03SEP14)

9015-10-216

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=456

Group 15

Sub-System Diagnostics Starting and Charging Circuit Theory of Operation TX1074386 —UN—05APR10

Starting and Charging Circuit Schematic

TM10721 (03SEP14)

Continued on next page

9015-15-1

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=457

AA95137,000120C -19-27APR10-1/2

Sub-System Diagnostics A3—Engine Control Unit (ECU) B6—Crankshaft Position Sensor F21— Start Relay 10-Amp Fuse F25— Start Aid/Alternator Excitation 15-Amp Fuse G1—Batteries G3—Alternator K1—Start Relay M1—Starter Motor

S1— Key Switch S2— Battery Disconnect Switch S20— Park Lock Lever Switch V1— Alternator 5-Amp Excitation Diode V2— Start Relay 1-Amp Diode V4— Starter Solenoid 5-Amp Diode W2—Cab/Canopy Harness Ground at Cab/Canopy Right Front

W3—Ground at Starter Motor W15—Main Frame Ground X10— Main Cab/Canopy Harness-to-Engine Harness 31-Pin Connector X26— Engine Control Unit (ECU) 48-Pin Connector X27— Engine Control Unit (ECU) 32-Pin Connector

X84— Main Cab/Canopy Harness-to-IGC Cab Harness 4-Pin Connector Y1— Fuel Pump Control Valve Solenoid

Starting Circuit—Unswitched power is supplied to the following components:

• Key Switch (S1) • Starter Motor (M1) • Start Relay (K1) When the park lock lever is in the LOCK (up) position, park lock lever switch (S20) will provide ground to pin C2 (coil) of start relay (K1). NOTE: The park lock lever switch also provides signals to the transmission control unit for park brake control. For information on park brake control, see Transmission Control Unit (TCU) Circuit Theory of Operation. (Group 9015-15.) When key switch (S1) is turned to the START position, current from the key switch terminal ST flows through start relay 10A fuse (F21) to pin C1 (coil) of the start relay, energizing the relay. With the start relay energized, current flows to the starter motor solenoid, engaging the starter motor. The start relay diode (V2) protects the start circuit from voltage spikes when the start relay de-energizes. As the starter motor cranks the engine, the crankshaft position sensor (B6) sends a signal representing engine rpm to the engine control unit (ECU) (A3). When the ECU detects this signal, it knows the crankshaft is turning. The ECU then sends a signal to the fuel pump control valve solenoid (Y1) to provide high-pressure fuel to the electronic fuel injectors. At the same time, the ECU sends a predetermined amount of current to the electronic fuel injectors to start the fuel injection process and, thus, start the engine. For more information on the ECU, pump control solenoid, and electronic fuel injectors, see Engine Control Unit (ECU) Circuit Theory of Operation. (Group 9015-15.) Charging Circuit—Alternator (G3) provides power to all machine circuits and charges the batteries when the engine is running. Terminal B+ of the alternator is connected to battery positive (+) at all times. When key switch (S1) is in the ON position, current flows through start aid/alternator excitation 10A fuse (F25) and alternator excitation 5A diode (V1) to the D+ terminal of the alternator. The current then flows through the alternator field windings, causing excitation of the windings. Alternator excitation diode (V1) prevents current feedback from the alternator if the alternator circuitry is improperly connected or if there is a major malfunction. See Alternator Test for more information. (Group 9015-20.) AA95137,000120C -19-27APR10-2/2

TM10721 (03SEP14)

9015-15-2

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=458

Sub-System Diagnostics

Controller Area Network (CAN) Circuit Theory of Operation TX1086492 —UN—29MAR11

120

X10 M12 YEL

M12 YEL (CAN HIGH)

M12 YEL

M13 LT GRN

M13 LT GRN (CAN LOW)

M13 LT GRN

LO C

R02 BLK

R02 BLK (CAN GND)

R02 BLK

M13 LT GRN

M12 YEL

R02 BLK

M13 LT GRN

M12 YEL

R02 BLK

M13 LT GRN

M12 YEL

M13 LT GRN

R02 BLK

M12 YEL

R02 BLK

M12 YEL

R4 CAN TERMINATION RESISTOR

M13 LT GRN

SHLD R02 BLK

SHLD

M13 LT GRN

120

R5 CAN TERMINATION RESISTOR

W3 GROUND AT STARTER MOTOR

A6000 MODULAR TELEMATICS GATEWAY (MTG) CONTROL UNIT

H1 STANDARD DISPLAY MONITOR (SDM)

A3 ENGINE CONTROL UNIT (ECU) = X26

= X6014

= X6 J H G F E D C B A

X3 SERVICE ADVISOR CONNECTOR

= X64

(S.N. 196418— )

R02 BLK M13 LT GRN M12 YEL P02 RED G01 BLK

A1 TRANSMISSION CONTROL UNIT (TCU)

= X2

(S.N. —196417)

B01 RED (UNSWITCHED)

X10 W3 GROUND AT STARTER MOTOR

A12 MACHINE INFORMATION GATEWAY (MIG) CONTROLLER

F2 SERVICE ADVISOR 5A FUSE

P02 RED

TX1086492 Controller Area Network (CAN) Circuit

WS68074,00037C4 -19-01APR11-1/2

Continued on next page

TM10721 (03SEP14)

9015-15-3

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=459

Sub-System Diagnostics 1— Unswitched Power A1—Transmission Control Unit (TCU) A3—Engine Control Unit (ECU) A12— Machine Information Gateway (MIG) Controller A6000—Modular Telematics Gateway (MTG) Control Unit

F2— Service ADVISOR™ 10-Amp Fuse H1—Standard Display Monitor (SDM) R4—CAN Termination Resistor R5—CAN Termination Resistor W3—Ground at Starter Motor X2— TCU 18-Pin Connector

X3— Service ADVISOR™ Connector X6— SDM 16-Pin Connector X10— Main Cab/Canopy Harness-to-Engine Harness 31-Pin Connector X26— Engine Control Unit (ECU) 48-Pin Connector X64— GlobalTRACS® Terminal (GTT) 70-Pin Connector

X6014—Modular Telematics Gateway (MTG) Control Unit 48-Pin Connector

This machine utilizes a controller area network (CAN) on which the following electronic control devices communicate.

• Transmission Control Unit (TCU) • Engine Control Unit (ECU) • Standard Display Monitor (SDM) • JDLink™ Machine Information Gateway (MIG) (if equipped) (S.N. —196417) • JDLink™ Modular Telematics Gateway (MTG) (A6000) Control Unit (S.N. 196418— ) Operations and functions of the individual devices on CAN 1 are covered separately.

• See Engine Control Unit (ECU) Circuit Theory of Operation. (Group 9015-15.) • See Transmission Control Unit (TCU) Circuit Theory of Operation. (Group 9015-15.) • See Standard Display Monitor (SDM) Circuit Theory of Operation. (Group 9015-15.) • For the JDLink™ MIG (S.N. —196417), see General Information in JDLink™ / ZXLink™ Machine Monitoring System. (CTM10006.) • For the JDLink™ MTG (S.N. 196418— ), see General Information in JDLink™ (MTG) Diagnosis and Test Manual. (TM114519.) The devices on the CAN are communicating at a high frequency, which makes the network susceptible to interference caused by many electrical sources. The devices on the CAN are connected via three wires woven together called a twisted triple. The twisted triple consists of a high-voltage signal wire, a low-voltage signal wire, and a ground wire. This method reduces interference and helps the devices communicate with minimal errors. There are a few more components connected to the CAN. The CAN termination resistors (R4 and R5) are 120-ohm resistors, which are connected on opposite ends of the bus to avoid signal errors. The Service ADVISOR™ connector (X3) is provided for machine diagnostic purposes. For connection information, see Service ADVISOR™ Connection Procedure. (Group 9015-20.) GlobalTRACS is a trademark of Qualcomm Incorporated JDLink is a trademark of Deere & Company ZXLink is a trademark of Deere & Company Service ADVISOR is a trademark of Deere & Company

WS68074,00037C4 -19-01APR11-2/2

TM10721 (03SEP14)

9015-15-4

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=460

Sub-System Diagnostics

Engine Control Unit (ECU) Circuit Theory of Operation TX1140704 —UN—07AUG13

X11 E25 WHT

X10 E25 WHT

E25 WHT

E25 WHT X07 YEL

B2 C4

X07 YEL X09 YEL

X09 YEL

F4 C2

X08 YEL P04 RED

1 A

2 A

B60 WATER IN FUEL (WIF) SENSOR

B12 ENGINE COOLANT TEMPERATURE SENSOR

B29 FUEL TEMPERATURE SENSOR B

B31 MANIFOLD AIR TEMPERATURE (MAT) SENSOR

B14 ENGINE OIL PRESSURE SENSOR A

N01 YEL R01 BLK

R01 BLK

S.N. 243764—

R10 BLK

B70 CAMSHAFT PISITION SENSOR

B10 RAIL PRESSURE SENSOR

R01 BLK

R10 BLK

E2 A3 ENGINE CONTROL UNIT (ECU)

B6 CRANKSHAFT PISITION SENSOR

= X27 A

R15 BLK

D4 B4

M20 PUR M22 PUR

A4 E4

R16 BLK E21 WHT

E21 WHT

E20 WHT

D4 E3

TX1140704 Engine Control Unit (ECU) Circuit Schematic (1 of 2) Continued on next page

TM10721 (03SEP14)

9015-15-5

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=461

AA95137,0001210 -19-11AUG14-1/6

Sub-System Diagnostics

TM10721 (03SEP14)

9015-15-6

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=462

Sub-System Diagnostics 1— Primary Fuel Filter Mounted by Hydraulic Reservoir 2— Primary Fuel Filter Mounted by Engine (S.N. 243764— ) A3—Engine Control Unit (ECU) B6—Crankshaft Position Sensor

B10— Fuel Rail Pressure Sensor B12— Engine Coolant Temperature Sensor B14— Engine Oil Pressure Sensor B29— Fuel Temperature Sensor B31— Manifold Air Temperature Sensor (MAT)

B60— Water In Fuel (WIF) Sensor X27— Engine Control Unit (ECU) B70— Camshaft Position Sensor 32-Pin Connector X10— Main Cab/Canopy Harness-to-Engine Harness 31-Pin Connector X11— Main Cab/Canopy Harness-to-Transmission Harness Connector

Continued on next page

TM10721 (03SEP14)

9015-15-7

AA95137,0001210 -19-11AUG14-2/6

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=463

Sub-System Diagnostics

TM10721 (03SEP14)

9015-15-8

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=464

Sub-System Diagnostics

TX1168699 —UN—19AUG14

Engine Control Unit (ECU) Circuit Schematic (2 of 2) Continued on next page

TM10721 (03SEP14)

9015-15-9

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=465

AA95137,0001210 -19-11AUG14-3/6

Sub-System Diagnostics

TM10721 (03SEP14)

9015-15-10

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=466

Sub-System Diagnostics

A1—Transmission Control Unit (TCU) A3—Engine Control Unit (ECU) F7— Engine Control Unit (ECU) and Standard Display Monitor (SDM) Unswitched Power Inline 10-Amp Fuse F24— Engine Control Unit (ECU) Switched Power 5-Amp Fuse

H1—Standard Display Monitor (SDM) H4—Engine Warmup Indicator W3—Ground at Starter Motor X2— TCU 18-Pin Connector X6— SDM 16-Pin Connector X10— Main Cab/Canopy Harness-to-Engine Harness 31-Pin Connector

Engine Control Unit (ECU) (A3)— For component location, see Engine Harness (W6) Component Location. (Group 9015-10.) The ECU uses information received from various sensors to determine the correct amount of fuel and injection timing based on load, temperatures, and operator input. Some of the data calculated by the ECU is transmitted across the CAN data line to other controllers. For more information concerning the CAN data line, see Controller Area Network (CAN) Circuit Theory of Operation. (Group 9015-15.) The ECU also detects malfunctions in the sensors and sensor circuits, or abnormal operating conditions. When this happens, the ECU will generate a diagnostic trouble code (DTC). See Engine Control Unit (ECU) Diagnostic Trouble Codes. (Group 9001-20.)

The ECU contains a barometric air pressure (BAP) sensor that is located inside the ECU. This sensor is used to determine the pressure of the ambient air at the mounting location of the ECU. The BAP sensor helps the ECU determine the air density for calculating the correct air/fuel ratio. This sensor cannot be repaired or replaced without replacing the entire ECU. The ECU also contains a temperature sensor that is located inside the ECU. This sensor is used to determine the internal temperature of the ECU. If the ECU temperature exceeds specification, the ECU will limit the speed of the engine in an attempt to protect the ECU from permanent damage. This sensor cannot be repaired or replaced without replacing the entire ECU. Ground is provided at pins L2, L3, and M2 of ECU connector X26. Unswitched battery power is available at pins L1, L4, M1, and M4 of ECU connector X26, through fuse (F7).

Warmup Indicator (H4)— For component location, see Main Cab/Canopy Harness (W5) Component Location. (Group 9015-10.)

When key switch (S1) is turned to the ON or START position, power is available at the anode of warmup indicator (H4), through fuse (F24). When the transmission oil temperature is below 0°C (32°F), the ECU will provide a ground to the cathode of the warmup indicator, causing the indicator to come on. During that time, the ECU limits the engine speed to 900 rpm in neutral and 1200 rpm in forward and reverse. The transmission control unit (TCU) also limits the transmission speed to 1.7 during the time the warmup indicator is lit. The transmission oil temperature is monitored by the standard display monitor (SDM) (H1), which transmits this information across the CAN data line to the ECU.

• For more information on the warmup indicator, see

Whenever an engine DTC occurs, the information is captured or recorded. The information generated is called a Snapshot. The Snapshot information is categorized in two types; Snapshot Capture and Snapshot Recording. For more information, see Snapshot Instructions. (CTM502.)

When key switch (S1) is turned to the ON or START position, current from fuse (F24) flows to pin B2 of ECU connector X26, causing the ECU to power up.

X23— Engine Harness-to-Fuel Y13— Electronic Injector Injection Harness Solenoid (Cylinder 2) Connector Y14— Electronic Injector X26— Engine Control Unit (ECU) Solenoid (Cylinder 3) 48-Pin Connector Y15— Electronic Injector X27— Engine Control Unit (ECU) Solenoid (Cylinder 4) 32-Pin Connector Y1— Fuel Pump Control Valve Solenoid Y12— Electronic Injector Solenoid (Cylinder 1)

Warm-Up Indicator. (Operator's Manual.)

• For more information on the TCU, see Transmission

Control Unit (TCU) Circuit Theory of Operation. (Group 9015-15.) • For more information on the SDM and monitoring transmission oil temperature, see Standard Display Monitor (SDM) Circuit Theory of Operation. (Group 9015-15.) • For more information concerning the CAN data line, see Controller Area Network (CAN) Circuit Theory of Operation. (Group 9015-15.) Fuel Rail Pressure Sensor (B10)— For component location, see Engine Harness (W6) Component Location. (Group 9015-10.) The ECU supplies a 5-volt reference voltage and ground to the fuel rail pressure sensor at pins E2 and D3 of ECU connector X27. The fuel rail pressure sensor sends an analog signal representing fuel rail pressure to pin E3 of ECU connector X27. The ECU uses this signal to monitor the high pressure side of the fuel system and apply derate conditions when needed. If the ECU senses a value that is out of valid range, the ECU will derate fuel delivery by 50%. The fuel delivery will recover to full power when the problem is corrected. For information on engine deration, see OEM Engines - Derate Specifications. (CTM502.) For information on how pressure sensors operate, see Measuring Pressure. (CTM502.) For sensor specifications, see Electrical Component Specifications. (Group 9015-20.) Engine Coolant Temperature (ECT) Sensor (B12)— For component location, see Engine Harness (W6) Component Location. (Group 9015-10.)

Continued on next page

TM10721 (03SEP14)

9015-15-11

AA95137,0001210 -19-11AUG14-4/6

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=467

Sub-System Diagnostics pressure, the ECU will derate the engine fuel delivery. For information on engine deration, see OEM Engines Derate Specifications. (CTM502.)

The ECU senses resistance from the engine coolant temperature sensor at pins D2 and C4 of ECU connector X27. The ECU transmits the engine coolant temperature information across the CAN data line to the SDM. The SDM uses this information to determine the position of the needle on the engine coolant temperature gauge and moves the needle accordingly. It also activates a warning indicator when coolant temperature becomes too high. See Instrument Panel Functions. (Operator's Manual.) The engine coolant temperature can also be displayed in the SDM service menu as a live value. See Standard Display Monitor (SDM) Menu Structure—Service Mode. (Group 9015-20.) The ECU uses the signal from the engine coolant temperature sensor to monitor the coolant temperature and apply derate conditions when needed. If the engine coolant temperature reaches 111°C (232°F), the ECU will derate fuel by 80% of full power. If the coolant temperature reaches 115°C (239°F), the ECU will derate fuel by 40% of full power. The fuel delivery will recover to full power when the engine coolant temperature drops below the derate threshold temperature. If the ECU senses a value that is out of valid range, the ECU will use the default temperature of 90°C (194°F). High ECT engine protection is disabled. For information on engine deration, see OEM Engines - Derate Specifications. (CTM502.) For information on how temperature sensors operate, see Measuring Temperature. (CTM502.)

For information on how pressure sensors operate, see Measuring Pressure. (CTM502.) For sensor specifications, see Electrical Component Specifications. (Group 9015-20.) Water In Fuel (WIF) Sensor (B60)— For component location, see Engine Harness (W6) Component Location, or Transmission Harness (W7) Component Location. (Group 9015-10.) The WIF sensor measures the amount of resistance of the fluid in the water separator bowl. Since water is a better conductor of electricity than fuel, and, if water is present in the separator bowl, the ECU senses a resistance drop between pins B2 and D2 of ECU connector X27. If the ECU senses low resistance indicating water in fuel, the ECU will derate fuel delivery by 50% of full power. The fuel delivery will recover to full power when the problem is corrected. For information on engine deration, see OEM Engines - Derate Specifications. (CTM502.) For sensor specifications, see Electrical Component Specifications. (Group 9015-20.) Fuel Temperature Sensor (B29)— For component location, see Engine Harness (W6) Component Location. (Group 9015-10.)

For sensor specifications, see Electrical Component Specifications. (Group 9015-20.) Engine Oil Pressure Sensor (B14)— For component location, see Engine Harness (W6) Component Location. (Group 9015-10.) The ECU supplies a 5-volt reference voltage and ground to the engine oil pressure sensor at pins F3 and D2 of ECU connector X27. The engine oil pressure sensor sends an analog signal representing engine oil pressure to pin A3 of ECU connector X27. The ECU transmits the engine oil pressure information across the CAN data line to the SDM. The SDM uses this information to determine position of the needle on the engine oil pressure gauge and moves the needle accordingly. It also activates a warning indicator when oil pressure is too low. See Instrument Panel Functions. (Operator's Manual.) The engine oil pressure can also be displayed in the SDM service menu as a live value. See Standard Display Monitor (SDM) Menu Structure—Service Mode. (Group 9015-16.) The ECU uses the engine oil pressure sensor to monitor the oil pressure and apply derate conditions when needed. If the oil pressure is below threshold

If the ECU senses a value that is out of valid range, the ECU will use the default pressure of 500 kPa (5 bar) (72.5 psi). Low oil pressure engine protection is disabled.

The ECU senses resistance from the fuel temperature sensor at pins D2 and F4 of ECU connector X27. The ECU transmits the fuel temperature information across the CAN data line to the SDM so it can be displayed in the SDM service menu as a live value. See Standard Display Monitor (SDM) Menu Structure—Service Mode. (Group 9015-16.) The ECU uses the signal from the fuel temperature sensor to monitor the fuel temperature and apply derate conditions when needed. If the ECU senses fuel temperature above 100°C (220°F), the ECU will derate the fuel delivery by 80% of full power. The fuel delivery will recover to full power when the fuel temperature drops below the derate threshold temperature. If the ECU senses a value that is out of valid range, the ECU will use the default temperature of 40°C (104°F). High fuel temperature engine protection is disabled. For information on engine deration, see OEM Engines - Derate Specifications. (CTM502.) For information on how temperature sensors operate, see Measuring Temperature. (CTM502.) For sensor specifications, see Electrical Component Specifications. (Group 9015-20.)

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450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=468

Sub-System Diagnostics

Manifold Air Temperature (MAT) Sensor (B31)—The ECU senses resistance from the MAT sensor at pins C2 and D2 of ECU connector X27. The ECU transmits the MAT sensor information across the CAN data line to the SDM where it can be displayed in the SDM service menu as a live value. See Standard Display Monitor (SDM) Menu Structure—Service Mode. (Group 9015-16.) The manifold air temperature can cause an engine fuel derate condition if it reaches 88°C (190°F). The ECU will derate fuel 2% per minute up to 20%. If the manifold air temperature falls below the derate temperature, the ECU will recovery fuel delivery 2% per minute until power is fully restored. For information on engine deration, see OEM Engines - Derate Specifications. (CTM502.) For information on how temperature sensors operate, see Measuring Temperature. (CTM502.) For more information on the MAT sensor, see electrical component specifications. (Group 9015-20.) Crankshaft Position Sensor (B6)— For component location, see Engine Harness (W6) Component Location. (Group 9015-10.) The ECU detects the signal from the crankshaft position sensor at pins B4 and D4 of ECU connector X27. The ECU uses this signal to determine when the number one cylinder is at top dead center. The ECU also uses this signal to calculate engine (crankshaft) speed and sends this information across the CAN data line to the SDM, where it appears in the monitor display window as engine rpm. The crankshaft speed can also be displayed in the SDM service menu as a live value. See Standard Display Monitor (SDM) Menu Structure—Service Mode. (Group 9015-20.) For information on how speed sensors operate, see Measuring Speed. (CTM502.) For sensor specifications, see Electrical Component Specifications. (Group 9015-20.)

Camshaft Position Sensor (B70)— For component location, see Engine Harness (W6) Component Location. (Group 9015-10.) The ECU detects the signal from the camshaft position sensor at pins A4 and E4 of ECU connector X27. The ECU uses this signal to determine which cylinder is approaching top dead center. The ECU uses this signal to calculate camshaft speed and transmits the information across the CAN data line to the SDM so it can be displayed in the SDM service menu as a live value. See Standard Display Monitor (SDM) Menu Structure—Service Mode. (Group 9015-16.) For information on how speed sensors operate, see Measuring Speed. (CTM502.) For sensor specifications, see Electrical Component Specifications. (Group 9015-20.) Fuel Pump Control Valve (PCV) Solenoid (Y1)— For component location, see Engine Harness (W6) Component Location. (Group 9015-10.) The pump control valve regulates delivery of fuel to the high-pressure common rail (HPCR). ECU sends a signal out pins H1 and H2 of ECU connector X27 to the fuel pump control valve solenoid. When the solenoid is energized, fuel is allowed to discharge from the fuel outlet on the high-pressure fuel pump to the HPCR. For more information, see High Pressure Fuel Pump Operation. (CTM502.) For more information on the high-pressure common rail (HCPR), see High Pressure Common Rail (HPCR) Operation. (CTM502.) Electronic Injectors (Y12—Y15)—The ECU controls the injection timing and the amount of fuel injected by energizing and de-energizing the electronic injectors (Y12—Y15). For more information on the electronic injectors, see Electronic Injector (EI) Operation. (CTM502.) AA95137,0001210 -19-11AUG14-6/6

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Sub-System Diagnostics

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Sub-System Diagnostics

Standard Display Monitor (SDM) Circuit Theory of Operation TX1168701 —UN—14AUG14

Standard Display Monitor (SDM) Circuit Schematic Continued on next page

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Sub-System Diagnostics

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Sub-System Diagnostics 1— Unswitched Power 2— Switched Power A1—Transmission Control Unit (TCU) A3—Engine Control Unit (ECU) B15— Transmission Oil Filter Restriction Switch B16— Hydraulic Oil Filter Restriction Switch B18— Engine Air Filter Restriction Switch B25— Hydraulic Oil Temperature Sensor

B35— Fuel Level Sensor B40— Transmission Oil Temperature Sensor F7— Engine Control Unit (ECU) and Standard Display Monitor (SDM) Unswitched Power Inline 10-Amp Fuse F23— Standard Display Monitor (SDM) Switched Power 5-Amp Fuse H1—Standard Display Monitor (SDM)

Standard Display Monitor (SDM) (H1)— The SDM receives unswitched battery power from the ECU/SDM 10A fuse (F7) at pin A of SDM connector X6. System ground is available at pin P of SDM connector X6. When the key switch is turned to the IGN or ST position, current flows to the coil of TCU/SDM relay (K4), energizing the relay. Current flows across the contacts of TCU/SDM relay, through SDM switched power 5A fuse (F23), to terminal L of SDM connector X6, powering up the SDM. When powered-up, the SDM performs a self-test by activating all indicators: lights, gauges, and the monitor display window. For more information on SDM, see Instrument Panel Functions. (Operator's Manual.) The SDM contains a menu structure designed for monitoring certain machine functions for operational and/or diagnostic purposes. It provides a means for viewing and clearing diagnostic trouble codes (DTC) and also provides a means for adjusting certain machine and monitor settings. For more information on the SDM menu structure, see Standard Display Monitor (SDM) Menu Structure—Service Mode. (Group 9015-16.) The SDM uses the controller area network (CAN) data line to communicate with the engine and transmission controllers. For more information on the CAN, see Controller Area Network (CAN) Circuit Theory of Operation. (Group 9015-15.)

The transmission control unit (TCU) (A1) transmits travel speed, charge oil pressure, TCU diagnostic trouble codes, and other transmission related information across the CAN data line. This information can be displayed on the monitor display window. Most TCU related information must be accessed using the SDM menus. To access the SDM menus, see Standard Display Monitor (SDM) Menu Structure—Service Mode. (Group 9015-16.) The following electrical components are hard wired directly to the SDM:

• Transmission Oil Filter Restriction Switch (B15) • Hydraulic Oil Filter Restriction Switch (B16) • Air Filter Restriction Switch (B18) • Hydraulic Oil Temperature Sensor (B25) • Fuel Level Sensor (B35) • Transmission Oil Temperature Sensor (B40) • Monitor Alarm (H5) Transmission Oil Filter Restriction Switch (B15)— is a normally open switch that closes when the transmission oil filter becomes restricted. When this happens, ground is applied to pin J of SDM connector X5, causing the transmission oil filter restriction light to come on. For component location, see Transmission Harness (W7) Component Location. (Group 9015-10.)

The engine control unit (ECU) (A3) transmits engine speed, engine coolant temperature, engine oil pressure, and any ECU related diagnostic trouble code (DTC) information across the CAN data line. The SDM receives the engine coolant temperature and engine oil pressure information and uses this information to determine the needle position of the corresponding gauge. Engine speed and diagnostic trouble codes can be displayed on the monitor display window. The ECU and SDM also exchange machine model information to prevent an ECU mismatch. Once an ECU or SDM is installed in a machine, the unit cannot be removed and put in a different model machine. For more information on the ECU, see Engine Control Unit (ECU) Circuit Theory of Operation. (Group 9015-15.)

H5—Monitor Alarm X10— Main Cab/Canopy K4—Transmission Control Unit Harness-to-Engine (TCU) and Standard Display Harness 31-Pin Connector Monitor (SDM) Relay X11— Main Cab/Canopy W2—Cab/Canopy Harness Harness-to-Transmission Ground at Cab/Canopy Harness Connector Right Front X26— Engine Control Unit (ECU) W3—Ground at Starter Motor 48-Pin Connector X2— TCU 18-Pin Connector X5— SDM 14-Pin Connector X6— SDM 16-Pin Connector

Hydraulic Oil Filter Restriction Switch (B16)— is a normally open switch that closes when the hydraulic oil filter becomes restricted. When this happens, ground is applied to pin F of SDM connector X5, causing the hydraulic oil filter restriction light to come on. For component location, see Transmission Harness (W7) Component Location. (Group 9015-10.) Air Filter Restriction Switch (B18)— is a normally open switch that closes when the engine air filter becomes restricted. When this happens, ground is applied to pin E of SDM connector X5, causing the engine air filter restriction light to come on. For component location, see Engine Harness (W6) Component Location. (Group 9015-10.)

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450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=473

Sub-System Diagnostics

Hydraulic Oil Temperature Sensor (B25)— provides the SDM with a variable resistance based on hydraulic oil temperature. The SDM senses resistance at pin K and B of SDM connector X5. When the hydraulic oil temperature reaches a specified set point, the SDM will cause the STOP warning light and the hydraulic temperature warning light to come on: Specification Hydraulic Oil Temperature Warning Set Point—Temperature................................................................ 113° C 235° F

For more information on the hydraulic oil temperature sensor, see Electrical Component Specifications. (Group 9015-20.) Fuel Level Sensor (B35)— is a resistive (rheostat) type sensor attached to a float arm. The changing fuel level causes the float arm to move up and down relative to the fuel level. The float arm moves the wiper in the rheostat causing resistance to change relative to the movement of the float arm. This resistance is sensed by the SDM at pin N of SDM connector X6 and pin B of SDM connector X5. The SDM uses this information to determine the position of the needle on the fuel gauge and moves the needle accordingly. For component location, see Transmission Harness (W7) Component Location. (Group 9015-10.)

For fuel lever sensor specifications, see Electrical Component Specifications. (Group 9015-20.) Transmission Oil Temperature Sensor (B40)— provides the SDM with a variable resistance based on transmission oil temperature. The SDM senses resistance at pins A and B of SDM connector X5. When the transmission oil temperature reaches a specified set point, the SDM will cause the STOP warning light and the transmission temperature warning light to come on: Specification Transmission Oil Temperature Warning Set Point—Temperature.................................................................. 96° C 205° F

For component location, see Engine Harness (W6) Component Location. (Group 9015-10.) For more information on the transmission oil temperature sensor, see Electrical Component Specifications. (Group 9015-20.) Monitor Alarm (H5)— is activated during monitor self test, during certain monitor selections, and when the STOP light is on. The SDM provides power at pin M of SDM connector X6, and a ground at pin D of SDM connector X6. For component location, see Main Cab/Canopy Harness (W5) Component Location. (Group 9015-10.) AA95137,000120E -19-19AUG14-3/3

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450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=474

Sub-System Diagnostics

Transmission Control Unit (TCU) Circuit Theory of Operation TX1074481 —UN—22APR10

Transmission Control Unit (TCU) Circuit Schematic

AA95137,000120F -19-06OCT09-1/4

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450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=475

Sub-System Diagnostics 2— Switched Power A1—Transmission Control Unit (TCU) A3—Engine Control Unit (ECU) B1—Decelerator Sensor B2—TCL Sensor B3—Motor Speed Sensor Right B4—Transmission Speed Control Sensor B5—Steer Sensor B7—Motor Speed Sensor Left B8—Pump Pressure Control Pilot (PCP) Rear B9—Pump Pressure Control Pilot (PCP) Front

B33— Charge Pressure Sensor (S.N. —173344) B41— Charge Pressure Sensor (S.N. 173345— ) F22— Transmission Control Unit (TCU) Switched Power 10-Amp Fuse H1—Standard Display Monitor (SDM) H6—Backup Alarm K4—Transmission Control Unit (TCU) and Standard Display Monitor (SDM) Relay R10— Engine Speed Control

S3— Neutral Switch S8— Decelerator Mode Switch S20— Park Lock Lever Switch W2—Cab/Canopy Harness Ground at Cab/Canopy Right Front W3—Ground at Starter Motor X1— TCU 30-Pin Connector X2— TCU 18-Pin Connector X6— SDM 16-Pin Connector X10— Main Cab/Canopy Harness-to-Engine Harness 31-Pin Connector

X11— Main Cab/Canopy Harness-to-Transmission Harness Connector X26— Engine Control Unit (ECU) 48-Pin Connector Y3— Motor Shift Solenoid Right Y4— Motor Shift Solenoid Left Y11— Park Brake Solenoid

The transmission control unit (TCU) (A1) receives information from various sensors, mostly commands from the operator, and uses this information to control travel direction, travel speed, engine speed, and steering. The TCU transmits some of this information across the CAN data line for use by the engine control unit (ECU) and the standard display monitor (SDM).

• For more information on the ECU, see Engine Control Unit (ECU) Circuit Theory of Operation. (Group 9015-15.) • For more information on the SDM, see Standard Display Monitor (SDM) Circuit Theory of Operation. (Group 9015-15.) • For more information on the CAN data line, see Controller Area Network (CAN) Circuit Theory of Operation. (Group 9015-15.) For location of transmission electrical components: • See Main Cab/Canopy Harness (W5) Component Location. (Group 9015-10.) • See Engine Harness (W6) Component Location. (Group 9015-10.) • See Transmission Harness (W7) Component Location. (Group 9015-10.) The TCU transmits any TCU diagnostic trouble codes (DTC) that may occur across the CAN data line to the SDM. The TCU diagnostic trouble codes, transmission settings, and other diagnostic information can be accessed using the SDM menu structure. For more information, see Standard Display Monitor (SDM) Menu Structure—Service Mode. (Group 9015-16.) When the engine is started, the TCU will keep the transmission in neutral, regardless of the position of the transmission control lever (TCL). If the transmission control lever is not in neutral during start-up, the TCU requires the transmission control lever to be moved first to neutral position, then to forward or reverse position before travel can be obtained. The TCU does this by monitoring the status of neutral switch (S3). Also, if the park lock lever is moved to the UNLOCK (down) position while the TCL is in either forward or reverse position, it will be necessary to return the TCL to neutral, then back to forward or reverse before the TCU allows machine movement. Neutral Switch (S3)—The neutral switch is located in the transmission control lever. The TCU knows the position of the TCL by monitoring the status of the neutral switch. When the TCL is in the neutral position, the neutral switch is closed and provides a ground to pin E2 of TCU connector X2. Moving the TCL out of neutral removes the ground from pin E2. If the neutral switch causes a DTC, the forward and reverse functions will be disabled. Park Lock Lever Switch (S20)—When the park lock lever is in the LOCK (up) position, the park lock lever switch provides a ground to pin B3 of TCU connector X2. With the park lock lever at this position, the TCU will not allow an output to the park brake solenoid (Y11). Park brake solenoid is de-energized. When the park lock lever is in the UNLOCK (down) position, the park lock lever switch provides a ground to pin E2 of TCU connector X1. With the park lock lever at this position, the TCU energizes the park brake solenoid. The park lock lever switch also provides an interlock for the starting circuit. When park lock lever is in the LOCK (up) position, the park lock lever switch provides a ground to the coil of the start relay. For more information on the starting circuit, see Starting and Charging Circuit Theory of Operation. (Group 9015-15.) Park Brake Solenoid (Y11)—The park brake solenoid controls the charge pressure which releases the park brake. When the engine is running and the park lock lever is moved to the UNLOCK (down) position, and as long as the decelerator pedal is not fully pushed to the pedal stop, the TCU will send current out pin E3 of TCU connector X2 to the park brake solenoid, energizing the solenoid. With the park brake solenoid energized, charge pressure oil is allowed to flow to the park brake, releasing the park brake. For more information on the park brake, see Park Brake Operation. (Group 9026-05.) If the park brake solenoid circuit causes a DTC, the forward and reverse functions will be disabled. The park brake solenoid will de-energize if the engine stops, the park lock lever is moved to the LOCK (up) position, or if the decelerator pedal is pushed fully to the pedal stop. Decelerator Mode Switch (S8)—The decelerator mode switch allows the operator the option of using the decelerator pedal to control engine speed or transmission speed. When the switch is pushed to transmission mode, the decelerator mode switch provides a ground to the pin C1 of TCU connector X2. When the TCU detects this ground, it decelerates the transmission only when the decelerator pedal is pushed. When the switch is pushed to the engine mode, the ground is removed from pin C1. The decelerator pedal now controls engine speed. TCL Sensor (B2)—The TCL sensor is a rotary sensor located on a rotating shaft within the TCL assembly. The TCL sensor receives 5-volt power from pin A1 of TCU connector X1 and a ground reference from pin A3 of TCU connector X1. When the TCL is moved into forward and reverse positions, the rotating shaft turns a keyed slot on the sensor, which changes the resistance measured by the TCU at pin A2 of connector X1. When the TCL is put at certain positions during TCU calibration, the resistance measured at those positions is stored in the TCU memory. If the TCL sensor causes a DTC, the forward and reverse functions will be disabled. Steer Sensor (B5)—The steer sensor is a rotary sensor located on a rotating shaft within the TCL assembly. The steer sensor receives 5-volt power from pin D1 of TCU connector X1 and a ground reference from pin D3 of TCU connector X1. When the TCL is moved to left and right positions, the rotating shaft turns a keyed slot on the sensor, which changes the resistance measured by the TCU at pin D2 of connector X1. When the TCL is put at certain positions during TCU calibration, the resistance measured at those positions is stored in the TCU memory. If this sensor causes a DTC, the steer functions will be disabled and the maximum machine speed will be limited to 5.23 km/h (3.25 mph). Decelerator Sensor (B1)—The decelerator sensor is a rotary sensor located on a rotating shaft on the decelerator pedal. The decelerator sensor receives 5-volt power from pin F1 of TCU connector X1 and a ground reference from pin F3 of TCU connector X1. When the decelerator pedal is pushed down, the rotating shaft turns a keyed slot on the sensor, which changes the resistance measured by the TCU at pin F2 of connector X1. When the decelerator pedal is put at certain positions during TCU calibration, the resistance measured at those positions (including brake positions) is stored in the TCU memory. Continued on next page

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Sub-System Diagnostics If this sensor causes a DTC, the maximum machine speed will be limited to creep. If this sensor causes a calibration code, the TCU default values will be used for this sensor. Transmission Speed Control Sensor (B4)—The transmission speed control sensor is used by the operator to control ground speed. The transmission speed control sensor receives 5-volt power from pin C1 of TCU connector X1 and a ground reference from pin C3 of TCU connector X1. When neither UP or DOWN buttons are pushed, the transmission speed control sensor sends approximately 2.20 volts to pin C2 of TCU connector X1. When the UP button is pushed, approximately 0.9 volts is sent to pin C2 of TCU connector X1. When the DOWN button is pushed, approximately 3.0 volts is sent to pin C2 of TCU connector X1. The values of the up, down, and null voltages are stored in the TCU during calibration. When either the UP or DOWN buttons are pushed, the TCU transmits the transmission speed across the CAN data line to the SDM. The SDM displays the transmission speed in the monitor display window. If this sensor causes a DTC, the maximum machine speed will be limited to 5.23 km/h (3.25 mph). Pump Pressure Control Pilot (PCP) (B8 and B9)—The rear and front PCPs control the displacement of the rear and front hydrostatic pumps, respectively. When the TCU receives a signal from any one of the operator controlled input sensors, the TCU applies positive or negative voltage to the PCPs, which causes electromagnetic valves to move accordingly. Movement of the electromagnetic valves creates differential control pressures, which varies the pump displacement and thus controls machine movement. For forward movement, the TCU will increase positive voltage (i.e. +3.5 V to +4.0 V) to increase pump displacement and decrease positive voltage (i.e. +3.5 V to +3.0 V) to decrease pump displacement. For reverse movement, the TCU will increase negative voltage (i.e. -3.5 V to -4.0 V) to increase pump displacement and decrease negative voltage (i.e. -3.5 V to -3.0 V) to decrease pump displacement. The TCU also applies voltage to the rear PCP in proportion to the front PCP for steering and counter-rotation commands. For more information on PCP operations, see Pump Pressure Control Pilot (PCP) Operation. (Group 9026-05.) If one of these component causes a DTC, either the forward or reverse functions will be disabled. Motor Speed Sensor (B3 and B7)—The motor speed sensors are feedback devices used by the TCU to determine actual track speed. The sensors enable the TCU to control tracking, thus allowing the machine to move in the desired motion. The TCU monitors track speeds and slows the faster track to match the slower track. Each sensor is supplied 5 volts and a ground reference from the TCU. The motor speed sensor right (B3) sends a pulsed signal to pin J2 of TCU connector X1. Motor speed sensor left (B7) sends a pulsed signal to pin H2 of TCU connector X1. If one of these sensors causes a DTC, the tracker function will be disabled and mistracking will occur. For motor speed sensor specifications, see Electrical Component Specifications. (Group 9015-20.) Motor Shift Solenoids (Y3 and Y4)—The TCU sends a signal from terminals D2 and F2 of TCU connector X2 to energize the shift solenoids. With the solenoids energized, the hydrostatic motors are at minimum displacement. As transmission speed increases from 2.1 to 2.2, the TCU will simultaneously energize the motor shift solenoids to bring the motors to minimum displacement and reduce voltage to the pump PCPs to reduce pump displacement. This provides smooth acceleration between motor speeds. If one of these components cause a DTC, the maximum machine speed will be limited to 5.23 km/h (3.25 mph). For more information on the motor shift solenoids and motor operation, see Hydrostatic Motor Operation. (Group 9026-05.) For solenoid specifications, see Electrical Component Specifications. (Group 9015-20.) Charge Pressure Sensor (B33 or B41) NOTE: The charge pressure sensor is B33 for (S.N. —173344) and B41 for (S.N. 173345— ). The charge pressure sensor provides the TCU with a variable resistance based on charge pressure. The charge pressure sensor receives 5-volt power from pin E1 of TCU connector X1 and a ground reference from pin E3 of TCU connector X1. The TCU measure sensor resistance at pin K2 of TCU connector X1. The TCU transmits this information across the CAN data line to the SDM. The charge pressure can be displayed as a live value on the SDM. See Standard Display Monitor (SDM) Menu Structure—Service Mode. (Group 9015-16.) If the charge pressure drops below 1310 kPa (13.1 bar) (190 psi) for more than 10 seconds while the engine is running, machine speed will ramp down and the machine will stop. Forward and reverse functions will be disabled, the engine speed will be limited to slow idle, and a diagnostic trouble code (DTC) will be generated. When the malfunction is fixed, the key switch must be cycled to clear the code. If the charge pressure exceeds 3447 kPa (34.5 bar) (500 psi) and the transmission oil temperature is above 32°C (90°F), or if the charge pressure exceeds 5170 kPa (51.7 bar) (750 psi) at any temperature, the TCU will transmit this information across the CAN data line to the ECU, which will then limit the engine speed to 1200 rpm. When the malfunction is fixed, the key switch must be cycled to clear the code. For charge pressure sensor specifications, see Electrical Component Specifications. (Group 9015-20.) Engine Speed Control (R10)—The engine speed control is a potentiometer which receives 5-volt power from pin G1 of TCU connector X1 and a ground reference from pin G3 of TCU connector X1. Turning the engine speed control sensor varies the amount of voltage sent to pin G2 of TCU connector X1. This signal represents desired engine speed, which the TCU compares with values recorded during TCU calibration, then transmits the engine speed command as a percentage across the CAN data line. The ECU detects this signal and responds by increasing or decreasing engine speed accordingly. The ECU detects the signal representing actual engine speed from crankshaft position sensor (B6). The ECU transmits the engine speed signal across the CAN data line. The TCU detects the actual engine speed signal and compares it to the desired engine speed command signal for antistall purposes. If the load on the engine causes the engine to pull down, the TCU will send the appropriate current to PCP solenoids (B8 and B9) to decrease pump displacement and prevent the engine from stalling. The TCU uses the engine speed to determine the pump speeds. For more information on the ECU, see Engine Control Unit (ECU) Circuit Theory of Operation. (Group 9015-15.) If machine is started and the TCU does not measure voltage at pin G2 that represents slow idle command, the engine speed control sensor must be rotated to slow idle position before the engine speed can be increased. If this sensor causes a DTC, engine speed will be limited to slow idle and machine speed will be limited to creep. If this sensor causes a calibration code, the TCU default values will be used for this sensor. Backup Alarm (H6)—When the key switch is ON and reverse travel is selected, the TCU will send current out pin F3 of TCU connector X2, to the backup alarm (H6), activating the alarm. Continued on next page

TM10721 (03SEP14)

9015-15-21

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=477

AA95137,000120F -19-06OCT09-3/4

Sub-System Diagnostics

Integrated Grade Control (IGC) Circuit Theory of Operation—If Equipped TX1074392 —UN—05APR10

Integrated Grade Control (IGC) Circuit Schematic Continued on next page

TM10721 (03SEP14)

9015-15-22

TW73308,0000122 -19-10JAN08-1/4 450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=478

Sub-System Diagnostics K3—Horn Relay K101— IGC Switched Power Relay (if equipped) K102— BCJ and Electrohydraulic Controller (EHC) Switched Power Relay (if equipped) M1—Starter Motor R6—IGC CAN Termination Resistor R7—IGC CAN Termination Resistor S1— Key Switch S2— Battery Disconnect Switch S30— Hydraulic Enable Switch (if equipped) W2—Cab/Canopy Harness Ground at Cab/Canopy Right Front W15—Main Frame Ground W20—IGC Ground X9— Main Cab/Canopy Harness-to-Engine Harness 1-Pin Connector

X10— Main Cab/Canopy Harness-to-Engine Harness 31-Pin Connector X81— RS232 3-Pin Connector (if equipped) X82— Electrohydraulic Controller (EHC) Connector (if equipped) X83— Electrohydraulic Controller (EHC) Connector (if equipped) X84— Main Cab/Canopy Harness-to-IGC Cab Harness 4-Pin Connector X85— Auxiliary Joystick Connector (if equipped) X86— Machine CAN Connector (if equipped) X87— IGC Power 1-Pin Connector X90— IGC Auxiliary Actuator 4-Pin Connector (if equipped)

X95— IGC Machine Harness-to-IGC Cab Harness 35-Pin Connector (if equipped) X96— IGC Interface 23-Pin Connector (if equipped) X97— BCJ Switch Module Connector (if equipped) X98— BCJ Four-Way Axis Module Connector (if equipped) Y30— Blade Angle Actuator (if equipped) Y31— Blade Tilt Actuator (if equipped) Y32— Blade Lift Actuator (if equipped)

The IGC system is an electric-over-hydraulic, plug and play control system designed to be an integral part of a fully automatic system using global positioning system (GPS) and/or laser guidance equipment provided by a third party. The base system consists of the following components:

• IGC Load Center (A8) • Electrohydraulic Controller (EHC) (A11) • Blade Control Joystick (BCJ) (A9) • Electrohydraulic Actuators (Y30—Y32) IGC Load Center (A8)—The IGC load center provides power to electrohydraulic controller (EHC) (A11), the four-way axis module of blade control joystick (BCJ) (A9), and the grade control supplier's equipment [IGC interface connector (X96)]. Unswitched battery power is provided to the IGC load center from batteries (G1). Switched power is provided to the IGC load center through 5-amp fuse (F29). The IGC fuse and relay box consists of the following components:

• IGC Switched Power 15-Amp Fuse (F101) • BCJ Switched Power 5-Amp Fuse (F102) • EHC Switch Power 10-Amp Fuse (F103) • IGC Unswitched Power_1 10-Amp Fuse (F104) • IGC Unswitched Power_2 10-Amp Fuse (F105) • IGC Unswitched Power_3 10-Amp Fuse (F106) • IGC Switched Power Relay (K101) • BCJ and EHC Switched Power Relay (K102) Electrohydraulic Controller (EHC) (A11)—The EHC is the machine's control center for the IGC system. The EHC powers up when switched power from 10 amp fuse (F103) is supplied to the EHC at pins 1 and 18 of connector (X83). Ground is provided at pins 6 and 23 of EHC connector (X83). When powered up, the EHC provides 5 volts at pin 3 of EHC connector (X82). The 5 volts are sent to pin 1 of BCJ switch module connector (X97), pin 1 of auxiliary joystick connector (X85), and pin 2 of hydraulic enable switch (S30). The EHC provides a ground for the 5-volt circuit at pin 22 of EHC connector (X82). This ground is available at pin 6 of the BCJ switch module connector and pin 4 of the auxiliary joystick connector. Putting the hydraulic enable switch to the DISABLED position sends 5 volts to pin 17 of EHC connector (X82). When the EHC detects 5 volts at pin 17 and no voltage at pin 18, the EHC disables all outputs to the electrohydraulic actuators (Y30—Y32). During this time, the blade controls will not function in manual or auto modes. Putting the hydraulic enable switch to the ENABLED position, sends 5 volts to pin 18 of EHC connector (X82). When the EHC detects 5 volts at pin 18 and no voltage at pin 17, the EHC enables all outputs to the electrohydraulic actuators allowing the blade controls to operate when commanded. If the EHC detects voltage at pins 17 and 18 of EHC connector (X82) at the same time, or no voltage at either pin at the same time, the EHC will disable the outputs and generate a diagnostic trouble code (DTC). The DTC information is transmitted through the machine CAN data link to standard display unit (SDM) (H1) to alert the operator. See Electrohydraulic Controller (EHC) Diagnostic Trouble Codes. (Group 9001-40.) When in manual mode, or manual override when in auto mode, the EHC receives blade control commands from the blade control joystick, then sends corresponding signals to the appropriate electrohydraulic actuators to move the blade to the desired position. When in auto mode, the EHC receives blade control commands from the grade control supplier's equipment, then sends corresponding signals to the appropriate electrohydraulic actuators to move the blade to the desired position. The EHC communicates with the grade control supplier's equipment through the IGC CAN data link. The IGC CAN data link connects pins 10 and 11 of EHC connector (X82) to pins G (shield), H, and J of IGC interface connector (X96). The EHC communicates with blade control joystick (BCJ) (A9) and standard display monitor (SDM) H1 through the machine CAN data link. The machine CAN data link connects pins 7 and 8 of EHC connector (X82) to pins 3 and 4 of BCJ connector (X98) and pins C and K of SDM connector (X6). NOTE: For EHC diagnostics, see Integrated Grade Control (IGC) Checks—If Equipped. (Group 9015-20.) For EHC diagnostic trouble codes, see Electrohydraulic Controller (EHC) Diagnostic Trouble Codes. (Group 9001-40.) Blade Control Joystick (BCJ) (A9)—The BCJ consists of a four-way axis module and a switch module (located in the joystick handle).

• Four-Way Axis Module: The BCJ four-way axis module controls blade lift and tilt in correlation with joystick lever movement. Data representing position of the joystick lever is transmitted across the machine CAN data link to the EHC. The EHC converts the data representing joystick position to a corresponding analog signal, then sends this signal to the appropriate electrohydraulic actuator to move the blade to the desired position. The data representing joystick position is also sent to the SDM where it can be displayed on the SDM menu structure for diagnostic purposes.

NOTE: For information on accessing the SDM menu structure, see Standard Display Monitor (SDM) Menu Structure—Service Mode. (Group 9015-16.) For BCJ diagnostics, see Integrated Grade Control (IGC) Checks—If Equipped. (Group 9015-20.) For BCJ diagnostic trouble codes, see Blade Control Joystick (BCJ) Diagnostic Trouble Codes. (Group 9001-50.) TW73308,0000122 -19-10JAN08-2/4

Continued on next page

TM10721 (03SEP14)

9015-15-23

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=479

Sub-System Diagnostics

• Switch Module: The BCJ switch module contain switches that control auto/manual mode (IGC on/off), blade angle, blade height increment/decrement, and screen swap (not used). The information from the various switches is transmitted through separate wires to individual inputs on the EHC. The EHC transmits the BCJ switch information

through the machine CAN data link to the SDM where it can be displayed on the SDM menu structure for diagnostic purposes. - IGC On/Off Switch: Pushing the IGC on/off switch button sends a signal out pin 4 of the BCJ connector (X97) to pin 21 of EHC connector (X83). When the EHC receives a signal at this input, the EHC toggles the IGC system to either manual and auto mode, depending on which mode the system is presently in. Before the EHC does this, it must detect inputs from the grade control supplier's controller, the standard display monitor (SDM), the blade control joystick (BCJ), the transmission control unit (TCU) (park lock lever in DOWN position), and the hydraulic enable switch in the ENABLED position. - Screen Swap Switch (not used): Pushing the screen swap button sends a signal out pin 5 of the BCJ connector (X97) to pin 22 of EHC connector (X83). The screen swap switch has no function at this time so the EHC ignores this signal. - Blade Angle Switch: Pushing the upper button of the blade angle (rotate) switch sends approximately 3.00 volts out pin 2 of the BCJ connector (X97) to pin 20 of EHC connector (X82). This causes the EHC to send current out pin 12 of EHC connector (X83) to pin 1 of blade angle actuator (Y30) (blade rotates to right). Pushing the lower button of the blade angle (rotate) switch sends approximately 0.90 volts to pin 20 of EHC connector (X82). This causes the EHC to send current out pin 5 of EHC connector (X83) to pin 4 of blade angle actuator (Y30) (blade rotates to left). When the blade angle switch is in neutral position, the BCJ sends approximately 2.20 volts to pin 20 of EHC connector (X82), causing the EHC to prevent any current flow to either pin 1 or 4 of the blade angle actuator. Blade angle stays in neutral - Blade Height Incr/Decr Switch: Pushing the upper button of the blade incr/decr switch sends approximately 3.00 volts out pin 2 of the BCJ connector (X97) to pin 21 of EHC connector (X82). If the system is in auto mode, the EHC will send an appropriate signal out pin 24 of EHC connector (X83) to pin 1 of blade lift actuator (Y32) (blade rises slightly). Pushing the lower button of the blade incr/decr switch sends approximately 0.90 volts to pin 21 of EHC connector (X82). If the system is in auto mode, the EHC will send an appropriate signal out pin 24 of EHC connector (X83) to pin 1 of blade lift actuator (Y32) (blade lowers slightly). When the blade incr/decr switch is in neutral position, the BCJ sends approximately 2.20 volts to pin 21 of EHC connector (X82), causing the EHC to take no action in regard to the blade increment and decrement.

Electrohydraulic Actuators—The base IGC system uses three electrohydraulic actuators:

• Blade angle actuator (Y30) • Blade tilt actuator (Y31) • Blade lift actuator (Y32) An auxiliary actuator can be added using connector (X90) to accommodate optional equipment such as a ripper. Each electrohydraulic actuator uses two pairs of solenoid valves to control the position of the actuator spool. One pair of solenoid valves control oil pressure at one end of the actuator spool. The other pair controls oil pressure at the opposite end of the actuator spool. Each pair contains a normally closed solenoid valve that controls supply (pressure) oil and a normally open solenoid valve that controls venting to tank. When in the neutral state, no current flows to either pair of solenoids, causing oil at both ends of the spool to vent to tank. With no oil pressure at either end of the spool, the centering springs will hold the spool at center (neutral) position. For more information on hydraulic operation of the actuators, see Hydraulic Control Valve Operation—IGC. (Group 9025-05.) Blade Angle Actuator (Y30): The blade angle actuator uses on/off type solenoid valves. Pins 2 and 3 of the actuator are connected to IGC ground (W20). When the EHC sends current to pin 1 of the actuator connector, the corresponding pair of solenoids are energized, causing the actuator spool to move to maximum stroke. With the actuator spool shifted, the blade rotates to the right. When the EHC sends current to pin 4 of the actuator connector, the other pair of solenoids are energized, causing the actuator spool to move in the opposite direction to maximum stroke. With the actuator spool shifted in the opposite direction, the blade rotates to the left. Blade Tilt Actuator (Y31): The blade tilt actuator uses proportional type solenoid valves. The EHC provides power out pin 19 of EHC connector (X83) to pin 4 of the actuator. Pin 3 of the actuator is connected to IGC ground (W20). For blade tilt operation, the EHC sends an analog signal out pin 20 of EHC connector (X83) to pin 1 of the blade tilt actuator. Depending on the blade operation, the analog signal will be one of three different voltage levels as follows:

• Blade tilt left = 6 volts (approximate) • Neutral = 12 volts (approximate) • Blade tilt right = 18 volts (approximate) The actuator's on-board controller converts the analog signal to individual pulse width modulated (PWM) signals that control each of the four proportional solenoid valves, which in turn, controls the position of the actuator spool. The position of the spool is monitored by an integral feedback sensor, which measures spool position relative to the input signal. When the feedback sensor detects the spool has reached the intended position, the on-board controller will stop the modulated signals to the four solenoids. The actuator has a built-in status light. If the actuator is operating correctly, the status light on the actuator will be green. If the actuator spool goes farther that the intended position as commanded by the input signal, the status light on the actuator will turn to red and a signal will be sent out pin 2 of the actuator to pin 4 of EHC connector (X83). When the EHC receives this signal, the EHC generates a diagnostic trouble code (DTC) and transmits the DTC information through the machine CAN data link to the standard display monitor (SDM) to alert the operator. See Electrohydraulic Controller (EHC) Diagnostic Trouble Codes. (Group 9001-40.) Blade Lift Actuator (Y32): The blade lift actuator uses proportional type solenoid valves. The EHC provides power out pin 19 of EHC connector (X83) to pin 4 of the actuator. Pin 3 of the actuator is connected to IGC ground (W20). For blade lift operation, the EHC sends an analog signal out pin 24 of EHC connector (X83) to pin 1 of the blade lift actuator. Depending on the blade operation, the analog signal will be one of four different voltage levels as follows:

• Blade float = 6 volts (approximate) • Blade lower = 8 volts (approximate) • Neutral = 12 volts (approximate) • Blade raise = 18 volts (approximate) The actuator's on-board controller converts the analog signal to individual pulse width modulated (PWM) signals that control each of the four proportional solenoid valves, which in turn, controls the position of the actuator spool. The position of the spool is monitored by an integral feedback sensor, which measures spool position relative to the input signal. When the feedback sensor detects the spool has reached the intended position, the on-board controller will stop the modulated signals to the four solenoids. The actuator has a built-in status light. If the actuator is operating correctly, the status light on the actuator will be green. If the actuator spool goes farther that the intended position as commanded by the input signal, the status light on the actuator will turn to red and a signal will be sent out pin 2 of the actuator to pin 10 of EHC connector (X83). When the EHC receives this signal, the EHC generates a diagnostic trouble code (DTC) and transmits the DTC information through the machine CAN data link to the standard display monitor (SDM) to alert the operator. See Electrohydraulic Controller (EHC) Diagnostic Trouble Codes. (Group 9001-40.) Continued on next page TW73308,0000122 -19-10JAN08-3/4

TM10721 (03SEP14)

9015-15-24

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=480

Sub-System Diagnostics

JDLink™ Circuit Theory of Operation—If Equipped TX1086208 —UN—29MAR11

P70 RED

= X6 K C

X63

CAN 1

M12 YEL

M13 LT GRN

21 22

M13 LT GRN

R13 BLK

CAN 1

G3 ALTERNATOR

B01 BLU B01 RED

M06 PUR 25

M06 PUR

8 7

GROUND STRAP

M17 YEL

M53 PUR

R40 BLK

M12 YEL

M13 LT GRN

R13 BLK

G71 BLK

G70 BLK

M74 PUR

M06 PUR

G70 BLK

M55 PUR

M56 PUR

M57 PUR

M58 PUR

M59 PUR

= X1

G71 BLK

CAN 1 CAN 1

R13 BLK

M75 PUR

1 2

8 7 = X82

M12 YEL

X86 A

M13 LT GRN

R13 BLK

= X6014 = X6001 = X6002

M76 PUR A2

4 5

A6002 SATELLITE (SAT) CONTROL UNIT

X6016

J1003 TAN

OPTION

A6003 SATELLITE ANTENNA

J3 A1

M1005 PUR M1004 PUR

G71 BLK

R13 BLK

F31 JDLINK GROUND 5A FUSE

A2 M2 M1

9 8 10 M12 YEL M13 LT GRN

BLK

W15 MAIN FRAME GROUND

X95

P1002 PUR

A11 ELECTROHYDRAULIC CONTROLLER (EHC)

G1001 PUR

X36

P70 RED

G4 H4

M52 PUR

X39

M13 LT GRN

P70 RED

M12 YEL

M18 LT GRN

G70 BLK

CAN 1

G70 BLK

G1 BATTERIES

BLK

X30

A1 TRANSMISSION CONTROL UNIT (TCU)

G05 BLK

RED

M1 STARTER MOTOR

BLK

M51 PUR

G70 BLK

X11

BATTERY CABLE RED

X62 X10

S2 BATTERY DISCONNECT SWITCH

M50 PUR

CAN 1

B01 RED

BLK

CAN1

P07 RED

= X27

P71 RED

M70 PUR M71 PUR M72 PUR M73 PUR

B01 RED M12 YEL R13 BLK

P70 RED

X38

X10 A1

B01 RED

A3 ENGINE CONTROL UNIT (ECU) B1

P70 RED P71 RED

M76 PUR M75 PUR

B03 RED

M74 PUR

S1 KEY SWITCH

H1 STANDARD DISPLAY MONITOR (SDM)

A6000 MODULAR TELEMATICS GATEWAY (MTG) CONTROL UNIT

A6001 GPS/CELL ANTENNA

P70 RED

B03 RED

BULB CHECK START

F6 JDLINK UNSWITCHED POWER 5A FUSE

R13 BLK

OFF ON

F26 JDLINK SWITCHED POWER 5A FUSE

M13 LT GRN

B01 RED

B IG ACC ST G BODY

M12 YEL

POSITION ACC

OPTION (S.N. 196418— )

P71 RED

B01 RED

G70 BLK

RED

W2 FRAME GROUND AT CAB/CANOPY RIGHT FRONT

= X6015 = X6005

BLK

TX1086208 WS68074,00037C5 -19-04APR11-1/2

Continued on next page

TM10721 (03SEP14)

9015-15-25

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=481

Sub-System Diagnostics

TM10721 (03SEP14)

9015-15-26

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=482

Sub-System Diagnostics

A1—Transmission Control Unit G3—Alternator X27— Engine Control Unit (ECU) X6001—Cellular Antenna (TCU) H1—Standard Display Monitor 32-Pin Connector Connector A3—Engine Control Unit (ECU) (SDM) X36— Transmission X6002—GPS Antenna Connector A11— Electrohydraulic K3—Ignition Relay Harness-to-JDLink™ X6005—Satellite Antenna Controller (EHC) (IGC M1—Starter Motor Ground Harness 1-Pin Connector option) S1— Key Switch Connector (if equipped) X6014—Modular Telematics A6000—Modular Telematics S2— Battery Disconnect Switch X38— Not Used Gateway (MTG) Control Gateway (MTG) Control W2—Frame Ground At X39— Not Used Unit 48-Pin Connector Unit Cab/Canopy Right Front X62— Not Used X6015—Satellite (SAT) Module A6001—GPS/Cellular Antenna W15—Main Frame Ground X63— Main Cab/Canopy Control Unit 48-Pin A6002—Satellite (SAT) Control X1— TCU 30-Pin Connector Harness-to-Machine Connector Unit X6— SDM 16-Pin Connector Information Gateway (MIG) X6016—Modular Telematics A6003—Satellite Antenna X10— Main Cab/Canopy Harness 12-Pin Connector Gateway (MTG) F6— JDLink™ Unswitched Power Harness-to-Engine (S.N. 153831— ) Harness-to-Satellite 5 Amp Fuse Harness 31-Pin Connector X82— Electrohydraulic (SAT) Harness 6-Pin F26— JDLink™ Switched Power X11— Main Cab/Canopy Controller (EHC) Connector 5 Amp Fuse Harness-to-Transmission Connector (if equipped) F31— JDLink™ Ground 5 Amp Harness Connector X86— Machine CAN Connector Fuse—If Equipped X30— Alternator 2-Pin Connector (if equipped) G1—Battery X95— IGC Machine Harness-to-IGC Cab Harness 35-Pin Connector (if equipped)

JDLink™ transmits information via cellular connection from the machine through the modular telematics gateway (MTG) control unit (A6000) to the JDLink™ server. The optional satellite (SAT) control unit (A6002) allows wireless data transfer in remote areas where cellular signal is not consistently available. For more information, see JDLink™ (MTG) Diagnosis and Tests Manual. (TM114519.) The MTG control unit (A6000) receives unswitched battery power from JDLink™ unswitched power 5-amp fuse (F6) at terminal M2 of MTG connector (X6014). When the ignition is on, power from JDLink™ switched power 5-amp fuse

(F26) is supplied at terminal L1 of MTG connector (X6014). Constant battery ground is provided from JDLink™ ground 5-amp fuse (F31) at terminal M1 of MTG connector (X6014). Ground is also provided from ground at frame ground (W2) at terminal F3 of MTG connector (X6014). The MTG control unit (A6000) transmits and receives data across the controller area network (CAN) with the systems controllers. For more information on the CAN network, see Controller Area Network (CAN) Circuit Theory of Operation. (Group 9015-15.)

JDLink is a trademark of Deere & Company WS68074,00037C5 -19-04APR11-2/2

TM10721 (03SEP14)

9015-15-27

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=483

Sub-System Diagnostics

TM10721 (03SEP14)

9015-15-28

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=484

Group 16

Monitor Operation Standard Display Monitor (SDM) Menu Structure—Service Mode

1. Active Codes 2. Stored Codes 3. Clear Codes (service mode only)

NOTE: The navigation buttons MENU, BACK, NEXT, and SELECT are located at the right side of the SDM display.

1. Active Codes: This menu displays the diagnostic trouble codes (DTC) SPN.FMI numbers that are currently active on the machine and the source controller (controller reporting the problem). The codes are listed in order, starting with the most recent fault. a. Push NEXT to display the next code or BACK to go to the previous menu screen. b. Push SELECT to view a detailed description of the DTC. 2. Stored Codes: This menu displays the DTC SPN.FMI numbers that are stored in memory and the source controller (controller reporting the problem). The codes are listed in order, starting with the most recent fault. a. Push NEXT to display the next code or BACK to go back to the previous menu screen. b. Push SELECT to view a detailed description of the DTC. 3. Clear Codes: (service mode only) This menu will clear all stored DTC on the machine. Push SELECT to clear the codes or BACK to go back to the codes submenu.

There are two versions of the standard display monitor (SDM) main menu structure: Operator Mode and Service Mode. Operator Mode is used to change user preferences, view operational settings, and view diagnostic trouble codes (DTC). To enter Operator Mode, turn key switch to the ON position, then push and immediately release the MENU button. Service Mode provides additional items not available in Operator Mode. This feature allows a service technician to change operational settings and clear DTC. It also allows the technician to monitor functions for diagnostic and testing purposes. To enter Service Mode, turn the key switch to the ON position, then push and hold the MENU button down for approximately 5 seconds until a beep is heard and Service Mode temporarily appears on the Main Menu. NOTE: When Service Mode is accessed, the Main Menu will stay in Service Mode even if the SDM display is returned to the home screen. As long as the key switch is kept in the ON position, the MENU button only needs to be pushed once to re-enter Service Mode.

2. Machine Settings: The machine settings menu consists of the following submenus:

Cycling the key switch to OFF, then back to ON resets the SDM menu mode. Pushing and releasing the MENU button after the key switch has been cycled only allows access to the Operator Mode menus. To navigate through the menu structure, do the following:

• Push the BACK button to go back one screen. • Push the NEXT button to scroll down the menu. • Push the SELECT button to select the highlighted item. Selecting an item in the main menu will bring up the corresponding submenu. Selecting an item in the submenu will bring up the next corresponding submenu, if applicable. Continue navigating through the submenus until the appropriate submenu is obtained, then select the desired screen. MAIN MENU—When in service mode, the main menu consists of the following submenus: 1. 2. 3. 4. 5. 6.

Codes Machine Settings Diagnostics Monitor Calibrate (service mode only) TCU Diagnostics (service mode only)

1. Codes: The codes menu consists of the following submenus:

1. 2. 3. 4. 5. 6.

Job Timer Track Info Controller Info Transmission Hydraulics (IGC equipped machines only) Brake Mode (service mode only)

1. Job Timer: This menu controls a continually running job timer. There are two options under this submenu. - Show Timer—Push SELECT and the job timer will be displayed. - Hide or Unhide Timer—Push SELECT and the job timer will either appear on monitor main menu or be hidden. - Reset Time—Push SELECT to reset the job timer. 2. Track Info: This menu displays track information calculated by the TCU. - Forward Miles—Displays number of miles tracks have traveled forward. - Reverse Miles—Displays number of miles tracks have traveled in reverse. - Forward Hours—Displays number of hours tracks have traveled forward. - Reverse Hours—Displays number of hours tracks have traveled in reverse. 3. Controller Info: This menu displays the machine ID, hardware part numbers, and software version numbers for various devices on the machine.

Continued on next page

TM10721 (03SEP14)

9015-16-1

TW73308,0000123 -19-31MAY11-1/4

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=485

Monitor Operation - SDM—Software number and the machine ID number will be displayed. - TCU—Software number and the TCU hardware part number will be displayed. - ECU—Software number and the ECU hardware part number will be displayed. - EHC—Software number and the EHC hardware part number will be displayed. (IGC equipped machines only) 4. Transmission: This menu contains settings that affect transmission function and performance. - Aggressiveness—Transmission aggressiveness can be set to low, medium, or high. - Decel Response—Decelerator response can be set to low, medium, or high. - FNR Shift Rate—TCL shift rate can be set to low, medium, or high. - Steer Rate—Steer rate can be set to low, medium, or high. - Steer Modulation—Steer modulation can be set to low, medium, or high.

- Test—This setting is used in various diagnostic testing procedures. - Tow—This setting is used when the machine is being towed. 3. Diagnostic: The diagnostic menu consists of the following submenus:

NOTE: Listed track speeds are approximate. - Fwd Track Speed—Maximum forward track speed can be set to low 4.8 km/h (3.0 mph); medium 8.0 km/h (5.0 mph); or high 9.7 km/h (6.0 mph). The speed minimum can be set to standard or cable plow. - Rev Track Speed—Maximum reverse track speed can be set to low 4.8 km/h (3.0 mph); medium 8.0 km/h (5.0 mph); or high 9.7 km/h (6.0 mph). The speed minimum can be set to standard or cable plow. - Shift Type—(service mode only) The shift type can be set to standard or fire plow. - Reverse Ratio—The reverse ratio can be set to 80%, 100%, 115%, or 130%. - Factory Settings—(service mode only) All settings can be set to the factory default settings. 5. Hydraulics: This menu allows the technician to change hydraulic settings. Menu only exists if machine is equipped with an Electrohydraulic Controller (EHC). - Lift—Lift settings can be set to low, medium, or high. - Power Down—The power down setting can be set to low, medium, or high. - Tilt Left—Tilt left setting can be set to low, medium, or high. - Tilt Right—Tilt right setting can be set to low, medium, or high. - Factory Settings—(service mode only) The hydraulic settings will be restored to the factory defaults. 6. Brake Mode: (service mode only) This menu is used to change the park brake mode. Push SELECT to activate desired mode, a check mark will appear next to selected mode. - Normal—This setting is normal operating mode for the park brake.

1. Live Values 2. Calibrated Values (service mode only) 1. Live Values: This menu displays the live values that the controllers detect. - Temperatures—Displays engine coolant temperature, fuel temperature, manifold air temperature, transmission oil temperature, and hydraulic oil temperature. - Pressures—Displays transmission charge oil pressure, engine oil pressure, and fuel rail pressure. - Speeds—Displays values for engine, left motor, right motor, and crankshaft speed. - Inputs (service mode only)—Displays voltages for all input sensors, as well as system voltages. 1-Speed Button

11-ECU Switched

2-Steer

12-ECU Unswitched

3-FNR

13-Oil Pressure

4-Decel

14-Coolant Temperature

5-Trans Temp

15-Manifold Temperature

6-Trans Charge

16-Fuel Temperature

7-Hydraulic Temperature

17-Blade Angle (Only with EHC)

8-Fuel Level

18-Blade Incr/Decr (Only with EHC)

9-Battery

19-Auxiliary Joystick 1

10-Engine Throttle

20-Auxiliary Joystick 2

- Outputs (service mode only)—Displays output currents for solenoids and PCPs, output states for solenoids and alarms, and resistance of PCPs and solenoids. 1-Left Pump PCP

6-Left Pump PCP Resistance

2-Right Pump PCP

7-Right Pump PCP Resistance

3-Left Motor

8-Left Motor Resistance

4-Right Motor

9-Right Motor Resistance

5-Backup Alarm

- Switches (service mode only)—Displays switch status (on or off) as interpreted by the controllers. 1-Neutral Switch

8-Water in Fuel

2-Park Lock—Park

9-Derate Override

3-Park Lock—Run

10-Crank Case Vent

4-Trans Charge Oil Filter

11-Hydraulic Enable (Only with EHC)

5-Engine Air Filter

12-Hydraulic Disable (Only with EHC)

6-Hydraulic Oil Filter

13-IGC Enable (Only with EHC)

7-Decouple Switch

- Performance (service mode only)—Displays engine, transmission, and IGC (if equipped) performance variables.

Continued on next page

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Monitor Operation 1-Trans Speed Set

10-ACU Connected (Only with EHC)

2-Antistall (Percent)

11-Lift Spool Command (Only with EHC)

3-Tracker Error

12-Tilt Spool Command (Only with EHC)

4-Reverse Ratio

13-Angle Command CW (Only with EHC)

5-Throttle (Percent)

14-Angle Command CCW (Only with EHC)

6-Load @ RPM

15-Joystick Lift Position (Only with EHC)

7-Fuel Rate

16-Joystick Power Down Position (Only with EHC)

8-Engine Hours

17-Joystick Tilt Left Position (Only with EHC)

9-Engine Derate

18-Joystick Tilt Right Position (Only with EHC)

3. Contrast: This menu sets the amount of contrast for the SDM LCD. a. Push SELECT to access the contrast menu. b. Push NEXT to increase the amount of contrast. c. Push BACK to decrease the amount of contrast. d. Press SELECT at desired amount of contrast to store the setting and return back to monitor screen. 4. Language: (service mode only) This menu sets the language for all functions of the SDM. Push SELECT to select the desired language. - English—The menu language will be set to English. - Spanish—The menu language will be set to Spanish. - French—The menu language will be set to French. - German—The menu language will be set to German. - Italian—The menu language will be set to Italian. 5. Hide Menu: This menu sets the display mode for the main menu. Push SELECT to select the desired mode. For more information on the hide menu feature, see Standard Display Monitor (SDM)—Hide/Unhide Main Menu. (Group 9015-20.) - Hide Main Menu—The main menu will not be available. The service mode will have to be entered to access any menus. - Show Main Menu—The main menu will be available when the MENU button is pushed.

2. XCalibrated Values: (service mode only) This menu displays the input and output values recorded during calibration. - Inputs—Displays sensor input voltages recorded during calibration. 1-Right Steer

9-Decel Up

2-Left Steer

10-Decel Brake Point

3-Right Counter

11-Decel Down

4-Left Counter

12-Throttle Low

5-FNR Forward

13-Throttle High

6-FNR Forward Switch

14-Speed Button Up

7-FNR Reverse Switch

15-Speed Button Neutral

8-FNR Reverse

16-Speed Button Down

NOTE: The key switch needs to be cycled off and back on after the hide menu screen is activated in order for the command to take effect. The SDM will also be in Operator Mode after cycling the key switch.

- Outputs—Displays output current values recorded during calibration. 1-Left Forward Threshold

7-Left Reverse Max Pump

2-Right Forward Threshold

8-Right Reverse Max Pump

3-Left Reverse Threshold

9-Left Threshold Motor

4-Right Reverse Threshold

10-Right Threshold Motor

5-Left Forward Max Pump

11-Left Max Motor

6-Right Forward Max Pump

12-Right Max Motor

6. Defaults: (service mode only) This menu allows a service technician to reset the SDM to the original factory settings. Push SELECT to enter the SDM will confirm the action to be performed. Push SELECT to restore factory defaults settings or BACK to cancel action and return to main menu screen.

4. XMonitor: The monitor menu is used to set SDM settings and consists of the following submenus: 1. 2. 3. 4. 5. 6.

5. Calibrate: This menu and corresponding submenu performs an automatic calibration of the TCU. For more information on calibrating the TCU, see Transmission Control Unit (TCU) Calibration. (Group 9015-20.)

Units Monitor Config Contrast Language (service mode only) Hide Menu (service mode only) Defaults (service mode only)

6. TCU Diagnostics: This menu allows a service technician to set TCU settings and perform diagnostic procedures.

1. Units: This menu sets the units for all functions of the SDM. Push SELECT to select the desired mode. For more information on the change units feature, see Standard Display Monitor (SDM)—Change Units. (Group 9015-20.) - English—All units will be English standard units. - Metric—All units will be Metric units. 2. Monitor Config: This menu displays the machine model number and level (tier 2 or tier 3).

1. Settings: The monitor menu is used to set SDM settings and consists of the following submenus: - Tracker Control—Tracker control settings can be set to normal or off. - Antistall—Antistall settings can be set to normal or off. Normal – Antistall operates normally, Off – Can turn antistall off to locate sources of instability with the machine.

Continued on next page

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Monitor Operation - Motor Solenoid—Solenoid settings can be set to normal, on, or off. TW73308,0000123 -19-31MAY11-4/4

Standard Display Monitor (SDM)—Change Units NOTE: The navigation buttons MENU, BACK, NEXT, and SELECT are located at the right side of the SDM display.

2. 3. 4.

The standard display monitor (SDM) will display the units of measure in English standard units or Metric units.

To change the way the units appear on the SDM, do the following:

1. Enter the Main Menu in Service Mode by pushing and holding the MENU button down for approximately

5 seconds until a beep is heard and Service Mode temporarily appears on the Main Menu. From the Main Menu, push NEXT until Monitor is highlighted. Push SELECT to enter the Monitor screen. Push SELECT in the Monitor submenu to enter Units submenu. Use the NEXT button to choose either English or Metric. Push SELECT to activate the change and return to the Units submenu. Exit the Main Menu screen by pushing the MENU button. Exit Service Mode by cycling the key switch off and back on. WS68074,0000B21 -19-25MAR10-1/1

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

NOTE: The hide menu function will not be activated until the key switch has been cycled off and back on again.

The Main Menu screen on the standard display monitor (SDM) can be made accessible or hidden from view using the hide/unhide Main Menu function.

To unhide main menu:

The Hide/Unhide Main menu is a function of Service Mode. See Standard Display Monitor (SDM) Menu Structure—Service Mode. (Group 9015-16.) NOTE: The navigation buttons MENU, BACK, NEXT, and SELECT are located at the right side of the SDM display.

1. Enter the Main Menu in Service Mode by pushing and holding MENU down for approximately 5 seconds until a beep is heard and Service Mode temporarily appears on the Main Menu. 2. Push NEXT until Monitor is highlighted. 3. Push SELECT to enter Monitor submenu. 4. From the Monitor submenu push NEXT until Unhide Menu is highlighted.

To hide main menu:

2. Push the NEXT button until Monitor is highlighted.

5. Push SELECT. The screen will momentarily flash Menu Unhidden and return to the Monitor submenu. Hide will now appear in the Monitor submenu.

3. Push SELECT to enter the Monitor submenu.

6. Push the MENU button to exit out of Service Mode.

4. From the monitor submenu push NEXT until Hide Menu is highlighted.

7. Return the SDM to Operator Mode.

1. Push the MENU button to access the Main Menu.

5. Push SELECT. The screen will momentarily flash Menu Hidden and return to the Monitor submenu. Unhide will now appear in the Monitor submenu.

NOTE: Cycling the key switch resets the SDM menu back to Operator Mode.

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450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=488

Monitor Operation

Standard Display Monitor (SDM)—Setting Hour Meter This procedure is used to transfer current hour meter information to a new standard display monitor (SDM) when a new SDM is installed.

NOTE: The ones digit is set first, followed by tens, hundreds, thousands and ten thousands digits in that order. 8. Using the NEXT and BACK buttons, input the existing hour meter value to the nearest full hour (no tenths).

NOTE: The standard display monitor (SDM) only allows five SDM ON/OFF power cycles to input existing hour meter value. If the value is not entered during these five power cycles, the SDM hour meter value will reflect time accumulated since installation of new SDM.

a. Press and release the NEXT button to advance the number displayed in the active (flashing) field. The NEXT button increments the current digit and will “roll over” from 9 to 0. b. Press and release the BACK button to accept the number displayed (flashing) in the active field and shift the active field to the next digit to the left.

1. Record existing hour meter value before removing existing SDM.

c. If an incorrect value is entered and the active field advanced, continue to press and release the BACK button until the incorrect value is in the active field. Correct the value using the NEXT button.

2. Install new SDM. 3. Turn key switch to ON position. 4. Using Service ADVISOR™, download and install latest SDM software on new SDM as necessary. 5. Turn key switch OFF and then ON after software has been downloaded and installed. 6. SDM display shows SELECT SET HOURS, press the SELECT button.

9. Once the existing hour meter value has been entered, press the SELECT button to store these values. 10. SDM display shows VERIFY XXXXX (XXXXX is the newly-entered hour meter value). 11. If the displayed value is correct, press the SELECT button to permanently store the value.

7. SDM display shows SET HOURS 00000. Last digit will be flashing.

If the displayed value is not correct, press the BACK button to re-enter the existing hour meter value.

Service ADVISOR is a trademark of Deere & Company CS33148,0002827 -19-05DEC07-1/1

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Monitor Operation

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Group 20

References Service ADVISOR™ Diagnostic Application

technician to add or remove a reading, set a readings baseline, and create and check recording triggers.

The Service ADVISOR™ application is what technicians use to diagnose and troubleshoot equipment. The application allows technicians to quickly and easily find information and solve equipment problems. The Service ADVISOR™ application provides access to manuals, the Dealer Technical Assistance Center (DTAC), real-time diagnostics, and system readings. The application also allows technicians to perform calibrations, run tests, and program controllers, when possible. The Connection - Readings shortcut bar within Service ADVISOR™ is used to connect to a machine. A connection allows a technician to take live system readings, create recordings, diagnose problems, calibrate, interactively test, and program controllers. With a connection established, the Readings menu allows a

With Service ADVISOR™ connected to a machine, the Diagnostics shortcut bar can be used to read machine diagnostic trouble codes. The diagnostic codes can then be reviewed by code number for specific details. When a diagnostic trouble code is opened, code information displays in a window similar to the way a manual would. The details of a diagnostic trouble code often are in a procedural format with links so the technician can work to correct the problem with the equipment while following the step-by-step process in the diagnostic trouble code details. See Service ADVISOR™ Connection Procedure. (Group 9015-20.) See Reading Diagnostic Trouble Codes with Service ADVISOR™ Diagnostic Application. (Group 9015-20.)

Service ADVISOR is a trademark of Deere & Company MH66O88,0000506 -19-25JAN07-1/1

Service ADVISOR™ Connection Procedure NOTE: For additional information on Service ADVISOR™, see Service ADVISOR™ Diagnostic Application and see Reading Diagnostic Trouble Codes with Service ADVISOR™ Diagnostic Application. (Group 9015-20.)

1— USB Cable 2— Electronic Data Link (EDL) 3— Diagnostic 9-Pin Connector Cable

TX1011710A —UN—30AUG06

1. Connect EDL (2) or PDM (5) to computer. 4— Parallel Port Cable 5— Parallel Port Data Module (PDM)

TX1011712A —UN—30AUG06

EDL and Cables

PDM and Cables Service ADVISOR is a trademark of Deere & Company Continued on next page

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References

2. Remove diagnostic 9-pin connector cover (7) from diagnostic 9-pin connector (6) located at left side panel. 3. Connect diagnostic 9-pin connector cable (3) to diagnostic 9-pin connector (6). 7— Diagnostic 9-Pin Connector Cover TX1014265A —UN—01NOV06

6— Diagnostic 9-Pin Connector

Diagnostic 9-Pin Connector and Cover MH66O88,0000505 -19-25JAN07-2/3

4. Turn key switch to ON position. Power LED (9) must come on.

6. If computer cannot connect to the CAN data line and the CAN connection LED does not come on, check all cable connections to the machine and computer. Make sure the key switch is in the ON position and the power LED is on. 9— Power LED (green)

TX1011713A —UN—30AUG06

8— CAN Connection LED (red)

TX1011711A —UN—30AUG06

5. The CAN connection LED (8) will come on when computer connects to the CAN data line. The CAN connection LED may flicker—this is normal. When the CAN connection LED is on, CAN data line is active and data is being transmitted.

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References

TX1002938A —UN—26JAN06

Reading Diagnostic Trouble Codes with Service ADVISOR™ Diagnostic Application

Service ADVISOR™—Diagnostic Trouble Codes 1— Diagnostics Shortcut Bar 2— Connected Diagnostic Trouble Codes Folder

3— Readings Tab 4— Connected Diagnostic Trouble Codes Tab

1. Connect service laptop to machine. See SERVICE ADVISOR™ Connection Procedure. (Group 9015-20.)

4. Click the Connected Diagnostic Trouble Codes folder (2).

2. Open Service ADVISOR™ and display appropriate model information. 3. From the Shortcut bar, click Diagnostics to open the Diagnostics shortcut bar (1). Service ADVISOR is a trademark of Deere & Company Continued on next page

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References

TX1002997A —UN—26JAN06

5. Select the Connect to Model(s) radio button on the Connection Options dialog box, and click OK.

Connection Options Dialog Box

TX1003001A —UN—26JAN06

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Select Readings Adapter Dialog Box 5— Available Adaptors Drop-Down List

6— Selected Models List

7— Change Selected Models Button

6. On the Select Readings Adapter dialog box, make sure the appropriate adapter is displayed. If not, select correct adapter from drop-down list (5). Options include:

10. Double-click an underlined code on the Connected Diagnostic Trouble Codes tab to display a detailed description for servicing that diagnostic trouble code.

• Electronic Data Link (EDL) Stand-alone USB Device • Electronic Data Link (EDL) Using Bluetooth • Parallel Data Module (PDM) • Parallel Data Module (PDM) With USB Adapter

NOTE: Use the lock topic feature within Service ADVISOR™ to open multiple windows if machine is transmitting more than one diagnostic trouble code. Refer to Service ADVISOR™ system instructions for using this feature.

7. Make sure correct machine to connect to displays in the Selected Models list (6). If not, click the Change Selected Models button (7). 8. Click OK to connect to machine.

11. Click the Connected Diagnostic Trouble Codes tab (4) to select and view details for additional diagnostic trouble codes.

9. After Service ADVISOR™ connects to machine, both the Readings tab (3) and Connected Diagnostic Trouble Codes tab (4) display. MH66O88,00004EB -19-31JAN07-3/3

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450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=494

References

JDLink™ System Identification

Locate JDLink™ system. The following are typical system locations according to machine family. JDLink™ system may not be installed at suggested location due to specific machine options or configuration. If necessary, refer to JDLink™ component location in Electrical—System Diagrams (Group 9015-10.)

Use the following information to identify which JDLink™ system is equipped. One of the following systems may be equipped:

• GlobalTRACS® Terminal (GTT) and Machine Information Gateway (MIG) JDLink™ System

• Modular Telematics Gateway (MTG) and Satellite (SAT) JDLink™ System

NOTE: If JDLink™ system contains two control units, control units may be installed side by side or stacked on top of each other. JDLink™ System Locations Machine Family

Location

Loader Backhoe

Inside battery box.

Crawler

Mounted to bottom of operator station floor or floor plate.

High Speed Dozer

Inside load center (outer access door on right side of cab).

4WD Loader

Inside load center (outer access door at right rear of cab).

Excavator

Inside compartment on left side of machine, directly behind cab. Mounted to sheet metal near swing motor.

Articulated Dump Truck (ADT)

Inside cab, behind front lower left panel (under load center).

Motor Grader

Below main frame sheet metal panel (directly in front of cab). Behind rear panel in cab (panel behind seat)

Skidder

Below right rear cab console.

Wheeled Feller Buncher/Harvester

Inside load center (outer access door on right side of cab).

Track Feller Buncher/Harvester

Below seat in cab. Mounted to inside of engine enclosure door.

Knuckleboom Loader

Mounted to bottom of plate covering heating and air conditioning system behind seat in cab.

Forestry Swing Machines

Left inner side of boom pivot pin/mounting frame.

Continued on next page

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References GTT and MIG System GTT is main control unit. MIG control unit is optional. Key distinguishing characteristics of GTT/MIG: TX1143631A —UN—09SEP13

• Single large 70-pin connector on face of control unit, along with antenna connectors.

• GTT is black, MIG is silver. 1— GTT (newer)

2— MIG (if equipped)

TX1143632A —UN—09SEP13

GTT (older)

TX1143633A —UN—09SEP13

MIG (if equipped)

GTT (newer) and MIG (stacked installation) JDLink is a trademark of Deere & Company GlobalTRACS is a registered trademark of Qualcomm Incorporated Continued on next page

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References MTG and SAT System MTG is main control unit. SAT control unit is optional. Key distinguishing characteristics of MTG/SAT: TX1143680A —UN—09SEP13

• Three smaller connectors on side of control unit. All connectors are located on sides of control unit.

• Both control units are silver. • Both control units are very similar (SAT has less connectors on one side).

TX1143681A —UN—09SEP13

MTG

SAT (if equipped) AA95137,00000DA -19-08NOV13-3/3

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References

JDLink™ Connection Procedure—If Equipped TX1086506A —UN—05JAN11

Connect to the GlobalTRACS® Terminal (GTT) Controller (S.N. —196417) 1. Locate GlobalTRACS® config tool adapter connector (2) in fuse box (1). NOTE: CV90-J1006 PC Based JDLink™ Config Tool Serial Cable is included in the 65-J1115-11 PC based JDLink™ Config Tool Kit. 2. Connect one end of CV90-J1006 PC Based JDLink™ Config Tool Serial Cable to the GTT config tool adapter connector (2), and connect the other end to a COM port on the computer.

Fuse Box

NOTE: If the computer is not equipped with COM ports, a USB-to-serial adapter cable will be required to simulate a COM port for use with the GTT Configuration Tool software. For more information on connecting to the GTT, see Connect PC Laptop to GlobalTRACS® Terminal (GTT). (CTM10006.) JDLink™ Connection Procedure (S.N. 196418— )

1— Fuse Box

2— GTT Config Tool Adapter Connector

TX1086508 —UN—05JAN11

Connect to JDLink™ via Service ADVISOR™. See Service ADVISOR™ Connection Procedure. (Group 9015-20.)

2 Laptop Connector

GlobalTracs is a trademark of Qualcomm Incorporated JDLink is a trademark of Deere & Company Service ADVISOR is a trademark of Deere & Company WS68074,00037F7 -19-17MAR11-1/1

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References

T7751GM —19—14SEP92

Alternator Test

12 V System

24 V System

1. With engine running at slow idle, check DC voltage between terminal D+ and ground. Voltage should be 13.5 VDC or greater1.

1. With engine running at slow idle, check DC voltage between terminal D+ and ground. Voltage should be 27.5 VDC or greater2.

2. With engine running at fast idle, check DC voltage between terminal B+ and ground. Voltage should be 13.5 VDC or greater1.

2. With engine running at fast idle, check DC voltage between terminal B+ and ground. Voltage should be 27.5 VDC or greater2.

3. If voltage from previous steps is below 13.5 VDC1, check excitation by placing a jumper wire between terminals D+ and B+ with the engine running. If output at terminals B+ and D+ rise to 13.5 VDC or greater, check for an open diode, wiring problem or blown fuse in the alternator excitation circuit (wire to D+ terminal). 4. With engine running, check AC voltage between terminal W (if equipped) and ground. Voltage should be 6—7 VAC.

4. With engine running, check AC voltage between terminal W (if equipped) and ground. Voltage should be 12—14 VAC.

5. Repeat above steps with lights on to load the alternator. 6. If alternator fails to produce specified voltage after testing, check for worn out brushes in the regulator/brush assembly. Replace brush/regulator assembly if necessary. For specific test and repair proceduressee Use Proper Tools. (CTM77.) If alternator still fails, replace it. If alternator tests OK, check indicator light circuit.

3. If voltage from previous steps is below 27.5 VDC2, check excitation by placing a jumper wire between terminals D+ and B+ with the engine running. If output at terminals B+ and D+ rise to 27.5 VDC or greater, check for an open diode, wiring problem or blown fuse in the alternator excitation circuit (wire to D+ terminal).

5. Repeat above steps with lights on to load the alternator. 6. If alternator fails to produce specified voltage after testing, check for worn out brushes in the regulator/brush assembly. Replace brush/regulator assembly if necessary. If alternator is still malfunctioning, replace it. If alternator tests OK, check indicator light circuit.

Note: For 12 V systems with maintenance free batteries, D+ and B+ voltage should be 14.1 VDC or greater. Continued on next page

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References 2

Note: For 24 V systems with maintenance free batteries, D+ and B+ voltage should be 28.2 VDC or greater. CS33148,00029E3 -19-03APR08-2/2

TX1008899 —UN—05JUL06

CAN Circuit Test

Generic CAN Circuit Schematic 1— Controller 1 2— Controller 2 3— Service ADVISOR™ Connector

4— Termination Resistor 1 5— Termination Resistor 2

6— CAN High Wire (Yellow) 7— CAN Low Wire (Green)

NOTE: For additional information on the controller area network (CAN) circuit, see Controller Area Network (CAN) Circuit Theory of Operation. (Group 6015-15.)

8— Grounded Shield Wire (Black)

with more than two controllers, repeat last step for all controllers if necessary.

The diagram and the following diagnostics are for a generic 2-controller network. For networks TW73308,00000FF -19-07JAN08-1/9

Controller Area Network (CAN) Diagnostics Continued on next page

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References

• 1

System Check

Connect Service ADVISOR™ application to diagnostic connector. See Service ADVISOR™ Connection Procedure. (Group 9015-20.)

YES: Perform CAN Termination Resistor Check. (Group 9015-20.)

Turn key switch to the ON position. Establish machine connection using Service ADVISOR™. See Service ADVISOR™ Diagnostic Application. (Group 9015-20.)

NO: Not all controllers show up. Check fuses for the missing controller(s). For fuse information, see Fuse and Relay Specifications. (Group 9015-10.) If OK, Perform Controller Check (Group 9015-20.) for missing controller.

Do all controllers show up under connected controllers?

NO: A connection could not be established. Check fuse for the Service ADVISOR™ connector. For fuse information, see Fuse and Relay Specifications. (Group 9015-10.) If OK, perform CAN Termination Resistor Check. (Group 9015-20.)

Service ADVISOR is a trademark of Deere & Company TW73308,00000FF -19-07JAN08-3/9

• 2

CAN Termination Resistor Check

Turn key switch to the OFF position. Remove and measure the resistance of each termination resistors (4 and 5).

YES: Install resistors and perform CAN High Wire Voltage Check. (Group 9015-20.)

Is the resistance of each resistor between 110—130 ohm?

NO: Replace resistor. Install new resistor and perform CAN High Wire Voltage Check. (Group 9015-20.)

Continued on next page

TM10721 (03SEP14)

9015-20-11

TW73308,00000FF -19-07JAN08-4/9

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=501

References

• 3

CAN High Wire Voltage Turn key switch to the ON position. Using a multimeter, measure the voltage from pin C YES: Perform CAN Low Check (CAN high) to pin A (ground) of Service ADVISOR™ connector (3). Wire Voltage Check. (Group 9015-10.) Is voltage between 2.50—3.50 volts?

NO: System voltage is measured. A short-to-power exists on the CAN high wire. Check CAN high voltage one controller at a time to locate short circuit. Repair or replace harness as necessary. See Main Cab/Canopy Harness (W5) Wiring Diagram and see Engine Harness (W6) Wiring Diagram. (Group 9015-10.) NO: Zero volts are measured. Perform CAN High Wire Circuit Check. (Group 9015-10.) NO: Voltage is out of range but greater than 0 and less than system voltage. Remove one controller at a time and recheck voltage. When voltage is in range, check harness of disconnected controller for short circuits. Repair or replace harness as necessary. See Main Cab/Canopy Harness (W5) Wiring Diagram and see Engine Harness (W6) Wiring Diagram. (Group 9015-10.)

Service ADVISOR is a trademark of Deere & Company Continued on next page

TM10721 (03SEP14)

9015-20-12

TW73308,00000FF -19-07JAN08-5/9

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=502

References

• 4

CAN Low Wire Voltage Using a multimeter, measure voltage from pin D (CAN low) to pin A (ground) of Service YES: Perform CAN High Check ADVISOR™ connector (3). Wire Circuit Check. (Group 9015-10.) Is voltage between 1.50—2.50 volts?

NO: System voltage is measured. A short-to-power exists on the CAN low wire. Check CAN low voltage one controller at a time to locate the short circuit. Repair or replace harness as necessary. See Main Cab/Canopy Harness (W5) Wiring Diagram and see Engine Harness (W6) Wiring Diagram. (Group 9015-10.) NO: Zero volts are measured. Perform CAN Low Wire Circuit Check. (Group 9015-10.) NO: Voltage is out of range but greater than 0 and less than system voltage. Remove one controller at a time and recheck voltage. When voltage is in range, check harness of disconnected controller for short circuits. Repair or replace harness as necessary. See Main Cab/Canopy Harness (W5) Wiring Diagram and see Engine Harness (W6) Wiring Diagram. (Group 9015-10.)

Service ADVISOR is a trademark of Deere & Company Continued on next page

TM10721 (03SEP14)

9015-20-13

TW73308,00000FF -19-07JAN08-6/9

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=503

References

• 5

CAN High Wire Circuit Check

Using a multimeter, measure continuity between pin C (CAN high) and pin A (ground) of Service ADVISOR™ connector (3).

YES: A short-to-ground exists on the CAN high wire. Check CAN high voltage one controller at a time to locate the short circuit. Repair or replace harness as necessary. See Main Cab/Canopy Harness (W5) Wiring Diagram and see Engine Harness (W6) Wiring Diagram. (Group 9015-10.)

Is continuity measured?

NO: An open circuit exists on the CAN high wire. Repair or replace harness(es) as necessary. See Main Cab/Canopy Harness (W5) Wiring Diagram and see Engine Harness (W6) Wiring Diagram. (Group 9015-10.)

Service ADVISOR is a trademark of Deere & Company TW73308,00000FF -19-07JAN08-7/9

• 6

CAN Low Wire Circuit Check

Using a multimeter, measure continuity between pin D (CAN low) and pin A (ground) of YES: A short-to-ground Service ADVISOR™ connector (3). exists on the CAN low wire. Check CAN low voltage one controller at a time to locate the trunk of the harness where the short is located. Repair or replace harness as necessary. See Main Cab/Canopy Harness (W5) Wiring Diagram and see Engine Harness (W6) Wiring Diagram. (Group 9015-10.) Is continuity measured?

NO: An open circuit exists on the CAN low wire. Repair or replace harness(es) as necessary. See Main Cab/Canopy Harness (W5) Wiring Diagram and see Engine Harness (W6) Wiring Diagram. (Group 9015-10.)

Service ADVISOR is a trademark of Deere & Company Continued on next page

TM10721 (03SEP14)

9015-20-14

TW73308,00000FF -19-07JAN08-8/9

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=504

References

• 7

Controller Check

Turn key switch to the OFF position. Locate the controller and disconnect the appropriate connector to disconnect the CAN wires. Using a multimeter, measure the resistance between the CAN high and CAN low wires.

YES: Connect the controller. Repeat Controller Check for all other controllers.

Is resistance between 55—65 ohms?

NO: An open or short circuit exists in one of the CAN wires. Work from the controller to the harness checking the CAN high and low wires for open and short circuit. Repair or replace harness as necessary. See Main Cab/Canopy Harness (W5) Wiring Diagram and see Engine Harness (W6) Wiring Diagram. (Group 9015-10.) TW73308,00000FF -19-07JAN08-9/9

TM10721 (03SEP14)

9015-20-15

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=505

References

Electrical Component Specifications Item

Measurement

Specification

B1—Decelerator Sensor

Calibration Limits

1.40—1.60 V @ High Decel Position 3.40—3.60 V @ Low Decel Position 3.79—3.99 V @ Brake Position

B2—TCL Sensor

Calibration Limits

2.37—2.63 V @ Neutral Position 3.09—3.95 V @ Forward Position 1.05—1.91 V @ Reverse Position

B3—Motor Speed Sensor Right B4—Transmission Speed Control Sensor

Output Signal Voltage (High)

4.0—14.5 V

Output Signal Voltage (Low)

0.0—0.9 V

Calibration Limits

2.11—2.36 V w/ no buttons pressed 0.85—1.01 V w/ Up button pressed 2.97—3.20 V w/ Down button pressed 1.46—1.67 V w/ Up and Down buttons pressed

B5—Steer Sensor

Calibration Limits

2.3—2.7 V @ Neutral Position 1.62—1.94 V @ Right Steer Position 1.43—1.75 V @ Right Counter Rotate Position 3.06—3.38 V @ Left Steer Position 3.25—3.57 V @ Left Counter Rotate Position

B6—Crankshaft Position Sensor

Resistance

2.7—3.3 kohms

B7—Motor Speed Sensor Left

Output Signal Voltage (High) Output Signal Voltage (Low)

4.0—14.5 V 0.0—0.9 V

B8—Pump Pressure Control Pilot (PCP) Rear

Resistance

20.7—25.3 ohms

Amperage

56—80 mA

Resistance

20.7—25.3 ohms

Amperage

56—80 mA

Operating Pressure

0—180 MPa 0—1800 bar

B9—Pump Pressure Control Pilot (PCP) Front B10—Fuel Rail Pressure Sensor

0—26100 psi B12—Engine Coolant Temperature Sensor

Resistance

120.6—147.4 ohms @ 60°C (140°F) 46.8—56.3 ohms @ 90°C (194°F) 34.6—42.35 ohms @ 100°C (212°F)

B13—Winch Pressure Switch

Opening pressure

1310—1448 kPa 13.1—14.5 bar 190—210 psi

Closing pressure

1034—1172 kPa 10.3—11.7 bar 150—170 psi

B14—Engine Oil Pressure Sensor

Operating pressure

0—2660 kPa 0—26.6 bar 0—385 psi

Continued on next page

TM10721 (03SEP14)

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AA95137,0001211 -19-06AUG13-1/4

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=506

References Item

Measurement

Specification

B15—Transmission Oil Filter Restriction Switch

Opening pressure

248—303 kPa 2.5—3 bar 36—44 psi

B16—Hydraulic Oil Filter Restriction Switch

Closing pressure

248—303 kPa 2.5—3 bar 36—44 psi

B18—Engine Air Filter Restriction Switch

Closing pressure

4.98—7.48 kPa 1.47—2.2 in. of Hg 20—30 in. of H2O

B22—A/C Freeze Switch

Opening temperature (decreasing)

-1.4°C 29.5°F

Closing temperature (increasing)

2.2°C 36°F

B25—Hydraulic Oil Temperature Sensor

Resistance

90—108 kohms @ -40°C (-40°F) 26—31 kohms @ -20°C (-4°F) 8.7—10.2 kohms @ 0°C (32°F) 3.3—3.8 kohms @ 20°C (68°F) 1.4—1.6 kohms @ 40°C (104°F) 648—708 ohms @ 60°C (140°F) 317—350 ohms @ 80°C (176°F) 170—186 ohms @ 100°C (212°F) 97—105 ohms @ 120°C (248°F)

B26—Heater Temperature Switch

B29—Fuel Temperature Sensor

Resistance between pins A and B

0 kohms @ maximum hot 5 kohms @ maximum cold

Resistance Between Pins A and C

5 kohms

Resistance

B31—Manifold Air Temperature Sensor

Resistance

B33—Charge Pressure Sensor (S.N. —173344)

Operating Pressure

0—5171 kPa 0—51.7 bar

Continued on next page

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AA95137,0001211 -19-06AUG13-2/4

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=507

References Item

Measurement

Specification

0—750 psi B35—Fuel Level Sensor

Resistance

168—192 ohms @ 100% Capacity (Full) 129.5—150.5 ohms @ 75% Capacity 96—114 ohms @ 50% Capacity 67.5—82.5 ohms @ 25% Capacity 4—16 ohms @ 0% Capacity (Empty)

B40—Transmission Oil Temperature Sensor

Resistance

90—108 kohms at -40°C (-40°F) 26—31 kohms at -20°C (-4°F) 8.7—10.2 kohms at 0°C (32°F) 3.3—3.8 kohms at 20°C (68°F) 1.4—1.6 kohms at 40°C (104°F) 648—708 ohms at 60°C (140°F) 317—350 ohms at 80°C (176°F) 170—186 ohms at 100°C (212°F) 97—105 ohms at 120°C (248°F)

B41—Charge Pressure Sensor (S.N. 173345— )

Operating Pressure

0—5171 kPa 0—51.7 bar 0—750 psi

B50—A/C Binary Pressure Switch

Opening pressure (high)

2620—2896 kPa (26.2—29 bar) (380—420 psi)

Closing pressure (high)

1379—2068 kPa (13.8—20.7 bar) (200—300 psi)

Opening pressure (low)

137.9—227.5 kPa (1.38—2.28 bar) (20—33 psi)

Closing pressure (low)

158.6—255.1 kPa (1.58—2.55 bar) (23—37 psi)

B60—Water In Fuel (WIF) Sensor

Resistance

209—231 kohms

R1—Start Circuit Resistor

Resistance

100 ohms

Maximum Power

12 W

Low Speed Resistance (X12 pins 2 and 6)

2.2—2.7 ohms

R2—Cab Heater Blower Resistor

Medium Low Speed Resistance (X12 1.3—1.9 ohms pins 3 and 6) Medium Speed Resistance (X12 pins 0.5—0.9 ohms 5 and 6) R3—Under-Seat Heater Blower Resistor

Low speed resistance (wires A15 and 1.2 ohms A18) Medium speed resistance (wires A16 0.6 ohms and A18) High speed resistance (wires A17 and 0.4 ohms A18)

R4—CAN Termination Resistor

Resistance

120 ohms

R5—CAN Termination Resistor

Resistance

120 ohms

R10—Engine Speed Control

Resistance between pins A and B

280—420 ohms Minimum Value 4.28—6.42 kohms Maximum Value 4—6 kohms

Resistance Between Pins A and C Continued on next page

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450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=508

References Item

Measurement

Specification

Calibration Limits

2.96—4.15 V @ Slow Idle 0.45—1.22 V @ Fast Idle

Y3—Motor Shift Solenoid Right

Resistance

6.9—12.7 ohms

Y4—Motor Shift Solenoid Left

Resistance

6.9—12.7 ohms

Y5—A/C Compressor Clutch Solenoid

Resistance

3.5—6 ohms

Y11—Park Brake Solenoid

Resistance

6—8 ohms AA95137,0001211 -19-06AUG13-4/4

Transmission Control Unit (TCU) Calibration Whenever transmission components are adjusted or replaced, the transmission control unit (TCU) calibration procedure must be performed. The TCU calibration procedure must be performed on level ground with enough room to accelerate to full speed for approximately 46—61 m (150—200 ft) or with machine off ground supported by blocks. Before performing the TCU calibration, clear tracks of excessive mud and verify track tension is within specification. See check track sag. (Operator's Manual.)

3. Start engine and warm machine to normal operating temperature. See Transmission Oil Warmup Procedure. (Group 9026-25.) 4. Check charge pressure during machine warmup by observing charge pressure reading on standard display monitor (SDM). If charge pressure is low, see High/Low Charge Pressure Malfunctions. (Group 9026-15.) 5. Select CALIBRATE in the Service Mode menu of the SDM. See Standard Display Monitor (SDM) Menu Structure—Service Mode. (Group 9015-16.) 6. Choose one of the following calibration modes by pushing the UP or DOWN buttons on the SDM, then push the SELECT button.

IMPORTANT: If pump was repaired or replaced, perform the pump null adjustment before performing TCU calibration to prevent possible machine damage. See Pump Displacement Control Valve (PDCV) Neutral (NULL) Adjustment. (Group 9026-25.)

• 1 FULL CAL—Calibrates all TCU inputs and outputs.

1. Check for diagnostic trouble codes (DTC). If DTC 158.3, 158.4, 620.3, or 620.4 is displayed, DO NOT perform the calibration procedure. Repair problem causing the code(s) before continuing with calibration procedure. See Transmission Control Unit (TCU) Diagnostic Trouble Codes. (Group 9001-30.) 2. Make sure park lock lever is in the LOCK (up) position and TCL is in neutral.

Use after any major component is repaired or replaced. • 2 SECTIONAL CAL—Calibrates TCU input and outputs individually as chosen. - Sensor Cal - Pump/Motor Cal - Motor Cal

7. Follow the commands displayed on the SDM. If any problems occur during the calibration period and the calibration procedure ends prematurely, check for diagnostic trouble codes. See Standard Display Monitor (SDM) Menu Structure—Service Mode. (Group 9015-16.) MH66O88,00008E7 -19-08JAN08-1/1

Integrated Grade Control (IGC) Checks—If Equipped Most problems with the IGC electrical control system will cause a diagnostic trouble code (DTC) to appear on the SDM or grade control supplier's monitor. Fixing the problem causing the DTC will usually resolve the overall problem.

Use the following series of checks, in conjunction with the IGC observable symptom diagnostics, to help determine what part of the IGC system is responsible for the malfunction. For IGC observable symptoms diagnostics, see Integrated Grade Control (IGC) Diagnose Malfunctions—If Equipped. (Group 9015-20.) TW73308,0000125 -19-07JAN08-1/11

IGC System Checks Continued on next page

TM10721 (03SEP14)

9015-20-19

TW73308,0000125 -19-07JAN08-2/11

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=509

References

• 1

Code Check—Machine Turn key switch to ON position and check for any active diagnostic trouble codes. Standard Display Monitor (SDM)

YES: Repair problem causing the code. Clear all active codes and repeat code check until all codes are clear. To access menu for clearing codes, see Standard Display Monitor (SDM) Menu Structure—Service Mode. (Group 9015-16.)

LOOK: Do any active codes appear on the standard display monitor (SDM)?

NO: Go to Code Check—Grade Control Supplier's Monitor. TW73308,0000125 -19-07JAN08-3/11

• 2

Code Check—Grade Control Supplier's Monitor

LOOK: Do any active codes appear on the grade control supplier's monitor?

YES: Refer to documentation of the grade control supplier. If code cannot be cleared, contact the supplier of the grade control equipment or contact John Deere DTAC. NO: Go to Auto Blade Light Check. TW73308,0000125 -19-07JAN08-4/11

• 3

Auto Blade Light Check

NOTE: Before the electrohydraulic controller (EHC) will allow the auto blade light to come on, it first must detect the appropriate signals from each of the following components:

• IGC on/off switch • Pilot control enable switch (ENABLED position) • Park brake switch (park lock lever at UNLOCKED position) • Blade control joystick (BCJ) (neutral position) • standard display monitor (SDM) • Transmission control unit (TCU) • Grade control supplier's controller Start engine. Move park lock lever to UNLOCKED (down) position. Put the pilot control enable switch in the ENABLED position. Push the IGC on/off switch button to enable blade auto mode. LOOK: Does the auto blade light come on? Push the IGC on/off switch button again to disable blade auto mode.

YES: If auto blade light is on but blade does not obey commands from the grade control supplier's equipment, see observable symptom “All Blade Functions Operate Normally In Manual Mode, But Not In Auto Mode” in the Integrated Grade Control (IGC) Diagnose Malfunctions—If Equipped procedure. (Group 9015-20.)

LOOK: Does the auto blade light go off?

NO: Go to IGC ON/OFF Switch Check.

Continued on next page

TM10721 (03SEP14)

9015-20-20

TW73308,0000125 -19-07JAN08-5/11

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=510

References

• 4

IGC ON/OFF Switch Check

NOTE: The switches in the blade control joystick (BCJ) handle can be verified for proper operation in the SDM menus.

Observe the status of the IGC on/off switch by accessing the Diagnostic / Live Values / Switch State menu to the SDM menu structure. See Standard Display Monitor (SDM) Menu Structure—Service Mode. (Group 9015-16.) Push and release the IGC on/off switch button several times while observing the switch YES: Go to Hydraulic status in the SDM menus. Enable Switch Check. LOOK: Does the status of the IGC on/off switch change when the IGC on/off switch is pushed and released?

NO: see Integrated Grade Control (IGC) Diagnose Malfunctions—If Equipped. (Group 9015-20.) TW73308,0000125 -19-07JAN08-6/11

• 5

Hydraulic Enable Switch Check

Observe the status of the hydraulic enable switch by accessing the Diagnostic / Live Values / Switch State menu on the SDM. See Standard Display Monitor (SDM) Menu Structure—Service Mode. (Group 9015-16.) Cycle the hydraulic enable switch several times while observing the switch states.

YES: Go to Manual Blade Operation Check.

LOOK: Does the status of switch conditions change when switch is cycled and are they always opposite?

NO: See observable symptom “All Blade Functions Do Not Operate in Manual or Auto Modes” in the Integrated Grade Control (IGC) Diagnose Malfunctions—If Equipped procedure. (Group 9015-20.) TW73308,0000125 -19-07JAN08-7/11

• 6

Manual Blade Operation Check

NOTE: The IGC system is in manual mode when the auto blade light on the SDM is off.

Put blade control in manual mode by pushing the IGC on/off switch button. Operate all blade functions in manual mode.

YES: If IGC does not function in auto mode, see observable symptom “All Blade Functions Operate Normally In Manual Mode, But Not In Auto Mode” in the Integrated Grade Control (IGC) Diagnose Malfunctions—If Equipped procedure. (Group 9015-20.)

LOOK: Do the blade controls function properly when in manual mode?

NO: Go to Blade Control Joystick (BCJ) Check—Blade Lift and Tilt.

Continued on next page

TM10721 (03SEP14)

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TW73308,0000125 -19-07JAN08-8/11

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=511

References

• 7

Blade Control Joystick NOTE: The four-way axis operation of the blade control joystick can be verified (BCJ) Check—Blade for proper operation in the SDM menus. Lift and Tilt

Observe the joystick's 4-way axis movement as a percentage by accessing the Diagnostic / Live Values / Performance menu in the SDM menu structure. See Standard Display Monitor (SDM) Menu Structure—Service Mode. (Group 9015-16.) Slowly move the joystick handle through complete range in all four axes. LOOK: Do the joystick values in the SDM menu correspond with the joystick movements? LOOK: From neutral (center) position, does full movement range from 0 to 100 percent at each axis? LOOK: Does the joystick handle return fully to neutral when released?

YES: Go to Blade Angle Switch Check.

NOTE: The joystick should be replaced if any of the following occurs:

NO: See observable symptom “All Blade Functions Do Not Operate in Manual or Auto Modes” and/or “Blade Lift and Tilt Operate Normally in Auto Mode, But Not in Manual Mode” in the Integrated Grade Control (IGC) Diagnose Malfunctions—If Equipped procedure. (Group 9015-20.)

• Percentage is inconsistent to corresponding joystick handle movement. (Joystick can not be calibrated.) • Less than desired percentage of movement is indicated when joystick handle is moved fully to any one of the four axes. (Joystick can not be calibrated.) • Percentage does NOT go to zero when joystick returns to neutral position. (Joystick can not be calibrated.) • Joystick movement is loose or sloppy. • Joystick handle does not return fully to neutral position when released.

Continued on next page

TM10721 (03SEP14)

9015-20-22

TW73308,0000125 -19-07JAN08-9/11

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=512

References

• 8

Blade Angle Switch Check

NOTE: The blade control joystick switches can be verified for proper operation in the SDM menus.

Observe the voltage input from the blade angle switch by accessing the Diagnostic / Live Values / Input Voltages menu in the SDM menu structure. See Standard Display Monitor (SDM) Menu Structure—Service Mode. (Group 9015-16.) Observe blade angle switch voltage reading in the SDM menu with no blade angle buttons pushed. LOOK: Is the voltage approximately 2.20 volts? Push and hold the upper button of the blade angle switch while observing the voltage reading in the SDM menu. LOOK: Is the voltage approximately 3.00 volts? Push and hold the lower button of the blade angle switch while observing the voltage reading in the SDM menu.

YES: Check actuator circuit. See observable symptom “Blade Lift and Tilt Operate Normally, But Blade Angle Does Not” in the Integrated Grade Control (IGC) Diagnose Malfunctions—If Equipped procedure. (Group 9015-20.)

LOOK: Is the voltage approximately 0.90 volts?

NO: See observable symptom “Blade Lift and Tilt Operate Normally, But Blade Angle Does Not” in the Integrated Grade Control (IGC) Diagnose Malfunctions—If Equipped procedure. (Group 9015-20.)

Continued on next page

TM10721 (03SEP14)

9015-20-23

TW73308,0000125 -19-07JAN08-10/11

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=513

References

• 9

Blade Increment/Decrement Switch Check

NOTE: The blade control joystick switches can be verified for proper operation in the SDM menus.

Observe the voltage input from the blade increment/decrement switch by accessing the Diagnostic / Live Values / Input Voltages menu in the SDM menu structure. See Standard Display Monitor (SDM) Menu Structure—Service Mode. (Group 9015-16.) Observe increment/decrement switch voltage reading in the SDM menu with no increment/decrement buttons pushed. LOOK: Is the voltage approximately 2.20 volts? Push and hold the increment (upper) button while observing the voltage reading in the SDM menu. LOOK: Is the voltage approximately 3.00 volts? Push and hold the decrement (lower) button while observing the voltage reading in the SDM menu.

YES: If both blade lift and blade incr/decr functions do not operate, check blade lift actuator circuit. If blade lift and angle functions operate normally, but the blade incr/decr function does not, reprogram the controller. If reprogramming the controller does not resolve the problem, replace controller.

LOOK: Is the voltage approximately 0.90 volts?

NO: Check blade increment/decrement switch circuit. See observable symptom “Blade Lift and Angle Operate Normally, But Blade Incr/Decr Does Not” in the Integrated Grade Control (IGC) Diagnose Malfunctions—If Equipped procedure. (Group 9015-20.) TW73308,0000125 -19-07JAN08-11/11

Integrated Grade Control (IGC) Diagnose Malfunctions—If Equipped Most problems with the IGC electrical control system will cause a diagnostic trouble code (DTC) to appear on the SDM or grade control supplier's monitor. Fixing the problem causing the DTC will usually resolve the overall problem.

Use the following diagnostics in conjunction with the IGC checks and general hydraulic symptom diagnostics to help determine the cause of the malfunction. For IGC operational checks, see Integrated Grade Control (IGC) Checks—If Equipped. (Group 9015-20.) For diagnosing general hydraulic symptoms, see Hydraulic System Diagnose Malfunctions—IGC. (Group 9025-15.) TW73308,0000100 -19-26MAR10-1/56

All Blade Functions Do Not Operate in Manual or Auto Modes Continued on next page

TM10721 (03SEP14)

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450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=514

References

• 1

Fuse Check

Check fuses F29 and F103. see Fuse and Relay Specifications. (Group 9015-10.)

NOTE: If no system power is available (all systems are off line), make sure battery disconnect switch is in the ON position.

YES: Go to Relay K102 Check.

Are fuses okay?

NO: Replace fuse(s). TW73308,0000100 -19-26MAR10-3/56

• 2

Relay K102 Check

Swap relays K101 and K102. see Fuse and Relay Specifications. (Group 9015-10.)

YES: Replace malfunctioning relay.

Do blade functions now operate in manual mode?

NO: Go to Hydraulic Enable Switch Circuit Check.

Continued on next page

TM10721 (03SEP14)

9015-20-25

TW73308,0000100 -19-26MAR10-4/56

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=515

References

• 3

Hydraulic Enable Switch Circuit Check

YES: Go to next step in this check.

Are approximately 5 volts present?

NO: Go to EHC 5-Volt Circuit Check

Key switch ON. Put hydraulic enable switch in the DISABLED position. NOTE: The hydraulic enable switch (S30) must be connected for this check. Check for voltage at pin 1 (wire H36 GRN) of hydraulic enable switch (S30).

YES: Go to next step in this check.

Are approximately 5 volts present?

NO: Check switch. Go to Hydraulic Enable Switch Check.

Key switch ON. Put hydraulic enable switch in the ENABLED position. NOTE: The hydraulic enable switch (S30) must be connected for this check.

YES: Check wire H23 GRN for open or short circuit between pin 3 of hydraulic enable switch and pin 18 of EHC connector X82. Check wire H36 GRN for open or short circuit between pin 1 of hydraulic enable switch and pin 17 of EHC connector X82.

Check for voltage at pin 3 (wire H23 GRN) of hydraulic enable switch (S30).

IF OK: If circuits H23 and H36 are good, check wiring between the electrohydraulic controller and all actuators (Y30—Y32). If actuator wiring is okay, check hydraulic system. See Hydraulic System Diagnose Malfunctions—IGC. (Group 9025-15.)

Are approximately 5 volts present?

NO: Check switch. Go to Hydraulic Enable Switch Check. Continued on next page

TM10721 (03SEP14)

9015-20-26

TW73308,0000100 -19-26MAR10-5/56

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=516

References

• 4

EHC 5-Volt Circuit Check

NOTE: For connector and wiring information, see Integrated Grade Control (IGC) Machine Harness (W21) Wiring Diagram—If Equipped. (Group 9015-10.)

Disconnect harness connector X82 from electrohydraulic controller (EHC) (A11). Turn key switch ON. NOTE: EHC connector X83 must be connected when performing this check. Check for voltage at pin 3 (controller side) of EHC connector X82.

YES: Check wire H22 BRN for open or short circuit between pin 3 of EHC connector X82 and pin 2 of hydraulic enable switch (S30).

Are approximately 5 volts present?

NO: Go to EHC Supply Voltage Circuit Check. TW73308,0000100 -19-26MAR10-6/56

• 5

EHC Supply Voltage Circuit Check

NOTE: For connector and wiring information, see Integrated Grade Control (IGC) Machine Harness (W21) Wiring Diagram—If Equipped. (Group 9015-10.)

Disconnect harness connector X83 from electrohydraulic controller (EHC) (A11). Turn key switch ON. Check for voltage at pins 1 and 18 (wire P58 RED) (harness side) of EHC connector X83. YES: Go to EHC Ground Check. Is system voltage (approximately 24 volts) present at the designated pins?

NO: Go to next step in this check.

Remove relay (K102) and check for voltage at pins 30 and 85 of the relay socket.

YES: Go to next step in this check. NO: If no voltage is present at pin 30, check wire P50 RED for open or short circuit between connector (X87) and pin 30 of relay (K102). Repair as necessary.

Is system voltage (approximately 24 volts) present at the designated pins?

NO: If no voltage is present at pin 85, check wire P14 RED for open or short circuit between fuse (F22) and pin 85 of relay (K102). Repair as necessary.

Relay (K102) removed. Check for ground at pin 86 of the relay (K102) socket.

YES: Check wire P51 RED for open or short circuit between fuse (F103) and pin 87 of relay (K102) socket. Repair as necessary.

Is ground present?

NO: Check continuity of wire G30 BLK between pin 86 of relay socket and W20 IGC ground. Repair as necessary. Continued on next page

TM10721 (03SEP14)

9015-20-27

TW73308,0000100 -19-26MAR10-7/56

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=517

References

• 6

EHC Ground Check

NOTE: For connector and wiring information, see Integrated Grade Control (IGC) Machine Harness (W21) Wiring Diagram—If Equipped. (Group 9015-10.) Key switch OFF. Harness connector X83 disconnected from electrohydraulic controller (A11).

YES: Reprogram electrohydraulic controller. If problem persists, replace controller.

Check for ground at pins 6 and 23 (wire G15 BLK) (harness side) of EHC connector X83. NO: If no ground is present at pin 6, check wire G15 BLK for open circuit between pin 6 of EHC connector X83 and pin 3 of connector (X84). Repair as necessary. Is ground present at the designated pins?

NO: If no ground is present at pin 23, check wire G15 BLK for open circuit between pin 23 of EHC connector X83 and pin 3 of connector (X84). Repair as necessary. TW73308,0000100 -19-26MAR10-8/56

• 7

Hydraulic Enable Switch Check

Disconnect hydraulic enable switch (S30).

Check hydraulic enable switch terminals for continuity. Refer to continuity table. Hydraulic Enable Switch (S30) Continuity Table Switch Position

Terminals

Continuity

Hydraulics Disabled

1 and 2

Yes

Hydraulics Disabled

2 and 3

Hydraulics Enabled

1 and 2

Hydraulics Enabled

2 and 3

Yes

Is continuity between switch terminals as indicated in the continuity table?

YES: Check complete.

NO: Replace switch. TW73308,0000100 -19-26MAR10-9/56

All Blade Functions Operate Normally in Manual Mode, But Not in Auto Mode NOTE: This symptom may result from poor reception from satellite or from other guidance equipment. Consult documentation of supplier's grade control equipment. If problem cannot be resolved, contact the grade control equipment supplier or John Deere DTAC. TW73308,0000100 -19-26MAR10-10/56

• 1

Fuse Check

Check fuses (F101, F104, F105, or F106). see Fuse and Relay Specifications. (Group 9015-10.)

YES: Go to Relay K101 Check.

Are fuses okay?

NO: Replace fuse(s). Continued on next page

TM10721 (03SEP14)

9015-20-28

TW73308,0000100 -19-26MAR10-11/56

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=518

References

• 2

Relay K101 Check

Swap relays K101 and K102. see Fuse and Relay Specifications. (Group 9015-10.)

YES: Replace malfunctioning relay.

Do blade functions no longer operate in manual mode?

NO: Go to IGC Interface Connector (X96) Supply Voltage Circuit Check.

Continued on next page

TM10721 (03SEP14)

9015-20-29

TW73308,0000100 -19-26MAR10-12/56

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=519

References

• 3

IGC Interface NOTE: For connector and wiring information, see Integrated Grade Control (IGC) Connector (X96) Machine Harness (W21) Wiring Diagram—If Equipped. (Group 9015-10.) Supply Voltage Circuit Check

Disconnect IGC interface connector X96. Key switch OFF. Check for unswitched voltage at pins T, V, and X (machine side) of IGC interface connector (X96).

YES: Go next step in this check.

Is system voltage (approximately 24 volts) present at the designated pins?

NO: If no voltage exists at pin T, check wire P57 RED for open or short circuit between connector X96 and fuse (F104). Repair as necessary. If no voltage exists at pin V, check wire P56 RED for open or short circuit between connector X96 and fuse (F105). Repair as necessary. If no voltage exists at pin X, check wire P55 RED for open or short circuit between connector X96 and fuse (F106). Repair as necessary. If no voltage is present at all three pins, check wire P50 RED for open or short circuit between connector X87 and fuses (F104, F105, and F106). Repair as necessary.

Connector X96 disconnected. Turn key switch ON. Check for voltage at pin R (machine side) of IGC interface connector (X96).

YES: Go to IGC Interface Connector (X96) Ground Circuit Check.

Is system voltage (approximately 24 volts) present?

NO: Go next step in this check.

Remove fuse (K101) and check for voltage at pin A1 of fuse socket.

YES: Check wire P60 RED for open or short circuit between pin R of connector X96 and pin AA1 of fuse (F101). Repair as necessary.

Is system voltage (approximately 24 volts) present?

NO: Go to next step in this check.

Remove relay (K101) and check for voltage at pins 30 and 85 of the relay socket.

YES: Go to next step in this check. NO: If no voltage is present at pin 30, check wire P50 RED for open or short circuit between connector X87 and pin 30 of relay (K101). Repair as necessary.

Continued on next page

TM10721 (03SEP14)

9015-20-30

TW73308,0000100 -19-26MAR10-13/56

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=520

References Is system voltage (approximately 24 volts) present at the designated pins?

NO: If no voltage is present at pin 85, check wire P14 RED for open or short circuit between fuse (F22) and pin 85 of relay (K101). Repair as necessary.

Check for ground at pin 86 (wire G30 BLK) of relay (K101) socket.

YES: Check wire P54 RED for open or short circuit between pin A1 of fuse (F101) and pin 87 of relay (K101) socket. Repair as necessary.

Is ground present at pin 86?

NO: Check wire G30 BLK for open circuit between relay (K101) and W20 IGC ground. Repair as necessary. TW73308,0000100 -19-26MAR10-14/56

• 4

IGC Interface Connector (X96) Ground Circuit Check

NOTE: For connector and wiring information, see Integrated Grade Control (IGC) Machine Harness (W21) Wiring Diagram—If Equipped. (Group 9015-10.)

Key switch OFF. Connector X96 disconnected. Check for ground at pins P, S, U, and W (machine side) of IGC interface connector X96. YES: Test CAN circuit. Go to CAN Circuit Test. (Group 9015-20.) If problem cannot be resolved, contact the grade control equipment supplier or John Deere DTAC. Is ground present?

NO: Check wire G30 BLK for open circuit between pins P, S, U, and W of connector X96 and W20 IGC ground. Repair as necessary. TW73308,0000100 -19-26MAR10-15/56

All Blade Functions Operate Normally in Auto Mode, But Not in Manual Mode TW73308,0000100 -19-26MAR10-16/56

• 1

IGC ON/OFF Switch Check

Turn key switch ON.

Observe the status of the IGC on/off switch by accessing the Diagnostic / Live Values / Switch State menu in the SDM menu structure. See Standard Display Monitor (SDM) Menu Structure—Service Mode. (Group 9015-16.) Push and release the IGC on/off switch button several times while observing the switch YES: Go to Joystick 5-Volt status in the SDM menu. Supply Circuit Check. Does the status of the IGC on/off switch change when the switch is pushed and released? NO: Go to IGC ON/OFF Switch Circuit Check. Continued on next page

TM10721 (03SEP14)

9015-20-31

TW73308,0000100 -19-26MAR10-17/56

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=521

References

• 2

IGC ON/OFF Switch Circuit Check

NOTE: For connector and wiring information, see Integrated Grade Control (IGC) Machine Harness (W21) Wiring Diagram—If Equipped and see Integrated Grade Control (IGC) Cab Harness (W22) Wiring Diagram—If Equipped. (Group 9015-10.) Check for voltage at pin 21 (wire H33 BLK) of EHC connector X83. Both EHC connectors X82 and X83 must be connected to the electrohydraulic controller (EHC) when performing this check. Push then release the IGC on/off switch button while observing the voltage reading.

YES: Reprogram electrohydraulic controller. If problem persists, replace controller.

Is the voltage approximately 0.5 volts when switch is pushed and approximately 21.5 volts when switch is released?

NO: Go to next step in this check.

Key switch OFF. Disconnect blade control joystick (BCJ) connector X97 and electrohydraulic controller (EHC) connector X83. Check wire H33 BLK for open or short circuit between pin 4 of connector X97 and pin 21 of connector X83.

YES: Repair as necessary.

Is an open or short circuit indicated?

NO: Go to Joystick 5-Volt Supply Circuit Check. TW73308,0000100 -19-26MAR10-18/56

• 3

Joystick 5-Volt Supply NOTE: For connector and wiring information, see Integrated Grade Control Circuit Check (IGC) Machine Harness (W21) Wiring Diagram—If Equipped and see Integrated Grade Control (IGC) Cab Harness (W22) Wiring Diagram—If Equipped. (Group 9015-10.) Disconnect electrohydraulic controller (EHC) connector X82. Connector X83 must be connected for this check. Turn key switch ON. At controller side of EHC connector X82, check for voltage across pin 3 (+) and pin 22 (-). YES: Go to next step in this check. Are approximately 5 volts present?

NO: Replace electrohydraulic controller.

Electrohydraulic controller (EHC) connector X82 and blade control joystick (BCJ) connector X97 disconnected. Key switch OFF. Check wire H22 BRN for open or short circuit between pin 1 of BCJ connector X97 and pin 3 of EHC connector X82.

YES: Repair wire H22 BRN as necessary.

Is an open or short circuit indicated?

NO: Go to Joystick Switch Module Ground Circuit Check. TW73308,0000100 -19-26MAR10-19/56

• 4

Joystick Switch NOTE: For connector and wiring information, see Integrated Grade Control Module Ground Circuit (IGC) Machine Harness (W21) Wiring Diagram—If Equipped and Check see Integrated Grade Control (IGC) Cab Harness (W22) Wiring Diagram—If Equipped. (Group 9015-10.) Key switch OFF. Electrohydraulic controller (EHC) connector X82 and blade control joystick (BCJ) connector X97 disconnected. Check continuity of wire R41 PNK between pin 6 of BCJ connector X97 and pin 22 of EHC connector X82.

YES: Replace joystick.

Is continuity indicated?

NO: Check circuit R41 for open circuit. Repair as necessary. Continued on next page

TM10721 (03SEP14)

9015-20-32

TW73308,0000100 -19-26MAR10-20/56

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=522

References Blade Lift and Tilt Operate Normally in Auto Mode, But Not in Manual Mode TW73308,0000100 -19-26MAR10-21/56

• 1

Joystick 4-Way Axis Check

Turn key switch ON.

YES: Reprogram electrohydraulic controller. If problem persists, replace controller.

Do the joystick values in the SDM menu correspond with the joystick movements?

NO: Go to Fuse F102 Check. TW73308,0000100 -19-26MAR10-22/56

• 2

Fuse F102 Check

Check fuse F102. see Fuse and Relay Specifications. (Group 9015-10.)

YES: Go to Relay K102 Check.

Is fuse okay?

NO: Replace fuse. TW73308,0000100 -19-26MAR10-23/56

• 3

Relay K102 Check

Swap relays K101 and K102. see Fuse and Relay Specifications . (Group 9015-10.)

YES: Replace malfunctioning relay.

Do blade functions now operate in manual mode?

NO: Go to Joystick 4-Way Axis Supply Voltage Check. TW73308,0000100 -19-26MAR10-24/56

• 4

Joystick 4-Way Axis Supply Voltage Check

NOTE: For connector and wiring information, see Integrated Grade Control (IGC) Machine Harness (W21) Wiring Diagram—If Equipped and see Integrated Grade Control (IGC) Cab Harness (W22) Wiring Diagram—If Equipped. (Group 9015-10.) Disconnect blade control joystick (BCJ) connector X98. Turn key switch ON. Check for voltage at pin 1 (wire P59 RED) (harness side) of BCJ connector X98.

YES: Go to Joystick 4-Way Axis Ground Check.

Is system voltage (approximately 24 volts) present?

NO: Go to next step in this check.

Remove fuse (F102) and check for voltage at pin A2 of fuse socket.

YES: Check wire P59 RED for open or short circuit between fuse (F102) and BCJ connector X98.

Is system voltage (approximately 24 volts) present?

NO: Check wire P51 RED for open or short circuit between fuse (F102) and pin 87 of relay (K102) socket.

Continued on next page

TM10721 (03SEP14)

9015-20-33

TW73308,0000100 -19-26MAR10-25/56

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=523

References

• 5

Joystick 4-Way Axis Ground Circuit Check

YES: Test CAN circuit. Go to CAN Circuit Test. (Group 9015-20.)

Check for ground at pin 2 (wire G30 BLK) of BCJ connector X98.

IF OK: If CAN circuit is okay, replace joystick.

Is ground present?

NO: Check wire G30 for open circuit between joystick connector X98 and W20 IGC ground. Repair as necessary. TW73308,0000100 -19-26MAR10-26/56

Blade Lift and Tilt Operate Normally, But Blade Angle Does Not TW73308,0000100 -19-26MAR10-27/56

• 1

Blade Angle Switch Check

Turn key switch ON.

Observe the voltage input for the blade angle switch by accessing the Diagnostic / Live Values / Input Voltages menu in the SDM menu structure. See Standard Display Monitor (SDM) Menu Structure—Service Mode. (Group 9015-16.) Observe blade angle switch voltage reading in the SDM menu with no blade angle buttons pushed. Is the voltage approximately 2.20 volts? Push and hold the upper button of the blade angle switch while observing the voltage reading in the SDM menu. Is the voltage approximately 3.00 volts? Push and hold the lower button of the blade angle switch while observing the voltage reading in the SDM menu.

YES: Go to Blade Angle Actuator Circuit Check.

Is the voltage approximately 0.90 volts?

NO: Go to Blade Angle Switch Circuit Check. Continued on next page

TM10721 (03SEP14)

9015-20-34

TW73308,0000100 -19-26MAR10-28/56

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=524

References

• 2

Blade Angle Switch Circuit Check

NOTE: For connector and wiring information, see Integrated Grade Control (IGC) Machine Harness (W21) Wiring Diagram—If Equipped and see Integrated Grade Control (IGC) Cab Harness (W22) Wiring Diagram—If Equipped. (Group 9015-10.) Key switch ON. NOTE: Connector X82 must be connected to the electrohydraulic controller (EHC) to perform this check. Check for voltage at pin 20 (wire H25 WHT) of EHC connector X82. Do not push blade YES: Reprogram angle switch buttons during this check. electrohydraulic controller. If problem persists, replace controller. Is approximately 2.20 volts present?

NO: Go to next step in this check.

Turn key switch OFF. Disconnect blade control joystick (BCJ) connector X97 and electrohydraulic controller (EHC) connector X82. Check wire H25 WHT for open or short circuit between pin 2 of connector X97 and pin 20 of connector X82.

YES: Repair as necessary.

Is an open or short circuit indicated?

NO: Go to Joystick 5-Volt Supply Circuit Check. TW73308,0000100 -19-26MAR10-29/56

• 3

Joystick 5-Volt Supply NOTE: For connector and wiring information, see Integrated Grade Control Circuit Check (IGC) Machine Harness (W21) Wiring Diagram—If Equipped and see Integrated Grade Control (IGC) Cab Harness (W22) Wiring Diagram—If Equipped. (Group 9015-10.) Electrohydraulic controller (EHC) connector X82 disconnected. Connector X83 must be connected for this check. Turn key switch ON. At controller side of EHC connector X82, check for voltage across pin 3 (+) and pin 22 (-). YES: Go to next step in this check. Are approximately 5 volts present?

NO: Replace electrohydraulic controller.

YES: Repair as necessary.

Is an open or short circuit indicated?

NO: Go to Joystick Switch Module Ground Circuit Check. TW73308,0000100 -19-26MAR10-30/56

• 4

YES: Replace joystick.

Is continuity indicated?

NO: Check circuit R41 for open circuit. Repair as necessary. Continued on next page

TM10721 (03SEP14)

9015-20-35

TW73308,0000100 -19-26MAR10-31/56

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=525

References

• 5

Blade Angle Actuator Circuit Check

NOTE: For connector and wiring information, see Integrated Grade Control (IGC) Machine Harness (W21) Wiring Diagram—If Equipped. (Group 9015-10.)

Turn key switch ON. NOTE: Blade angle actuator (Y30) must be connected when performing this check. Push and hold upper blade angle button on joystick while checking for voltage at pin 1 (wire H31 RED) of blade angle actuator (Y30) connector.

YES: Go to next step in this check.

Are approximately 5 volts present?

NO: Check circuit H31 for open or short circuit between blade angle actuator and pin 12 of EHC connector X83. Repair as necessary.

NOTE: Blade angle actuator (Y30) must be connected when performing this check. Key switch ON. Push and hold lower blade angle button on joystick handle while checking for voltage at YES: Go to Actuator pin 4 (wire H34 BLK) of blade angle actuator (Y30) connector. Ground Circuit Check. Are approximately 5 volts present?

NO: Check circuit H34 for open or short circuit between blade angle actuator and pin 5 of EHC connector X83. TW73308,0000100 -19-26MAR10-32/56

• 6

Actuator Ground Circuit Check

NOTE: For connector and wiring information, see Integrated Grade Control (IGC) Machine Harness (W21) Wiring Diagram—If Equipped. (Group 9015-10.)

Key switch OFF. Disconnect blade angle actuator (Y30) connector. Check for ground at pins 2 and 3 (wire G30 BLK) (harness side) of actuator connector.

YES: See Hydraulic System Diagnose Malfunctions—IGC. (Group 9025-15.) If problem cannot be resolved, contact the grade control equipment supplier or John Deere DTAC.

Is ground present?

NO: Check wire G30 BLK for open circuit between pins 2 and 3 of actuator connector and W20 IGC ground. Repair as necessary. TW73308,0000100 -19-26MAR10-33/56

Blade Lift and Angle Operate Normally, But Blade Incr/Decr Does Not Continued on next page

TM10721 (03SEP14)

9015-20-36

TW73308,0000100 -19-26MAR10-34/56

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=526

References

• 1

Blade Increment/Decrement Switch Check

Turn key switch ON.

Observe the voltage input for the blade increment/decrement switch by accessing the Diagnostic / Live Values / Input Voltages menu in the SDM menu structure. See Standard Display Monitor (SDM) Menu Structure—Service Mode. (Group 9015-16.) Observe increment/decrement switch voltage reading in the SDM menu with no increment/decrement buttons pushed. LOOK: Is the voltage approximately 2.20 volts? Push and hold the increment (upper) button while observing the voltage reading in the SDM menu. LOOK: Is the voltage approximately 3.00 volts? Push and hold the decrement (lower) button while observing the voltage reading in the SDM menu.

YES: Reprogram electrohydraulic controller. If problem persists, replace controller.

LOOK: Is the voltage approximately 0.90 volts?

NO: Go to Blade Increment/Decrement Switch Circuit Check. TW73308,0000100 -19-26MAR10-35/56

• 2

Blade Increment/Decrement Switch Circuit Check

NOTE: For connector and wiring information, see Integrated Grade Control (IGC) Machine Harness (W21) Wiring Diagram—If Equipped and see Integrated Grade Control (IGC) Cab Harness (W22) Wiring Diagram—If Equipped. (Group 9015-10.) Key switch ON. NOTE: Connector X83 must be connected to the electrohydraulic controller (EHC) to perform this check. Check for voltage at pin 21 (wire H20 GRN) of EHC connector X82. Do not push switch YES: Reprogram buttons during this check. electrohydraulic controller. If problem persists, replace controller. Is approximately 2.20 volts present?

NO: Go to next step in this check.

Turn key switch OFF. Disconnect blade control joystick (BCJ) connector X97 and electrohydraulic controller (EHC) connector X82. Check wire H20 GRN for open or short circuit between pin 3 of connector X97 and pin 21 of connector X82.

YES: Repair as necessary.

Is an open or short circuit indicated?

NO: Replace joystick. TW73308,0000100 -19-26MAR10-36/56

Blade Response Is Not Smooth TW73308,0000100 -19-26MAR10-37/56

• 1

Hydraulic Oil Level Check

Check hydraulic oil level.

YES: Add oil as necessary. See Transmission and Hydraulic Oil. (Operator's Manual.)

Is hydraulic oil level low?

NO: Go to Actuator Circuit Check. Continued on next page

TM10721 (03SEP14)

9015-20-37

TW73308,0000100 -19-26MAR10-38/56

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=527

References

• 2

Actuator Circuit Check NOTE: A problem with an actuator circuit will most likely cause a diagnostic trouble code to occur. A flashing red light on the actuator usually indicates a problem with the input signal. A steady red light on the actuator usually indicates an internal malfunction. For connector and wiring information, see Integrated Grade Control (IGC) Machine Harness (W21) Wiring Diagram—If Equipped. (Group 9015-10.) Check wires between affected actuator and electrohydraulic controller (EHC) for intermittent open or short circuit.

YES: Repair wiring of affected actuator circuit as necessary.

Is an open or short circuit indicated?

NO: Go to next step in this check.

Check for ground at pin 3 of affected actuator connector.

YES: Go to CAN Circuit Check.

Is ground present?

NO: Check continuity of wire G30 BLK between pin 3 of affected actuator and W20 IGC ground. Repair as necessary. TW73308,0000100 -19-26MAR10-39/56

• 3

CAN Circuit Check

NOTE: A malfunctioning CAN circuit may cause the symptom “Blade Response Is Not Smooth”, but only in manual mode. A problem with an CAN circuit will most likely cause a diagnostic trouble code to occur. For connector and wiring information, see Integrated Grade Control (IGC) Machine Harness (W21) Wiring Diagram—If Equipped and see Integrated Grade Control (IGC) Cab Harness (W22) Wiring Diagram—If Equipped. (Group 9015-10.) Check if a CAN termination resistor is missing.

YES: Install or replace termination resistor.

Is termination resistor missing?

NO: Go to nest step in this check.

Check for intermittent problem in CAN wiring. See CAN Circuit Test. (Group 9015-20.)

YES: Go to Valve Calibration / Valve Offset and Gain Check (Auto Mode Only).

Is CAN circuit okay?

NO: If problem cannot be resolved, contact the grade control equipment supplier or John Deere DTAC. TW73308,0000100 -19-26MAR10-40/56

• 4

Valve Calibration / Valve Offset and Gain Check (Auto Mode Only)

Depending on supplier, perform either the valve calibration procedure or adjust valve offset and gain procedure per grade control supplier's instructions. Consult documentation provided by the grade control supplier.

YES: Check complete.

Did performing the valve calibration procedure or valve offset and gain set procedure resolve problem?

NO: Go to Actuator Valve Check.

Continued on next page

TM10721 (03SEP14)

9015-20-38

TW73308,0000100 -19-26MAR10-41/56

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=528

References

• 5

Actuator Valve Check

Inspect hydraulic actuator valve of affected circuit for sticking spool or sticking control YES: If problem cannot be valve load sense relief valve. See Hydraulic Control Valve Remove and Install and see resolved, contact the grade Hydraulic Control Valve Disassemble and Assemble—IGC. (Group 3260.) control equipment supplier or John Deere DTAC. Does actuator valve pass inspection?

NO: Repair or replace actuator valve as necessary. TW73308,0000100 -19-26MAR10-42/56

All Blade Functions Are Slow or Sluggish TW73308,0000100 -19-26MAR10-43/56

• 1

Valve Calibration / Valve Offset and Gain Check (Auto Mode Only)

YES: Check complete.

Did performing the valve calibration procedure or valve offset and gain set procedure resolve problem?

NO: Go to Actuator Valve Check. TW73308,0000100 -19-26MAR10-44/56

• 2

Actuator Valve Check

Inspect hydraulic actuator valve of affected circuit for sticking spool or sticking control YES: See Hydraulic valve load sense relief valve. See Hydraulic Control Valve Remove and Install and see System Diagnose Hydraulic Control Valve Disassemble and Assemble—IGC. (Group 3260.) Malfunctions—IGC. (Group 9025-15.) If problem cannot be resolved, contact the grade control equipment supplier or John Deere DTAC. Does actuator valve pass inspection?

NO: Repair or replace actuator valve as necessary. TW73308,0000100 -19-26MAR10-45/56

Blade Response Is Too Fast TW73308,0000100 -19-26MAR10-46/56

• 1

Valve Calibration / Valve Offset and Gain Check (Auto Mode Only)

YES: Check complete.

Did performing the valve calibration procedure or valve offset and gain set procedure resolve problem?

NO: Go to Actuator Valve Check.

Continued on next page

TM10721 (03SEP14)

9015-20-39

TW73308,0000100 -19-26MAR10-47/56

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=529

References

• 2

Actuator Valve Check

NO: Repair or replace actuator valve as necessary. TW73308,0000100 -19-26MAR10-48/56

Blade Moves Quickly (Jumps) to One Side, Then Slowly Comes Back on Grade TW73308,0000100 -19-26MAR10-49/56

• 1

Valve Calibration / Valve Offset and Gain Check (Auto Mode Only)

YES: Check complete.

Did performing the valve calibration procedure or valve offset and gain set procedure resolve problem?

NO: Go to Actuator Circuit Check. TW73308,0000100 -19-26MAR10-50/56

• 2

Actuator Circuit Check NOTE: A problem with an actuator circuit will most likely cause a diagnostic trouble code to occur. When the actuator status light flashes red, the input signal is usually the problem. When the actuator status light is steady red, the problem is usually inside the actuator. For connector and wiring information, see Integrated Grade Control (IGC) Machine Harness (W21) Wiring Diagram—If Equipped. (Group 9015-10.) Check wires between affected actuator and electrohydraulic controller (EHC) for intermittent open or short circuit.

YES: Repair wiring of affected actuator circuit as necessary.

Is an open or short circuit indicated?

NO: Go to next step in this check.

Check for ground at pin 3 of affected actuator.

YES: Go to Actuator Valve Check

Is ground present?

NO: Check continuity of wire G30 BLK between affected actuator and W20 IGC ground. Repair as necessary. TW73308,0000100 -19-26MAR10-51/56

• 3

Actuator Valve Check

NO: Repair or replace actuator valve as necessary. Continued on next page

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450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=530

References Waves in Graded Surface NOTE: When operating in auto mode, this symptom may result from poor reception from satellite or from other guidance equipment. It may also be caused by malfunctioning grade control supplier's equipment. Consult documentation of supplier's grade control equipment. If problem cannot be resolved, contact the grade control equipment supplier or John Deere DTAC. TW73308,0000100 -19-26MAR10-53/56

• 1

Valve Calibration / Valve Offset and Gain Check (Auto Mode Only)

YES: Check complete.

Did performing the valve calibration procedure or valve offset and gain set procedure resolve problem?

NO: Go to Actuator Circuit Check. TW73308,0000100 -19-26MAR10-54/56

• 2

YES: Repair wiring of affected actuator circuit as necessary.

Is an open or short circuit indicated?

NO: Go to next step in this check.

Check for ground at pin 3 affected actuator.

YES: Go to Actuator Valve Check

Is ground present?

NO: Check continuity of wire G30 BLK between affected actuator andW20 IGC ground. Repair as necessary. TW73308,0000100 -19-26MAR10-55/56

• 3

Actuator Valve Check

NO: Repair or replace actuator valve as necessary. TW73308,0000100 -19-26MAR10-56/56

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References

Decelerator/Brake Pedal Adjustment

1.40—1.55 Volts

Low Position Voltage

3.40—3.60 Volts

Brake Position Voltage

3.79—3.99 Volts T198884 —UN—13APR04

SPECIFICATIONS High Position Voltage

ESSENTIAL TOOLS JT07329-1 Test Harness JT07329-3 Test Harness

1. Disconnect harness from decelerator sensor (B1) (1) and connect JT07329-3 test harness between sensor and harness. Connect JT07329-1 test harness to the white and black leads of the JT07329-3 test harness. 2. Turn key switch on measure the sensor DC voltage on a multimeter. Adjust high position stop (2) until reading is within specification. Specification High Position—Voltage...................................................1.40—1.55 Volts

3. Press the decel pedal down to the low position stop. Adjust low position stop (3) until reading is within specification.

1— Decelerator Sensor 2— High Position Stop

3— Low Position Stop 4— Brake Position Stop

4. Press the decel pedal down to the brake stop. Adjust brake position stop (4) until reading is within specification. Specification Brake Position—Voltage.................................................3.79—3.99 Volts

Specification Low Position—Voltage...................................................3.40—3.60 Volts MH66O88,00004F4 -19-01AUG07-1/1

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450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=532

References

TX1135636A —UN—29APR13

Engine Speed Control Remove and Install

Engine Speed Control Components 1— Knob 2— Push Nut (2 used) 3— Stop Tab 4— Nut (included with engine speed control)

5— Stop Plate 8— Engine Speed Control 6— Plate 7— Washer (included with engine speed control)

SPECIFICATIONS Engine Speed Control Nut Torque

NOTE: Install switch as shown, knob indicator must align with decal on plate.

2.7 N·m 24 lb.-in.

1. Remove screws from left console to gain access to engine speed control (8) electrical connector. 2. Disconnect engine speed control electrical connector. NOTE: Engine speed control assembly on machines (S.N. —231752) used only one push nut (2). For these machines, order one additional R78035 Push Nut and assemble engine speed control assembly as shown.

5. Install engine speed control, plate, washer, and nut. Tighten nut to specification. Specification Engine Speed Control Nut—Torque.................................................................................2.7 N·m 24 lb.-in.

6. Install stop plate, push nut, stop tab, push nut, and knob. If engine speed control assembly was assembled with only one push nut, order one additional R78035 Push Nut and assemble engine speed control assembly as shown.

3. Remove knob (1), push nut (2), stop tab (3), push nut (2), stop plate (5), nut (4), washer (7), plate (6), and engine speed control (8). 4. Repair or replace parts as necessary.

7. Install engine speed control into left console. KK70125,000008F -19-29APR13-1/1

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450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=533

References

Rotary Sensor Remove and Install

SPECIFICATIONS 5 N·m 48 lb-in.

1. To ease removal and installation, remove the Transmission Control Lever (TCL) or decelerator assembly. See Transmission Control Lever (TCL) Remove and Install (Group 0315.) or

T199285 —UN—19APR04

Rotary Sensor Mounting Cap Screws Torque

2. Remove the two cap screws and sensor (2). 3. Install O-ring (3) if needed. Rotary Sensor Remove and Install (Steer Sensor shown)

4. Position sensor (2) at about a 4 o'clock position to install sensor on keyed shaft (1). 5. Twist sensor to line up sensor with mounting holes.

1— Shaft 2— Sensor

3— O-Ring

6. Install cap screws and tighten to specification. Specification Rotary Sensor Mounting Cap Screws—Torque......................................................................5 N·m 48 lb-in.

7. Install the TCL or decelerator assembly.

MH66O88,00004F5 -19-11JAN07-1/1

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450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=534

References

Transmission Control Lever (TCL) Adjustment SPECIFICATIONS Neutral Adjustments Steer Input—Neutral Voltage

2.48—2.52 V

FNR Input—Neutral Voltage

2.37—2.63 V

Steer Linkage Adjustment Steer Linkage—Right Voltage

1.62—1.94 V

Steer Linkage—Right Counter-Rotate Voltage

1.43—1.75 V

Steer Linkage—Left Voltage

3.06—3.38 V

Steer Linkage—Left Counter-Rotate Voltage

3.25—3.57 V

TCL Linkage Adjustments TCL Linkage—Forward Position Voltage

3.09—3.95 V

TCL Linkage—Reverse Position Voltage

1.05—1.91 V

ESSENTIAL TOOLS JT07237-1 Test Harness T118886B —UN—09DEC98

JT07329-3 Test Harness

This procedure is used to adjust the steer sensor linkage and TCL sensor linkage to provide the correct voltage for the rotary sensors. 1. Key switch on, engine off. 2. Press and hold the MENU button on the SDM until three beeps are heard and Service Mode flashes. 3. Select DIAGNOSTICS from the SDM main menu. 4. Select LIVE VALUES from the diagnostics submenu. Push NEXT until STEER is displayed. The steer input voltage must be as specified. Neutral Adjustments—Specification Steer Input—Neutral—Voltage........................................................................ 2.48—2.52 V

5. Push NEXT button until FNR appears. FNR input voltage in neutral position must be as specified. Neutral Adjustments—Specification FNR Input—Neutral—Voltage........................................................................ 2.37—2.63 V

6. If voltages are not to specification, remove SLC assembly from machine. Steer Linkage Adjustment—Procedure adjusts the steer linkage. 1. Install JT07329-3 test harness (1) to machine harness and to steer sensor (2). Connect JT07237-1 test harness to the white and black leads of the JT07329-3 test harness.

1— JT07329-3 Test Harness 2— Steer Sensor 3— Lock Nut

4— Rod Assembly 5— TCL Sensor

3. Move steer lever to right steer position. Do not go into counter-rotate. Voltage must be as specified. Steer Linkage Adjustment—Specification Steer Linkage—Right—Voltage........................................................... 1.62—1.94 V

4. Move steer lever to right counter-rotate position. Voltage must be as specified. Steer Linkage Adjustment—Specification Steer Linkage—Right CounterRotate—Voltage.................................................................. 1.43—1.75 V

5. Move steer lever to left steer position. Do not go into counter-rotate. Voltage must be as specified. Steer Linkage Adjustment—Specification Steer Linkage—Left—Voltage............................................................. 3.06—3.38 V

2. Loosen lock nut (3) from ball joint. Turn rod assembly (4) while monitoring the STEER input reading on the SDM. Adjust to specification and tighten lock nut. Continued on next page

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450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=535

References

6. Move steer lever to left counter-rotate position. Voltage must be as specified.

9. Route all wiring harnesses back to their original location and replace all tie bands that were removed.

Steer Linkage Adjustment—Specification Steer Linkage—Left CounterRotate—Voltage.................................................................. 3.25—3.57 V

NOTE: Recalibrate whenever control linkages are adjusted or replaced.

7. If voltage is not to specification, calibrate machine and recheck voltage. If voltage is still not to specification, replace sensor.

TCL Linkage Adjustment—Procedure adjusts the TCL linkage.

8. If no voltage can be recorded, see Transmission Control Unit (TCU) Circuit Theory of Operation. (Group 9015-15.) KV70328,000025B -19-27AUG07-2/3

1. Install JT07329-3 test harness to FNR sensor. Connect JT07237-1 test harness to the white and black leads of the JT07329-3 test harness.. 2. Remove nut (7) and ball joint (8). Loosen lock nut (6) and adjust to specification. 3. Move transmission control lever to forward position. Voltage must be as specified. TCL Linkage Adjustments—Specification TCL Linkage—Forward Position—Voltage................................................................ 3.09—3.95 V

4. Move transmission control lever to reverse position. Voltage must be as specified. TCL Linkage Adjustments—Specification TCL Linkage—Reverse Position—Voltage................................................................ 1.05—1.91 V

T118887B —UN—09DEC98

5. If voltage cannot be adjusted to specification, verify sensor is installed correctly. See Rotary Sensor Remove and Install. (Group 9015-20.) 6. If no voltage can be recorded, see Transmission Control Unit (TCU) Circuit Theory of Operation. (Group 9015-15.) 7. Route all wiring harnesses back to their original location and replace all tie bands that were removed. NOTE: Recalibrate whenever control linkages are adjusted or replaced. 6— Lock Nut 7— Nut

8— Ball Joint

KV70328,000025B -19-27AUG07-3/3

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450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=536

References

Replace WEATHER PACK™ Connector

1. Open connector body. 2. Insert JDG364 Extraction Tool over terminal contact in connector body. 3. Hold extractor tool fully seated and pull wire from connector body.

TS0128 —UN—23AUG88

IMPORTANT: Identify wire color locations with connector terminal letters.

NOTE: If terminal cannot be removed, insert wire or nail through extractor tool handle and push terminal contact from connector. WEATHER PACK is a trademark of Packard Electric. DX,ECONN,O -19-03NOV94-1/2

IMPORTANT: Carefully spread contact lances to assure good seating on connector body.

4. Push contact into new connector body until fully seated. 5. Pull on wire slightly to be certain contact is locked in place. 6. Transfer remaining wires to correct terminal in new connector.

TS0130 —UN—23AUG88

NOTE: Connector bodies are "keyed" for proper contact mating. Be sure contacts are in proper alignment.

7. Close connector body. DX,ECONN,O -19-03NOV94-2/2

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450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=537

References

Install WEATHER PACK™ Contact

• Green - 18 to 20 gauge wire • Gray - 14 to 16 gauge wire • Blue - 10 to 12 gauge wire 1. Slip correct size cable seal on wire. 2. Strip insulation from wire to expose 6 mm (1/4 in.) and align cable seal with edge of insulation.

TS0136 —UN—23AUG88

NOTE: Cable seals are color coded for three sizes of wire:

NOTE: Contacts have numbered identification for two sizes of wire: a) #15 for 14 to 16 gauge wire b) #19 for 18 to 20 gauge wire

TS1623 —UN—02NOV94

3. Put proper size contact on wire and crimp in place with a "W" type crimp, using JDG783 Terminal Applicator.

WEATHER PACK is a trademark of Packard Electric. DX,ECONN,AA -19-04JUN90-1/2

IMPORTANT: Proper contact installation for "sleeve" (A) and "pin” (B) is shown.

TS0139 —UN—02DEC88

4. Secure cable seal to contact as shown, using JDG783 Terminal Applicator.

DX,ECONN,AA -19-04JUN90-2/2

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450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=538

References

Replace DEUTSCH™ Connectors

• JDG361 Extractor Tool for 12 to 14 gauge wire. • JDG362 Extractor Tool for 16 to 18 gauge wire. • JDG363 Extractor Tool for 20 gauge wire. 2. Start correct size extractor tool over wire at handle (A). 3. Slide extractor tool rearward along wire until tool tip snaps onto wire.

TS0124 —UN—23AUG88

1. Select correct size extractor tool for size of wire to be removed:

IMPORTANT: Do NOT twist tool when inserting in connector.

5. Pull wire out of connector body, using extractor tool.

TS120 —UN—23AUG88

4. Slide extractor tool along wire into connector body until it is positioned over terminal contact.

DEUTSCH is a trademark of the Deutsch Co. DX,ECONN,J -19-03NOV94-1/2

IMPORTANT: Install contact in proper location using correct size grommet.

7. Pull on wire slightly to be certain contact is locked in place. 8. Transfer remaining wires to correct terminal in new connector.

TS122 —UN—23AUG88

6. Push contact straight into connector body until positive stop is felt.

DX,ECONN,J -19-03NOV94-2/2

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450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=539

References

NOTE: Connector shown is the female half or a 4-pin square connector. Other similar styles of Deutsch connectors can be serviced using the same procedure. 1.

Pull connector (1) apart. Inspect and clean connector seal and contacts.

2. Remove locking wedge (2) from connector using hook on JDG1383 service tool. 1— Connector

T130688B —UN—01MAY00

Replace DEUTSCH™ Rectangular or Triangular Connectors

2— Locking Wedge

DEUTSCH is a trademark of Deutsch Co. CED,TX17994,305 -19-24APR00-1/2

Release primary locking latch (3) next to the pin to be removed using screwdriver on JDG1383 service tool.

5. Replace connector contact as necessary. See Install Deutsch Contact. (Group 9015-20.) 6. Install wire terminal back into connector until it clicks into place. NOTE: Locking wedge in 2-pin connector is not symmetrical. Position latch shoulder next to terminals.

T130689B —UN—01MAY00

4. Gently pull wire out from back of connector.

7. Install locking wedge until it snaps into place.

T130690B —UN—01MAY00

3— Primary Locking Latches

CED,TX17994,305 -19-24APR00-2/2

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450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=540

References

Install DEUTSCH™ Contact 1. Strip 6 mm (1/4 in.) insulation from wire. 2. Adjust selector (A) on JDG360 Crimper for correct wire size. TS117 —UN—23AUG88

3. Loosen lock nut (B) and turn adjusting screw (C) in until it stops.

DEUTSCH is a trademark of the Deutsch Co. DX,ECONN,W -19-04JUN90-1/4

IMPORTANT: Select proper size contact "sleeve" or "pin" to fit connector body. 4. Insert contact (A) and turn adjusting screw (D) until contact is flush with cover (B). TS0134 —UN—23AUG88

5. Tighten lock nut (C).

DX,ECONN,W -19-04JUN90-2/4

IMPORTANT: Contact must remain centered between indentors while crimping. 6. Insert wire in contact and crimp until handle touches stop. TS118 —UN—23AUG88

7. Release handle and remove contact.

Continued on next page

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450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=541

References

IMPORTANT: If all wire strands are not crimped into contact, cut off wire at contact and repeat contact installation procedures.

TS0135 —UN—23AUG88

NOTE: Readjust crimping tool for each crimping procedure. 8. Inspect contact to be certain all wires are in crimped barrel.

DX,ECONN,W -19-04JUN90-4/4

Repair 32 and 48 Way CINCH™ Connectors 1. Push tab (A) and rotate locking cam (B) 90° to disconnect connector from flexbox. RXA0070459 —UN—10SEP03

2. Move cover locks (C) slightly outward with a small screwdriver. 3. Remove cover (D) away from wires. C—Cover Locks D—Cover

RXA0070463 —UN—10SEP03

RXA0070462 —UN—10SEP03

A—Tab B—Locking Cam

Continued on next page

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References

4. Pull terminal lock (A) out until it stops. Do not force its removal.

RXA0070464 —UN—10SEP03

A—Terminal Lock

MH66O88,0000502 -19-16JAN07-2/4

NOTE: JDG1725 terminal extractor tool has two different sizes of pins: 0.6 for smaller 20 gauge holes (A) and 1.5 for larger 16 and 18 gauge holes (B). RXA0070471 —UN—10SEP03

5. Insert JDG1725 Terminal Extractor Tool into holes (C) next to terminal opening (D) to unlock terminal. 6. Pull wire and terminal (E) from connector body. D—Terminal Hole E—Terminal

RXA0070473 —UN—10SEP03

RXA0070472 —UN—10SEP03

A—20 Gauge Holes B—16 and 18 Gauge Holes C—Holes

Continued on next page

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References

8. Firmly grip JDG1727 terminal crimping tool (A). Squeeze ratcheting mechanism until it bottoms out, then allow it to open completely. 9. With tool in ready position (open handle), open terminal receptacle (B). 10. Insert terminal (C) into correct wire gauge window so crimp wings are facing up. 11. Close terminal receptacle (B).

RXA0070479 —UN—10SEP03

7. Remove old terminal and strip 4.85 mm (0.191 in.) of insulation from wire.

12. Squeeze handle until two clicks are heard.

14. Hold wire stationary and squeeze tool together until ratchet releases. 15. Remove terminated wire from tool. 16. Push terminal into connector body until fully seated. Pull on wire slightly to ensure terminal is locked in position. 17. Push terminal lock closed.

RXA0070480 —UN—10SEP03

13. Insert stripped wire (D) into terminal.

18. Install cover. 19. Install connector to controller and close connector body locking cam. C—Terminal D—Wire

RXA0070481 —UN—10SEP03

A—CINCH Terminal Crimping Tool B—Terminal Receptacle

MH66O88,0000502 -19-16JAN07-4/4

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References

Replace (Pull Type) Metri-Pack™ Connectors

Insert a “T” pin (B) 6.4 mm (1/4 in.) into connector body socket (C). NOTE: Use JDG7772 Terminal Extraction Tool or “T” pin to remove terminals. Angle “T” pin so pin tip slides close to the plastic socket edge pushing terminal locking tab (D) inward.

RW16933 —UN—26APR89

Disconnect the Metri-Pack1 connector (A). Remove tie bands and tape.

Remove “T” pin and push terminal (E) out of socket.

Check to make sure locking tab on new terminal is in outward position, then pull on wire until terminal locks in connector body socket. NOTE: Terminal will seat only one way. If terminal does not pull into the connector body socket, check to make sure terminal is aligned correctly. D—Locking Tab E—Push Terminal

RW16935 —UN—26APR89

A—Connector B—“T” Pin C—Body Socket

RW16934 —UN—26APR89

Remove terminal, cut strip and crimp wire through connector.

Metri-Pack is a trademark of Packard Electric Included in JT07195A Electrical Repair Kit

LW86157,00003B5 -19-08FEB08-1/1

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References

Replace (Push Type) Metri-Pack™ Connectors Disconnect the Metri-Pack1 connector. Remove the tie bands and tape. RW21325 —UN—29JUN92

Remove the connector lock (A), and mark wire colors for identification. Identify wire color locations with connector terminal letters. Insert JDG776 or JDG7772 Terminal Extraction Tool (B) into connector body socket (C) pushing the terminal locking tab inward. NOTE: Use JDG776 Extraction Tool with 56, 280 and 630 series METRI-PACK terminals. Use JDG777 Extraction Tool with 150 series METRI-PACK terminals. Remove extraction tool and pull terminal (D) out of the socket. Replace terminal. Make sure locking tab (E) on the new terminal is in the outward position.

A—Connector Lock B—Extraction Tool JDG777 C—Connector Body Socket

D—Terminal E—Locking Tab

Push terminal into connector body socket until terminal locks.

Metri-Pack is a trademark of Packard Electric Included in JT07195A Electrical Repair Kit

LW86157,00003B6 -19-08FEB08-1/1

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Section 9025 Hydraulic System Contents Page Page

Group 05—Theory of Operation Hydraulic System Operation...................... 9025-05-1 Hydraulic Pump Operation ........................ 9025-05-2 Hydraulic Pump and Reservoir Operation............................................... 9025-05-3 Hydraulic Filter Operation.......................... 9025-05-5 Hydraulic Control Valve Operation............................................... 9025-05-9 Hydraulic System Relief Valve Operation............................................. 9025-05-10 Inlet Valve Operation ............................... 9025-05-12 Auxiliary Valve Operation ........................ 9025-05-14 Blade Lift Valve Operation ....................... 9025-05-16 Blade Angle Valve Operation................... 9025-05-18 Blade Tilt Valve Operation ....................... 9025-05-20 Outlet Valve Cover Operation.................. 9025-05-21 Hydraulic Control Valve Operation—IGC................................... 9025-05-22 Hydraulic Cylinder Operation................... 9025-05-26 Group 15—Diagnostic Information Hydraulic System Schematic..................... 9025-15-1 Hydraulic System Schematic—IGC.................................... 9025-15-4 Hydraulic Component Location ................. 9025-15-7 Hydraulic Component Location—IGC ..................................... 9025-15-14 Ripper Hydraulic Component Location ............................................... 9025-15-20 Hydraulic System Diagnose Malfunctions ........................................9025-15-16 No Hydraulic Functions Diagnostic Procedure............................................9025-15-16 Hydraulic Functions Slow Diagnostic Procedure............................................9025-15-16 Hydraulic Pump Noisy Diagnostic Procedure............................................9025-15-18 Blade Float Does Not Work Diagnostic Procedure............................................9025-15-19 One Hydraulic Function Does Not Work Diagnostic Procedure ................9025-15-19 Function Drifts Down Diagnostic Procedure............................................9025-15-20 Oil Overheats Diagnostic Procedure............................................9025-15-21 Hydraulic System Diagnose Malfunctions—IGC ..............................9025-15-24 No Hydraulic Functions Diagnostic Procedure—IGC..................................9025-15-24 Hydraulic Functions Slow Diagnostic Procedure—IGC..................................9025-15-25 Blade Float Does Not Work Diagnostic Procedure—IGC..................................9025-15-27

TM10721 (03SEP14)

One Hydraulic Function Does Not Work Diagnostic Procedure—IGC................9025-15-27 Hydraulic Power Low Diagnostic Procedure—IGC..................................9025-15-28 Function Drifts Down Diagnostic Procedure—IGC..................................9025-15-29 Oil Overheats Diagnostic Procedure—IGC..................................9025-15-30 Blade Response Not Smooth Diagnostic Procedure—IGC................9025-15-31 Group 20—Adjustments Hydraulic Control Lever Linkage Adjustment............................................. 9025-20-1 Auxiliary Lever Linkage Adjustment............................................. 9025-20-3 Blade Pitch Linkage Adjustment................ 9025-20-4 Group 25—Tests Hydraulic Oil Warm-Up Procedure .............................................. 9025-25-1 Hydraulic Oil Sampling Procedure—If Equipped ........................ 9025-25-1 Hydraulic Pump Flow Test ......................... 9025-25-1 Hydraulic System Relief Valve Test ........................................................ 9025-25-3 Hydraulic System Relief Valve Test—IGC .............................................. 9025-25-4 Circuit Relief Valve Test—With Remote Pump........................................ 9025-25-5 Hydraulic Pump Cycle Time Test............... 9025-25-6 Lift Cylinder Drift Test ................................ 9025-25-6 Cylinder Leakage Test ............................... 9025-25-7 Oil Clean-up Procedure ............................. 9025-25-8

9025-1

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=1

Contents

TM10721 (03SEP14)

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Group 05

Theory of Operation Hydraulic System Operation This machine has an open-center hydraulic system. Oil flows from the sealed hydraulic reservoir to the hydraulic external gear pump. The pump is bolted to, and driven through, the hydrostatic pump stack. Oil from the hydraulic pump flows to the inlet of the control valve. The control valve is an open-center, three-spool stack-type valve. Sections are connected in parallel, permitting multiple dozer functions to be used at the same time. The valve controls the blade lift, angle, and tilt functions. On these machines a fourth auxiliary section can be added for use with rear-mounted equipment. Each section contains a lift check poppet to prevent oil on the actuated side of a cylinder from flowing back through the valve section. The lift check poppets also prevent interaction between actuated sections.

The blade lift section contains a detent to hold the spool in the float position. The spool must be manually released from the float (detent) position. With no function actuated (neutral spools), all oil is directed to the outlet section outlet port by the valve spool. This oil flows through a hydraulic oil cooler or directly to the return oil filter and back to the hydraulic oil reservoir. When a function is activated, oil flow through the open-center passage is restricted or stopped. Oil flows through the valve section to work port and cylinder. Oil from the cylinder is forced back to the other work port, through the control valve return passage, out the outlet section return port through a hydraulic oil cooler or directly to the return oil filter and then back to the hydraulic oil reservoir.

The inlet section contains a system relief valve. This section also contains a hydraulic test port to check oil pressure. SW03989,00001DD -19-07DEC07-1/1

TM10721 (03SEP14)

9025-05-1

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=549

Theory of Operation

Hydraulic Pump Operation 1

T197407 —UN—26JAN04

4 5

T197407 Drive-Thru Pump 1— Pump Inlet 2— Pump Output Drive-Thru Shaft (optional)

3— Pump Outlet 4— Pressure Oil

5— Inlet Oil from Reservoir

The hydraulic pump is a fixed displacement external gear-type pump. The pump is mounted to and driven by the rear hydrostatic transmission pump. The pump draws

its inlet oil (5) from the hydraulic reservoir and directs oil to the control valve. An optional drive-thru shaft (2) is used to operate a winch. CED,TX03768,2298 -19-05MAR04-1/1

TM10721 (03SEP14)

9025-05-2

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=550

Theory of Operation

Hydraulic Pump and Reservoir Operation NOTE: Later models revised cooler return oil to go directly to reservoir instead of to oil filter. See Hydraulic

Component Location, or See Hydraulic Component Location—IGC. (Group 9025-15.)

2 3 4 1 5

7 9

10 13 14

TX1033209 —UN—05MAY11

TX1033209 Hydraulic Pump and Reservoir Operation (earlier models) Continued on next page

TM10721 (03SEP14)

9025-05-3

SW03989,00001DE -19-09MAR10-1/2

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=551

Theory of Operation 1— Hydraulic Control Valve 2— Hydraulic Oil Filter 3— Cleanout Access Cover 4— Reservoir Oil Fill Cap

5— Hydraulic Reservoir 6— Return Oil Tube 7— Drain Port 8— Suction Hose 9— Pressure Hose

The hydraulic pump (10) is an external gear pump mounted to the rear end of the tandem hydrostatic pump assemblies. The tandem hydrostatic pump assemblies are mounted to the rear of the engine. Low pressure oil (15) is routed to the pump by a suction hose (8). Pressure oil (13) is routed by a pressure hose (9) to the inlet port of the hydraulic control valve (1). The control valve is located in a compartment on the right side of the operator cab in front of the hydraulic reservoir (5). A service door on the right side of the operator cab provides access to a number of hydraulic components. The control valve is an open-center design that continually directs return oil either through the hydraulic oil cooler (12) and then to, or directly to, the hydraulic oil filter (2). Later models route all cooler oil directly to the reservoir and is not filtered. In addition an orifice was added in cooler return line to cooler from the control valve. See Hydraulic Component Location, or see Hydraulic Component Location—IGC. (Group 9025-15.)

10— Hydraulic Pump 11— Return Oil from the Hydraulic Oil Cooler 12— Return Oil to the Hydraulic Oil Cooler

13— Pressure Oil 14— Return Oil 15— Low Pressure Oil

The hydraulic filter is a spin-on type, vertically mounted in the service compartment. Return oil then enters the hydraulic reservoir through the return oil tube (6) that is welded through the front panel of the reservoir and extends in and down, close to the bottom of the reservoir. The hydraulic reservoir is a welded assembly with a bolt-on cleanout access cover (3), which is sealed with a gasket. The cleanout access cover is located on the front panel of the reservoir with access through the service door. The reservoir oil fill cap (4) is located on the right side of the hydraulic reservoir. The oil level sight gauge is inside the service compartment, next to the hydraulic filter. A drain port (7) is also located at the bottom of the front panel of the reservoir. Access to the drain is made through the service door and an access panel on the bottom of the hydraulic service compartment. SW03989,00001DE -19-09MAR10-2/2

TM10721 (03SEP14)

9025-05-4

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=552

Theory of Operation

Hydraulic Filter Operation Filter Operation—Normal (S.N. —180554)

T197418

T197418 —UN—26JAN04

SECTION A-A

7 Filter Operation—Normal (S.N. —180554)

1— High Pressure Passage 2— Low Pressure Passage

3— Filter Restriction Indicator Switch 4— Switch Spring

5— Bypass Valve 6— Hydraulic Filter Element 7— Return Oil

to line restriction is sensed on the left side of the bypass valve by the high pressure passage (1).

The hydraulic filter element (6) removes contaminants from the hydraulic system return oil. The filter housing contains a filter bypass valve (5) and a filter restriction indicator switch (3).

Pressure in the outlet passage and the bypass valve spring force hold the valve closed.

Return oil (7) flows from the hydraulic control valve, through the hydraulic oil cooler to the filter inlet (8), or directly into the filter inlet, through the hydraulic filter element (6), and out the filter outlet (9) to the hydraulic reservoir. Pressure on the inlet side of the filter element is sensed by the low pressure passage (2) on the right side of the bypass valve. Any pressure at the filter outlet due

As the filter starts to plug, pressure at the filter inlet increases. When the filter becomes restricted to the point where pressure at the filter inlet increases enough to overcome outlet pressure plus bypass valve spring force, the bypass valve opens, allowing unfiltered oil to flow to the reservoir.

Continued on next page

TM10721 (03SEP14)

8— Inlet 9— Outlet

9025-05-5

SW03989,00001DF -19-04FEB10-1/4

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=553

Theory of Operation Filter Operation—Restricted (S.N. —180554)

1 3

2 10 9

T197427 —UN—03FEB04

SECTION A-A

7 8

T197427 Filter Operation—Restricted (S.N. —180554) 1— High Pressure Passage 2— Low Pressure Passage 3— Filter Restriction Indicator Switch

4— Switch Spring 5— Bypass Valve 6— Filter Element

7— Return Oil 8— Restricted Oil Flow 9— Inlet 10— Outlet

Filter restriction indicator switch (3) works on same principle as the filter bypass valve. High pressure oil is sensed through the high pressure passage (1). Restricted oil flow (8) caused by a clogged filter element (6) will create higher oil pressure on the inlet side. When this inlet pressure overcomes outlet pressure plus switch spring (4) force, the switch moves right (closes) providing

a ground for the filter restriction indicator. The switch causes an indicator light on the standard display monitor (SDM) to illuminate. The filter restriction indicator switch is set to close at 68 kPa (0.7 bar) (10 psi) before the bypass valve opens. This will allow the operator to perform maintenance of hydraulic system before unclean oil passes through hydraulic oil system.

Continued on next page

TM10721 (03SEP14)

9025-05-6

SW03989,00001DF -19-04FEB10-2/4

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=554

Theory of Operation Filter Operation—Normal (S.N. 180555— )

B 1

2 8

B-B B 604 TX1068328

TX1068328 —UN—10DEC09

Filter Operation—Normal (S.N. 180555— ) 1— High Pressure Passage 2— Low Pressure Passage

3— Filter Restriction Indicator Switch 4— Switch Spring

5— Bypass Valve 6— Filter Element 7— Filter Head

to line restriction is sensed on the left side of the bypass valve by the high pressure passage (1).

The hydraulic filter element (6) removes contaminants from the hydraulic system return oil. The filter head (7) contains a filter bypass valve (5) and a filter restriction indicator switch (3).

Pressure in the outlet passage and the bypass valve spring force holds the bypass valve closed.

Return oil (604) flows from the hydraulic control valve, through the hydraulic oil cooler to the filter inlet (8), or directly into the filter inlet, through the hydraulic filter element (6), and out the filter outlet (9) to the hydraulic reservoir. Pressure on the inlet side of the filter element is sensed by the low pressure passage (2) on the right side of the bypass valve. Any pressure at the filter outlet due

Continued on next page

TM10721 (03SEP14)

8— Inlet 9— Outlet 604— Return Oil

9025-05-7

SW03989,00001DF -19-04FEB10-3/4

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=555

Theory of Operation Filter Operation—Restricted (S.N. 180555— )

B-B 602 B

604

TX1068329

TX1068329 —UN—10DEC09

Filter Operation—Restricted (S.N. 180555— ) 1— High Pressure Passage 2— Low Pressure Passage 3— Filter Restriction Indicator Switch

8— Inlet 9— Outlet 602— Restricted Oil Flow 604— Return Oil

4— Switch Spring 5— Bypass Valve 6— Filter Element 7— Filter Head

Filter restriction indicator switch (3) works on same principle as the filter bypass valve (5). High pressure oil is sensed through the high pressure passage (1). Restricted oil flow (602) caused by a clogged filter element (6) will create higher oil pressure on the inlet (8) side. When this inlet pressure overcomes outlet pressure plus switch spring (4) force, the switch moves right (closes) providing a ground for the filter restriction indicator switch. The

switch causes an indicator light on the standard display monitor (SDM) to illuminate. The filter restriction indicator switch is set to close at 68 kPa (0.7 bar) (10 psi) before the bypass valve opens. This allows the operator to perform maintenance of hydraulic system before unclean oil passes through hydraulic oil system. SW03989,00001DF -19-04FEB10-4/4

TM10721 (03SEP14)

9025-05-8

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=556

Theory of Operation

Hydraulic Control Valve Operation 8 9

3 4 TX1036232 —UN—11FEB08

6 7 TX1036232

8 Hydraulic Control Valve (Optional Auxiliary Section Shown)

1— System Relief Valve 2— Outlet Section 3— Blade Lift Section

4— Blade Tilt Section 5— Blade Angle Section 6— Auxiliary Section (optional)

The control valve assembly is located below the 6-way blade control handle. The control valve is sectionalized for flexibility of adding additional functions. The blade lift section (3) has a detent position to obtain blade float condition. An optional auxiliary section (6) can be installed and fitted with its own circuit relief valves (9) to operate additional functions such as a ripper or winch. The inlet

7— Inlet Section 8— Blade Angle Circuit Relief Valve (2 used) 9— Auxiliary Circuit Relief Valve (optional)

section (7) contains a system relief valve (1) and a port for checking hydraulic pressure. The outlet section sends oil to cooler and oil filter and then to reservoir. Later models send cooler oil directly to reservoir and is not filtered. See Hydraulic Component Location (Group 9025-15.) for location of hydraulic control valve. OUO1020,00015FD -19-02MAR10-1/1

TM10721 (03SEP14)

9025-05-9

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=557

Theory of Operation

Hydraulic System Relief Valve Operation

2 9 3

T213862 —UN—26MAR10

T213862 System Relief Valve

Continued on next page

TM10721 (03SEP14)

9025-05-10

OUO1020,0001604 -19-30JAN07-1/2

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=558

Theory of Operation 1— Valve Plug 2— O-Ring (3 used) 3— Adjusting Screw

4— Lock Nut 5— Back-Up Ring 6— Spring 7— Seal

8— Valve Poppet 9— Valve Body 10— Flat Washer

The relief valve is direct acting, and screw adjustable. It does not have anticavitation operation. The pressure set point is adjusted by loosening the lock nut (4) and adjusting screw (3). Turn the screw in to increase pressure setting.

11— Return Oil 12— Pressure Oil

In relief operation, when the pressure difference is great enough to overcome the force applied on the valve poppet (8), pressure oil (12) overcomes the valve poppet and oil flows from the pressurized oil to return oil (11). OUO1020,0001604 -19-30JAN07-2/2

TM10721 (03SEP14)

9025-05-11

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=559

Theory of Operation

Inlet Valve Operation 3

4 3

T197433 —UN—30MAR04

T197433 Inlet Valve 1— Plug 2— Inlet Port 3— Parallel Passage

4— System Relief Valve 5— Return Oil Passage

The inlet valve section contains the system relief valve (4) and an optional return port blocked with a plug (1). The inlet port (2) supplies oil to the control valve through

6— Pressure Oil 7— Return Oil

neutral and parallel passages (3), as well as the system relief valve (4). The return oil passage (5) receives oil from the control valve and system relief valve (when relieving). MR50960,0000105 -19-03MAY06-1/1

TM10721 (03SEP14)

9025-05-12

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=560

Theory of Operation

TM10721 (03SEP14)

9025-05-13

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=561

Theory of Operation

Auxiliary Valve Operation 4

2 1

7 10 11

T197434

T197434 —UN—03FEB04

Auxiliary Valve—Neutral Position (no other function activated)

Continued on next page

TM10721 (03SEP14)

9025-05-14

MR50960,0000102 -19-03MAY06-1/2

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=562

Theory of Operation 1— Workport 2— Parallel Passage 3— Load Check 4— Bridge Passage

5— Workport 6— Shutoff Plug (2 used) 7— Thru-Neutral Passage

The auxiliary valve is a three-position, four-way, spool-type valve containing a load check (3) and two shutoff plugs (6), in place of relief valves. Shutoff plugs may be replaced with circuit relief valves. The valve spool is returned to neutral by a centering spring in spool end cap. When the spool is moved to activate a function, oil flows from the parallel passage (2), past the load check (3),

8— Return Oil Passage 9— Spool 10— Return Oil 11— Trapped Oil

spool (9), and out the workport (5) to the cylinders. Return oil from the cylinders flow into the other workport, past the spool (9), into the return oil passage (8), then out of the control valve to the system reservoir. The spool (9) has grooves that meter oil through the valve to allow smooth starts and stops. MR50960,0000102 -19-03MAY06-2/2

TM10721 (03SEP14)

9025-05-15

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=563

Theory of Operation

Blade Lift Valve Operation 4

2 5 7 A B

7 10 11

TX1003171

TX1003171 —UN—26SEP06

Blade Lift Valve--Lift Position (no other functions activated)

Continued on next page

TM10721 (03SEP14)

9025-05-16

CED,TX03768,2305 -19-27JAN06-1/2

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=564

Theory of Operation 1— Blade Lower Workport 2— Parallel Passage 3— Load Check

4— Bridge Passage 5— Blade Lift Workport 6— Valve Spool End Cap (with detent)

7— Neutral Passage 8— Return Oil Passage 9— Spool 10— Pressure Oil

11— Return Oil

The blade lift valve is a four-position, four-way, spool-type valve containing a load check (3). The valve spool is returned to neutral by a centering spring in the spool end cap except when the spool is in the float (detent) position.

the spool (9), into the return passage (8), and out of the control valve to the system reservoir. The spool (9) has grooves that meter the oil through the valve to allow smooth starts and stops.

When the spool is moved to activate a function, oil flows from the parallel passage (2), past the load check (3), spool (9), and out the workport to the cylinders. Return oil from the cylinders flow into the other workport, past

When the spool is moved to the blade float (spool out) position, both workports (1 and 5) are open to the return passage (8), thus allowing oil to flow in and out both ends of the cylinders. CED,TX03768,2305 -19-27JAN06-2/2

TM10721 (03SEP14)

9025-05-17

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=565

Theory of Operation

Blade Angle Valve Operation 3

7 4

A B

2 1

9 10

T197443

T197443 —UN—30MAR04

Blade Angle Valve—Right Angle Position

Continued on next page

TM10721 (03SEP14)

9025-05-18

SW03989,00001E0 -19-07DEC07-1/2

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=566

Theory of Operation 1— Blade Angle Left Work port 2— Parallel Passage 3— Load Check

4— Bridge Passage 5— Blade Angle Right Work port 6— Spool 7— Neutral Passage

The blade angle valve is a three-position, four-way spool-type valve containing a load check (3). The valve spool is returned to neutral by a centering spring in the spool end cap. When the spool is moved to activate a function, oil pressure is increased by closing off the neutral passage (7). Oil flows from the parallel passage (2), past the load check (3) into the bridge passage (4), past the spool (6),

8— Return Oil Passage 9— Pressure Oil 10— Return Oil 11— Circuit Relief Valve with Anticavitation (2 used)

and out through the work port to the cylinders. Return oil from the cylinders flows into the other work port, past the spool, into the return oil passage (8), then out the control valve to the hydraulic reservoir. The spool has grooves that meter oil through the valve to allow smooth starts and stops. Work port circuit relief valves with anticavitation (11) are provided for protection of the angle circuit. SW03989,00001E0 -19-07DEC07-2/2

TM10721 (03SEP14)

9025-05-19

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=567

Theory of Operation

Blade Tilt Valve Operation 3

5 7 A 2

T197444

T197444 —UN—26JAN04

Blade Tilt Valve—Tilt Right Position

Continued on next page

TM10721 (03SEP14)

9025-05-20

CED,TX03768,2293 -19-05MAR04-1/2

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=568

Theory of Operation 1— Tilt Left (Head End) Workport 3— Load Check 6— Spool 2— Parallel Passage 4— Bridge Passage 7— Neutral Passage 5— Tilt Right (Rod End) Workport 8— Return Oil Passage

The blade tilt valve is a three-position, four-way, spool-type valve containing a load check (3). The valve spool is returned to neutral by a centering spring in the spool end cap. When the spool is moved to activate a function, oil flows from the parallel passage (2), past the load check (3) and

9— Pressure Oil 10— Return Oil

spool (6), and out the workport to the cylinder. Return oil from the cylinder flows into the other workport, past the spool (6), into the return oil passage (8), and out the control valve to the system reservoir. The spool has grooves that meter oil through the valve to allow for smooth starts and stops. CED,TX03768,2293 -19-05MAR04-2/2

Outlet Valve Cover Operation

2 T197445

T197445 —UN—03FEB04

Outlet Valve Cover—Normal Operation 1— Return Port to Hydraulic Filter 2— Return Oil

Return oil is routed through the hydraulic filter to the hydraulic reservoir. CED,TX03768,2301 -19-05MAR04-1/1

TM10721 (03SEP14)

9025-05-21

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=569

Theory of Operation

Hydraulic Control Valve Operation—IGC 12 13 14 21

19 10 TX1036259 —UN—11FEB08

7 5 2

20 3

TX1036259 Hydraulic Control Valve—IGC (Optional Auxiliary Section shown) 1— LS Relief Valve 2— Pressure Reducing Valve 3— Inlet/Outlet Section 5— Blade Angle Section

7— Blade Tilt Section 12— Blade Lift Actuator 9— LS Pressure Limiting Valve (2 13— Blade Tilt Actuator used) 14— Blade Angle Actuator 10— Blade Lift Section 19— Outlet

The hydraulic control valve is designed to be used with the optional Integrated Grade Control (IGC). See Hydraulic System Schematic—IGC, see Hydraulic Component Location—IGC (Group 9025-15), and see Integrated Grade Control (IGC) Circuit Theory of Operation—If Equipped. (Group 9015-15). The control valve is a closed-center, load sensing (LS), proportional valve type, with unloading valve and electrical actuation. The control valve is sectionalized, and is composed of the inlet/outlet section (3), blade angle section (5), blade tilt section (7), blade lift section (10), and the outlet section (19). An optional auxiliary section (20) is also available. Supply oil from the fixed displacement pump enters the control valve port P. The internal passage P routes supply

oil to the unloading valve, the pressure reducing valve, each compensator valve, and each blade function spool. The pressure reducing valve regulates the pressure of the supply oil to the blade actuators. When a function is actuated, supply oil flows through the compensator valve and is routed through the function spool to the cylinders. At the same time, supply oil is also routed through the function spool to the spring chamber of the compensator valve, LS shuttle valve, and the LS signal circuit. Return oil from the cylinder is routed back through the function spool and out of the control valve port T, where it is routed through the hydraulic oil cooler, hydraulic oil filter and bypass and then the reservoir. All cooler oil is directly sent to reservoir and is not filtered.

Continued on next page

TM10721 (03SEP14)

20— Auxiliary Section 21— Auxiliary Actuator

9025-05-22

OUO1020,0001631 -19-02MAR10-1/4

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=570

Theory of Operation

When one or more of the spools are actuated, the highest load pressure is sensed through the LS signal circuit at the spring chamber of the unloading valve. This pressure completely or partially closes the unloading valve connection to tank. Pump pressure is applied to the opposite side of the unloading valve, thus regulating the pump pressure. The compensator valve maintains a constant pressure drop across the main spool when the load changes or when a section with a higher load pressure is actuated. This means that all work sections will continue to function regardless of differences in their load and regardless of the pump flow.

B, but are not used in this application. Therefore the limiting valves adjusting screws must be turned in completely to ensure maximum available pressure to the lift cylinders. The electrohydraulic blade function actuators are controlled by a signal from the electrohydraulic controller (EHC). See Integrated Grade Control (IGC) Circuit Theory of Operation—If Equipped. (Group 9015-15.) The actuators control the function spools by varying the flow of oil to and from the ends of the spool. In this way precise placement of the spool is accomplished.

NOTE: Adjustable LS pressure limiting valves are incorporated in the blade lift section ports A and Continued on next page

TM10721 (03SEP14)

9025-05-23

OUO1020,0001631 -19-02MAR10-2/4

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=571

Theory of Operation

M 4 LS 14

6 12 8 B

9 10

15 16

11 LSA

LSB 6

TX1020093

Continued on next page

TM10721 (03SEP14)

9025-05-24

17 18

TX1020093 —UN—06MAR07

OUO1020,0001631 -19-02MAR10-3/4

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=572

Theory of Operation 1— LS Relief Valve 2— Pressure Reducing Valve 3— Inlet/Outlet Section 4— Unloading Valve 5— Blade Angle Section 6— Compensator Valve (3 used)

12— PVEH Proportional Blade 7— Blade Tilt Section Lift Actuator 8— Anticavitation Valve (2 used) 9— LS Pressure Limiting Valve (2 13— PVEH Proportional Blade Tilt Actuator used) 14— PVEO On/Off Blade Angle 10— Blade Lift Section Actuator 11— LS Shuttle Valve (3 used)

15— Supply Oil 16— Pilot Oil 17— Trapped Oil 18— Return Oil

Inlet/Outlet Section—contains the pressure reducing valve (2), unloading valve (4), LS relief valve (1), valve inlet port P, valve outlet port T that routes oil to the hydraulic oil cooler, test port M (pump pressure), and test port LS (load sense pressure).

Blade Lift Section—contains a four position valve spool with a blade float position, an LS shuttle valve, a compensator valve, two anticavitation valves (8), two LS pressure limiting valves (9), a LS pressure limiting valve shuttle, and a PVEH proportional blade lift actuator (12).

Blade Angle Section—contains a three position valve spool, an LS shuttle valve (11), a compensator valve (6), and an PVEO on/off blade angle actuator (14).

Outlet Section—contains the port T that routes oil through an orifice to the hydraulic oil filter and bypass and then to the reservoir.

Blade Tilt Section—contains a three position valve spool, an LS shuttle valve, a compensator valve, and a PVEH proportional blade tilt actuator (13). OUO1020,0001631 -19-02MAR10-4/4

TM10721 (03SEP14)

9025-05-25

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=573

Theory of Operation

Hydraulic Cylinder Operation 7 8

2 4

T197446 —UN—26JAN04

T197446 Angle Hydraulic Cylinder 1— Barrel 2— Rod 3— Piston

4— Nut 5— Rod Guide 6— Spanner Nut

7— Cap Seal 8— Step Seal

The hydraulic cylinders are John Deere 120 Series design. The barrel (1) is welded to the head end and the rod (2) is welded to the rod eye. The piston (3) is retained on rod by a nut (4). The rod guide (5) is retained in the barrel by a snap ring and held against the snap ring by a spanner nut (6) or a snap ring (angle cylinder only). A cap seal (7) is used to seal the piston to the barrel (1).

The rod guide (5) uses a cup seal against the rod. A step seal (8) is used ahead of the cup seal. The step seal reduces the oil pressure to the cup seal resulting in a more durable rod guide seal. Dozer angle cylinders have short grooves in barrel head end to relieve pressure when cylinder is fully retracted. CED,TX03768,2299 -19-05MAR04-1/1

TM10721 (03SEP14)

9025-05-26

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=574

Theory of Operation

TM10721 (03SEP14)

9025-05-27

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=575

Group 15

Diagnostic Information Hydraulic System Schematic

600

604

606

TX1111336

TX1111336 —UN—02APR12

Hydraulic System Schematic—Neutral

Continued on next page

TM10721 (03SEP14)

9025-15-1

WC20922,0004209 -19-02APR12-1/2

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=576

Diagnostic Information 1— System Relief Valve 2— Anticavitation Valve (2 used) 3— Circuit Relief Valve (4 used) 4— Hydraulic Oil Filter and Bypass Valve

5— Hydraulic Reservoir 6— Hydraulic Pump 7— Load Check Valve (4 used) 8— Inlet Section 9— Auxiliary Section 10— Angle Section

11— Blade Tilt Section 12— Blade Lift Section 13— Outlet Section 14— Check Valve (2 used) 15— Hydraulic Oil Cooler

16— Orifice 600— High Pressure Oil 604— Return Oil 606— Trapped Oil

WC20922,0004209 -19-02APR12-2/2

TM10721 (03SEP14)

9025-15-2

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=577

Diagnostic Information

TM10721 (03SEP14)

9025-15-3

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=578

Diagnostic Information

Hydraulic System Schematic—IGC TX1111339 —UN—04APR12

6 RIPPER CYLINDER 3 RIPPER ACTUATOR 4

BLADE TILT ACTUATOR 10

ANGLE CYLINDERS 9 BLADE ANGLE ACTUATOR

RIPPER SECTION

BLADE LIFT ACTUATOR 13

16 LIFT CYLINDERS

14 BLADE LIFT SECTION

11 BLADE TILT SECTION

8 BLADE ANGLE SECTION

12 TILT CYLINDER

B OUTLET SECTION 15

37 T

2 INLET SECTION PRESSURE REDUCING VALVE

UNLOADING 32 VALVE M 31 TEST PORT M 30 LOAD SENSE RELIEF VALVE 29

23 20

LS 23 T

TEST PORT LS

ORIFICE 28

LSB

HYDRAULIC 27 OIL COOLER

22 24 HYDRAULIC PUMP

HYDRAULIC OIL FILTER AND BYPASS 26

Hydraulic System Schematic with Integrated Grade Control (IGC)—Neutral Continued on next page

9025-15-4

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=579

21 33 SUPPLY OIL 34 PILOT OIL 35 TRAPPED OIL

25 HYDRAULIC RESERVOIR

TX1111339

TM10721 (03SEP14)

LSA

36 RETURN OIL WC20922,000420B -19-03APR12-1/2

Diagnostic Information

TM10721 (03SEP14)

9025-15-5

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=580

Diagnostic Information 1— Pressure Reducing Valve 2— Inlet Section 3— Ripper Actuator 4— Ripper Section 5— Auxiliary Work Port Relief (2 used) 6— Ripper Cylinder 7— Blade Angle Actuator 8— Blade Angle Section 9— Angle Cylinders 10— Blade Tilt Actuator

11— Blade Tilt Section 20— Load Sense Shuttle Valve (4 29— Test Port LS 12— Tilt Cylinder used) 30— Load Sense Relief Valve 13— Blade Lift Actuator 21— Test Port LSA 31— Test Port M 14— Blade Lift Section 22— Test Port LSB 32— Unloading Valve 15— Anticavitation Valve (2 used) 23— Compensator Valve (4 used) 33— Supply Oil 16— Lift Cylinder (2 used) 24— Hydraulic Pump 34— Pilot Oil 17— Outlet Section 25— Hydraulic Reservoir 35— Trapped Oil 18— LS Pressure Limiting Valve 26— Hydraulic Oil Filter and 36— Return Oil (2 used) Bypass 37— Angle Work Port Relief (2 19— LS Pressure Limiting Valve 27— Hydraulic Oil Cooler used) Shuttle 28— Orifice WC20922,000420B -19-03APR12-2/2

TM10721 (03SEP14)

9025-15-6

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=581

Diagnostic Information

Hydraulic Component Location

5 6

8 9 10 T197448

T197448 —UN—26JAN04

Blade Lift Cylinder Circuit—Blade Lift Operation

Continued on next page

TM10721 (03SEP14)

9025-15-7

WC20922,0004208 -19-30MAR12-1/7

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=582

Diagnostic Information 1— Blade Raise Port 2— Blade Lower Port 3— Blade Lift Valve Section

4— Hydraulic Control Valve 5— Cylinder Rod End Hose 6— Right Lift Cylinder

7— Cylinder Head End Hose 8— Left Lift Cylinder 9— Pressure Oil Continued on next page

TM10721 (03SEP14)

9025-15-8

10— Return Oil

WC20922,0004208 -19-30MAR12-2/7

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=583

Diagnostic Information

9 8

T197540

T197540 —UN—03FEB04

Blade Angle Cylinder Circuit—Angle Left Operation

Continued on next page

TM10721 (03SEP14)

9025-15-9

WC20922,0004208 -19-30MAR12-3/7

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=584

Diagnostic Information 1— Top Port-to-Right Angle Cylinder Head End and Left Cylinder Rod End Port 2— Blade Angle Valve Section

3— Bottom Port-to-Right Cylinder 5— Angle Cylinder Hose Rod End and Left Cylinder 6— Angle Cylinder Hose Head End 7— Right Angle Cylinder 4— Hydraulic Control Valve 8— Left Angle Cylinder Continued on next page

TM10721 (03SEP14)

9025-15-10

9— Pressure Oil 10— Return Oil

WC20922,0004208 -19-30MAR12-4/7

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=585

Diagnostic Information

3 5

T197449 —UN—26JAN04

8 9

T197449 Blade Tilt Cylinder—Tilt Left Operation 1— Tilt Right (Rod End) Port 2— Blade Tilt Valve Section

3— Tilt Left (Head End) Port 4— Hydraulic Control Valve

5— Cylinder Rod End Hose 6— Cylinder Head End Hose 7— Tilt Cylinder Continued on next page

TM10721 (03SEP14)

9025-15-11

8— Pressure Oil 9— Return Oil WC20922,0004208 -19-30MAR12-5/7

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=586

Diagnostic Information

6 4 5

TX1070617 —UN—09FEB10

TX1070617 Hydraulic Oil Cooler—Standard Hydraulics

Continued on next page

TM10721 (03SEP14)

9025-15-12

WC20922,0004208 -19-30MAR12-6/7

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=587

Diagnostic Information 1— Hydraulic Oil Cooler 2— Hydraulic Control Valve 3— Hydraulic Oil Filter

4— Hydraulic Oil Reservoir 7— Hydraulic Oil Cooler-to5— Hydraulic Pump Hydraulic Oil Reservoir Hose 6— Hydraulic Control 8— Orifice Valve-to-Hydraulic Oil Cooler Hose WC20922,0004208 -19-30MAR12-7/7

TM10721 (03SEP14)

9025-15-13

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=588

Diagnostic Information

Hydraulic Component Location—IGC TX1070829 —UN—11FEB10

7 2

3 8

TX1070829 Hydraulic System with Integrated Grade Control (IGC) Component Location Continued on next page

TM10721 (03SEP14)

9025-15-14

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=589

SW03989,00001E6 -19-18FEB10-1/4

Diagnostic Information

TM10721 (03SEP14)

9025-15-15

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=590

Diagnostic Information

1— Tilt Cylinder 2— Angle Cylinder (2 used) 3— Lift Cylinder (2 used)

4— Hydraulic Oil Cooler 5— Hydraulic Pump 6— Hydraulic Control Valve

7— Hydraulic Oil Filter 8— Hydraulic Reservoir Continued on next page

TM10721 (03SEP14)

9025-15-16

SW03989,00001E6 -19-18FEB10-2/4

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=591

Diagnostic Information

3 2

8 6 4 5

TX1070619 —UN—09FEB10

TX1070619 Hydraulic Oil Cooler with IGC

Continued on next page

TM10721 (03SEP14)

9025-15-17

SW03989,00001E6 -19-18FEB10-3/4

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=592

Diagnostic Information 1— Hydraulic Oil Cooler 2— Hydraulic Control Valve 3— Hydraulic Oil Filter

4— Hydraulic Oil Reservoir 7— Hydraulic Oil Cooler-to5— Hydraulic Pump Hydraulic Oil Reservoir Hose 6— Hydraulic Control 8— Orifice Valve-to-Hydraulic Oil Cooler Hose SW03989,00001E6 -19-18FEB10-4/4

TM10721 (03SEP14)

9025-15-18

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=593

Diagnostic Information

TM10721 (03SEP14)

9025-15-19

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=594

Diagnostic Information

Ripper Hydraulic Component Location TX1026554 —UN—26JUL07

TX1026554 TF44157,0000014 -19-13JUL07-1/2

Continued on next page

TM10721 (03SEP14)

9025-15-20

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=595

Diagnostic Information

TM10721 (03SEP14)

9025-15-21

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=596

Diagnostic Information

1— Ripper Control Lever

2— Main Control Valve

3— Ripper Cylinder TF44157,0000014 -19-13JUL07-2/2

Hydraulic System Diagnose Malfunctions WC20922,000420A -19-30MAR12-1/50

No Hydraulic Functions Diagnostic Procedure WC20922,000420A -19-30MAR12-2/50

• 1

Hydraulic System Relief Valve Stuck Open

Check system relief valve. See Hydraulic Control Valve Disassemble and Assemble. (Group 3260.)

YES: Repair or replace system relief valve.

Is system relief valve worn or damaged?

NO: Go to System Pressure Low. WC20922,000420A -19-30MAR12-3/50

• 2

System Pressure Low

Check system pressure. Perform Hydraulic System Relief Valve Test. (Group 9025-25.) YES: Go to Hydraulic Lines Blocked or Damaged. Is system pressure adjusted to specification?

NO: Replace system relief valve. WC20922,000420A -19-30MAR12-4/50

• 3

Hydraulic Lines Blocked or Damaged

Inspect hydraulic lines. See Hydraulic Component Location. (Group 9025-15.)

YES: Repair or replace damaged lines.

Are any hydraulic lines blocked or damaged?

NO: Go to Hydraulic Pump Worn or Damaged. WC20922,000420A -19-30MAR12-5/50

• 4

Hydraulic Pump Worn or Damaged

Check pump Flow. Perform Hydraulic Pump Flow Test. (Group 9025-25.)

YES: Checks complete.

Is pump flow to specification?

NO: Repair or replace pump as necessary. WC20922,000420A -19-30MAR12-6/50

Hydraulic Functions Slow Diagnostic Procedure WC20922,000420A -19-30MAR12-7/50

• 1

Hydraulic Oil Cold

Check hydraulic oil temperature.

YES: Go to Engine Speed Slow.

Is hydraulic oil at normal operating temperature?

NO: Warm-up hydraulic oil.

Continued on next page

TM10721 (03SEP14)

9025-15-22

WC20922,000420A -19-30MAR12-8/50

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=597

Diagnostic Information

• 2

Engine Speed Slow

Check engine speed.

YES: Go to Pump Suction Line Air Leak.

Is engine speed to specification?

NO: Perform Engine Speed Check. (Group 9010-25.) WC20922,000420A -19-30MAR12-9/50

• 3

Pump Suction Line Air Leak

Check for foamy hydraulic oil. See Check Hydraulic Oil Level. (Operator's Manual.)

YES: Repair pump suction line leak.

Is hydraulic oil foamy?

NO: Go to Hydraulic Oil Level Low. WC20922,000420A -19-30MAR12-10/50

• 4

Hydraulic Oil Level Low

Check hydraulic oil level. See Check Hydraulic Oil Level. (Operator's Manual.)

YES: Go to Oil Viscosity Wrong.

Is hydraulic oil level to specification?

NO: Add recommended oil. See Transmission and Hydraulic Oil. (Operator's Manual.) WC20922,000420A -19-30MAR12-11/50

• 5

Oil Viscosity Wrong

Check reservoir oil. See Transmission and Hydraulic Oil. (Operator's Manual.)

YES: Go to Hydraulic Lines Blocked or Damaged.

Is correct oil used?

NO: Replace reservoir oil with recommended oil. WC20922,000420A -19-30MAR12-12/50

• 6

Hydraulic Lines Blocked or Damaged

Inspect hydraulic lines. See Hydraulic Component Location. (Group 9025-15.)

YES: Repair or replace damaged lines.

Are any hydraulic lines blocked or damaged?

NO: Go to Load Check Valve Sticking. WC20922,000420A -19-30MAR12-13/50

• 7

Load Check Valve Sticking

Check load check valve. See Hydraulic Control Valve Disassemble and Assemble. (Group 3260.)

YES: Repair or replace load check valve.

Is load check valve worn or damaged?

NO: Go to Hydraulic Cylinders Leaking Internally. Continued on next page

TM10721 (03SEP14)

9025-15-23

WC20922,000420A -19-30MAR12-14/50

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=598

Diagnostic Information

• 8

Hydraulic Cylinders Leaking Internally

Check cylinders for leakage. Perform Lift Cylinder Drift Test. (Group 9025-25.)

YES: Repair or replace leaking cylinders.

Are any cylinders leaking?

NO: Go to Hydraulic System Relief Valve Stuck Open. WC20922,000420A -19-30MAR12-15/50

• 9

Hydraulic System Relief Valve Stuck Open

Check system relief valve. See Hydraulic Control Valve Disassemble and Assemble. (Group 3260.)

YES: Repair or replace system relief valve.

Is system relief valve worn or damaged?

NO: Go to System Pressure Low. WC20922,000420A -19-30MAR12-16/50

•

10 System Pressure Low

Check system pressure. Perform Hydraulic System Relief Valve Test. (Group 9025-25.) YES: Go to Hydraulic Control Valve Spool Binding. Is system pressure adjusted to specification?

NO: Replace system relief valve. WC20922,000420A -19-30MAR12-17/50

•

11 Hydraulic Control Valve Spool Binding

Inspect and repair control valve. See Hydraulic Control Valve Disassemble and Assemble. (Group 3260.)

YES: Repair or replace control valve.

Is control valve spool binding?

NO: Go to Hydraulic Pump Worn or Damaged. WC20922,000420A -19-30MAR12-18/50

•

12 Hydraulic Pump Worn or Damaged

Check pump Flow. Perform Hydraulic Pump Flow Test. (Group 9025-25.)

YES: Checks complete.

Is pump flow to specification?

NO: Repair or replace pump as necessary. WC20922,000420A -19-30MAR12-19/50

Hydraulic Pump Noisy Diagnostic Procedure WC20922,000420A -19-30MAR12-20/50

• 1

Pump Suction Line Air Leak

Check for foamy hydraulic oil. See Check Hydraulic Oil Level. (Operator's Manual.)

YES: Repair pump suction line leak.

Is hydraulic oil foamy?

NO: Go to Hydraulic Oil Level Low. Continued on next page

TM10721 (03SEP14)

9025-15-24

WC20922,000420A -19-30MAR12-21/50

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=599

Diagnostic Information

• 2

Hydraulic Oil Level Low

Check hydraulic oil level. See Check Hydraulic Oil Level. (Operator's Manual.)

YES: Go to Oil Viscosity Wrong.

Is hydraulic oil level to specification?

NO: Add recommended oil. See Transmission and Hydraulic Oil. (Operator's Manual.) WC20922,000420A -19-30MAR12-22/50

• 3

Oil Viscosity Wrong

Check reservoir oil. See Transmission and Hydraulic Oil. (Operator's Manual.)

YES: Go to Hydraulic Lines in Contact with Frame.

Is correct oil used?

NO: Replace reservoir oil with recommended oil. WC20922,000420A -19-30MAR12-23/50

• 4

Hydraulic Lines in Contact with Frame

Inspect line routing.

YES: Adjust lines as necessary.

Are any lines against frame?

NO: Go to Hydraulic Pump Worn or Damaged. WC20922,000420A -19-30MAR12-24/50

• 5

Hydraulic Pump Worn or Damaged

Check pump flow. Perform Hydraulic Pump Flow Test. (Group 9025-25.)

YES: Checks complete.

Is pump flow to specification?

NO: Repair or replace pump as necessary. WC20922,000420A -19-30MAR12-25/50

Blade Float Does Not Work Diagnostic Procedure WC20922,000420A -19-30MAR12-26/50

• 1

Hydraulic Control Valve Spool Binding

Inspect and repair control valve. See Hydraulic Control Valve Disassemble and Assemble. (Group 3260.)

YES: Repair or replace control valve.

Is control valve spool binding?

NO: Checks complete. WC20922,000420A -19-30MAR12-27/50

One Hydraulic Function Does Not Work Diagnostic Procedure WC20922,000420A -19-30MAR12-28/50

• 1

Circuit Relief Valve Stuck Open

Check circuit relief valves. See Hydraulic Control Valve Disassemble and Assemble. (Group 3260.)

YES: Repair or replace circuit relief valve.

Is circuit relief valve worn or damaged?

NO: Go to Anticavitation Valve Stuck Open. Continued on next page

TM10721 (03SEP14)

9025-15-25

WC20922,000420A -19-30MAR12-29/50

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=600

Diagnostic Information

• 2

Anticavitation Valve Stuck Open

Check anticavitation valves. See Hydraulic Control Valve Disassemble and Assemble. (Group 3260.)

YES: Repair or replace anticavitation valve.

Is anticavitation valve worn or damaged?

NO: Go to Hydraulic Lines Blocked or Damaged. WC20922,000420A -19-30MAR12-30/50

• 3

Hydraulic Lines Blocked or Damaged

Inspect hydraulic lines. See Hydraulic Component Location. (Group 9025-15.)

YES: Repair or replace damaged lines.

Are any hydraulic lines blocked or damaged?

NO: Go to Load Check Valve Sticking. WC20922,000420A -19-30MAR12-31/50

• 4

Load Check Valve Sticking

Check load check valve. See Hydraulic Control Valve Disassemble and Assemble. (Group 3260.)

YES: Repair or replace load check valve.

Is load check valve worn or damaged?

NO: Go to Hydraulic Cylinders Leaking Internally. WC20922,000420A -19-30MAR12-32/50

• 5

Hydraulic Cylinders Leaking Internally

Check cylinders for leakage. Perform Lift Cylinder Drift Test. (Group 9025-25.)

YES: Repair or replace leaking cylinders.

Are any cylinders leaking?

NO: Go to Hydraulic Control Valve Spool Binding. WC20922,000420A -19-30MAR12-33/50

• 6

Hydraulic Control Valve Spool Binding

Inspect and repair control valve. See Hydraulic Control Valve Disassemble and Assemble. (Group 3260.)

YES: Repair or replace control valve.

Is control valve spool binding?

NO: Checks complete. WC20922,000420A -19-30MAR12-34/50

Function Drifts Down Diagnostic Procedure WC20922,000420A -19-30MAR12-35/50

• 1

Hydraulic Cylinders Leaking Internally

Check cylinders for leakage. Perform Lift Cylinder Drift Test. (Group 9025-25.)

YES: Repair or replace leaking cylinders.

Are any cylinders leaking?

NO: Go to Circuit Relief Valve Stuck Open or Leaking. Continued on next page

TM10721 (03SEP14)

9025-15-26

WC20922,000420A -19-30MAR12-36/50

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=601

Diagnostic Information

• 2

Circuit Relief Valve Check circuit relief valves. See Hydraulic Control Valve Disassemble and Assemble. Stuck Open or Leaking (Group 3260.)

Is circuit relief valve worn or damaged?

YES: Repair or replace circuit relief valve.

NO: Go to Anticavitation Valve Stuck Open or Leaking. WC20922,000420A -19-30MAR12-37/50

• 3

Anticavitation Valve Check anticavitation valves. See Hydraulic Control Valve Disassemble and Assemble. Stuck Open or Leaking (Group 3260.)

Is anticavitation valve worn or damaged?

YES: Repair or replace anticavitation valve.

NO: Go to Hydraulic Control Valve Spool Leaking. WC20922,000420A -19-30MAR12-38/50

• 4

Hydraulic Control Valve Spool Leaking

Inspect and repair control valve. See Hydraulic Control Valve Disassemble and Assemble. (Group 3260.)

YES: Replace control valve.

Is control valve spool worn or damaged?

NO: Checks complete. WC20922,000420A -19-30MAR12-39/50

Oil Overheats Diagnostic Procedure WC20922,000420A -19-30MAR12-40/50

• 1

Oil Cooler Coils Plugged

Check oil cooler coils for external dirt and debris. See Hydraulic Component Location. (Group 9025-15.)

YES: Remove dirt and debris from oil cooler coils.

Are oil cooler coils plugged or dirty?

NO: Go to Oil Viscosity Wrong check. WC20922,000420A -19-30MAR12-41/50

• 2

Oil Viscosity Wrong

Check reservoir oil. See Transmission and Hydraulic Oil. (Operator's Manual.)

YES: Go to Hydraulic Oil Cooler Line Orifice Plugged (S.N. 180506— ).

Is correct oil used?

NO: Replace reservoir oil with recommended oil. WC20922,000420A -19-30MAR12-42/50

• 3

Hydraulic Oil Cooler Line Orifice Plugged

Inspect orifice in control valve to cooler line fitting at control valve. See Hydraulic Component Location. (Group 9025-15.)

YES: Remove debris from orifice.

Is orifice dirty or plugged?

NO: Go to Hydraulic System Relief Valve Stuck Open or Leaking Continued on next page

TM10721 (03SEP14)

9025-15-27

WC20922,000420A -19-30MAR12-43/50

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=602

Diagnostic Information

• 4

Hydraulic System Relief Valve Stuck Open or Leaking

Check system relief valve. See Hydraulic Control Valve Disassemble and Assemble. (Group 3260.)

YES: Repair or replace system relief valve.

Is system relief valve worn or damaged?

NO: Go to Circuit Relief Valve Stuck Open or Leaking. WC20922,000420A -19-30MAR12-44/50

• 5

Circuit Relief Valve Check circuit relief valves. See Hydraulic Control Valve Disassemble and Assemble. Stuck Open or Leaking (Group 3260.)

Is circuit relief valve worn or damaged?

YES: Repair or replace circuit relief valve.

NO: Go to Anticavitation Valve Stuck Open or Leaking. WC20922,000420A -19-30MAR12-45/50

• 6

Anticavitation Valve Check anticavitation valves. See Hydraulic Control Valve Disassemble and Assemble. Stuck Open or Leaking (Group 3260.)

Is anticavitation valve worn or damaged?

YES: Repair or replace anticavitation valve.

NO: Go to Hydraulic Lines Blocked or Damaged WC20922,000420A -19-30MAR12-46/50

• 7

Hydraulic Lines Blocked or Damaged

Inspect hydraulic lines. See Hydraulic Component Location. (Group 9025-15.)

YES: Repair or replace damaged lines.

Are any hydraulic lines blocked or damaged?

NO: Go to Load Check Valve Sticking. WC20922,000420A -19-30MAR12-47/50

• 8

Load Check Valve Sticking

Check load check valve. See Hydraulic Control Valve Disassemble and Assemble. (Group 3260.)

YES: Repair or replace load check valve.

Is load check valve worn or damaged?

NO: Go to Hydraulic Cylinders Leaking Internally. WC20922,000420A -19-30MAR12-48/50

• 9

Hydraulic Cylinders Leaking Internally

Check cylinders for leakage. Perform Lift Cylinder Drift Test. (Group 9025-25.)

YES: Repair or replace leaking cylinders.

Are any cylinders leaking?

NO: Go to Hydraulic Pump Worn or Damaged. Continued on next page

TM10721 (03SEP14)

9025-15-28

WC20922,000420A -19-30MAR12-49/50

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=603

Diagnostic Information

•

10 Hydraulic Pump Worn or Damaged

Check pump Flow. Perform Hydraulic Pump Flow Test. (Group 9025-25.)

YES: Checks complete.

Is pump flow to specification?

NO: Repair or replace pump as necessary. WC20922,000420A -19-30MAR12-50/50

TM10721 (03SEP14)

9025-15-29

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=604

Diagnostic Information

Hydraulic System Diagnose Malfunctions—IGC AA95137,0001219 -19-02MAR10-1/61

No Hydraulic Functions Diagnostic Procedure—IGC AA95137,0001219 -19-02MAR10-2/61

• 1

Hydraulic Enable Switch in Off Position

Check position of hydraulic enable switch.

YES: Move switch to on position.

Is switch in off position?

NO: Go to Hydraulic Enable Switch Malfunction. AA95137,0001219 -19-02MAR10-3/61

• 2

Hydraulic Enable Switch Malfunction

Perform hydraulic control enable circuit check.

Check hydraulic control enable switch and circuit. See Integrated Grade Control (IGC) Diagnose Malfunctions—If Equipped. (Group 9015-20.)

YES: Go to Hydraulic System Unloading Valve Stuck Open.

Are switch and circuit working correctly?

NO: Repair or replace hydraulic enable switch and circuit. AA95137,0001219 -19-02MAR10-4/61

• 3

Hydraulic System Unloading Valve Stuck Open

Check hydraulic system unloading valve. See Hydraulic Control Valve Disassemble and Assemble—IGC. (Group 3260.)

YES: Replace unloading valve.

Is unloading valve worn or damaged?

NO: Go to Pilot Control Pressure Low. AA95137,0001219 -19-02MAR10-5/61

• 4

Pilot Control Pressure Low

Check pressure reducing valve. See Hydraulic Control Valve Disassemble and Assemble—IGC. (Group 3260.)

YES: Replace pressure reducing valve.

Is pressure reducing valve worn or damaged?

NO: Go to Hydraulic System Pressure Low. AA95137,0001219 -19-02MAR10-6/61

• 5

Hydraulic System Pressure Low

Check system pressure. Perform Hydraulic System Relief Valve Test—IGC. (Group 9025-25.)

YES: Go to Electrical Malfunction.

Is system pressure to specification?

NO: Replace load sense relief valve. Continued on next page

TM10721 (03SEP14)

9025-15-30

AA95137,0001219 -19-02MAR10-7/61

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=605

Diagnostic Information

• 6

Electrical Malfunction

Check electrical system malfunctions. See Integrated Grade Control (IGC) Diagnose Malfunctions—If Equipped. (Group 9015-20.)

YES: Repair or replace electrical components as necessary.

Is an electrical malfunction found?

NO: Checks complete. AA95137,0001219 -19-02MAR10-8/61

Hydraulic Functions Slow Diagnostic Procedure—IGC AA95137,0001219 -19-02MAR10-9/61

• 1

Hydraulic Oil Cold

Check hydraulic oil temperature.

YES: Go to Engine Speed Slow.

Is hydraulic oil at normal operating temperature?

NO: Warm-up hydraulic oil. AA95137,0001219 -19-02MAR10-10/61

• 2

Engine Speed Slow

Check engine speed. See Engine Speed Check. (Group 9010-25.)

YES: Go to Pump Suction Line Air Leak.

Is engine speed to specification?

NO: Engine malfunction. See CTM104 for diagnostic procedure. AA95137,0001219 -19-02MAR10-11/61

• 3

Pump Suction Line Air Leak

Check for foamy hydraulic oil. See Check Hydraulic Oil Level. (Operator's Manual.)

YES: Repair pump suction line leak.

Is hydraulic oil foamy?

NO: Go to Hydraulic Oil Level Low. AA95137,0001219 -19-02MAR10-12/61

• 4

Hydraulic Oil Level Low

Check hydraulic oil level. See Check Hydraulic Oil Level. (Operator's Manual.)

YES: Go to Oil Viscosity Wrong.

Is hydraulic oil level to specification?

NO: Add recommended oil. See Transmission and Hydraulic Oil. (Operator's Manual.) AA95137,0001219 -19-02MAR10-13/61

• 5

Oil Viscosity Wrong

Check reservoir oil. See Transmission and Hydraulic Oil. (Operator's Manual.)

YES: Go to Hydraulic Lines Blocked or Damaged.

Is correct oil used?

NO: Replace reservoir oil with recommended oil. AA95137,0001219 -19-02MAR10-14/61

• 6

Hydraulic Lines Blocked or Damaged

Inspect hydraulic lines. See Hydraulic Component Location. (Group 9025-15.)

YES: Repair or replace damaged lines.

Are any hydraulic lines blocked or damaged?

NO: Go to Hydraulic Cylinders Leaking Internally.

Continued on next page

TM10721 (03SEP14)

9025-15-31

AA95137,0001219 -19-02MAR10-15/61

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=606

Diagnostic Information

• 7

Hydraulic Cylinders Leaking Internally

Check cylinders for leakage. Perform Lift Cylinder Drift Test. (Group 9025-25.)

YES: Repair or replace leaking cylinders.

Are any cylinders leaking?

NO: Go to Hydraulic System Unloading Valve Stuck Open. AA95137,0001219 -19-02MAR10-16/61

• 8

Hydraulic System Unloading Valve Stuck Open

Check hydraulic system unloading valve. See Hydraulic Control Valve Disassemble and Assemble—IGC. (Group 3260.)

YES: Replace unloading valve.

Is unloading valve worn or damaged?

NO: Go to Pilot Control Pressure Low. AA95137,0001219 -19-02MAR10-17/61

• 9

Pilot Control Pressure Low

Check pressure reducing valve. See Hydraulic Control Valve Disassemble and Assemble—IGC. (Group 3260.)

YES: Replace pressure reducing valve.

Is pressure reducing valve worn or damaged?

NO: Go to Hydraulic System Pressure Low. AA95137,0001219 -19-02MAR10-18/61

•

10 Hydraulic System Pressure Low

Check system pressure. Perform Hydraulic System Relief Valve Test—IGC. (Group 9025-25.)

YES: Go to Hydraulic Control Valve Spool Binding.

Is system pressure to specification?

NO: Replace load sense relief valve. AA95137,0001219 -19-02MAR10-19/61

•

11 Hydraulic Control Valve Spool Binding

Inspect and repair control valve. See Hydraulic Control Valve Disassemble and Assemble—IGC. (Group 3260.)

YES: Repair or replace control valve.

Is control valve spool binding?

NO: Go to Electrohydraulic Actuator Malfunction. AA95137,0001219 -19-02MAR10-20/61

•

12 Electrohydraulic Actuator Malfunction

Check electrohydraulic actuator. See Integrated Grade Control (IGC) Diagnose Malfunctions—If Equipped. (Group 9015-20.)

YES: Replace actuator.

Is actuator malfunctioning?

NO: Go to Joystick Malfunction. AA95137,0001219 -19-02MAR10-21/61

•

13 Joystick Malfunction

Check joystick. See Integrated Grade Control (IGC) Diagnose Malfunctions—If Equipped. (Group 9015-20.)

YES: Repair or replace joystick as necessary.

Is joystick malfunctioning?

NO: Go to Hydraulic Pump Worn or Damaged. Continued on next page

TM10721 (03SEP14)

9025-15-32

AA95137,0001219 -19-02MAR10-22/61

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=607

Diagnostic Information

•

14 Hydraulic Pump Worn or Damaged

Check pump flow. Perform Hydraulic Pump Flow Test. (Group 9025-25.)

YES: Checks complete.

Is pump flow to specification?

NO: Repair or replace pump as necessary. AA95137,0001219 -19-02MAR10-23/61

Blade Float Does Not Work Diagnostic Procedure—IGC AA95137,0001219 -19-02MAR10-24/61

• 1

Pilot Control Pressure Low

Check pressure reducing valve. See Hydraulic Control Valve Disassemble and Assemble—IGC. (Group 3260.)

YES: Replace pressure reducing valve.

Is pressure reducing valve worn or damaged?

NO: Go to Joystick Malfunction. AA95137,0001219 -19-02MAR10-25/61

• 2

Joystick Malfunction

Check joystick. See Integrated Grade Control (IGC) Diagnose Malfunctions—If Equipped. (Group 9015-20.)

YES: Repair or replace joystick as necessary.

Is joystick malfunctioning?

NO: Go to Electrohydraulic Actuator Malfunction. AA95137,0001219 -19-02MAR10-26/61

• 3

Electrohydraulic Actuator Malfunction

Check electrohydraulic actuator. See Integrated Grade Control (IGC) Diagnose Malfunctions—If Equipped. (Group 9015-20.)

YES: Replace actuator.

Is actuator malfunctioning?

NO: Go to Hydraulic Control Valve Spool Binding. AA95137,0001219 -19-02MAR10-27/61

• 4

Hydraulic Control Valve Spool Binding

Inspect and repair control valve. See Hydraulic Control Valve Disassemble and Assemble—IGC. (Group 3260.)

YES: Repair or replace control valve.

Is control valve spool binding?

NO: Checks complete. AA95137,0001219 -19-02MAR10-28/61

One Hydraulic Function Does Not Work Diagnostic Procedure—IGC AA95137,0001219 -19-02MAR10-29/61

• 1

LS Pressure Limiting Valve Stuck Open

Check LS pressure limiting valves. See Hydraulic Control Valve Disassemble and Assemble—IGC. (Group 3260.)

Is LS pressure limiting valve worn or damaged?

YES: Repair or replace LS pressure limiting valve.

IMPORTANT: The LS pressure limiting valves are located in the blade lift section but are not used in this application. The LS pressure limiting valves must be turned all the way in (closed) to allow full circuit pressure.

NO: Go to Anticavitation Valve Stuck Open.

Continued on next page

TM10721 (03SEP14)

9025-15-33

AA95137,0001219 -19-02MAR10-30/61

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=608

Diagnostic Information

• 2

Anticavitation Valve Stuck Open

Check anticavitation valves. See Hydraulic Control Valve Disassemble and Assemble—IGC. (Group 3260.)

YES: Repair or replace anticavitation valve.

Is anticavitation valve worn or damaged?

NO: Go to Hydraulic Lines Blocked or Damaged. AA95137,0001219 -19-02MAR10-31/61

• 3

Hydraulic Lines Blocked or Damaged

Inspect hydraulic lines. See Hydraulic Component Location—IGC. (Group 9025-15.)

YES: Repair or replace damaged lines.

Are any hydraulic lines blocked or damaged?

NO: Go to Hydraulic Cylinders Leaking Internally. AA95137,0001219 -19-02MAR10-32/61

• 4

Hydraulic Cylinders Leaking Internally

Check cylinders for leakage. Perform Lift Cylinder Drift Test. (Group 9025-25.)

YES: Repair or replace leaking cylinders.

Are any cylinders leaking?

NO: Go to Electrohydraulic Actuator Malfunction. AA95137,0001219 -19-02MAR10-33/61

• 5

Electrohydraulic Actuator Malfunction

Check electrohydraulic actuator. See Integrated Grade Control (IGC) Diagnose Malfunctions—If Equipped. (Group 9015-20.)

YES: Replace actuator.

Is actuator malfunctioning?

NO: Go to Hydraulic Control Valve Spool Binding. AA95137,0001219 -19-02MAR10-34/61

• 6

Hydraulic Control Valve Spool Binding

Inspect and repair control valve. See Hydraulic Control Valve Disassemble and Assemble—IGC. (Group 3260.)

YES: Repair or replace control valve.

Is control valve spool binding?

NO: Checks complete. AA95137,0001219 -19-02MAR10-35/61

Hydraulic Power Low Diagnostic Procedure—IGC AA95137,0001219 -19-02MAR10-36/61

• 1

Hydraulic System Pressure Low

Check system pressure. Perform Hydraulic System Relief Valve Test—IGC. (Group 9025-25.)

YES: Go to Pilot Control Pressure Low.

Is system pressure to specification?

NO: Replace load sense relief valve. Continued on next page

TM10721 (03SEP14)

9025-15-34

AA95137,0001219 -19-02MAR10-37/61

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=609

Diagnostic Information

• 2

Pilot Control Pressure Low

Check pressure reducing valve. See Hydraulic Control Valve Disassemble and Assemble—IGC. (Group 3260.)

YES: Replace pressure reducing valve.

Is pressure reducing valve worn or damaged?

NO: Go to LS Pressure Limiting Valve Stuck Open. AA95137,0001219 -19-02MAR10-38/61

• 3

LS Pressure Limiting Valve Stuck Open

Check LS pressure limiting valves. See Hydraulic Control Valve Disassemble and Assemble—IGC. (Group 3260.)

Is LS pressure limiting valve worn or damaged?

YES: Repair or replace LS pressure limiting valve.

NO: Go to Anticavitation Valve Stuck Open. AA95137,0001219 -19-02MAR10-39/61

• 4

Anticavitation Valve Stuck Open

Check anticavitation valves. See Hydraulic Control Valve Disassemble and Assemble—IGC. (Group 3260.)

YES: Repair or replace anticavitation valve.

Is anticavitation valve worn or damaged?

NO: Go to Hydraulic Pump Worn or Damaged. AA95137,0001219 -19-02MAR10-40/61

• 5

Hydraulic Pump Worn or Damaged

Check pump flow. Perform Hydraulic Pump Flow Test. (Group 9025-25.)

YES: Checks complete.

Is pump flow to specification?

NO: Repair or replace pump as necessary. AA95137,0001219 -19-02MAR10-41/61

Function Drifts Down Diagnostic Procedure—IGC AA95137,0001219 -19-02MAR10-42/61

• 1

Hydraulic Cylinders Leaking Internally

Check cylinders for leakage. Perform Lift Cylinder Drift Test. (Group 9025-25.)

YES: Repair or replace leaking cylinders.

Are any cylinders leaking?

NO: Go to LS Pressure Limiting Valve Stuck Open. AA95137,0001219 -19-02MAR10-43/61

• 2

LS Pressure Limiting Valve Stuck Open

Check LS pressure limiting valves. See Hydraulic Control Valve Disassemble and Assemble—IGC. (Group 3260.)

Is LS pressure limiting valve worn or damaged?

YES: Repair or replace LS pressure limiting valve.

NO: Go to Anticavitation Valve Stuck Open.

Continued on next page

TM10721 (03SEP14)

9025-15-35

AA95137,0001219 -19-02MAR10-44/61

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=610

Diagnostic Information

• 3

Anticavitation Valve Stuck Open

Check anticavitation valves. See Hydraulic Control Valve Disassemble and Assemble—IGC. (Group 3260.)

YES: Repair or replace anticavitation valve.

Is anticavitation valve worn or damaged?

NO: Go to Hydraulic Control Valve Spool Leaking. AA95137,0001219 -19-02MAR10-45/61

• 4

Hydraulic Control Valve Spool Leaking

Inspect and repair control valve. See Hydraulic Control Valve Disassemble and Assemble—IGC. (Group 3260.)

YES: Repair or replace control valve.

Is control valve spool worn or damaged?

NO: Checks complete. AA95137,0001219 -19-02MAR10-46/61

Oil Overheats Diagnostic Procedure—IGC AA95137,0001219 -19-02MAR10-47/61

• 1

Oil Cooler Coils Plugged

Check oil cooler coils for external dirt and debris. See Hydraulic Component Location—IGC. (Group 9025-15.)

YES: Remove dirt and debris from oil cooler coils.

Are oil cooler coils plugged or dirty?

NO: Go to Oil Viscosity Wrong check. AA95137,0001219 -19-02MAR10-48/61

• 2

Oil Viscosity Wrong

Check reservoir oil. See Transmission and Hydraulic Oil. (Operator's Manual.)

YES: Go to Hydraulic Oil Cooler Line Orifice Plugged.

Is correct oil used?

NO: Replace reservoir oil with recommended oil. AA95137,0001219 -19-02MAR10-49/61

• 3

Hydraulic Oil Cooler Line Orifice Plugged

Inspect orifice in control valve to cooler line fitting at control valve. See Hydraulic Component Location—IGC. (Group 9025-15.)

YES: Remove debris from orifice.

Is orifice dirty or plugged?

NO: Go to LS Pressure Limiting Valve Stuck Open. AA95137,0001219 -19-02MAR10-50/61

• 4

LS Pressure Limiting Valve Stuck Open

Check LS pressure limiting valves. See Hydraulic Control Valve Disassemble and Assemble—IGC. (Group 3260.)

Is LS pressure limiting valve worn or damaged?

YES: Repair or replace LS pressure limiting valve.

NO: Go to Anticavitation Valve Stuck Open.

Continued on next page

TM10721 (03SEP14)

9025-15-36

AA95137,0001219 -19-02MAR10-51/61

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=611

Diagnostic Information

• 5

Anticavitation Valve Stuck Open

Check anticavitation valves. See Hydraulic Control Valve Disassemble and Assemble. (Group 3260.)

YES: Repair or replace anticavitation valve.

Is anticavitation valve worn or damaged?

NO: Go to Hydraulic Lines Blocked or Damaged. AA95137,0001219 -19-02MAR10-52/61

• 6

Hydraulic Lines Blocked or Damaged

Inspect hydraulic lines. See Hydraulic Component Location. (Group 9025-15.)

YES: Repair or replace damaged lines.

Are any hydraulic lines blocked or damaged?

NO: Go to Hydraulic Cylinders Leaking Internally. AA95137,0001219 -19-02MAR10-53/61

• 7

Hydraulic Cylinders Leaking Internally

Check cylinders for leakage. Perform Lift Cylinder Drift Test. (Group 9025-25.)

YES: Repair or replace leaking cylinders.

Are any cylinders leaking?

NO: Go to Hydraulic Pump Worn or Damaged. AA95137,0001219 -19-02MAR10-54/61

• 8

Hydraulic Pump Worn or Damaged

Check pump Flow. Perform Hydraulic Pump Flow Test. (Group 9025-25.)

YES: Checks complete.

Is pump flow to specification?

NO: Repair or replace pump as necessary. AA95137,0001219 -19-02MAR10-55/61

Blade Response Not Smooth Diagnostic Procedure—IGC AA95137,0001219 -19-02MAR10-56/61

• 1

Electrical Connection to Spool Actuators Intermittent

YES: Repair or replace Check harness and connections to control valve actuators. See Integrated Grade Control (IGC) Machine Harness (W21) Wiring Diagram—If Equipped. (Group 9015-10.) harness or connectors as necessary.

Are harness or connectors worn or damaged?

NO: Go to Solenoid Malfunction (DTC). AA95137,0001219 -19-02MAR10-57/61

• 2

Solenoid Malfunction (DTC)

Check for blade solenoid EHC diagnostic trouble codes. See Standard Display Monitor YES: Repair or replace (SDM) Menu Structure—Service Mode. (Group 9015-16.) solenoid as necessary.

Is solenoid malfunctioning?

NO: Go to Hydraulic System Pressure Low. Continued on next page

TM10721 (03SEP14)

9025-15-37

AA95137,0001219 -19-02MAR10-58/61

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=612

Diagnostic Information

• 3

Hydraulic System Pressure Low

Check system pressure. Perform Hydraulic System Relief Valve Test—IGC. (Group 9025-25.)

YES: Go to Hydraulic Control Valve Spool Binding.

Is system pressure to specification?

NO: Replace load sense relief valve. AA95137,0001219 -19-02MAR10-59/61

• 4

Hydraulic Control Valve Spool Binding

Inspect and repair control valve. See Hydraulic Control Valve Disassemble and Assemble—IGC. (Group 3260.)

YES: Repair or replace control valve.

Is control valve spool binding?

NO: Go to Electrohydraulic Malfunction. AA95137,0001219 -19-02MAR10-60/61

• 5

Electrohydraulic Malfunction

Check electrohydraulic circuit. See Integrated Grade Control (IGC) Diagnose Malfunctions—If Equipped. (Group 9015-20.)

YES: Replace or replace as necessary.

Is electrohydraulic circuit malfunctioning?

NO: Checks complete. AA95137,0001219 -19-02MAR10-61/61

TM10721 (03SEP14)

9025-15-38

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=613

Group 20

Adjustments

T201075 —UN—22JUN04

Hydraulic Control Lever Linkage Adjustment

Continued on next page

TM10721 (03SEP14)

9025-20-1

WS68074,0001B99 -19-31MAR08-1/2

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=614

Adjustments 1— Control Housing 2— Ball Bearing (2 used) 3— Universal Joint 4— Control Shaft 5— Washer 6— Snap Ring 7— Washer (2 used) 8— Link

9— Bell Crank 10— Ball Joint 11— Eyebolt 12— Ball Joint 13— Ball Joint 14— Cap Screw (2 used) 15— Lock Nut (5 used) 16— Lock Nut (2 used)

1. Viewing the hydraulic control lever handle from the front of the machine, adjust linkage until lever is tilted 12.3° inward and 9.6° forward. Make adjustment at the control valve by loosening jam nut (17) and turning the spool. Tighten jam nut to specification.

17— Lock Nut (3 used) 18— Washer (4 used) 19— Cap Screw (4 used) 20— Washer (2 used) 21— Cap Screw 22— Washer 23— Boot 24— Screw (4 used)

25— Handle 26— Nut 27— Pin 28— Cotter Pin 29— Grommet (2 used) 30— Ball Joint (2 used)

2. With linkage fully assembled, operate lever through full stroke of all functions. Make adjustments as necessary for operator comfort as long as it does not limit travel of spools.

Specification Jam Nut—Torque...........................................................................20 Nm 177 lb-in. WS68074,0001B99 -19-31MAR08-2/2

TM10721 (03SEP14)

9025-20-2

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=615

Adjustments

T198500 —UN—16MAR04

Auxiliary Lever Linkage Adjustment

Continued on next page

TM10721 (03SEP14)

9025-20-3

CED,TX03768,2292 -19-05OCT98-1/2

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=616

Adjustments 1— Control Valve Linkage Assembly 2— Bracket 3— Washer (2 used)

4— Lever 5— Ball Joint 6— Rod 7— Cap Screw 8— Lock Nut

9— Lock Nut 10— Nut 11— Cap Screw (2 used) 12— Pin

1. Viewing the auxiliary lever from the front of the machine, adjust linkages by loosening nut (10), removing pin (12) from control valve, and turning eyebolt (6). Align lever forward approximately 7.5°.

13— Cotter Pin 14— Grip 16— Boot

3. With linkage fully assembled, operate lever through full stroke of all functions. Make adjustments as necessary for operator comfort as long as it does not limit travel of spools.

2. Tighten lock nut (9) on ball joint to specification. Specification Lock Nut—Torque..........................................................................20 N·m 15 lb-ft CED,TX03768,2292 -19-05OCT98-2/2

Blade Pitch Linkage Adjustment

T200336A —UN—27MAY04

This machine has an adjustable pitch link that can vary the pitch of the blade (angle cutting edge makes with ground) from 52° to 60°. The pitch link has a threaded turnbuckle with left and right hand threads. 1. Raise blade off the ground. Support blade with a floor jack. 2. Relieve all hydraulic system pressure. 3. Turn threaded turnbuckle (2) in or out until desired pitch is achieved. Blade Pitch—Specification Forward—Pitch.............................................................................. 42 mm 1.65 in. Mid—Pitch..................................................................................... 21 mm 0.83 in. Back—Pitch..................................................................................... 0 mm 0 in.

1— 42 mm (1.65 in.) Minimum Pitch 21 mm (0.83 in.) Mid Pitch 0 mm (0 in.) Maximum Pitch

Back pitch is used for fine grading.

Forward pitch is used for maximum material carrying. Mid pitch is used for a combination between maximum material carrying and fine grading.

2— Threaded Turnbuckle

4. Remove floor jack and lower blade to the ground. BR81691,000005B -19-14JAN08-1/1

TM10721 (03SEP14)

9025-20-4

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=617

Adjustments

TM10721 (03SEP14)

9025-20-5

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=618

Group 25

Tests Hydraulic Oil Warm-Up Procedure

3. Place park lock lever in operating position.

SPECIFICATIONS

4. Hold control valve lever in blade lift position over relief for one minute.

Fast idle

Engine Speed

1. Operate engine at fast idle with transmission in park. Specification Engine—Speed...........................................................................Fast idle

2. Observe hydraulic oil temperature from gauge on overhead console.

5. Cycle each hydraulic function twice, observe temperature. 6. Repeat cycle until oil temperature stabilizes to test specification. RR71361,0000115 -19-11DEC07-1/1

Hydraulic Oil Sampling Procedure—If Equipped For hydraulic oil sampling procedure, see Fluid Sampling Procedure—If Equipped. (Group 9010-25.) AA95137,00013E2 -19-25MAR08-1/1

Hydraulic Pump Flow Test 59—71°C 140—160°F

Oil Pressure

13 720—13 860 kPa 137.3—138.7 bar 1990—2010 psi

Engine Speed

1990—2100 rpm

New Pump—Minimum Flow

56.8 L/min 15.0 gpm

Used Pump—Minimum Flow

47.3 L/min 12.5 gpm

X9811 —UN—23AUG88

SPECIFICATIONS Oil Temperature

ESSENTIAL TOOLS JT05691 (1-5/16 M 37° x -16 F ORFS) Adapter (2 Used)

If an accident occurs, see a doctor immediately. Any fluid injected into the skin must be surgically removed within a few hours or gangrene may result. Doctors unfamiliar with this type of injury should reference a knowledgeable medical source. Such information is available from Deere & Company Medical Department in Moline, Illinois, U.S.A.

38H1098 (—16 F x —16 M ORFS) (Parker No. 16C6LO-S) 90° Elbow (2 Used) 38H1281 (—16 M x —16 M ORFS) (Parker No. 16HLO-S) Connector SERVICE EQUIPMENT AND TOOLS Flowmeter Gauge 0—35 000 kPa (0—350 bar) (0—5000 psi)

CAUTION: Escaping fluid under pressure can penetrate the skin causing serious injury. Avoid the hazard by relieving pressure before disconnecting hydraulic or other lines. Tighten all connections before applying pressure. Search for leaks with a piece of cardboard. Protect hands and body from high pressure fluids.

1. Activate control valve levers to release pressure in hydraulic system. 2. Apply vacuum to hydraulic reservoir.

Continued on next page

TM10721 (03SEP14)

9025-25-1

RR71361,0000116 -19-14MAR06-1/2

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=619

T117350B —UN—23SEP98

Tests

A—Inlet Hose B—Flowmeter Valve

C—Connectors D—Control Valve Inlet Port

3. Disconnect control valve inlet hose (A) from control valve inlet port (D). 4. Connect control valve inlet hose (A) to inlet of flowmeter. 5. Connect flowmeter outlet to control valve inlet port. 6. Install connectors (C) of wire harness from flowmeter to flowmeter monitor (E). 7. Heat oil to specification. Slowly turn flowmeter valve (B) to adjust oil pressure. Specification Oil—Temperature......................................................................59—71°C 140—160°F

E—Flowmeter Monitor

Oil—Pressure.......................................................... 13 720—13 860 kPa 137.3—138.7 bar 1990—2010 psi Engine—Speed............................................................. 1990—2100 rpm

8. Record flow. Specification New Pump—Minimum Flow—Flow.............................................................................. 56.8 L/min 15.0 gpm Used Pump—Minimum Flow—Flow.............................................................................. 47.3 L/min 12.5 gpm

9. If flow is below specification, replace pump. RR71361,0000116 -19-14MAR06-2/2

TM10721 (03SEP14)

9025-25-2

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=620

Tests

Hydraulic System Relief Valve Test CAUTION: Escaping fluid under pressure can penetrate the skin causing serious injury. Relieve pressure before disconnecting hydraulic or other lines. Tighten all connections before applying pressure. Keep hands and body away from pinholes and nozzles which eject fluids under high pressure. Use a piece of cardboard or paper to search for leaks. Do not use you hand.

SPECIFICATIONS Engine Speed

Fast idle

Oil Temperature

40—50°C 104—122°F

Hydraulic System Relief Valve Pressure Setting

20 684—22 064 kPa 207—221 bar 3000—3200 psi

ESSENTIAL TOOLS

If ANY fluid is injected into the skin, it must be surgically removed within a few hours by a doctor familiar with this type of injury or gangrene may result.

JT05488 Connector SERVICE EQUIPMENT AND TOOLS

T197856A —UN—16FEB04

Gauge 0—34 000 kPa (0—350 bar) (0—5000 psi)

1— Connector

2— Gauge 3— System Relief Valve

1. Activate control valve levers to release pressure in hydraulic system.

Specification Oil—Temperature......................................................................40—50°C 104—122°F

2. Remove plug from inlet section and install connector (1).

5. Hold blade raise function over relief and record relief pressure of the system relief valve (3).

3. Connect pressure gauge (2). 4. Start engine and run at fast idle. Specification Engine—Speed...........................................................................Fast idle

Heat oil to specification. See Hydraulic Oil Warm-Up Procedure. (Group 9025-25.)

Specification Hydraulic System Relief Valve—Pressure Setting..................................................................... 20 684—22 064 kPa 207—221 bar 3000—3200 psi

Continued on next page

TM10721 (03SEP14)

9025-25-3

AA95137,0000787 -19-03DEC09-1/2

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=621

Tests pressure and out to reduce pressure. See Hydraulic System Relief Valve Operation. (Group 9025-05.)

If needed, adjust system relief valve (3) located in inlet end cap of control valve. Adjust relief in to increase

AA95137,0000787 -19-03DEC09-2/2

Hydraulic System Relief Valve Test—IGC SPECIFICATIONS Engine Speed

Fast idle

Hydraulic Oil Temperature

40—50°C 104—122°F

Hydraulic System Pressure

20 700—21 200 kPa 207—212 bar 3000—3200 psi

SERVICE EQUIPMENT AND TOOLS JT02156A Digital Pressure and Temperature Analyzer

CAUTION: Escaping fluid under pressure can penetrate the skin causing serious injury. Relieve pressure before disconnecting hydraulic or other lines. Tighten all connections before applying pressure. Keep hands and body away from pinholes and nozzles which eject fluids under high pressure. Use a piece of cardboard or paper to search for leaks. Do not use you hand.

If ANY fluid is injected into the skin, it must be surgically removed within a few hours by a doctor familiar with this type of injury or gangrene may result. 1. Relieve pressure in hydraulic system. 2. Remove plug from port M (1) of inlet section and install quick coupler. 3. Connect JT02156A Digital Pressure Analyzer with pressure transducers to quick coupler. 4. Start engine and run at specification. Specification Engine—Speed...........................................................................Fast idle

5. Heat hydraulic oil to specifications.

TX1017933 —UN—25JAN07

Transducer 0—34 450 kPa (0—345 bar) (0—5000 psi)

1— Port M

2— Load Sense Relief Valve

Specification Hydraulic Oil—Temperature......................................................................40—50°C 104—122°F

6. Hold blade lift function over relief and record system pressure. 7. Adjust LS relief valve (2) to specification. Turn adjusting screw in to increase system pressure or out to decrease system pressure. Specification Hydraulic System—Pressure.................................................. 20 700—21 200 kPa 207—212 bar 3000—3200 psi OUO1020,0001601 -19-26NOV07-1/1

TM10721 (03SEP14)

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450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=622

Tests

Circuit Relief Valve Test—With Remote Pump SPECIFICATIONS Oil Temperature

40—50°C 104—122°F

Ripper Circuit Relief Valve Pressure

T148989B —UN—08DEC01

Angle Circuit Relief Valve Pressure 51 710—53 090 kPa 517—531 bar 7500—7700 psi 23 442—24 821 kPa 234.42—248.21 bar 3400—3600 psi

SERVICE EQUIPMENT AND TOOLS JT07192 Electric/Hydraulic Pump 70 000 kPa (700 bar) (10 000 psi) Gauge

IMPORTANT: The circuit relief valve is flow sensitive. A flow rate greater than 7.5 L/min 2 gpm will flood the valve causing an inaccurate pressure reading. A hydraulic source that will provide a continuous flow must be used to get an accurate reading. 1. Warm oil to specification. Perform Hydraulic Oil Warm-Up Procedure. (Group 9025-25.) Specification Oil—Temperature......................................................................40—50°C 104—122°F

2. Stop engine and operate hydraulic functions to relieve pressure.

T148990B —UN—08DEC01

CAUTION: To avoid injury from escaping fluid under pressure, stop engine and relieve the pressure in the system before disconnecting or connecting hydraulic or other lines. Tighten all connections before applying pressure. 3. Disconnect hose from angle valve workport and cap (3). 4. Connect remote pump pressure hose (2) to angle valve workport. Install 10000 psi gauge (5). NOTE: Take reading when pressure on gauge starts to decrease. The point at which pressure decreases is the opening pressure of the relief valve.

1— Circuit Relief Valve (2 used) 2— Remote Pump Pressure Hose 3— Cap

5. Start remote pump to pressurize valve circuit. Record pressure reading when circuit relief valve opens.

4— Remote Pump JT07192 5— 10 000 psi Gauge 6— Remote Pump Switch

6. Adjust or replace as required. Specification Angle Circuit Relief Valve—Pressure...................................................... 51 710—53 090 kPa 517—531 bar 7500—7700 psi

Specification Ripper Circuit Relief Valve—Pressure...................................................... 23 442—24 821 kPa 234.42—248.21 bar 3400—3600 psi

7. Repeat procedure for other angle circuit relief valve. 8. Repeat procedure for ripper circuit relief valves. MR50960,0000109 -19-06SEP07-1/1

TM10721 (03SEP14)

9025-25-5

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=623

Tests

Hydraulic Pump Cycle Time Test

2. Raise blade from ground to maximum height. Record cycle time. Stop watch available in SERVICE ADVISOR readings tab.

SPECIFICATIONS Oil Temperature

40—72° C 104—160° F

Engine Speed

Slow Idle

Blade Lift Cycle Time (Typical New)

6.5 seconds

Blade Lift Cycle Time (Maximum)

7.5 seconds

3. Compare average reading to specification. Specification Blade Lift—Cycle Time (Typical New).........................................................................6.5 seconds Blade Lift —Cycle Time (Maximum)............................................................................7.5 seconds

SERVICE EQUIPMENT AND TOOLS Stop Watch Specification Oil—Temperature.....................................................................40—72° C 104—160° F Engine—Speed..........................................................................Slow Idle

1. Start engine and operate at slow idle.

If average cycle time is greater than either specification, verify engine slow idle speed. See Engine Speed Check. (Group 9010-25.) If average cycle times exceed cycle time (maximum) specification, perform Hydraulic Pump Flow Test. (Group 9025-25.) before replacing pump.

NOTE: Take the average cycle time of three raise cycles. The average cycle time is a general indication of hydraulic pump performance. AA95137,000121D -19-07JAN08-1/1

Lift Cylinder Drift Test 34—46°C 94—114°F

Cylinder Drift With Engine Off

7 mm/min 0.28 in./min

T6222AM —UN—26MAY89

SPECIFICATIONS Oil Temperature

SERVICE EQUIPMENT AND TOOLS Steel Rule Dial Indicator

1. Warm hydraulic oil to specification. Perform Hydraulic Oil Warm-Up Procedure. (Group 9025-25.) Specification Oil—Temperature......................................................................34—46°C 94—114°F

T6222AN —UN—26OCT88

Cycle all functions to circulate oil through system. 2. Raise blade about two feet off the ground and record amount of drift down in one minute. 3. If drift is more than two inches in a minute, measure cylinder rod movement and compare to specifications. Specification Cylinder—Drift With Engine Off................................................................................ 7 mm/min 0.28 in./min

4. If drift is excessive, load cylinder in opposite direction and record amount of drift.

If cylinder drifts in both directions, leakage could be in the control valve.

If cylinder drifts in rod extend function only. Perform Cylinder Leakage Test. (Group 9025-25.) MR50960,0000107 -19-03MAY06-1/1

TM10721 (03SEP14)

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450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=624

Tests

Cylinder Leakage Test SPECIFICATIONS 60—72°C 140—160°F

Approximate Engine Speed

1000 rpm

Cylinder Leakage Test Maximum Allowable Flow

5 mL/min 1/6 oz/min

X9811 —UN—23AUG88

Oil Temperature

1. Heat hydraulic oil to specification. Specification Oil Temperature—Temperature.....................................................................................60—72°C 140—160°F

2. Fully extend rod on cylinder to be checked. Turn engine off.

If ANY fluid is injected into the skin, it must be surgically removed within a few hours by a doctor familiar with this type of injury or gangrene may result. 3. Remove hose from rod end of cylinder. Position a beaker under rod end port. 4. Plug hose that was disconnected from rod end of cylinder.

T6222AL —UN—26OCT88

6. Activate rod extend function and record leakage from rod end of cylinder for one minute. Specification Cylinder Leakage Test—Maximum Allowable Flow.......................................................................... 5 mL/min 1/6 oz/min

If leakage is excessive, remove and repair cylinder.

5. Start and run engine at specification. Specification Approximate Engine—Speed......................................................................... 1000 rpm

MR50960,0000108 -19-03MAY06-1/1

TM10721 (03SEP14)

9025-25-7

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=625

Tests

Oil Clean-up Procedure This procedure is to be used on machines that have had hydraulic system repair without a catastrophic component failure. Filter procedure must be done prior to starting machine after a component has been repaired or replaced. The use of attachments increase the need to monitor and filter oil to a safe contamination level. IMPORTANT: Oil types and filters should not be intermixed. Use filter element in same type oil to avoid intermixing of oils. Avoid operating filter caddy in dusty or wet conditions. Oil contamination could result. Filter caddy requires a 20 amp electric circuit. Use of electrical extension cord is not recommended.

T200210A —UN—21MAY04

NOTE: Instrument cleanliness and clean practices are critical when filtering oil or taking oil samples. Dust, wind, and moisture, as well as contaminated sample pumps, bottles and tubing can effect results. 1. Install proper particle filter cartridge and water filter for type of oil to be filtered. 2. With machine off, remove tank cap slowly to release pressure in hydraulic or hydrostatic oil tank. 29— Oil Filter Storage

30— Water Filter Storage AA95137,000121C -19-07JAN08-1/7

3. Remove cap screw (31) to remove drain cover (32). 32— Drain Valve Cover

T199802A —UN—12MAY04

31— Cap Screw

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450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=626

Tests

4. Attach filter caddy suction wand to drain valve. SERVICE EQUIPMENT AND TOOLS 0.75 in. ID Hose (1 ft) 1.0 in. ID Hose (1 ft) T199803A —UN—12MAY04

1.0 in. Pipe Thread Coupler 1.0 in. Hose Nipple with 1.0 in. Pipe Thread 0.75 in. Hose Nipple with 1.0 in. Pipe Thread Hose Clamp (4 used)

5. Use hose, fittings and hose clamps to attach oil suction wand (24) to tank drain valve. 6. Open drain valve. 24— Suction Wand 33— Clamp (4 used) 34— Drain Valve 35— 0.75 in. ID Hose

Continued on next page

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36— 0.75 in. Hose Nipple 37— 1.0 in. Pipe Thread Coupler 38— 1.0 in. Hose Nipple 39— 1.0 in. ID Hose AA95137,000121C -19-07JAN08-3/7

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=627

T200205A —UN—21MAY04

Tests

1— Stop Button 2— Start Button 3 — Oil Temperature—Moisture Sensor Display 4— ISO Code Monitor 5— Selector Switch 6— Oil Flow Control 7— System Clean Indicator (Yellow) 8— Low Oil Temperature Indicator (Blue) 9— Particle Clean Filter Indicator (Green) 10— Water Clean Filter Indicator (Green)

T200206A —UN—21MAY04

7. Plug oil filter caddy into a 20 amp electrical outlet. Observe filter condition indicators. Green filter condition indicators (9 and 10) should be ON. Red filter condition indicators (11 and 12) ON, requires filter element change. Blue indicator (8) ON, indicates oil temperature is below 27°C (80°F). Use INFO SCROLL (18) button to display oil temperature. 11— Change Particle Filter Reset Button (Red) 12— Change Water Filter Reset Button (Red) 13— Peak ISO Code Value 14— 4-Micron (c) Indicator 15— 6-Micron (c) Indicator 16— 14-Micron (c) Indicator 17— 21- Micron (c) Indicator 18— Code Scroll 19 — Peak ISO Code Value 20— Info Scroll

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TM10721 (03SEP14)

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AA95137,000121C -19-07JAN08-4/7

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=628

Tests

8. Place oil discharge wand (25) in 19 L (5 gal) container. 9. Move particle filter control valve (28) handle on caddy to FILTER position. 10. Move oil moisture filter valve (23) to FILTER position. 11. Place caddy control switch (5) to MANUAL position. 12. Rotate pump oil flow control (6) to 25 percent position. Blue cold start indicator (8) may be ON if oil temperature is below 27°C (80°F). Filter caddy will still allow oil to be filtered at a slower flow rate. 26— Moisture Filter Access Panel 27— Oil Flow Gauge 28— Particle Filter Control Valve 29— Oil Filter Storage 30— Water Filter Storage

T200210A —UN—21MAY04

T198044B —UN—21MAY04

21— Particle Filter Vent Plug 22— Particle Filter Cap 23— Moisture Filter Control Valve 24— Oil Suction Wand (Large) 25— Oil Discharge Wand (Small)

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AA95137,000121C -19-07JAN08-5/7

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=629

Tests

13. Slowly loosen particle filter vent plug (21) to release air trapped in particle filter cartridge container. Close vent plug when oil flow is steady. 14. Allow approximately 4 L (1 gal) of oil to flow through oil filter system into container to purge filter system. Dispose of purged oil properly. 15. Push caddy stop switch (1) to OFF position to stop oil transfer. T198043B —UN—21MAY04

16. Move caddy control switch to AUTO position. 17. Place oil discharge wand in tank below oil surface. IMPORTANT: Discharge oil flow can cause wands to move in tank. Position or block wands if left unattended during filter operation. 18. Wands must maintain position in tank. Suction wand near bottom of tank and discharge wand below oil surface.

21— Particle Filter Vent Plug

22— Particle Filter Cap

19. Reset stop button. CLEAN indicator (7) will illuminate and ISO Code will appear on monitor. The value in the tenths position is not used to determine ISO Codes. Example 13.3 = ISO Code 13, 13.8 = ISO Code 13.

20. Move caddy control switch to AUTO position. 21. Push start button. NOTE: Higher viscosity oil or filter elements that have reached a higher level of contamination, can cause the CHANGE FILTER indicator to come on. Flow rate can be reduced to allow continued use of filter. Filter element should be changed as filtering time increases because flow rate is reduced and possible filter element by-pass.

Specification Contaminant ISO Code Levels—4-micron (c) and Larger.................................................................................. ISO Code 19 6-micron (c) and Larger ...................................................... ISO Code 16 14-micron (c) and Larger ................................................................................. ISO Code 13

22. Rotate oil flow control knob to approximately full flow. Adjust flow to prevent caddy pump cavitation. Pump cavitation will aerate oil and cause ISO particle count to increase. Reduce flow rate to allow continued use of filter with higher levels of contamination. Filter element should be changed as filtering time increases. Filter elements should be changed to avoid system filter by-pass. Dispose of contaminated filters properly.

27. Red filter change indicator (11 and 12) will illuminate should filters become contaminated and restrict oil flow. Flow rate can be reduced to allow continued use of filter. Filter element should be changed as filtering time increases. Filter elements should be changed to avoid system filter by-pass. Dispose of contaminated filters properly.

23. Release air trapped in particle filter cartridge container again. Close when oil flow is steady.

28. When filter caddy is OFF remove filter caddy wands from tank. Wipe wands clean and place in caddy holder.

24. Check flow meter for oil flow rate.

29. Replace hydraulic oil tank cap.

25. Flush sidewalls and bottom of oil tank with discharge wand to loosen oil contaminants and mix with tank oil. Maintain oil suction wand positioned near bottom of tank. Oil discharge wand should be kept under the oil surface as much as possible to avoid aeration of oil. Air trapped in the oil will cause particle count to raise above actual contamination level. 26. Use CODE SCROLL button (18) on lower right corner on ISO Code monitor (4) to scroll and view ISO Codes at 4, 6, and 14-micron (c) sizes. ISO Code counts in each position should be within 3 of each other. Caddy will stop when particle count is approximately ISO Code 13 or lower at 14-micron (c) setting. SYSTEM

CAUTION: Avoid entanglement and possible electrocution from filter caddy power cord. Do not operate machine while filter caddy is connected to machine. IMPORTANT: Do not force the hydraulic system over system relief or over the return filter by-pass. 30. Perform start-up and bleed procedures for components to prevent component damage during startup. See technical manual for start-up and bleed procedures.

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TM10721 (03SEP14)

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AA95137,000121C -19-07JAN08-6/7

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=630

Tests

31. Keep hydraulic oil tank filled to specified operating level. See Check Hydraulic Oil Level. (Operator's Manual 3-4.) 32. Run machine at slow idle. Operate each circuit a minimum of two minutes in each direction to flush any remaining contaminants back through hydraulic oil machine filter. 33. Filter oil again. Repeat process until oil has been cycled through all functions 3—5 times and oil contaminant level is ISO Code 13 or lower at 14-micron (c) level. Use CODE SCROLL to check 4 and 6-micron (c) levels. ISO codes should be within 3 of each other.

38. Return machine to service. NOTE: Additional filtration equipment is recommended for machines in extreme environments. By-pass filtration systems are available. 39. Check and record oil particle counts. After a 100 hours of operation check oil particle count to confirm system is within ISO particle count specification. See Follow-Up Oil Cleanup Procedure. (CTM310.) Some hydraulic systems may not be able to maintain ISO Code 19/16/13 without additional filtration equipment. Auxiliary hydraulic attachments or components can be a point of entry for contamination. Frequent component changes also increase the chances for contaminants to enter the hydraulic system. Use care when connecting and removing components to not introduce contamination. Quick couplers should not be connected until they have been cleaned and capped when not in use. Fluid sampling and filter changes should increase if the application requires frequent component changes.

34. When machine reaches acceptable level of cleanliness, install new machine hydraulic oil return filter. 35. Fill tank to proper operating level. NOTE: Instrument cleanliness and clean practices are critical when filtering oil or taking oil samples. Dust, wind, and moisture, as well as contaminated sample pumps, bottles and tubing can effect results. 36. Obtain oil sample for fluid analysis. Oil sample should be taken just before the return filter when oil is warm.

40. Every Six Months for validation purposes use sample valve on Super Caddy to check for correct instrument readings. Results from lab cannot be identical to Super Caddy particle counter readings, but a correlation should exist. If validation testing shows a discrepancy of more than one code per particle size, sample oil again. If discrepancy in instrument readings persist, the particle counter must be checked by PALL Corporation.

37. Remove caddy filters and place in correct sealed containers in filter storage area. AA95137,000121C -19-07JAN08-7/7

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450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=631

Tests

TM10721 (03SEP14)

9025-25-14

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=632

Section 9026 Hydrostatic System Contents Page Page

Group 05—Theory of Operation Hydrostatic System.................................... 9026-05-1 Transmission Control Circuit Operation (Flow Chart) .......................... 9026-05-2 Charge Pump Operation............................ 9026-05-3 Hydrostatic Filter Operation....................... 9026-05-4 Neutral Charge Relief Valve Operation............................................... 9026-05-7 Park Brake Operation ................................ 9026-05-8 Multi-Function Valve Operation ............... 9026-05-10 Oil Cooler Bypass Valve Operation............................................. 9026-05-12 Pump Pressure Control Pilot (PCP) Operation............................................. 9026-05-13 Pump Displacement Control Valve (PDCV) Operation ............................... 9026-05-14 Hydrostatic Pump Operation ................... 9026-05-15 Flushing Valve and Operating Charge Relief Valve Operation ............ 9026-05-16 Hydrostatic Motor Operation.................... 9026-05-18 Group 15—Diagnostic Information Hydrostatic Schematic—Neutral (Park Brake ON) .................................... 9026-15-1 Hydrostatic System Component Location ................................................. 9026-15-5 Hydrostatic System Diagram—Park Brake On (Neutral)............................................... 9026-15-13 Hydrostatic System Diagram—Forward (Slow Speed) ................................................. 9026-15-17 Hydrostatic System Diagram—Reverse (Fast Speed) ................................................. 9026-15-21 Overheating Malfunctions........................9026-15-11 Overheating Diagnostic Procedure............................................9026-15-11 High/Low Charge Pressure Malfunctions ........................................9026-15-13 High/Low Charge Pressure Diagnostic Procedure............................................9026-15-13 Mistrack/Index Malfunctions ....................9026-15-16 Mistrack or Index Diagnostic Procedure............................................9026-15-16 Machine Full Speed Malfunctions.....................................................9026-15-21 Machine Will Not Reach Full Speed Diagnostic Procedure..........................9026-15-21 Low Power Malfunctions..........................9026-15-23 Low Power Diagnostic Procedure .....................................................9026-15-23 Track Malfunctions ..................................9026-15-28

TM10721 (03SEP14)

Engine Starts but Both Tracks Either Do Not Move or Come to a Stop Diagnostic Procedure..........................9026-15-28 Machine Moves in Only One Direction or One Track Does Not Move Diagnostic Procedure..........................9026-15-30 TCU Calibration Malfunctions..................9026-15-32 TCU Calibration Malfunctions Diagnostic Procedure..........................9026-15-32 Group 25—Test JT05800 Digital Thermometer Installation ............................................. 9026-25-1 Digital Pressure And Temperature Analyzer Installation .............................. 9026-25-1 Hydraulic Oil Cleanup Procedure .............. 9026-25-1 JDG1770 Ultra Clean® Hand Launcher................................................ 9026-25-1 Transmission Oil Warmup Procedure .............................................. 9026-25-2 Hydrostatic Oil Sampling Procedure—If Equipped ........................ 9026-25-2 Releasing Park Brake to Tow the Machine ................................................. 9026-25-3 Hydrostatic Pump and Motor Initial Start-Up Procedure................................ 9026-25-6 Hydrostatic Pump Flushing Procedure .............................................. 9026-25-8 Pressure Control Pilot (PCP) Manual Override Test ............................ 9026-25-9 Pressure Control Pilot (PCP) Test............ 9026-25-10 Pressure Control Pilot (PCP) Internal Adjustment.............................. 9026-25-12 Multi-Function Relief Valve Test .............. 9026-25-14 Transmission Efficiency Test ................... 9026-25-17 Neutral Charge Relief and Operating Charge Relief Pressure Test....................................... 9026-25-21 Pump Displacement Control Valve (PDCV) Neutral (Null) Adjustment........................................... 9026-25-23 Pump Servo Pressure Test...................... 9026-25-25 Hydrostatic Motor Min./Max. Angle Servo Piston Pressure Test ................. 9026-25-27 Hydrostatic Motor Min. Angle Stop Adjustment........................................... 9026-25-28 Charge Pump Flow Test .......................... 9026-25-30 Cooler Bypass Valve Test........................ 9026-25-32

9026-1

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=1

Contents

TM10721 (03SEP14)

9026-2

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=2

Group 05

Theory of Operation Hydrostatic System The dual path hydrostatic drive system consists of axial piston pumps and 2-position axial piston motors. The transmission control is governed by an electronic controller. The pumps are mounted directly to the engine in a tandem configuration and are designed for through torque capability. This means the main hydraulic pump and the winch can be driven from the back of the tandem pump. High pressure hoses transmit pump flow to the motors. The variable displacement 2-position motors are mounted directly to the final drive. The transmission control can be divided into three groups: inputs, outputs and feedbacks. The operator sends inputs into the transmission controller from steering sensors, decelerator sensor, FNR sensor, transmission speed control sensor and engine speed control sensor.

The transmission controller sends a current signal to the Pressure Control Pilot (PCP) on each pump. The PCP is a servo valve which produces a hydraulic pressure differential relative to amount of current. The pressure differential is sent to the Pump Displacement Control Valve (PDCV) on the pump. The transmission controller also sends a current signal to energize the solenoid valve on the motor. The motor is normally held at its maximum displacement (lower speed, up to 3.25 mph). Energizing the solenoid will cause the motor to go to its minimum displacement (higher speed, above 3.25 mph). The left and right track motor speed sensors provide the feedback to the transmission controller for tracking. Rpm feedback for anti-stall is read from engine controller. The transmission controller compares the operator input command and the feedback from the sensors and regulates the output accordingly. CED,TX03543,2286 -19-16MAY03-1/1

TM10721 (03SEP14)

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450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=635

Theory of Operation

Transmission Control Circuit Operation (Flow Chart) B5 STEER SENSOR

B2 TCL SENSOR

R10 ENGINE SPEED CONTROL

B4 TRANSMISSION SPEED CONTROL SWITCH

1 OPERATOR INPUT COMMANDS

H1 STANDARD DISPLAY MONITOR (SDM)

2 POWER IN 12V DC 3 (TRACKING FEEDBACK)

B8 PUMP PRESSURE CONTROL PILOT (PCP) REAR

(TRACKING FEEDBACK) 3

A1 TRANSMISSION CONTROL UNIT (TCU) 4 CURRENT

B1 DECELERATOR SENSOR

CURRENT 4

TO LEFT 7 8 TRACK THROTTLE ANTI5 COMMAND STALL

TO RIGHT TRACK 6

B9 PUMP PRESSURE CONTROL PILOT (PCP) FRONT

Y4 MOTOR SHIFT SOLENOID LEFT

19 CONTROL PRESSURE

10 DIFFERENTIAL CONTROL PRESSURE

11 FUEL DELIVERY COMMAND

REAR PUMP DISPLACEMENT CONTROL VALVE (PDCV) 12

ENGINE 14

CHARGE PRESSURE 20

FRONT PUMP 15

LEFT MOTOR

CLOSED LOOP 21 PRESSURE RPM

FRONT PUMP DISPLACEMENT CONTROL VALVE (PDCV) 13

10 DIFFERENTIAL CONTROL PRESSURE

A3 ENGINE CONTROL UNIT (ECU)

CHARGE 20 PRESSURE CLOSED LOOP 21 PRESSURE

REAR PUMP 16

B7 MOTOR SPEED SENSOR LEFT

VOLTAGE

Y3 MOTOR SHIFT SOLENOID RIGHT

19 CONTROL PRESSURE

18 RIGHT MOTOR

B3 MOTOR SPEED SENSOR RIGHT

(TRACKING FEEDBACK) 3

RPM

3 (TRACKING FEEDBACK)

TX1074826

TX1074826 —UN—22APR10

VOLTAGE

Transmission Control Circuit

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KK70125,00005B3 -19-26MAR10-1/2

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=636

Theory of Operation 12— Rear Pump Displacement 1— Operator Input Commands Control Valve (PDCV) 2— Power in 12V DC 13— Front Pump Displacement 3— Tracking Feedback Control Valve (PDCV) 4— Current 14— Engine 5— To Left Track 15— Front Pump 6— To Right Track 16— Rear Pump 7— Throttle Command 17— Left Motor 8— Anti-Stall 18— Right Motor 9— Voltage 10— Differential Control Pressure 19— Control Pressure 20— Charge Pressure 11— Fuel Delivery Command 21— Closed Loop Pressure

A1—Transmission Control Unit B9—Pump Pressure Control Pilot (TCU) (PCP) Front A3—Engine Control Unit (ECU) H1—Standard Display Monitor B1—Decelerator Sensor (SDM) B2—TCL Sensor R10— Engine Speed Control B3—Motor Speed Sensor Right Y3— Motor Shift Solenoid Right B4—Transmission Speed Control Y4— Motor Shift Solenoid Left Sensor B5—Steer Sensor B7—Motor Speed Sensor Left B8—Pump Pressure Control Pilot (PCP) Rear KK70125,00005B3 -19-26MAR10-2/2

Charge Pump Operation

T197492 —UN—30JAN04

3 4

T197492 Charge Pump 1— To Hydrostatic Filter

2— From Reservoir 3— Return Oil

4— Charge Pressure Oil

The charge pump is an integral part of each hydrostatic pump. The charge pump is a gerotor type pump and is driven directly at engine speed. Each pump has a separate suction line from the reservoir (2). Charge pressure oil from each pump is then combined and sent to a single

filter (1). Passing through the filter, the charge oil is routed to the control circuit for each hydrostatic pump and to the park brake valve. A neutral charge relief valve located on the front pump return line from the hydrostatic filter regulates charge pressure and protects the charge pumps. CED,TX03543,2288 -19-07OCT98-1/1

TM10721 (03SEP14)

9026-05-3

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=637

Theory of Operation

Hydrostatic Filter Operation Filter Operation (S.N. —180554)

7 6

A-A 9

T197493

T197493 —UN—30JAN04

Filter Operation (S.N. —180554) 1— High Pressure Passage 2— Low Pressure Passage

3— Filter Restriction Indicator Switch 4— Switch Spring

5— Bypass Valve 6— Filter Element 7— Inlet 8— Outlet

The hydrostatic filter removes contaminants from the hydrostatic oil system. The filter head (9) contains a bypass valve (5) and a filter restriction indicator switch (3). Under normal operation, charge pressure oil (9) enters the inlet (7), flows through the filter element (6), up through the filter canister, and out the outlet (8) to the neutral charge relief, park brake valve, pump pressure control pilot valve (PCP), and pump displacement control valve (PDCV) control circuit for each hydrostatic pump. If the pressure differential between the inlet and outlet increases past a set level due to cold oil or partially restricted filter element, inlet pressure in the housing increases, moving the filter relief valve against spring force and outlet pressure. Inlet pressure also moves the switch piston causing the filter restriction indicator light to glow.

As the filter element becomes plugged, the pressure differential between the inlet and outlet increases. Inlet pressure is sensed on one side of the valve which opens against spring force and outlet pressure. The oil then bypasses the filter while the restriction indicator light glows. It is normal for the restriction indicator light to glow when operating the machine with cold oil. If the restriction indicator light continues to glow after the oil reaches operating temperature, the filter is being bypassed and the filter element should be replaced. Extended operation in the bypass mode could cause damage to the hydrostatic system.

Continued on next page

TM10721 (03SEP14)

9— Charge Pressure Oil

9026-05-4

JW40272,0000014 -19-04FEB10-1/3

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=638

Theory of Operation Filter Operation (S.N. 180555— )

B 9 3

B-B B 611 TX1068362

TX1068362 —UN—10DEC09

Filter Operation—Normal (S.N. 180555— ) 1— High Pressure Passage 2— Low Pressure Passage 3— Filter Restriction Indicator Switch

7— Inlet 8— Outlet 9— Filter Head 611— Charge Pressure Oil

4— Switch Spring 5— Bypass Valve 6— Filter Element

Filter Operation—Normal:

control pilot valve (PCP), and pump displacement control valve (PDCV) control circuit for each hydrostatic pump.

The hydrostatic filter removes contaminants from the hydrostatic oil system. The filter head contains a bypass valve (5) and a filter restriction indicator switch (3). Under normal operation, charge pressure oil (611) enters the inlet (7), flows through the filter element (6), up through the filter canister, and out the outlet (8) to the neutral charge relief, park brake valve, pump pressure

If the pressure differential between the inlet and outlet increases past a set level due to cold oil or partially restricted filter element, inlet pressure in the housing increases, moving the filter relief valve against spring force and outlet pressure. Inlet pressure also moves the switch piston causing the filter restriction indicator light to glow.

Continued on next page

TM10721 (03SEP14)

9026-05-5

JW40272,0000014 -19-04FEB10-2/3

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=639

Theory of Operation

B-B B

611 613

TX1068363

TX1068363 —UN—10DEC09

Filter Operation—Restricted (S.N. 180555— ) 1— High Pressure Passage 2— Low Pressure Passage 3— Filter Restriction Indicator Switch

4— Switch Spring 5— Bypass Valve 6— Filter Element 7— Inlet

8— Outlet 9— Filter Head 611— Charge Pressure Oil 613— Reduced Charge Pressure Oil

Filter Operation—Restricted: Filter restriction indicator switch (3) works on same principle as the filter bypass valve (5). High pressure oil is sensed through the high pressure passage (1). When charge pressure oil (611) flow is restricted due to a clogged filter element (6) it creates higher oil pressure on the inlet (7) side. As the filter element becomes plugged, the pressure differential between the inlet and outlet increases. Inlet pressure is sensed on one side of the valve which opens

against spring force and outlet pressure. The oil then bypasses the filter while the restriction indicator light glows. It is normal for the restriction indicator light to glow when operating the machine with cold oil. If the restriction indicator light continues to glow after the oil reaches operating temperature, the filter is being bypassed and the filter element should be replaced. Extended operation in the bypass mode could cause damage to the hydrostatic system. JW40272,0000014 -19-04FEB10-3/3

TM10721 (03SEP14)

9026-05-6

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=640

Theory of Operation

Neutral Charge Relief Valve Operation The neutral charge relief valve sets charge pressure and provides relief for the charge circuit in neutral. It is direct acting and adjustable. It is located on the front hydrostatic pump return line from the filter housing. While the machine is in neutral, charge pressure oil coming from the hydrostatic filter (4) opens the relief valve poppet (3) allowing oil to flow to both front and rear pumps (1) and (2) for cooling . 1— To Front Pump Side Cover 2— To Rear Pump Side Cover 3— Relief Valve Poppet

4— From Hydrostatic Filter 5— Charge Pressure Oil 6— Lubrication (Cooling) Oil

T197494 —UN—24FEB04

2 5 6 Neutral Charge Relief Valve

CED,TX03543,2290 -19-23AUG02-1/1

TM10721 (03SEP14)

9026-05-7

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=641

Theory of Operation

Park Brake Operation

5 6 2

T197551

T197551 —UN—04FEB04

Park Brake Valve (Brake ON) 1— Charge Pressure Inlet 2— To Reservoir

3— To Brakes 4— Park Brake Solenoid

5— Charge Pressure Oil 6— Return Oil Continued on next page

TM10721 (03SEP14)

9026-05-8

TE14778,000001E -19-13JAN04-1/3

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=642

Theory of Operation

T197648 —UN—16FEB04

8 9

T197648 Park Brake Operation - Park Brake ON 1— Pressure Plate 2— Friction Disk 3— Final Drive Gear

4— Piston 5— Spring 6— Park Brake Solenoid

7— From Charge Pump 8— Charge Pressure Oil

The multiple wet disk park brakes are located in the final drives. The park brakes are spring applied and hydraulically released. When the park lock lever is in the DOWN position or the brake pedal is fully depressed or the machine is shut off, spring force applies the park brakes. When the park lock lever is in the UP position and pressure on the brake pedal is removed, the park brake is released.

9— Return Oil

gear. When the park brake is released, the park brake solenoid is energized and charge pressure oil enters the cavity behind the piston which compresses the springs. This allows the friction disks to rotate with the final drive gear and the machine is free to move.

The separator plates are held stationary with the brake housing. The friction disks are splined to the final drive Continued on next page

TM10721 (03SEP14)

9026-05-9

TE14778,000001E -19-13JAN04-2/3

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=643

Theory of Operation

When the park brake is applied or the machine is shut off, the park brake solenoid is de-energized. The solenoid valve blocks oil from the charge pump and opens the piston cavity to return. The springs force the piston towards the final drive compressing the pressure plates

against the friction disks. This locks the final drive gear to the brake housing to apply the brake. To manually release the park brake See Releasing Park Brake to Tow the Machine. (Group 9026-25.) TE14778,000001E -19-13JAN04-3/3

Multi-Function Valve Operation 2

T197495 —UN—30JAN04

6 7 T197495

4 Multi-Function Valve - Make-Up operation

1— High Pressure Relief Valve Poppet 2— Check Valve Poppet

3— Pressure Limiter Poppet 6— Charge Pressure Oil 4— Spring Seat 7— Return Oil 5— Pressure Limiter Poppet Seat

The multi-function valves are located in the pump end cap. There are two multi-function valves for each pump. The valves are in the closed-loop circuit. They sense closed-loop pressure. Two functions performed by each valve include closed-loop charge and high pressure relief. Closed-Loop Charge As soon as there is charge pressure, it is sensed at the check valve poppet (2). The

check valve also senses closed-loop pressure. Any time the closed-loop pressure is less than charge pressure the check valve moves the high pressure relief valve poppet (1) off its seat and there is charge flow into the closed loop. This keeps the closed loop filled with charge oil under all normal operating conditions. This function is similar to that of an anticavitation valve in a hydraulic system.

Continued on next page

TM10721 (03SEP14)

9026-05-10

CED,TX03543,2292 -19-03JAN06-1/2

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=644

Theory of Operation

6 T197496 —UN—30JAN04

7 8 9 T197496

Multi-Function Valve - High Pressure Relief Operation 1— High Pressure Relief Valve Poppet 2— Check Valve Poppet

3— Pressure Limiter Poppet 6— High Pressure Oil 4— Spring Seat 7— Reduced High Pressure Oil 5— Pressure Limiter Poppet Seat 8— Charge Pressure Oil

High Pressure Relief During normal operation of the machine, the pressure limiter poppet (3) senses closed-loop pressure and is held against its seat by spring force through the spring seat (4). Relief operation occurs when the closed-loop pressure on the limiter poppet overcomes the spring force on it causing it to move off its seat. In this condition there is oil

9— Return Oil

flow through the high pressure relief valve poppet orifice (1), the unseated limiter poppet (3), and out of the housing to pump case. The oil flow through the orifice causes a pressure drop across the high pressure relief moving it off the valve seat. This allows closed-loop high pressure oil to flow past the poppet and into the charge circuit. CED,TX03543,2292 -19-03JAN06-2/2

TM10721 (03SEP14)

9026-05-11

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=645

Theory of Operation

Oil Cooler Bypass Valve Operation 3

T197497 —UN—30JAN04

7 T197497 Oil Cooler Bypass Valve 1— To Oil Cooler 2— From Pump Case Drain

3— Transmission Temperature Switch 4— From Motor Case Drain

The oil cooler bypass valve provides a means of quickly warming up the transmission oil after machine start up. The bypass valve prevents transmission cold oil from entering the cooler. The bypass also relieves cooling flow from the hydrostatic pump and motor cases directly to the reservoir in case the oil cooler becomes plugged. The operation of the oil cooler bypass valve is similar to that of a water thermostat in an engine. When oil temperature reaches approximately 140°, the thermostat begins to open. As oil temperature increases, the valve opens further until it reaches the full open position at approximately 165°.

5— To Reservoir 6— From Oil Cooler 7— Return Oil

This allows full case cooling oil to flow around the valve and out to the oil cooler. Return flow from the cooler goes around the land of the valve and returns to the reservoir. If the oil cooler becomes plugged, the pressure overcomes the relief spring and closes the valve. With the valve closed, case flow returns directly to the reservoir protecting the case seals and oil cooler from excessive pressure buildup. There is an indicator on the monitor that reads transmission oil temperature. The sending unit for the indicator is located in the case oil inlet to the bypass valve. CED,TX03543,2293 -19-07OCT98-1/1

TM10721 (03SEP14)

9026-05-12

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=646

Theory of Operation

Pump Pressure Control Pilot (PCP) Operation

3 1 4 2 5

T197498 —UN—30JAN04

6 7 8 T197498 Pressure Control Pilot (PCP) - Neutral 1— Torque Motor 2— Coil 3— Orifice

4— Nozzle 5— Flapper Valve 6— Charge Pressure Oil

There are two identical pressure control pilots (PCP's), one for each pump. The basic function of each PCP is to take a current signal from the transmission controller and convert it to a differential control pressure which is sent to each pump displacement control valve to regulate swash angles. The major components of the PCP are the torque motor and the flapper valve. The coil establishes a magnetic force to position the flapper valve. One coil is used for forward and reverse. The flapper is centered between two nozzles. Centering springs help keep the flapper at null. Upstream from each nozzle is an orifice which provides a nominal pressure drop when the system is at null. With the flapper at null there is equal charge oil flow and both output pressures are equal. When the machine is in neutral, no current signal is sent to the torque motor. The centering springs hold the flapper in a null (centered) position. Charge oil is equal through both upstream orifices and through each nozzle. With equal flow and pressure drop the two output pressures are exactly the same and the pressure differential is zero. In this condition the pump swash angle will be zero and the motor will be at maximum swash angle.

7— Low Pressure Control Oil 8— Return Oil

When the machine is in forward, the transmission controller will send a positive current signal to the coil in the pump PCP's. The coil produces a magnetic field in a given direction which in turn causes the flapper to move accordingly. The flapper restricts oil flow through one nozzle and opens the other. This produces a higher pressure at the restricted nozzle and a lower pressure at the unrestricted nozzle. Thus an output pressure differential is produced. This in turn will cause the pump displacement control valve to increase the pump swash angle and increase machine speed. For reverse operation, the transmission controller sends a negative current signal in the opposite direction compared to forward. Thus the magnetic field in the pump PCP is in the opposite direction which cause the flapper to move toward the opposite nozzle orifice. There is a manual mode which is controlled by a small external lever on the PCP. The lever is connected to the flapper valve. The lever can be moved in both directions which causes the flapper valve to move the same as with a current signal. This will manually override the transmission controller current signal. CED,TX03543,2294 -19-03MAR99-1/1

TM10721 (03SEP14)

9026-05-13

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=647

Theory of Operation

Pump Displacement Control Valve (PDCV) Operation 2 1

4 5 6

4 10

T197499 —UN—30JAN04

9 8

7 T197499 Pump Displacement Control Valve (PDCV) - Neutral 1— Null Adjustment Screw 2— Control Pressure From Pressure Control Pilot (PCP) 3— Connects To Pump Swashplate Feedback Linkage

4— To Reservoir 5— Charge Pressure Inlet 6— Control Pressure From Pressure Control Pilot (PCP)

The major components in the pump displacement control valve are the valve spool with centering spring, feedback linkage to the pump swash plate, and a null adjusting screw. The PDCV is supplied with charge pressure and a differential control pressure from the Pressure Control Pilot (PCP). It produces a servo pressure at two output ports which directs the pump servo piston. In a neutral condition with zero differential control pressure, the valve spool is centered by the feedback linkage and the centering spring. Charge pressure is blocked at the spool center and both output ports are connected to case. In forward, a given differential control pressure will shift the spool against the centering spring. Charge oil is now directed to the servo piston that swashes the pump in forward. As the swash plate moves, the feedback linkage

7— To Pump Servo 8— To Pump Servo 9— Charge Pressure Oil 10— Low Pressure Control Oil

11— Return Oil

causes a movement on the centering spring opposite to that of the differential control pressure. The spool moves back toward neutral to a point where a given servo pressure is maintained to the servo piston. This provides control of the pump swash plate relative to differential control pressure. In reverse the PCP produces a differential control pressure of the opposite polarity, the spool is moved in the opposite direction and charge oil is directed to the opposite servo piston. Thus the pump is swashed for reverse operation. The null adjust screw through the feedback linkage adjusts the centering position of the spool. The adjustment is made so that with no current signal to the PCP the valve spool is exactly centered. Charge pressure is blocked and both output ports are connected to case. CED,TX03543,2295 -19-07OCT98-1/1

TM10721 (03SEP14)

9026-05-14

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=648

Theory of Operation

Hydrostatic Pump Operation 2

4 T197500 —UN—30JAN04

6 7 5 T197500 Hydrostatic Pump - Neutral 1— Swash Plate 2— Case Drain 3— Piston

4— Servo Piston 5— From Neutral Charge Relief Valve

Two pumps are mounted directly to the engine in a tandem configuration and are designed for through torque capability. This means the main hydraulic pump and the winch can be driven from the back of the tandem pump. Each pump consists of a nine piston rotating group of the parallel axial piston/slipper design, a tiltable cradle swash plate that controls pump flow and direction and a integral geroter type charge pump mounted on the pump drive shaft. A hydraulic displacement control valve directs swash plate angle through a double servo piston assembly and a pressure control pilot (PCP) which controls the hydraulic displacement control valve. The output of the PCP is controlled by a milliamp current signal from the transmission controller. In addition each pump has two multi-function valves in the end cap. The front pump is connected to the right motor by pressure hoses. In the same manner the rear pump is connected to the left motor.

6— Charge Pressure Oil 7— Return Oil

movement of the pistons and no pump flow. In forward the transmission controller sends an current signal to the pressure control pilot (PCP) which sends a differential control pressure to the pump displacement control valve (PDCV). The PDCV sends a controlled charge pressure to one of the servo pistons. As the piston is moved the swash plate which is connected to it also moves. Now with a given amount of swash plate angle, there will be a given amount of axial movement of pistons and a given amount of pump flow. In reverse the transmission controller sends a current signal of opposite polarity to the PCP. In turn then all the control signals and movements are reversed. With the swash plate movement reversed the pump output will be switched from one side of the closed loop to the other side. The pump is protected from high pressure by two multi-function valves, one for each direction.

Both pump rotating groups turn at engine speed. In neutral the swash plate is at zero and there is no axial CED,TX03543,2296 -19-16MAY03-1/1

TM10721 (03SEP14)

9026-05-15

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=649

Theory of Operation

Flushing Valve and Operating Charge Relief Valve Operation

T197501 —UN—04FEB04

5 4

T197501

Flushing Valve and Operating Charge Relief Valve - Neutral 1— Flushing Valve 3— To Motor Case 2— Operating Charge Relief Valve 4— From Closed Loop

5— Charge Pressure Oil 6— Return Oil

The flushing valve and the operating charge relief valve are a part of the closed loop and are used to cool both the oil and the hydraulic components of the closed loop circuit.

operating charge relief valve. Its setting is approximately 30 psi below that of the neutral charge pressure relief valve. With this pressure difference relationship and with pressure oil taking the path of least resistance, there will be oil flow through the operating charge pressure relief valve. In this condition, oil on the low pressure side of the closed loop will be lost through the flushing and operating charge pressure relief valves. To make up for this loss, cool filtered oil from the charge circuit will enter the low side of the closed loop through the multi-function valve. Thus there is constant flow of clean cool oil into the closed loop when in forward.

The flushing valve (shuttle valve) is a spring balanced spool that senses pressure on both sides of the closed loop. The operating charge pressure relief valve is of the direct acting, orificed, poppet type design. In neutral with equal pressure on both sides of the closed loop, the springs center the flushing valve spool. In the centered position operating charge pressure relief valve is not connected to the closed loop. The closed loop pressure is controlled by the neutral charge pressure relief valve. In forward, one side of the closed loop will be at a higher pressure than the other. The flushing valve senses this and shifts away from the high pressure. In this position the lower pressure side of the closed loop is connected to the

In reverse, the closed loop pressures switch from one side to the other, the flushing valve shifts to the opposite side and the low side pressure is again connected to the operating charge pressure relief valve. As in forward the hot oil in the closed loop is routed out and clean oil is directed in. CED,TX03543,2297 -19-07OCT98-1/1

TM10721 (03SEP14)

9026-05-16

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=650

Theory of Operation

TM10721 (03SEP14)

9026-05-17

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=651

Theory of Operation

Hydrostatic Motor Operation 10 7

5 8

11 12 1

9 4

T197502 —UN—19FEB04

13 14

T197502 Hydrostatic Motor - Neutral

Continued on next page

TM10721 (03SEP14)

9026-05-18

CED,TX03543,2298 -19-05JAN06-1/2

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=652

Theory of Operation 1— To Reservoir 2— Not used 3— Charge Pressure 4— To Reservoir 5— Motor Shift Solenoid Valve

10— Minimum Displacement 6— Servo Piston Limiter 7— Hydrostatic Motor 11— From Charge Pump 8— Motor Speed Sensor 9— Operating Charge Relief Valve 12— To Oil Cooler Bypass Valve

13— Charge Pressure Oil 14— Return Oil

Two hydrostatic motors are mounted to the rear of the machine frame. The motors are two position, variable displacement. An internal shaft connects each motor to the final drive. The control utilizes an electric three way, two position, solenoid operated, hydraulic valve to port system pressure to the servo piston. The motor is normally held at its maximum displacement. Energizing the solenoid will shift the motor swash to minimum displacement.

pressure to the Pump Displacement Control Valve (PDCV). The PDCV will send differential control pressure to swash the pump from 0––16.5°. Until the pump swash reaches 16.5°, there will be zero voltage to the motor shift solenoid and the machine will remain at slow speed, maximum torque.

Neutral Operation

As the TCU receives input commands for increased speed, the current to the pump PCP increases. When the pump reaches its maximum swash (16.5°), the TCU also applies voltage to the motor shift solenoid, energizing the solenoid, sending closed loop pressure to the fast speed and slow speed ends of the servo piston. Since the differential area is greater on the fast speed end of the piston, it shifts, moving the motor swash from 23° to 19.5° degrees (fast speed, minimum torque). At the same time, the TCU applies a lower current to the pump PCP which in turn moves the pump swash angle from 16.5° to 13° degrees. As the command for speed increases the pump swash will continue until it again reaches 16.5° or maximum speed.

With the Transmission Control Lever (TCL) in neutral the Transmission Control Unit (TCU) applies zero voltage to the motor shift solenoid. Closed loop pressure, charge pressure when in neutral, is sent to the solenoid. With zero voltage at the solenoid, control pressure is routed to the slow speed end of the servo piston. Since the opposite end of the piston is connected to return, the piston shifts, moving the motor swash angle to the slow speed, maximum angle position. Therefore, when the TCL is moved out of neutral, the motor always starts turning at slow speed, maximum torque.

Forward or Reverse (Fast Speed)

Forward or Reverse (Slow Speed) The TCU applies a low current to the pump Pressure Control Pilot (PCP) which in turn sends a differential CED,TX03543,2298 -19-05JAN06-2/2

TM10721 (03SEP14)

9026-05-19

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=653

Theory of Operation

TM10721 (03SEP14)

9026-05-20

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=654

Group 15

Diagnostic Information Hydrostatic Schematic—Neutral (Park Brake ON) TX1074331 —UN—05APR10

12 PARK BRAKE VALVE

2 ORIFICE 4 OPERATING CHARGE RELIEF VALVE

13 CHARGE PRESSURE SENSOR

FLUSHING VALVE

2 ORIFICE

NEUTRAL CHARGE RELIEF VALVE 21

7 1

SERVO PISTON

MOTOR SHIFT SOLENOID

HYDROSTATIC OIL FILTER 22

20 HYDROSTATIC PUMP FRONT

11 BRAKE PISTON

23 QUICK COUPLER

5 HYDROSTATIC MOTOR LEFT (TWO SPEED)

24 CHARGE PRESSURE OIL 25 LOW PRESSURE OIL 26 RETURN OIL

8 TRANSMISSION TEMPERATURE SWITCH

MULTIFUNCTION VALVE 15

HYDRAULIC PUMP 14

9 OIL COOLER BYPASS VALVE

MULTIFUNCTION VALVE 15

6 HYDROSTATIC MOTOR RIGHT (TWO SPEED) 10 OIL COOLER

2 ORIFICE 4 OPERATING CHARGE RELIEF VALVE

MULTIFUNCTION VALVE 15

18 CHARGE PUMP

3 FLUSHING VALVE

PUMP DISPLACEMENT CONTROL 16 VALVE (PDCV)

ORIFICE 7 1

SERVO PISTON

MOTOR SHIFT SOLENOID

23 QUICK COUPLER

19 HYDROSTATIC PUMP REAR

17 PRESSURE CONTROL PILOT (PCP)

TX1074331 Hydrostatic Schematic—Neutral (park brake on)

TX18203,0000054 -19-25MAR10-1/2

Continued on next page

TM10721 (03SEP14)

9026-15-1

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=655

Diagnostic Information

TM10721 (03SEP14)

9026-15-2

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=656

Diagnostic Information 8— Transmission Temperature 1— Motor Shift Solenoid Switch 2— Orifice 9— Oil Cooler Bypass Valve 3— Flushing Valve 4— Operating Charge Relief Valve 10— Oil Cooler 11— Brake Piston 5— Hydrostatic Motor Left (two 12— Park Brake Valve speed) 6— Hydrostatic Motor Right (two 13— Charge Pressure Sensor 14— Hydraulic Pump speed) 15— Multi-Function Valve 7— Servo Piston

16— Pump Displacement Control 22— Hydrostatic Oil Filter Valve (PDCV) 23— Quick Coupler 17— Pressure Control Pilot (PCP) 24— Charge Pressure Oil 18— Charge Pump 25— Low Pressure Oil 19— Hydrostatic Pump Rear 26— Return Oil 20— Hydrostatic Pump Front 27— Screen Filter (6 used) 21— Neutral Charge Relief Valve

TX18203,0000054 -19-25MAR10-2/2

TM10721 (03SEP14)

9026-15-3

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=657

Diagnostic Information

TM10721 (03SEP14)

9026-15-4

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=658

Diagnostic Information

Hydrostatic System Component Location T197503 —UN—04MAR04

9 1 4

12 6

14 10

13 10

7 T197503 Component Location Drawing (Neutral - Park Brake Off) Continued on next page

TM10721 (03SEP14)

9026-15-5

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=659

MR50960,00001B4 -19-08DEC06-1/4

Diagnostic Information

TM10721 (03SEP14)

9026-15-6

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=660

Diagnostic Information 1— Park Brake Valve 2— Hydrostatic Oil Filter 3— To Charge Pumps 4— To Reservoir 5— Neutral Charge Relief Valve

6— From Oil Cooler 7— To Oil Cooler 8— Charge Pressure Oil 9— Return Oil 10— Charge Pump

11— Hydrostatic Pump Front 14— Operating Charge Relief 12— Hydrostatic Pump Rear Valve 13— Pump Displacement Control 15— Motor Shift Solenoid Valve (PDCV) Continued on next page

TM10721 (03SEP14)

9026-15-7

MR50960,00001B4 -19-08DEC06-2/4

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=661

Diagnostic Information

TM10721 (03SEP14)

9026-15-8

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=662

Diagnostic Information

T197505 —UN—04MAR04

25 24

23 22

20 27 21 20

4 16

25 8

23 16

T197505 Component Location Drawing (Neutral - Park Brake Off) Continued on next page

TM10721 (03SEP14)

26 18

9026-15-9

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=663

MR50960,00001B4 -19-08DEC06-3/4

Diagnostic Information

TM10721 (03SEP14)

9026-15-10

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=664

Diagnostic Information 1— Park Brake Valve 2— Hydrostatic Oil Filter 3— To Charge Pumps 4— To Reservoir 6— From Oil Cooler 7— To Oil Cooler 8— Charge Pressure Oil

20— Multi-Function Valve 9— Return Oil (Reverse) 16— Park Brake 17— Hydrostatic Motor Left (Two 21— Multi-Function Valve (Forward) speed) 22— Left Forward (LF) 18— Hydrostatic Motor Right 23— Left Reverse (LR) (Two speed) 19— Pressure Control Pilot (PCP) 24— Right Forward (RF)

25— Right Reverse (RR) 26— Minimum Displacement Limiter Oil Cooler Bypass Valve

MR50960,00001B4 -19-08DEC06-4/4

TM10721 (03SEP14)

9026-15-11

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=665

Diagnostic Information

TM10721 (03SEP14)

9026-15-12

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=666

Diagnostic Information

Hydrostatic System Diagram—Park Brake On (Neutral) T197554 —UN—16JUN04

12 30 10

17 26

8 23 4 19 11

20 15

16 22

28 24

31 32

33 29

T197554

Park Brake On (Neutral) Continued on next page

TM10721 (03SEP14)

9026-15-13

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=667

MR50960,00001B3 -19-08DEC06-1/2

Diagnostic Information

TM10721 (03SEP14)

9026-15-14

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=668

Diagnostic Information

1— Pressure Control Pilot (PCP) 2— Servo Piston 3— Pump Displacement Control Valve (PDCV) 4— Control Screen 5— Hydrostatic Pump 6— Control Screen 7— Multi-Function Valve 8— Control Screen

9— Oil Cooler Bypass Valve 10— Reservoir 11— Charge Pump 12— Operating Charge Relief Valve 13— Flushing Valve 14— Orifice 15— Control Screen 16— Motor Shift Solenoid Valve 17— Servo Piston

18— Rotating Group 19— Hydrostatic Motor (Two speed) 20— Motor Speed Sensor 21— Hydrostatic Oil Filter 22— Park Brake Valve 23— Quick Coupler 24— Neutral Charge Relief Valve 25— To Oil Cooler

26— From Oil Cooler 27— To Motor Case 28— To Brake 29— To Rear Pump Side Cover 30— Minimum Displacement Limiter 31— Charge Pressure Oil 32— Low Pressure Oil 33— Return Oil MR50960,00001B3 -19-08DEC06-2/2

TM10721 (03SEP14)

9026-15-15

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=669

Diagnostic Information

TM10721 (03SEP14)

9026-15-16

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=670

Diagnostic Information

Hydrostatic System Diagram—Forward (Slow Speed) T197555 —UN—16JUN04

12 30 10

17 26

8 23 4 19 11

20 15

31 32

33 34 28

24 23

T197555

Forward (Slow Speed) Continued on next page

TM10721 (03SEP14)

9026-15-17

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=671

MR50960,00001B2 -19-08DEC06-1/2

Diagnostic Information

TM10721 (03SEP14)

9026-15-18

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=672

Diagnostic Information

10— Reservoir 11— Charge Pump 12— Operating Charge Relief Valve 13— Flushing Valve 14— Orifice 15— Control Screen 16— Motor Shift Solenoid Valve 17— Servo Piston 18— Rotating Group 19— Hydrostatic Motor (Two speed)

20— Motor Speed Sensor 21— Hydrostatic Oil Filter 22— Park Brake Valve 23— Quick Coupler 24— Neutral Charge Relief Valve 25— To Oil Cooler 26— From Oil Cooler 27— To Motor Case 28— To Brake 29— To Rear Pump Side Cover

30— Minimum Displacement Limiter 31— Charge Pressure Oil 32— Low Pressure Oil 33— Return Oil 34— High Pressure Oil 35— Medium Pressure Oil

MR50960,00001B2 -19-08DEC06-2/2

TM10721 (03SEP14)

9026-15-19

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=673

Diagnostic Information

TM10721 (03SEP14)

9026-15-20

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=674

Diagnostic Information

Hydrostatic System Diagram—Reverse (Fast Speed) T197556 —UN—07NOV05

12 30 18

17 9 26 8 23 4 19 11

20 15

16 22

31 32

33 23

34 35 29

T197556

Reverse (Fast Speed) Continued on next page

TM10721 (03SEP14)

9026-15-21

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=675

MR50960,00001B1 -19-08DEC06-1/2

Diagnostic Information

TM10721 (03SEP14)

9026-15-22

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=676

Diagnostic Information

30— Minimum Displacement Limiter 31— Charge Pressure Oil 32— Low Pressure Oil 33— Return Oil 34— High Pressure Oil 35— Medium Pressure Oil

MR50960,00001B1 -19-08DEC06-2/2

Overheating Malfunctions TW73308,0000103 -19-02JAN08-1/14

Overheating Diagnostic Procedure TW73308,0000103 -19-02JAN08-2/14

• 1

Overheating Component Check

Check what system of machine is overheating.

YES: Go to Oil Type and Level Check.

Is only the hydrostatic system overheating?

NO: If engine is only system overheating, see 4.5L/6.8L - C1 - Engine Coolant Temperature Above Normal. (CTM104.) NO: If engine and hydrostatic systems are overheating, go to Cooling Package Check. TW73308,0000103 -19-02JAN08-3/14

• 2

Oil Type and Level Check

Check transmission oil level. See Check Transmission Oil Level. (Operator's Manual.)

YES: Go to Oil Cooler Check.

Check transmission oil for correct type.

NO: If oil level is low, fill oil reservoir to correct level. See Check Transmission Oil Level. (Operator's Manual.)

Is transmission oil at correct level and type?

NO: If transmission oil is not correct type, drain and fill with correct oil. See Transmission and Hydraulic Oil. (Operator's Manual.)

Continued on next page

TM10721 (03SEP14)

9026-15-23

TW73308,0000103 -19-02JAN08-4/14

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=677

Diagnostic Information

• 3

Oil Cooler Check

Check hydrostatic oil cooler. See Hydraulic Component Location. (Group 9025-15.)

YES: Clean hydrostatic oil cooler.

Is there excessive debris in transmission oil cooler?

NO: Go to next step in this check.

Inspect transmission oil cooler fins.

YES: Repair or replace hydrostatic oil cooler. Install sand shield for abrasive conditions.

Are cooler fins damaged?

NO: Go to Fan Belt and Shroud Check. TW73308,0000103 -19-02JAN08-5/14

• 4

Fan Belt and Shroud Check

Check serpentine belt and fan shroud. See Inspect Serpentine Belt. (Operator's Manual.)

YES: Go to Temperature Measurement.

Is belt and shroud in good condition?

NO: Replace serpentine belt. NO: Repair or replace shroud. TW73308,0000103 -19-02JAN08-6/14

• 5

Temperature Measurement

Install temperature gauge on oil cooler bypass valve to oil cooler line. See Hydrostatic System Component Location. (Group 9026-15.)

Compare temperature reading to transmission oil temperature displayed on SDM. See Standard Display Monitor (SDM) Menu Structure—Service Mode. (Group 9015-16)

YES: Go to Track Stall Check.

Is transmission oil temperature displayed on SDM approximately the same as reading from temperature gauge?

NO: Replace transmission oil temperature sensor (B40). See Engine Harness (W6) Component Location. (Group 9015-10.) TW73308,0000103 -19-02JAN08-7/14

• 6

Track Stall Check

Operate machine under load to stall tracks.

YES: Go to Multi-Function Relief Valve Check.

Do one or both tracks stall easily under load?

NO: Go to Cooler Bypass Valve Check. TW73308,0000103 -19-02JAN08-8/14

• 7

Cooler Bypass Valve Check

Perform Cooler Bypass Valve Test. (Group 9026-25.)

YES: Checks complete.

Is oil cooler bypass valve OK?

NO: Repair or replace oil cooler bypass valve. See Oil Cooler Bypass Valve Operation. (Group 9026-05.) Continued on next page

TM10721 (03SEP14)

9026-15-24

TW73308,0000103 -19-02JAN08-9/14

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=678

Diagnostic Information

• 8

Multi-Function Relief Valve Check

Perform Multi-Function Relief Valve Test. (Group 9026-25.)

YES: Perform Hydrostatic Motor Min. Angle Stop Adjustment. (Group 9026-25.)

Are pressures within specifications?

NO: Adjust multi-function relief valve and perform Transmission Efficiency Test. (Group 9026-25.) TW73308,0000103 -19-02JAN08-10/14

• 9

Cooling Package Check

Inspect radiator and transmission oil cooler for debris.

YES: Clean debris from radiator and oil cooler.

Is there excessive debris in radiator and oil cooler?

NO: Go to next step in this check.

Inspect transmission oil cooler and radiator fins.

YES: Repair or replace radiator and/or transmission oil cooler.

Are fins damaged?

NO: Go to Serpentine Belt Check. TW73308,0000103 -19-02JAN08-11/14

•

10 Serpentine Belt Check Check serpentine belt. See Inspect Serpentine Belt. (Operator's Manual.)

Is belt OK?

YES: Go to Fan Check.

NO: Replace serpentine belt. TW73308,0000103 -19-02JAN08-12/14

•

11 Fan Check

Inspect fan to make sure fan is installed properly and is correct size fan.

YES: Go to Engine Compartment Check.

Is the correct fan installed properly?

NO: Install correct fan, or re-install fan properly. TW73308,0000103 -19-02JAN08-13/14

•

12 Engine Compartment Check

Check baffles around radiator and fan.

YES: Checks complete.

Are baffles present and free of obstruction from debris?

NO: Install correct hood and side panels or clean debris from baffles. TW73308,0000103 -19-02JAN08-14/14

High/Low Charge Pressure Malfunctions TW73308,0000104 -19-28DEC12-1/13

High/Low Charge Pressure Diagnostic Procedure Continued on next page

TM10721 (03SEP14)

9026-15-25

TW73308,0000104 -19-28DEC12-2/13

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=679

Diagnostic Information

• 1

Reading Pressure with Remove plug on hydrostatic oil filter housing. Gauge Check

Install a gauge or pressure transducer on filter housing.

YES: Checks complete.

Start engine, run at fast idle and check neutral charge pressure.

NO: If neutral charge pressure is low, go to Engine Slow Idle Charge Pressure Check.

Specification Neutral Charge—Pressure.................................................................... 2034—2377 kPa 20—24 bar 295—345 psi

NO: If neutral charge pressure is high, go to Relief Valve Adjustment Check.

Is neutral charge pressure within specifications? TW73308,0000104 -19-28DEC12-3/13

• 2

Relief Valve Adjustment Check

Adjust neutral charge relief valve. See Neutral Charge Relief and Operating Charge Relief Pressure Test. (Group 9026-25.)

YES: Checks complete.

After relief valve is adjusted, is pressure within specifications?

NO: Repair or replace neutral charge relief valve. See Neutral Charge Relief Valve Disassemble and Assemble. (Group 0360.) TW73308,0000104 -19-28DEC12-4/13

• 3

Engine Slow Idle Charge Pressure Check

Verify that transmission oil is at correct level and temperature. See Check Transmission Oil Level. (Operator's Manual.)

Start engine and run at slow idle. Move transmission control lever (TCL) to neutral.

YES: Go to Engine High Idle Check.

Specification Neutral Charge—Pressure.................................................................... 2034—2377 kPa 20—24 bar 295—345 psi

NO: Go to Charge Pressure Extremely Low Check.

Is neutral charge pressure within specifications? TW73308,0000104 -19-28DEC12-5/13

• 4

Engine High Idle Check Start engine and run at fast idle.

YES: Transmission oil filter restricted. Replace transmission oil filter. See Change Transmission Oil and Filter. (Operator's Manual.)

Is transmission oil filter restriction light on?

NO: Go to Closed Loop Leakage Check.

Continued on next page

TM10721 (03SEP14)

9026-15-26

TW73308,0000104 -19-28DEC12-6/13

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=680

Diagnostic Information

• 5

Closed Loop Leakage Check

Set brake mode to TEST by accessing the MACHINE SETTINGS / BRAKE MODE submenu on the SDM. See Standard Display Monitor (SDM) Menu Structure—Service Mode. (Group 9015-16.) View charge pressure by accessing the DIAGNOSTIC / LIVE VALUES / PRESSURES submenu on the SDM. Move TCL to forward and reverse, while increasing the engine speed to approximately 1600 rpm.

YES: Go to Operating Charge Relief Check.

Does charge pressure drop very low as engine speed is increased?

NO: Checks complete. TW73308,0000104 -19-28DEC12-7/13

• 6

Operating Charge Relief Check

View charge pressure by accessing the DIAGNOSTIC / LIVE VALUES / PRESSURES submenu on the SDM. See Standard Display Monitor (SDM) Menu Structure—Service Mode. (Group 9015-16.) Steer to stop on one side.

YES: Perform Transmission Efficiency Test on low (stopped) side. (Group 9026-25.) Repair or replace components based on results of transmission efficiency test.

Does operating charge pressure build back up?

NO: Perform Transmission Efficiency Test on both sides. (Group 9026-25.) Repair or replace components based on results of transmission efficiency test. TW73308,0000104 -19-28DEC12-8/13

• 7

Charge Pressure Extremely Low Check

YES: Go to Hydraulic Functions Check.

Is charge pressure 0 kPa (0 bar) (0 psi)?

NO: Go to Neutral Charge Relief Pressure Check. TW73308,0000104 -19-28DEC12-9/13

• 8

Hydraulic Functions Check

Start engine.

Operate hydraulic functions.

YES: Inspect pump or motor for broken shaft.

Do hydraulic functions operate?

NO: Repair drive coupling between engine and hydrostatic pumps. Continued on next page

TM10721 (03SEP14)

9026-15-27

TW73308,0000104 -19-28DEC12-10/13

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=681

Diagnostic Information

• 9

Neutral Charge Relief Pressure Check

Perform Neutral Charge Relief and Operating Charge Relief Pressure Test. (Group 9026-25.)

Specification Neutral Charge—Pressure.................................................................... 2034—2377 kPa 20—24 bar 295—345 psi Minimum Operating Charge—Pressure............................................................ 1830 kPa 18.3 bar 265 psi

YES: Go to Hydraulics Relief Charge Pressure Check.

Is charge pressure within specifications?

NO: Adjust relief valves. See Neutral Charge Relief and Operating Charge Relief Pressure Test. (Group 9026-25.) TW73308,0000104 -19-28DEC12-11/13

•

10 Hydraulics Relief Charge Pressure Check

View charge pressure by accessing the DIAGNOSTIC / LIVE VALUES / PRESSURES submenu on the SDM. See Standard Display Monitor (SDM) Menu Structure—Service Mode. (Group 9015-16.)

Start engine and run at fast idle. Hold hydraulics over relief and counter rotate machine.

YES: Checks complete.

NO: Go to Charge Pump Flow Check.

Is charge pressure within specifications? TW73308,0000104 -19-28DEC12-12/13

•

11 Charge Pump Flow Check

Perform Charge Pump Flow Test. (Group 9026-25.)

YES: Perform Transmission Efficiency Test on both sides. (Group 9026-25.) Repair or replace components based on results of transmission efficiency test.

Is charge pump flow within specifications?

NO: Repair or replace charge pump. See Hydrostatic Charge Pump Disassemble and Assemble. (Group 0360.) TW73308,0000104 -19-28DEC12-13/13

Mistrack/Index Malfunctions TW73308,0000105 -19-02JAN13-1/21

Mistrack or Index Diagnostic Procedure Continued on next page

TM10721 (03SEP14)

9026-15-28

TW73308,0000105 -19-02JAN13-2/21

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=682

Diagnostic Information

• 1

Diagnostic Trouble Code Check

Are diagnostic trouble codes displayed?

YES: Correct malfunction causing diagnostic trouble codes. NO: Go to Track Sag Check. TW73308,0000105 -19-02JAN13-3/21

• 2

Track Sag Check

Check track sag. See Check Track Sag. (Operator's Manual.)

YES: Go to Park Lock Lever Test.

Is the track sag within specification?

NO: Adjust tracks. See Adjust Track Sag. (Group 0130.) TW73308,0000105 -19-02JAN13-4/21

• 3

Park Lock Lever Test CAUTION: Prevent possible injury from unexpected track movement. Raise machine off the ground and support with appropriate stands. Tracks must be free to rotate in either direction; check for objects on tracks before rotating tracks. Raise machine off the ground and support with D01182AA 20-Ton Floor Stands. Lower YES: Go to PCP Check. blade to ground. Tracks must be free to rotate in either direction. Do tracks move when park lock lever is lowered with transmission control lever (TCL) in NO: Go to Charge neutral? Pressure Check. TW73308,0000105 -19-02JAN13-5/21

• 4

PCP Check

Perform Pressure Control Pilot (PCP) Manual Override Test. (Group 9026-25.)

YES: Electrical problem is indicated. Diagnose problem in circuits T38 BLU, T41 BLU, T42 BLU and T45 BLU. See Transmission Control Unit (TCU) Circuit Theory of Operation. (Group 9015-15.)

Do tracks move in both forward and reverse when manual override is engaged?

NO: Hydraulic problem is indicated. Closed loop system is not functioning correctly. Go to Pump Flushing Check. TW73308,0000105 -19-02JAN13-6/21

• 5

Pump Flushing Check

Perform Hydrostatic Pump Flushing Procedure. (Group 9026-25.)

Perform Pressure Control Pilot (PCP) Manual Override Test. (Group 9026-25.)

YES: Checks complete.

Do tracks move in both forward and reverse when manual override is engaged?

NO: Go to Pump Servo Pressure Test Check.

Continued on next page

TM10721 (03SEP14)

9026-15-29

TW73308,0000105 -19-02JAN13-7/21

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=683

Diagnostic Information

• 6

Pump Servo Pressure Test Check

Perform Pump Servo Pressure Test. (Group 9026-25.)

YES: Disassemble pump and re-level swashplate. See Hydrostatic Pumps Disassemble. (Group 0360.)

Is mistracking problem corrected?

NO: Go to PCP Check. TW73308,0000105 -19-02JAN13-8/21

• 7

Charge Pressure Check

YES: Go to Tracker On/Off Check.

Is charge pressure OK?

NO: Go to Flushing Valve Check. TW73308,0000105 -19-02JAN13-9/21

• 8

Flushing Valve Check

Check flushing valves in hydrostatic motors. Inspect for any debris that would prevent normal valve operation. See Flushing Valve and Operating Charge Relief Valve Operation. (Group 9026-05.)

YES: Diagnose cause of low charge pressure malfunction. See High/Low Charge Pressure Malfunctions. (Group 9026-15.)

Are hydrostatic motor flushing valves functioning correctly?

NO: Repair or replace hydrostatic motor flushing valves, as needed. See Hydrostatic Motor Disassemble. (Group 0360.) TW73308,0000105 -19-02JAN13-10/21

• 9

Tracker On/Off Check

Turn TRACKER CONTROL OFF by accessing the TCU DIAGNOSTICS / SETTINGS / TRACKER CONTROL submenu on the SDM. See Standard Display Monitor (SDM) Menu Structure—Service Mode. (Group 9015-16.)

YES: Motor speed sensor or wiring problem. See Electrical Component Specifications for sensor resistance information. (Group 9015-20.) See Transmission Control Unit (TCU) Circuit Theory of Operation for circuit information. (Group 9015-15.)

Is mistrack problem corrected?

NO: Go to Tracking and Maximum Speed Check. Continued on next page

TM10721 (03SEP14)

9026-15-30

TW73308,0000105 -19-02JAN13-11/21

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=684

Diagnostic Information

•

10 Tracking and Maximum Speed Check

Perform Tracking and Maximum Speed Check, operational check. (Group 9005-10.)

YES: Go to next step in this check.

Can 2100 rpm be obtained?

NO: Go to Multi-Function Relief Valve Check. YES: Calibrate TCU. See Transmission Control Unit (TCU) Calibration. (Group 9015-20.)

Can 3230 or 3875 rpm be obtained without hesitation?

NO: Go to Min/Max Control Piston Check. TW73308,0000105 -19-02JAN13-12/21

•

11 Min/Max Control Piston Check

Perform Hydrostatic Motor Min./Max. Angle Servo Piston Pressure Test. (Group 9026-25.)

YES: Perform Hydrostatic Motor Min. Angle Stop Adjustment. (Group 9026-25.)

Are servo piston pressures OK?

NO: Check for a stuck motor shift solenoid. Repair or replace as necessary. See Transmission Harness (W7) Component Location. (Group 9015-20.) TW73308,0000105 -19-02JAN13-13/21

•

12 Multi-Function Relief Valve Pressure Check

Perform Multi-Function Relief Valve Test. (Group 9026-25.)

YES: Go to Pump Servo Pressure Check.

Is pressure within specification?

NO: Go to Multi-Function Relief Valve Check. TW73308,0000105 -19-02JAN13-14/21

•

13 Multi-Function Relief Valve Check

Switch the two multi-function relief valves.

YES: Repair or replace relief valve. See Multi-Function Valve Disassemble and Assemble. (Group 0360.)

Does the problem move along with the suspected faulty valve?

NO: Go to Transmission Efficiency Check. TW73308,0000105 -19-02JAN13-15/21

•

14 Transmission Efficiency Check

Perform Transmission Efficiency Test. (Group 9026-25.)

YES: Go to Speed In Grip Check.

Does test indicate pump problem?

NO: Internal leak in motor. Repair or replace. See Hydrostatic Motor Remove and Install. (Group 0300.) Continued on next page

TM10721 (03SEP14)

9026-15-31

TW73308,0000105 -19-02JAN13-16/21

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=685

Diagnostic Information

•

15 Speed In Grip Check

Increase speed in grip (SIG) from 1.0 to 2.0 while moving in forward and then in reverse. YES: Remove pump displacement control valve (PDCV) from the slow track. Clean the screens on the top of the pump housing. See Pump Displacement Control Valve (PDCV) Disassemble and Assemble. (Group 0360.) Does machine index when SIG value is changed?

NO: Internal leak in pump. Repair or replace. See Hydrostatic Pumps Disassemble. (Group 0360.) TW73308,0000105 -19-02JAN13-17/21

•

16 Pump Servo Pressure Check

Perform Pump Servo Pressure Test. (Group 9026-25.)

YES: Perform Transmission Efficiency Test. (Group 9026-25.)

Is mistracking problem corrected?

NO: Go to PCP Check. TW73308,0000105 -19-02JAN13-18/21

•

17 PCP Check

Perform Pressure Control Pilot (PCP) Test. (Group 9026-25.)

YES: Go to Pump Displacement Control Valve (PDCV) Neutral Adjustment Turn Check.

Is differential pressure less than 34 kPa (0.34 bar) (5 psi)?

NO: Go to Hydrostatic System Flushing Check.

Continued on next page

TM10721 (03SEP14)

9026-15-32

TW73308,0000105 -19-02JAN13-19/21

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=686

Diagnostic Information

•

18 Hydrostatic System Flushing Check

Perform Hydrostatic Pump Flushing Procedure. (Group 9026-25.)

YES: Go to Pump Displacement Control Valve (PDCV) Neutral Adjustment Turn Check.

After system has been flushed, perform Pressure Control Pilot (PCP) Test. (Group 9026-25.)

NO: If differential pressure is more than 34 kPa (0.34 bar) (5 psi) but less than 103 kPa (1.03 bar) (15 psi), adjust PCP. See Pressure Control Pilot (PCP) Internal Adjustment. (Group 9026-25.) After PCP is adjusted, go to Pump Displacement Control Valve (PDCV) Neutral Adjustment Turn Check.

Is differential pressure less than 34 kPa (0.34 bar) (5 psi)?

NO: If differential pressure is more than 103 kPa (1.03 bar) (15 psi), replace PCP. See Hydrostatic Pumps Disassemble. (Group 0360.) After PCP is replaced, go to Pump Displacement Control Valve (PDCV) Neutral Adjustment Turn Check. TW73308,0000105 -19-02JAN13-20/21

•

19 Pump Displacement Control Valve (PDCV) Neutral Adjustment Turn Check

Perform Pump Displacement Control Valve (PDCV) Neutral (Null) Adjustment. (Group 9026-25.)

YES: Recalibrate the TCU. See Transmission Control Unit (TCU) Calibration. (Group 9015-20.)

Count the number of turns to achieve a 276 kPa (2.76 bar) (40 psi) difference between forward and reverse.

NO: If the number of turns is more than 2 turns, disassemble pressure displacement control valve (PDCV) and check for a worn feedback link. See Hydrostatic Pumps Disassemble. (Group 0360.)

Is the number or turns more than a 1/2 turn but less than 2 turns?

NO: If the number of turns is less than 1/2 turn, disassemble pump and re-level swash plate. See Hydrostatic Pumps Disassemble. (Group 0360.) TW73308,0000105 -19-02JAN13-21/21

Machine Full Speed Malfunctions TW73308,0000106 -19-12NOV09-1/10

Machine Will Not Reach Full Speed Diagnostic Procedure Continued on next page

TM10721 (03SEP14)

9026-15-33

TW73308,0000106 -19-12NOV09-2/10

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=687

Diagnostic Information

• 1

Diagnostic Trouble Codes

Are diagnostic trouble codes displayed?

YES: Correct malfunction causing diagnostic trouble codes. NO: Go to Track Sag Check. TW73308,0000106 -19-12NOV09-3/10

• 2

Track Sag Check

Check track sag. See Check Track Sag. (Operator's Manual.)

YES: Go to Decelerator/Brake Pedal Check.

Is track sag acceptable?

NO: Adjust track sag. See Adjust Track Sag. (Operator's Manual.) TW73308,0000106 -19-12NOV09-4/10

• 3

Decelerator/Brake Pedal Check

Set decelerator mode to transmission mode.

Check fast idle engine speed with decelerator/brake pedal not pressed. Set decelerator mode to engine mode. Check fast idle engine speed with decelerator/brake pedal not pressed.

YES: Adjust decelerator sensor (B1). See Decelerator/Brake Pedal Adjustment. (Group 9015-20.)

Did engine speed decrease when decelerator mode was switched to engine mode?

NO: Go to Engine Speed Check. TW73308,0000106 -19-12NOV09-5/10

• 4

Engine Speed Check

Start engine and run at fast idle.

Move the transmission control lever (TCL) to neutral. View engine speed by accessing the DIAGNOSTIC / LIVE VALUES / SPEEDS submenu on the SDM. See Standard Display Monitor (SDM) Menu Structure—Service Mode. (Group 9015-16.)

YES: Go to next step in this check.

Is engine speed 2330—2360 rpm?

NO: Recalibrate TCU. See Transmission Control Unit (TCU) Calibration. (Group 9015-20.) If engine speed is not correct after calibration, perform Slow and Fast Idle Check. (Group 9005-10.)

Set aggressiveness to medium by accessing the MACHINE SETTINGS / TRANSMISSION / AGGRESSIVENESS submenu on the SDM. Turn ANTISTALL to ON by accessing the TCU DIAGNOSTICS / SETTINGS / ANTISTALL submenu on the SDM. Set transmission speed to 3.0.

YES: Go to Hydrostatic Motor Speed Check.

Is the engine speed during machine travel at least 2200 rpm?

NO: See Low Power Malfunctions. (Group 9026-15.)

Continued on next page

TM10721 (03SEP14)

9026-15-34

TW73308,0000106 -19-12NOV09-6/10

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=688

Diagnostic Information

• 5

Hydrostatic Motor Speed Check

View motor speeds by accessing the DIAGNOSTIC / LIVE VALUES / SPEEDS submenu on the SDM. See Standard Display Monitor (SDM) Menu Structure—Service Mode. (Group 9015-16.) Compare motor speeds to specification. See Hydrostatic Motor Min. Angle Stop Adjustment. (Group 9026-25.)

YES: Checks complete.

Do hydrostatic motors have correct rpm?

NO: Go to Tracker Check. TW73308,0000106 -19-12NOV09-7/10

• 6

Tracker Check

Turn off tracker by accessing the TCU DIAGNOSTICS / SETTINGS / TRACKER CONTROL submenu on the SDM. See Standard Display Monitor (SDM) Menu Structure—Service Mode. (Group 9015-16.)

YES: See Mistrack/Index Malfunctions. (Group 9026-15.)

Does unit mistrack?

NO: Go to Decelerator/Brake Pedal Check. TW73308,0000106 -19-12NOV09-8/10

• 7

Decelerator/Brake Pedal Check

Check decelerator/brake pedal position.

YES: Go to Minimum Angle Stop Adjustment Check.

Is decelerator/brake pedal against upper stop at high idle?

NO: Adjust decelerator/brake pedal. TW73308,0000106 -19-12NOV09-9/10

• 8

Minimum Angle Stop Adjustment Check

Check motor minimum angle stop adjustment. See Hydrostatic Motor Min. Angle Stop Adjustment. (Group 9026-25.)

YES: Calibrate TCU. See Transmission Control Unit (TCU) Calibration. (Group 9015-20.) If TCU does not calibrate, see TCU Calibration Malfunctions. (Group 9026-15.)

Is motor minimum angle stop adjusted to the desired setting?

NO: Adjust motor minimum angle stop. See Hydrostatic Motor Min. Angle Stop Adjustment. (Group 9026-25.) TW73308,0000106 -19-12NOV09-10/10

Low Power Malfunctions TW73308,0000107 -19-03JAN13-1/21

Low Power Diagnostic Procedure TW73308,0000107 -19-03JAN13-2/21

• 1

Low Power Check

Is power low in both tracks and both directions?

YES: Go to Diagnostic Trouble Code Check. NO: Go to Neutral Charge Relief and Operating Charge Relief Pressure Check.

Continued on next page

TM10721 (03SEP14)

9026-15-35

TW73308,0000107 -19-03JAN13-3/21

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=689

Diagnostic Information

• 2

Diagnostic Trouble Code Check

Check for active diagnostic trouble codes (DTCs).

YES: Correct malfunction causing diagnostic trouble codes.

Are any active DTCs displayed?

NO: Go to Transmission Charge Oil Pressure Check. TW73308,0000107 -19-03JAN13-4/21

• 3

Transmission Charge Oil Pressure Check

View TRANS CHARGE OIL pressure by accessing the DIAGNOSTIC / LIVE VALUES / PRESSURES submenu on the SDM. See Standard Display Monitor (SDM) Menu Structure—Service Mode. (Group 9015-16.) Shift transmission to neutral and monitor charge pressure. Specification Neutral Charge—Pressure.................................................................... 2034—2377 kPa 20—24 bar 295—345 psi Is neutral charge pressure within specifications?

YES: Go to Turbo Boost Power Check.

NO: Adjust neutral charge relief valve. See Neutral Charge Relief and Operating Charge Relief Pressure Test. (Group 9026-25.) Diagnose cause of low charge pressure. See High/Low Charge Pressure Malfunctions. (Group 9026-15.) TW73308,0000107 -19-03JAN13-5/21

• 4

Turbo Boost Power Check

Perform Intake Manifold Pressure Test—Turbocharger Boost. (Group 9010-25.)

YES: Go to Track Sag Check.

Is intake manifold boost pressure above minimum value?

NO: Diagnose cause of low engine power. See E3 Engine Does Not Develop Full Power. (CTM502.) TW73308,0000107 -19-03JAN13-6/21

• 5

Track Sag Check

Check track sag. See Check Track Sag. (Operator’s Manual.)

YES: Go to Anti-Stall Setting Check.

Is track sag within specification?

NO: Adjust track sag. See Adjust Track Sag. (Operator’s Manual.) Continued on next page

TM10721 (03SEP14)

9026-15-36

TW73308,0000107 -19-03JAN13-7/21

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=690

Diagnostic Information

• 6

Anti-Stall Setting Check

View ANTI-STALL by accessing the DIAGNOSTIC / LIVE VALUES / PERFORMANCE submenu on the SDM. See Standard Display Monitor (SDM) Menu Structure—Service Mode. (Group 9015-16.)

YES: Go to Transmission Speed Setting Check.

Is anti-stall set to NORMAL?

NO: Turn anti-stall to ON, then calibrate TCU. See Transmission Control Unit (TCU) Calibration. (Group 9015-20.) If TCU will not calibrate, see TCU Calibration Malfunctions. (Group 9026-25.) TW73308,0000107 -19-03JAN13-8/21

• 7

Transmission Speed Setting Check

View track forward and reverse speed by accessing the MACHINE SETTINGS / TRANSMISSION / TRACK SPEED submenu on the SDM. See Standard Display Monitor (SDM) Menu Structure—Service Mode. (Group 9015-16.)

YES: Go to Minimum Angle Stop Adjustment Check.

Are forward speed and reverse speed settings set to the desired value?

NO: Adjust forward and reverse speed to the correct settings. See Standard Display Monitor (SDM) Menu Structure—Service Mode. (Group 9015-16.) TW73308,0000107 -19-03JAN13-9/21

• 8

Minimum Angle Stop Adjustment Check

Check minimum angle stop in hydrostatic motors. See Hydrostatic Motor Min. Angle Stop Adjustment. (Group 9026-25.)

YES: Go to Transmission Efficiency Check.

Is the motor minimum angle stop adjustment set correctly?

NO: Adjust motor minimum angle stop. See Hydrostatic Motor Min. Angle Stop Adjustment. (Group 9026-25.) If minimum angle stop is adjusted, calibrate transmission control unit (TCU). See Transmission Control Unit (TCU) Calibration. (Group 9015-20.) TW73308,0000107 -19-03JAN13-10/21

• 9

Transmission Efficiency Check

Perform Transmission Efficiency Test. (Group 9026-25.)

YES: Make sure machine weight is within operating range and not overloaded. Verify that multi-function relief valve pressures are all within specification. See Multi-Function Relief Valve Test. (Group 9026-25.)

Are hydrostatic motors and pumps OK?

NO: Repair or replace component based on results of efficiency test. Continued on next page

TM10721 (03SEP14)

9026-15-37

TW73308,0000107 -19-03JAN13-11/21

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=691

Diagnostic Information

•

10 Neutral Charge Relief and Operating Charge Relief Pressure Check

Perform Neutral Charge Relief and Operating Charge Relief Pressure Test. (Group 9026-25.)

YES: Go to Machine Load Check.

NO: Adjust neutral charge relief valve until pressure is within specification, as needed. Remove and inspect operating charge relief valves in hydrostatic motors, as needed. TW73308,0000107 -19-03JAN13-12/21

•

11 Machine Load Check

YES: Perform Transmission Efficiency Test. (Group 9026-25.) Repair or replace component based on results of efficiency test.

Does charge pressure drop?

NO: Go to Multi-Function Relief Valve Pressure Check. TW73308,0000107 -19-03JAN13-13/21

•

12 Multi-Function Relief Valve Pressure Check

Perform Multi-Function Relief Valve Test. (Group 9026-25.)

YES: Go to PCP Check.

Are multi-function relief valve pressures within specification?

NO: Go to next step in this check.

Adjust multi-function relief valves. See Multi-Function Relief Valve Test. (Group 9026-25.)

YES: Checks complete.

Can multi-function relief valve pressures be adjusted to within specification?

NO: Go to Multi-Function Relief Valve Check. TW73308,0000107 -19-03JAN13-14/21

•

13 Multi-Function Relief Valve Check

Switch multi-function relief valve that could not be adjusted with multi-function relief valve that is within pressure specification.

Check multi-function relief valve pressures. See Multi-Function Relief Valve Test. (Group 9026-25.)

YES: Repair or replace multi-function relief valve. See Multi-Function Valve Disassemble and Assemble. (Group 0360.)

Does out-of-specification pressure reading move with multi-function relief valve that could not be adjusted?

NO: Go to PCP Test Check.

Continued on next page

TM10721 (03SEP14)

9026-15-38

TW73308,0000107 -19-03JAN13-15/21

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=692

Diagnostic Information

•

14 PCP Test Check

Perform Pressure Control Pilot (PCP) Test. (Group 9026-25.) Specification Neutral PCP Differential—Pressure................................................................ 0—34 kPa 0—0.34 bar 0—5 psi Is differential pressure for front and back pumps within specification?

YES: Go to Pump Servo Pressure Test Check.

NO: Repair or adjust PCP. See Pressure Control Pilot (PCP) Internal Adjustment. (Group 9026-25.) TW73308,0000107 -19-03JAN13-16/21

•

15 Pump Servo Pressure Test Check

Perform Pump Servo Pressure Test. (Group 9026-25.)

YES: Perform Transmission Efficiency Test. (Group 9026-25.) Repair or replace component based on results of efficiency test.

Are pressures OK?

NO: Repair or replace PDCV. See Pump Displacement Control Valve (PDCV) Disassemble and Assemble. (Group 9026-25.) TW73308,0000107 -19-03JAN13-17/21

•

16 PCP Check

YES: Go to Pump Servo Pressure Check.

NO: Repair or adjust PCP. See Pressure Control Pilot (PCP) Internal Adjustment. (Group 9026-25.) TW73308,0000107 -19-03JAN13-18/21

•

17 Pump Servo Pressure Check

Perform Pump Servo Pressure Test. (Group 9026-25.)

YES: Go to Minimum/Maximum Control Piston Check.

Are pressures OK?

NO: Repair or replace PDCV. See Pump Displacement Control Valve (PDCV) Disassemble and Assemble. (Group 9026-25.) Continued on next page

TM10721 (03SEP14)

9026-15-39

TW73308,0000107 -19-03JAN13-19/21

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=693

Diagnostic Information

•

18 Minimum/Maximum Control Piston Check

Perform Hydrostatic Motor Min./Max. Angle Servo Piston Pressure Test. (Group 9026-25.)

YES: Go to Minimum Angle Stop Adjustment Check.

Are servo piston pressures OK?

NO: Repair or replace PDCV. See Pump Displacement Control Valve (PDCV) Disassemble and Assemble. (Group 9026-25.) TW73308,0000107 -19-03JAN13-20/21

•

19 Minimum Angle Stop Adjustment Check

Check minimum angle stop in hydrostatic motors. See Hydrostatic Motor Min. Angle Stop Adjustment. (Group 9026-25.)

YES: Perform Transmission Efficiency Test. (Group 9026-25.) Repair or replace component based on results of efficiency test.

Is the motor minimum angle stop adjustment set correctly?

Track Malfunctions TW73308,0000108 -19-10JAN08-1/22

Engine Starts but Both Tracks Either Do Not Move or Come to a Stop Diagnostic Procedure TW73308,0000108 -19-10JAN08-2/22

• 1

Diagnostic Trouble Code Check

Are diagnostic trouble codes (DTC) displayed?

YES: Take appropriate action to correct diagnostic trouble codes. NO: Go to Hydraulic Functions Check. TW73308,0000108 -19-10JAN08-3/22

• 2

Hydraulic Functions Check

Operate hydraulic functions.

YES: Go to TCU Power Check.

Do hydraulic functions work?

NO: Check drive couplers. Continued on next page

TM10721 (03SEP14)

9026-15-40

TW73308,0000108 -19-10JAN08-4/22

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=694

Diagnostic Information

• 3

TCU Power Check

Check power light on transmission control unit (TCU).

YES: Go to Park Brake Lever Check.

Is TCU powered up?

NO: Go to Fuse Check. TW73308,0000108 -19-10JAN08-5/22

• 4

Fuse Check

Check continuity of TCU 10-amp fuse (F22). See Fuse and Relay Specifications. (Group 9015-10.)

YES: Check wiring from fuse block to transmission control unit. See Transmission Control Unit (TCU) Circuit Theory of Operation. (Group 9015-15.)

Is continuity indicated?

NO: Replace fuse (F22). TW73308,0000108 -19-10JAN08-6/22

• 5

Park Brake Lever Check

YES: Go to Charge Pressure Check.

Does charge pressure drop slightly when park lever is released?

NO: Repair decelerator pedal or park lever. See Park Lock Linkage Disassemble and Assemble. (Group 1115.) Also, See Park Brake Disassemble and Assemble. (Group 1160.) TW73308,0000108 -19-10JAN08-7/22

• 6

Charge Pressure Check

YES: Go to Pump Manual Override Check.

Specification Neutral Charge—Pressure.................................................................... 2034—2377 kPa 20—24 bar 295—345 psi

NO: See High/Low Charge Pressure Malfunctions. (Group 9026-15.)

Is charge pressure within specifications? TW73308,0000108 -19-10JAN08-8/22

• 7

Pump Manual Override Activate manual overrides on pressure control pilot. See Pressure Control Pilot (PCP) Check Manual Override Test. (Group 9026-25.)

Did tracks move?

NO: Go to Multi-Function Valve Bypass Check. Continued on next page

TM10721 (03SEP14)

YES: Recalibrate TCU. See Transmission Control Unit (TCU) Calibration. (Group 9015-20.)

9026-15-41

TW73308,0000108 -19-10JAN08-9/22

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=695

Diagnostic Information

• 8

Multi-Function Valve Bypass Check

Are multi-function valves in bypass for towing?

YES: Adjust multi-function valves.

NO: Go to Pressure Control Pilot Check. TW73308,0000108 -19-10JAN08-10/22

• 9

Pressure Control Pilot Check

Perform Pressure Control Pilot (PCP) Test. (Group 9026-25.)

YES: Perform Multi-Function Relief Valve Test. (Group 9026-25.)

Specification Neutral PCP Differential—Pressure...................................................................... 34 kPa 0.34 bar 0—5 psi

NO: Adjust or replace PCP. See Pressure Control Pilot (PCP) Internal Adjustment. (Group 9026-25.)

Is differential pressure within specifications? TW73308,0000108 -19-10JAN08-11/22

Machine Moves in Only One Direction or One Track Does Not Move Diagnostic Procedure TW73308,0000108 -19-10JAN08-12/22

• 1

Hydrostatic Motor RPM Check

View engine speed by accessing the DIAGNOSTIC / LIVE VALUES / SPEEDS submenu on the SDM. See Standard Display Monitor (SDM) Menu Structure—Service Mode. (Group 9015-16.).

YES: Go to Motor Shaft Check.

Is motor rpm OK?

NO: Go to Diagnostic Trouble Code Check. TW73308,0000108 -19-10JAN08-13/22

• 2

Motor Shaft Check

Disengage hydrostatic motor from final drive.

Check motor for shaft failure. See Hydrostatic Motor Disassemble. (Group 0360.)

YES: Final drive failure. Repair final drive. See Final Drive Disassemble and Assemble. (Group 0250.)

Is motor shaft OK?

NO: Repair or replace hydrostatic motor. See Hydrostatic Motor Disassemble. (Group 0360.) TW73308,0000108 -19-10JAN08-14/22

• 3

Diagnostic Trouble Code Check

Check SDM for diagnostic trouble codes. See Standard Display Monitor (SDM) Menu Structure—Service Mode. (Group 9015-16.)

YES: Correct diagnostic trouble codes.

Are any codes active?

NO: Go to Pump Manual Override Check. Continued on next page

TM10721 (03SEP14)

9026-15-42

TW73308,0000108 -19-10JAN08-15/22

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=696

Diagnostic Information

• 4

Pump Manual Override Activate manual overrides on malfunctioning pump. Check

YES: Go to Pump Current Check.

Do both tracks move in both directions?

NO: Go to Hydraulic Operation Check. TW73308,0000108 -19-10JAN08-16/22

• 5

Pump Current Check

Perform Pressure Control Pilot (PCP) Test. (Group 9026-25.)

YES: Adjust pressure control pilot (PCP). See Pressure Control Pilot (PCP) Internal Adjustment. (Group 9026-25.)

Are current outputs from left pump PCP and right pump PCP OK?

NO: Calibrate transmission control unit (TCU). See Transmission Control Unit (TCU) Calibration. (Group 9015-20.) TW73308,0000108 -19-10JAN08-17/22

• 6

Hydraulic Operation Check

Operate hydraulic functions.

YES: Go to Neutral/Operating Charge Pressure Check.

Do hydraulic functions work?

NO: Repair coupler between front and rear hydrostatic pumps. TW73308,0000108 -19-10JAN08-18/22

• 7

Neutral/Operating Charge Pressure Check

Perform Neutral Charge Relief and Operating Charge Relief Pressure Test. (Group 9026-25.)

YES: Go to Pump Servo Pressure Check.

NO: Go to Flushing Valve and Operating Charge Relief Valve Check.

Are neutral and operating charge pressures within specification? Continued on next page

TM10721 (03SEP14)

9026-15-43

TW73308,0000108 -19-10JAN08-19/22

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=697

Diagnostic Information

• 8

Flushing Valve and Operating Charge Relief Valve Check

Check pump flushing valve and operating charge relief valve.

YES: Perform Transmission Efficiency Test. (Group 9026-25.) Isolate pump or motor problem and rerun efficiency test. Repair or replace motor or pump. See Hydrostatic Pumps Disassemble or see Hydrostatic Motor Disassemble. (Group 0360.)

Are pump flushing valve and operating charge relief valves OK?

NO: Repair or replace flushing valve or operating charge relief valve. See Hydrostatic Pumps Disassemble or see Neutral Charge Relief Valve Disassemble and Assemble. (Group 0360.) TW73308,0000108 -19-10JAN08-20/22

• 9

Pump Servo Pressure Check

Perform Pump Servo Pressure Test. (Group 9026-25.)

YES: Perform Transmission Efficiency Test. (Group 9026-25.)

Are servo pressures approximately equal and less than charge pressure?

NO: Go to Pressure Control Pilot Check. TW73308,0000108 -19-10JAN08-21/22

•

10 Pressure Control Pilot Check

Perform Pressure Control Pilot (PCP) Test. (Group 9026-25.)

YES: Clean screens between pump housing and pump displacement control valve (PDCV) and inspect PDCV.

Specification Neutral PCP Differential—Pressure...................................................................... 34 kPa 0.34 bar 0—5 psi

NO: Repair or adjust pressure control pilot (PCP). See Pressure Control Pilot (PCP) Internal Adjustment. (Group 9026-25.)

Is differential pressure within specifications?

TW73308,0000108 -19-10JAN08-22/22

TCU Calibration Malfunctions TW73308,0000109 -19-11JAN08-1/14

TCU Calibration Malfunctions Diagnostic Procedure Continued on next page

TM10721 (03SEP14)

9026-15-44

TW73308,0000109 -19-11JAN08-2/14

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=698

Diagnostic Information

• 1

Diagnostic Trouble Code Check

Check for codes by accessing the appropriate SDM menu. see Standard Display Monitor (SDM) Menu Structure—Service Mode. (Group 9015-16.)

NOTE: A pump threshold DTC containing FMI 15 indicates that pump threshold high current is greater than 25 mA. A pump threshold DTC containing FMI 17 indicates that pump threshold low current is less than 6 mA.

YES: If a code containing 15 FMI is active, go to Pump Servo Pressure Check.

Are any of the codes listed in the following table active?

YES: If a code containing 17 FMI is active, go to Pressure Control Pilot Test Check.

Pump Threshold Codes

NO: Go to next step in this check.

Codes with FMI 15

Codes with FMI 17

522450.15—Left Track Fwd

522450.17—Left Track Fwd

522447.15—Right Track Fwd

522447.17—Right Track Fwd

522449.15—Left Track Rev

522449.17—Left Track Rev

522448.15—Right Track Rev

522448.17—Right Track Rev

Check for codes by accessing the appropriate SDM menu. NOTE: A max pump calibration DTC containing FMI 16 indicates that max pump calibration high current is greater than 83 mA. A max pump calibration DTC containing FMI 18 indicates that max pump calibration low current is less than 51 mA. Are any of the codes listed in the following table active?

YES: If a code containing 16 FMI is active, go to Track Tension Check. YES: If a code containing 18 FMI is active, go to PCP Differential Pressure Check.

Max Pump Calibration Codes Codes with FMI 16

Codes with FMI 18

522450.16—Left Track Fwd

522450.18—Left Track Fwd

522447.16—Right Track Fwd

522447.18—Right Track Fwd

522449.16—Left Track Rev

522449.18—Left Track Rev

522448.16—Right Track Rev

522448.18—Right Track Rev

NO: Checks complete.

TW73308,0000109 -19-11JAN08-3/14

• 2

Pump Servo Pressure Check

Perform Pump Servo Pressure Test. (Group 9026-25.)

YES: Perform Transmission Efficiency Test. (Group 9026-25.) Repair or replace component based on results of efficiency test.

Are servo pressures equal for both pumps and less than charge pressures?

NO: Go to Pressure Control Pilot Test Check. TW73308,0000109 -19-11JAN08-4/14

• 3

Pressure Control Pilot Test Check

Perform Pressure Control Pilot (PCP) Test. (Group 9026-25.)

YES: Go to Pump Displacement Control Valve (PDCV) Neutral Adjustment Turn Check.

Is differential pressure less than 34 kPa (0.34 bar) (5 psi)?

NO: Go to Hydrostatic System Flushing Check.

Continued on next page

TM10721 (03SEP14)

9026-15-45

TW73308,0000109 -19-11JAN08-5/14

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=699

Diagnostic Information

• 4

Hydrostatic System Flushing Check

Perform Hydrostatic Pump Flushing Procedure. (Group 9026-25.)

YES: Go to Pump Displacement Control Valve (PDCV) Neutral Adjustment Turn Check.

After system has been flushed, perform Pressure Control Pilot (PCP) Test. (Group 9026-25.)

Is differential pressure less than 34 kPa (0.34 bar) (5 psi)?

• 5

Pump Displacement Control Valve (PDCV) Neutral Adjustment Turn Check

Perform Pump Displacement Control Valve (PDCV) Neutral (Null) Adjustment. (Group 9026-25.)

YES: Recalibrate the TCU. See Transmission Control Unit (TCU) Calibration. (Group 9015-20.)

Count the number of turns to achieve a 276 kPa (2.76 bar) (40 psi) difference between forward and reverse.

NO: If the number of turns is more than 2 turns, disassemble pressure displacement control valve (PDCV) and check for a worn feedback link. See Hydrostatic Pumps Disassemble. (Group 0360.)

Is the number or turns more than a 1/2 turn but less than 2 turns?

NO: If the number of turns is less than 1/2 turn, disassemble pump and re-level swash plate. See Hydrostatic Pumps Disassemble. (Group 0360.)

Continued on next page

TM10721 (03SEP14)

9026-15-46

TW73308,0000109 -19-11JAN08-7/14

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=700

Diagnostic Information

• 6

PCP Differential Pressure Check

Perform Pressure Control Pilot (PCP) Test. (Group 9026-25.)

YES: Perform Hydrostatic Motor Min. Angle Stop Adjustment. (Group 9026-25.)

Is differential pressure less than 34 kPa (0.34 bar) (5 psi)?

NO: Go to Hydrostatic Pump Flushing Check. TW73308,0000109 -19-11JAN08-8/14

• 7

Hydrostatic Pump Flushing Check

Perform Hydrostatic Pump Flushing Procedure. (Group 9026-25.)

YES: Perform Hydrostatic Motor Min. Angle Stop Adjustment. (Group 9026-25.)

After system has been flushed, perform Pressure Control Pilot (PCP) Test. (Group 9026-25.)

NO: If differential pressure is more than 34 kPa (0.34 bar) (5 psi) but less than 103 kPa (1.03 bar) (15 psi), adjust PCP. See Pressure Control Pilot (PCP) Internal Adjustment. (Group 9026-25.) After PCP is adjusted, perform Hydrostatic Motor Min. Angle Stop Adjustment. (Group 9026-25.)

Is differential pressure less than 34 kPa (0.34 bar) (5 psi)?

NO: If differential pressure is more than 103 kPa (1.03 bar) (15 psi), replace PCP. See Hydrostatic Pumps Disassemble. (Group 0360.) After PCP is replaced, perform Hydrostatic Motor Min. Angle Stop Adjustment. (Group 9026-25.) TW73308,0000109 -19-11JAN08-9/14

• 8

Track Tension Check

Check track sag. See Check Track Sag. (Operator's Manual.)

YES: Go to Engine Speed Check.

Is track sag within specifications?

NO: Adjust tracks. See Adjust Track Sag. (Operator's Manual.) Continued on next page

TM10721 (03SEP14)

9026-15-47

TW73308,0000109 -19-11JAN08-10/14

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=701

Diagnostic Information

• 9

Engine Speed Check

Check engine speed on the SDM main menu screen. See Standard Display Monitor (SDM) Menu Structure—Service Mode. (Group 9015-16.) Start engine and run at fast idle.

YES: Go to Engine Performance Check.

Is engine speed 2250—2300 rpm?

NO: Engine speed is too low. Replace engine speed control (R10). See Main Cab/Canopy Harness (W5) Component Location. (Group 9015-10.) See CTM104 for engine diagnostics. TW73308,0000109 -19-11JAN08-11/14

•

10 Engine Performance Check

CAUTION: Beware of possible injury from sudden machine movement. Move blade to maximum height before performing this check. Check engine speed on the SDM main menu screen. See Standard Display Monitor (SDM) Menu Structure—Service Mode. (Group 9015-16.) Start engine and run at fast idle. Operate machine at maximum forward. Bottom blade tilt function and counter-rotate machine.

YES: Go to Neutral and Operating Charge Pressure Check.

Is engine speed greater than 1800 rpm (both tracks must turn)?

NO: Go to next step in this check.

Set engine speed to 1800 rpm. Set anti-stall to off by accessing the TCU Diagnostics / Settings menu on the SDM. See Standard Display Monitor (SDM) Menu Structure—Service Mode. (Group 9015-16.) Set transmission speed (SIG) to 2.0. Operate machine in forward counter-rotate.

YES: Go to Neutral and Operating Charge Pressure Check.

Do tracks continue to move and engine does not stall?

NO: Perform Intake Manifold Pressure Test—Turbocharger Boost. (Group 9010-25.) If intake pressure is low, see CTM104 for repair procedure.

Continued on next page

TM10721 (03SEP14)

9026-15-48

TW73308,0000109 -19-11JAN08-12/14

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=702

Diagnostic Information

•

11 Neutral and Operating Charge Pressure Check

Perform Neutral Charge Relief and Operating Charge Relief Pressure Test. (Group 9026-25.)

YES: Perform Transmission Efficiency Test. (Group 9026-25.) Repair or replace component based on results of efficiency test.

NO: Go to Pump Screen Check.

Are neutral and operating charge pressures within specifications? TW73308,0000109 -19-11JAN08-13/14

•

12 Pump Screen Check

Inspect screens in pump housing.

YES: Replace pump screens. See Hydrostatic Pumps Disassemble. (Group 0360.)

Are the screens clogged with debris?

NO: Pump malfunction. Repair or replace pump. See Hydrostatic Pump Remove and Install. (Group 0300.) TW73308,0000109 -19-11JAN08-14/14

TM10721 (03SEP14)

9026-15-49

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=703

Diagnostic Information

TM10721 (03SEP14)

9026-15-50

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=704

Group 25

Test JT05800 Digital Thermometer Installation SERVICE EQUIPMENT AND TOOLS JTO5800 Digital Thermometer

T6808CE —UN—28FEB89

Temperature Probe - Fasten to a bare metal line using a tie band. Wrap with shop towel. Cable

A—Temperature Probe B—Cable

C—Digital Thermometer

CED,OUTX466,1276 -19-13FEB06-1/1

Digital Pressure And Temperature Analyzer Installation SERVICE EQUIPMENT AND TOOLS JT02156A Digital Pressure and temperature Analyzer

A—Digital Pressure and Temperature Analyzer

T8543AI —UN—25AUG95

Use the digital pressure and temperature analyzer in place of analog gauges and a separate temperature reader. B—3400 kPa (35 bar) (500 psi) Transducer 34 000 kPa (350 bar) (5000 psi) Transducer 70 000 kPa (700 bar) (10 000 psi) Transducer

Digital Pressure And Temperature Analyzer BR81691,0000058 -19-01MAR04-1/2

Digital Pressure and temperature Analyzer....... JT02156A

Used to check hydraulic pressure and temperature. BR81691,0000058 -19-01MAR04-2/2

Hydraulic Oil Cleanup Procedure A hydraulic oil cleanup procedure must be done prior to starting machine after a component has been repaired or

replaced. The use of attachments increases the need to monitor and filter oil to a safe contamination level. See Oil Cleanup General Procedure. (CTM310.) AA95137,000121F -19-08JAN08-1/1

JDG1770 Ultra Clean® Hand Launcher Use the Ultra Clean Hand Launcher Kit to help eliminate contamination in hydraulic systems. All newly installed

hose and tube assemblies should be cleaned using this tool.

Ultra Clean is a trademark of Ultra Clean Technologies Corp. MR50960,0000123 -19-26JUN06-1/1

TM10721 (03SEP14)

9026-25-1

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=705

Test

Transmission Oil Warmup Procedure SPECIFICATIONS

6. Oil Heating Cycle:

Fast Idle

Engine Speed

a. Depress and hold decelerator pedal to lower stop. SERVICE EQUIPMENT AND TOOLS

b. Pull park lock lever to up position.

D01182AA 20-Ton Floor Stands

The hydraulic and hydrostatic circuits have separate oil reservoirs. Use this procedure to stabilize and circulate warm oil to travel motors to meet hydrostatic (HST) test temperature specifications. The SDM monitor must be used to select Brake Test Mode which will keep the park brake applied for this procedure. CAUTION: Prevent possible injury from unexpected track movement. Raise the machine off the ground and support with appropriate stands. Tracks must be free to rotate in either direction, check for objects on tracks before rotating tracks. 1. Raise machine off the ground and support with D01182AA Floor Stands. Lower blade to the ground. Tracks must be free to rotate in either direction.

c. Push transmission control lever (TCL) to forward detent. IMPORTANT: To prevent damage to multi-function valves, the test software limits the test function to 20 seconds before returning TCU to neutral. The tracks must be operated between test function to prevent localized overheating of multi-function valves. Rotating the tracks will circulate hot oil out of closed loop circuit through the case drain filter, hydrostatic oil cooler, and to reservoir for cooling. d. Slowly release decelerator pedal and run until TCU returns to neutral, approximately 20 seconds. e. Go to next step and circulate oil. 7. Oil Circulate Cycle:

2. Start engine.

a. Depress and hold decelerator pedal to lower stop.

3. Set brake mode to TEST by accessing the MACHINE SETTINGS / BRAKE MODE submenu on the SDM. See Standard Display Monitor (SDM) Menu Structure—Service Mode. (Group 9015-16.)

b. Push park lock lever to down position.

4. View the transmission oil temperature by accessing the DIAGNOSTIC / LIVE VALUES / TEMPS submenu on the SDM. See Standard Display Monitor (SDM) Menu Structure—Service Mode. (Group 9015-16.)

d. Slowly release decelerator pedal and run for fifteen seconds in forward.

NOTE: The warmup indicator will remain lit and engine speed will be limited until the transmission oil reaches a specified temperature or the engine has run for ten minutes. Indicator light will turn off automatically when system is to operating temperature.

c. Push transmission control lever (TCL) to forward detent.

e. Shift TCL to reverse and run for fifteen seconds. 8. Alternate heating and circulating cycles until hydrostatic oil temperature reaches test specification. NOTE: Stopping engine by turning key off will reset brake mode TEST setting back to Normal setting. 9. Stop engine.

5. Run engine at fast idle. Specification Engine—Speed.......................................................................... Fast Idle TW73308,000010A -19-05JUN09-1/1

Hydrostatic Oil Sampling Procedure—If Equipped For hydrostatic oil sampling procedure, see Fluid Sampling Procedure—If Equipped. (Group 9010-25.) AA95137,00013E3 -19-25MAR08-1/1

TM10721 (03SEP14)

9026-25-2

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=706

Test

Releasing Park Brake to Tow the Machine SPECIFICATIONS Brake Circuit Release Pressure

1379—2758 kPa 13.79—27.58 bar 200—400 psi

Multi-Function Valve Lock Nut Torque

79 N.m 58 lb-ft

SERVICE EQUIPMENT AND TOOLS AM102420 Male Quick Coupler Porta-Power Pump With Gauge 1 3/8 in. Socket

This procedure is used to release the park brakes for towing the machine.

T158857C —UN—14JUN04

CAUTION: Prevent possible injury from unexpected machine movement. Place blocks at front and rear of tracks and secure machine to prevent it from rolling. Do not allow an operator on the machine being towed unless the operator can control the steering and brakes. 1. Remove rubber mat and floor plate from operator's station. NOTE: Multi-Function valves can be turned out using a 1 3/8 in. socket and a flexible head ratchet. Engine does not have to be running to tow machine. IMPORTANT: The lower multi-function valves are in the reverse side of the closed loop circuit and must be loosened to tow the machine in forward. Likewise, the upper multi-function valves are in the forward side of the closed loop circuit and must be loosened to tow the machine in reverse. 2. TO TOW MACHINE FORWARD both front and rear pump reverse multi-function relief valves (1) MUST be turned out (counterclockwise) 1/2 to 1 turn and blade

Multi-Function Valves 1— Forward Multi-Function Valve

must be raised off the ground. (If engine will crank but will not start, blade can be raised by cranking engine while holding blade raise function on control valve.) TO TOW MACHINE IN REVERSE both front and rear pump forward multi-function valves (2) MUST be turned out (counterclockwise) 1/2 to 1 turn.

Continued on next page

TM10721 (03SEP14)

9026-25-3

2— Reverse Multi-Function Valve

TW73308,000010B -19-08FEB10-1/3

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=707

Test

Disconnect brake hose quick coupler (6) from pump.

T198205A —UN—01MAR04

NOTE: If spare AM102420 male quick coupler is not available, the male quick coupler can be removed from HST pump and used to adapt porta-power hose. Install fitting cap to seal hydrostatic (HST) pump fitting. Install AM102420 male quick coupler fitting on porta-power hose. Connect quick coupler fittings so porta-power can pump off brakes.

5. Set brake mode to TOW by accessing the MACHINE SETTINGS / BRAKE MODE submenu on the SDM. See Standard Display Monitor (SDM) Menu Structure—Service Mode. (Group 9015-16.)

Top View of Front pump Shown

NOTE: TOW will allow the machine to be towed without automatically applying the brakes (hill hold disabled). 6. View TRANS CHARGE OIL pressure by accessing the DIAGNOSTIC / LIVE VALUES / PRESSURES submenu on the SDM. See Standard Display Monitor (SDM) Menu Structure—Service Mode. (Group 9015-16.)

1— Pressure Control Pilot (PCP) Internal Adjustment Port 2— Reverse Servo Test Port 3— Forward Servo Test Port 4— Reverse Pump Displacement Control Valve (PDCV) Test Port

5— Forward Pump Displacement Control Valve (PDCV) Test Port 6— Park Brake Release Hose Quick Coupler 7— Pressure Control Pilot (PCP) Manual Override Lever 8— Drain Line To Rear Pump

NOTE: TRANS CHARGE OIL will display pressure seen in the brake circuit. Continued on next page

TM10721 (03SEP14)

9026-25-4

TW73308,000010B -19-08FEB10-2/3

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=708

Test

NOTE: When towing the machine with person in operator's seat, the park brake can be applied to stop machine at any time by moving the park lock lever to the up (locked) position. T119229B —UN—22DEC98

7. Put park lock lever in DOWN position. NOTE: The brakes initially start to release at approximately 896 kPa (8.96 bar) (130 psi) and are fully released at approximately 1310 kPa (13.1 bar) (190 psi). The pressure can be monitored with the park lock lever down on the charge pressure gauge on the TCU. IMPORTANT: Brake seals can be damaged if pressurized above 2758 kPa (27.58 bar) (400 psi). DO NOT exceed the limits of the charge pressure gauge on TCU. Release brakes using port-a-power with a MINIMUM pressure of 1378 kPa (13.79 bar) (200 psi) and a MAXIMUM pressure of 2758 kPa (27.58 bar) (400 psi). The porta-power used must have a pressure gauge to prevent over pressurizing brake circuit. 8. Pressurize brake circuit to specification. Specification Brake Circuit Release—Pressure....................................................... 1379—2758 kPa 13.79—27.58 bar 200—400 psi

IMPORTANT: DO NOT tow machine faster than 1.6 km/h (1 mph) (646 motor rpm max) for 10 minutes or not to exceed 305 m (1000 ft) of total tow distance. Failure to do this may result in extensive machine damage.

Port-a-Power With Pressure Gauge

9. Tow machine. NOTE: Brake pressure will degrade due to internal brake valve leakage. Brake pressure will fall quickly from 2068 kPa (20.68 bar) (300 psi), however, the brake pistons won't need to be pumped up again until pressure drops below 1000 kPa (10 bar) (145 psi). 10. Remove porta-power and connect brake hose to HST pump. 11. Tighten multi-function valve lock nut to specification. Specification Multi-Function Valve Lock Nut—Torque..................................................................................79 N.m 58 lb-ft

TW73308,000010B -19-08FEB10-3/3

TM10721 (03SEP14)

9026-25-5

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=709

Test

Hydrostatic Pump and Motor Initial Start-Up Procedure SPECIFICATIONS 345 kPa 3.45 bar 50 psi

T198205A —UN—01MAR04

Transmission Charge Pressure

SERVICE EQUIPMENT AND TOOLS D01182AA 20-Ton Floor Stands JT03477 Male Quick Coupler JT03029 Plug JT03448 Test Hose Rear Pump Shown

JT05594 Gauge

This procedure is used to bleed air from the hydrostatic circuit after a major component repair.

1— Pressure Control Pilot (PCP) Internal Adjustment Port 2— Reverse Servo Test Port 3— Forward Servo Test Port 4— Reverse Pump Displacement Control Valve (PDCV) Test Port

CAUTION: Prevent possible injury from unexpected track movement. Raise the machine off the ground and support with appropriate stands. Tracks must be free to rotate in either direction, check for objects on tracks before rotating tracks. IMPORTANT: Failure to follow this procedure when a pump or motor case is drained of oil may result in damage to the internal components of pump and motor. 1. Raise machine off the ground and support with D01182AA stands. Lower blade to ground. Tracks must be free to rotate in either direction.

5— Forward Pump Displacement Control Valve (PDCV) Test Port 6— Park Brake Quick Coupler 7— Pressure Control Pilot (PCP) Manual Override Lever 8— Drain Line To Rear Pump

3. Disconnect drain line to rear pump (8), at tee fitting on front pump case drain port. When oil flows from both line and fitting, connect line. 4. Disconnect crankshaft position sensor (B6). See Engine Harness (W6) Component Location. (Group 9015-10.)

2. Fill reservoir with specified oil. Leave reservoir cap OFF. Continued on next page

TM10721 (03SEP14)

9026-25-6

TE14778,0000031 -19-02JUN09-1/2

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=710

Test

5. Disconnect park brake hydraulic line quick coupler (B) from charge pump. Assemble park brake quick coupler (B) with JT03477 Male Quick Coupler (A) and JT03029 Plug (C). T157949B —UN—23JUL02

6. Connect test hose and gauge onto charge pump quick coupler. IMPORTANT: Never operate starting motor more than 30 seconds. Allow at least 2 minutes for cooling and battery recovery before operating again. Overheating, caused by excessive operation, will seriously damage starting motor. Quick Coupler

7. Crank engine in 30 second intervals until transmission charge pressure reaches specification.

A—JT03477 Male Quick Coupler B—Park Brake Quick Coupler

Specification Transmission Charge—Pressure....................................................................... 345 kPa 3.45 bar 50 psi

for several minutes. This will flush the displacement control valve areas.

8. Connect crankshaft position sensor (B6). 9. Start engine and leave at low idle. Operate machine in forward and reverse cycles through counter-rotate

C—JT03029 Plug

10. Check reservoir oil level and install cap. TE14778,0000031 -19-02JUN09-2/2

TM10721 (03SEP14)

9026-25-7

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=711

Test

Hydrostatic Pump Flushing Procedure Slow Idle

Transmission Speed Position

2.0 T198205A —UN—01MAR04

SPECIFICATIONS Engine Speed

SERVICE EQUIPMENT AND TOOLS D01182AA 20-Ton Floor Stands 38H1004 90° Fitting (2 used) 38H1160 Fitting (4 used) Parker #1JS43-6-6 Fitting 9/16 ORB (4 used) Parker #601-6 Hose 2 m (7 ft) (4 used) Rear Pump Shown

This procedure is used whenever major repair has been done to the hydrostatic circuit.

1— Pressure Control Pilot (PCP) Internal Adjustment Port 2— Reverse Servo Test Port 3— Forward Servo Test Port 4— Reverse Pump Displacement Control Valve (PDCV) Test Port

CAUTION: Prevent possible injury from unexpected track movement. Raise the machine off the ground and support with appropriate stands. Tracks must be free to rotate in either direction, check for objects on tracks before rotating tracks. 1. Raise machine off the ground and support with D01182AA stands. Lower blade to ground. Tracks must be free to rotate in either direction. NOTE: Test ports (4 and 5) must be closed to shift displacement control valve and allow flow from servos (2 and 3) NOTE: Bulkhead wiring bracket will need to be loosened to give access to test ports. 2. Install test hoses and fittings into ports (4 and 5) on both pump displacement control valves. Route opposite end of hoses back to reservoir. 3. Start engine. Set transmission speed and engine to specification.

5— Forward Pump Displacement Control Valve (PDCV) Test Port 6— Park Brake Quick Coupler 7— Pressure Control Pilot (PCP) Manual Override Lever 8— Drain Line To Rear Pump

Specification Engine—Speed..........................................................................Slow Idle Transmission Speed—Position.................................................................................. 2.0

4. Cycle transmission control lever to forward left counter-rotate through right counter-rotate position. This will flush the displacement control valve areas. 5. Continue cycling machine at low idle for several minutes. 6. Increase engine speed to 1500 rpm and continue cycling control to actuate transmission pumps for approximately 10 minutes. 7. Repeat procedure using servo test ports (2 and 3). TE14778,0000032 -19-04JUN09-1/1

TM10721 (03SEP14)

9026-25-8

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=712

Test

Pressure Control Pilot (PCP) Manual Override Test SPECIFICATIONS Engine Speed

Slow Idle SERVICE EQUIPMENT AND TOOLS

D01182AA 20-Ton Floor Stands

This procedure will help isolate between electrical and hydraulic problems. Moving the manual override lever produces a hydraulic differential pressure signal to the pump displacement control valve (PDCV). If operation is normal, pressure will be produced in the closed-loop and tracks will rotate.

T119056B —UN—16DEC98

Specification Engine—Speed..........................................................................Slow Idle

3. View motor speeds by accessing the DIAGNOSTIC / LIVE VALUES / SPEEDS submenu on the SDM. See Standard Display Monitor (SDM) Menu Structure—Service Mode. (Group 9015-16.) NOTE: In order to allow manual override in neutral, the brake rate setting must be set to TEST. In NORMAL mode the brakes will engage after three seconds.

1— PCP Manual Override Lever

NOTE: Stopping engine by turning key off will reset brake mode TEST setting back to Normal setting. 6. Stop engine.

4. Set brake mode to TEST by accessing the MACHINE SETTINGS / BRAKE MODE submenu on the SDM. See Standard Display Monitor (SDM) Menu Structure—Service Mode. (Group 9015-16.) CAUTION: Prevent possible injury from unexpected track movement. Tracks will rotate when PCP manual override lever is moved. 5. Momentarily move the PCP manual override lever (1) in each direction. The tracks must rotate as the lever is moved in each direction. This indicates normal hydraulic operation in the closed-loop system. TW73308,000010C -19-05JUN09-1/1

TM10721 (03SEP14)

9026-25-9

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=713

Test

Pressure Control Pilot (PCP) Test 57—66°C 135—150°F

Neutral PCP Differential Pressure

34 kPa 0.34 bar 0—5 psi

Engine Speed

Fast Idle

Transmission Speed Position

1.0—3.0

Input Current-to-Control Pressure

1 mA/1 psi

T198205A —UN—01MAR04

SPECIFICATIONS Transmission Oil Temperature

SERVICE EQUIPMENT AND TOOLS D01182AA 20-Ton Floor Stands

Front Pump Test Ports Shown

XPD361 Quick Coupler (9/16-20UN M ORB) (2 used) JT03448 Test Hose (2 used)

1— Pressure Control Pilot (PCP) Internal Adjustment Port 2— Reverse Servo Test Port 3— Forward Servo Test Port 4— Reverse Pump Displacement Control Valve (PDCV) Test Port

JT05753 Hydrostatic Test Switch Box JT02156A Digital Pressure/Temperature Analyzer JT02161 350 kPa (35 bar) (500 PSI) Transducer

This procedure will test if pump PCPs are in neutral and also in operational mode. CAUTION: Prevent possible injury from unexpected track movement. Raise the machine off the ground and support with appropriate stands. Tracks must be free to rotate in either direction, check for objects on tracks before rotating tracks.

5— Forward Pump Displacement Control Valve (PDCV) Test Port 6— Park Brake Quick Coupler 7— Pressure Control Pilot (PCP) Manual Override Lever 8— Drain Line To Rear Pump

Specification Neutral PCP Differential—Pressure................................................................... 34 kPa 0.34 bar 0—5 psi

• If neutral PCP differential pressure is within

1. Raise machine off the ground and support with D01182AA Floor Stands. Lower blade to the ground. Tracks must be free to rotate in either direction.

specification PCP is OK, repeat test procedure on rear pump. • If both pump PCP differential pressures are OK, test is complete, remove test equipment. • If either pump neutral PCP differential pressure is greater than specification and less than 103 kPa (1.03 bar) (15 psi), PCP must be adjusted. See Pressure Control Pilot (PCP) Internal Adjustment. (9026-25.) • If either pump differential pressure is over 103 kPa (1.03 bar) (15 psi), PCP must be replaced.

2. Remove rubber mat and floor plate from operator's station. 3. Install fittings and test hoses in ports (4 and 5). IMPORTANT: A switching valve and a single gauge or a differential pressure gauge or reader must be used to obtain an accurate differential pressure reading. Two separate pressure gauges cannot be used.

Adjustment Procedure: a. View LEFT PUMP PCP and RIGHT PUMP PCP values by accessing the DIAGNOSTIC / CALIBRATED VALS / SWITCHES submenu on the SDM. See Standard Display Monitor (SDM) Menu Structure—Service Mode. (Group 9015-16.) Record mA value.

4. Connect hydrostatic test switch box, digital pressure/temperature analyzer and transducer or a gauge. 5. Start engine and heat hydrostatic oil to specified temperature. See Transmission Oil Warmup Procedure. (Group 9026-25.)

b. Depress decelerator pedal to floor and move park brake lever to down position.

Specification Transmission Oil—Temperature......................................................................57—66°C 135—150°F

c. Run engine at fast idle and set transmission speed to specification.

6. Adjust transmission speed to 1.0 and record pump neutral PCP differential pressure in neutral. Compare to specifications.

Specification Engine—Speed.......................................................................... Fast Idle Transmission Speed—Position.................................................................................. 1.0

Continued on next page

TM10721 (03SEP14)

9026-25-10

TW73308,000010D -19-29APR08-1/2

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=714

Test

d. Move transmission control lever to forward. Slowly release decelerator pedal. Carefully monitor the mA as the decelerator is released. The reading will suddenly go from 0 to some low reading (e.g., 15.9 mA). Note and record this threshold or initial reading on chart.

NOTE: At approximately transmission speed 2.0, the mA will increase and then decrease momentarily as the transmission shifts to high speed.

e. With the decelerator fully released, slowly increase transmission speed to maximum speed 3.0 position to get each of the higher Control Milliamp mA readings to match chart. Transmission Speed

Control Milliamp

Neutral Reading at (1.0).

Initial Reading at (1.0) (record actual mA).

__mA

Increase speed to get—

35 mA

Increase speed to get—

50 mA

Increase speed to get—

75 mA

Maximum Reading at (3.0) (record actual mA).

__mA

f. Record the pump control pressure and calculate the pressure differential at each control milliamp setting on below chart:

Front Pump Control Pressure

Rear Pump Control Pressure

Calculated Pressure Differential

Forward

Front Pump

Reverse

g. Repeat the procedure for reverse. h. Analyze test results as follows: Specification Input Current-to-Control Pressure—Ratio...................................................................... 1 mA/1 psi

• The initial reading when coming out of neutral is

the threshold of movement value (point tracks begin to move). • The relationship between control milliamps and control pressure differential is approximately 7

Reverse

Rear Pump

kPa (0.07 bar) (1 psi) pressure out for each milliamp of current in. • The operation of the PCP can be considered acceptable if pressure reading is reasonably close to the theoretical value and linear to the milliamps values. • If PCP needs to be adjusted, perform Pressure Control Pilot (PCP) Internal Adjustment. (Group 9026-25.)

TW73308,000010D -19-29APR08-2/2

TM10721 (03SEP14)

9026-25-11

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=715

Test

Pressure Control Pilot (PCP) Internal Adjustment SPECIFICATIONS 57—66°C 135—150°F

Engine Speed

Fast Idle

Transmission Speed Position

1.0

Differential Pressure

34.5 kPa 0.34 bar 0—5 psi

T198205A —UN—01MAR04

Transmission Oil Temperature

SERVICE EQUIPMENT AND TOOLS XPD361 Quick Coupler (9/16-20UN M ORB) (2 used)

Front Pump Test Ports Shown

JT03448 Test Hose (2 used) JT05753 Hydrostatic Test Switch Box JT02156A Digital Pressure/Temperature Analyzer JT02161 350 kPa (35 bar) (500 PSI) Transducer 3/32 Hex Key Wrench

The purpose of this test is to adjust the internal flapper valve in the pressure control pilot (PCP) to have less than 5 psi forward to reverse pressure differential in neutral. 1. Remove rubber mat and floor plate from operators station.

1— Pressure Control Pilot (PCP) Internal Adjustment Port 2— Reverse Servo Test Port 3— Forward Servo Test Port 4— Reverse Pump Displacement Control Valve (PDCV) Test Port

6. Disconnect PCP wire connector. 7. Run engine at fast idle, set transmission speed at 1.0.

2. Thoroughly clean area around PCP and pump displacement control valve (PDCV) test ports.

With park lock lever in up position, record differential pressure.

3. Install fittings and test hoses in ports (4 and 5).

IMPORTANT: A switching valve and gauge or some type of differential pressure gauge or reader must be used to obtain an accurate differential pressure reading. Two separate pressure gauges cannot be used.

8. Read or calculate differential pressure and compare to specifications.

4. Connect switching valve, digital pressure/temperature analyzer and transducer or a gauge. 5. Start engine and heat hydrostatic oil to normal operating temperature. See Transmission Oil Warmup Procedure. (Group 9026-25.)

Specification Differential—Pressure................................................................ 34.5 kPa 0.34 bar 0—5 psi

• If differential pressure is within specifications, test is complete.

Specification Transmission Oil—Temperature......................................................................57—66°C 135—150°F

• If differential pressure is too high, go to next step to adjust.

Continued on next page

TM10721 (03SEP14)

5— Forward Pump Displacement Control Valve (PDCV) Test Port 6— Park Brake Quick Coupler 7— Pressure Control Pilot (PCP) Manual Override Lever 8— Drain Line To Rear Pump

9026-25-12

WS68074,0000936 -19-12JAN07-1/2

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=716

Test

IMPORTANT: The coil and flapper valve area of the PCP must be kept clean for proper operation. Always use clean wrenches and keep entire area clear of any dirt. T119062B —UN—16DEC98

NOTE: Some silicone oil will leak from port when screw is removed. 9. Remove slotted screw (1) with O-ring on side of PCP. 10. Adjust internal hex screw as necessary to get differential pressure to specification. Specification Differential—Pressure................................................................ 34.5 kPa 0.34 bar 0—5 psi

IMPORTANT: DO NOT overtighten PCP screw (1). 11. Install screw (1) by hand until O-ring contacts housing. Turn screw an additional 1/8 turn.

PCP Valve (Top view of HST Front Pump) 1— PCP Internal Adjustment Port

14. Calibrate machine. See Transmission Control Unit (TCU) Calibration. (Group 9015-20.)

12. Remove test equipment and connect wire lead to PCP. 13. Route all wiring harnesses back to their original location and replace all tie bands that were removed. WS68074,0000936 -19-12JAN07-2/2

TM10721 (03SEP14)

9026-25-13

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=717

Test

Multi-Function Relief Valve Test 57—66°C 135—150°F

Engine Speed

Fast Idle

Transmission Speed Setting

1.6

T198077A —UN—25FEB04

SPECIFICATIONS Transmission Oil Temperature

Multi-Function Valve 450J Relief Valve Pressure

36 301—38 645 kPa 363—386 bar 5265—5605 psi

550J Relief Valve Pressure

39 300—41 644 kPa 393—416 bar 5700—6035 psi

650J Relief Valve Pressure

43 299—45 643 kPa 433—456 bar 6280—6620 psi

Relief Valve Pressure Change

7000 kPa per 1/2 Turn 70 bar per 1/2 Turn 1000 psi per 1/2 Turn

Lock Nut Torque

16.3 N·m 144 lb.-in.

1— Left Forward (LF) 2— Left Reverse (LR)

3— Right Reverse (RR) 4— Right Forward (RF)

• Use test ports (1 and 2) to check rear pump (left track) multi-function valve relief settings.

• Use test ports (3 and 4) to check front pump (right track) multi-function valve relief settings.

ESSENTIAL TOOLS JT03482 High Pressure Test Kit

4. Start engine and heat oil to specification. See Transmission Oil Warmup Procedure. (Group 9026-25.)

SERVICE EQUIPMENT AND TOOLS D01182AA 20-Ton Floor Stand (4 used)

Specification Transmission Oil—Temperature......................................................................57—66°C 135—150°F

JT02158 Digital Pressure and Temperature Analyzer JT02160 70 000 kPa (700 bar) (10 000 psi) Transducer (2 used)

The purpose of this test is to check and adjust multi-function valve relief settings. For more information, see Multi-Function Valve Operation. (Group 9026-05.)

5. Set brake mode to TEST: a. Enter service mode on the standard display monitor (SDM). Press and hold MENU for approximately 5 seconds until monitor alarm is heard and SERVICE MENU is temporarily displayed on SDM.

b. Select MACHINE SETTINGS from SDM main menu. c. Press NEXT until BRAKE MODE appears and then press SELECT. Set brake mode to TEST. For more information on using SDM, see Standard Display Monitor (SDM) Menu Structure—Service Mode. (Group 9015-16.)

1. Raise machine off the ground and support with D01182AA 20-Ton Floor Stands. Lower blade to ground. Tracks must be free to rotate in either direction.

6. Run engine at fast idle.

2. Stop engine. CAUTION: To avoid injury from escaping fluid under pressure, stop engine and relieve the pressure in the system before disconnecting or connecting hydraulic or other lines. Tighten all connections before applying pressure. Pressure spikes in the transmission closed loop can approach 68 950 kPa (690 bar) (10 000 psi). Use hoses and fittings rated for these pressures when checking transmission system pressures.

Specification Engine—Speed.......................................................................... Fast Idle

7. Pull park lock lever to UP position and set transmission speed to specification. Specification Transmission Speed—Setting................................................................................... 1.6

3. Install test fittings, lines, and gauges in appropriate diagnostic test ports. Continued on next page

TM10721 (03SEP14)

9026-25-14

TW73308,000010E -19-30APR14-1/3

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=718

Test

IMPORTANT: To prevent damage to multi-function valves, the test software limits the test function to 20 seconds before returning transmission to neutral. The tracks must be operated between test functions to prevent localized overheating of multi-function valves. Rotating the tracks will circulate some hot oil out of closed-loop circuit to the hydrostatic oil reservoir for cooling. NOTE: Brake test mode allows the machine to be out of neutral for 20 seconds, after which the transmission control unit (TCU) returns the machine to neutral. Return transmission control lever (TCL) to neutral for at least 20 seconds before moving TCL to forward or reverse to start cycle again. 8. Check multi-function valve relief pressure: a. Depress decelerator/brake pedal to lower stop and hold in that position. b. Place transmission control lever (TCL) in appropriate detent corresponding with test being performed. Hold TCL to stop track on opposite side. (Test multi-function valve relief pressure one side at a time to obtain accurate results.) NOTE: In order to obtain an accurate gauge reading it is important not to flood the relief valve with excessive oil flow. Do not continue increasing engine speed after pressure levels out.

NOTE: Pressure should rise as the engine speed is slowly increased and then levels out. The point at which the pressure levels out is the relief valve setting. d. If high-pressure reading is erratic (very unstable), rotate tracks slightly to reposition motor speed ring and sensor. Repeat test. If pressures remain erratic, turn TRACKER CONTROL off in SDM and perform test. e. Compare reading to specification. If the relief setting cannot be reached at fast idle, then slowly increase transmission speed until pressure levels out. Multi-Function Valve—Specification 450J Relief Valve—Pressure...................................................... 36 301—38 645 kPa 363—386 bar 5265—5605 psi 550J Relief Valve—Pressure...................................................... 39 300—41 644 kPa 393—416 bar 5700—6035 psi 650J Relief Valve—Pressure...................................................... 43 299—45 643 kPa 433—456 bar 6280—6620 psi

9. Repeat procedure to test other relief valve settings and record pressures.

c. Slowly release decelerator/brake pedal and record highest pressure reading. Continued on next page

TM10721 (03SEP14)

9026-25-15

TW73308,000010E -19-30APR14-2/3

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=719

Test

10. If multi-function valve relief setting does not meet test specification: a. Remove hex cover, if installed. (Later version machines do not have covers on relief valves.) b. Loosen the outer lock nut. c. Insert hex wrench in center of valve. d. Turn hex wrench in to increase pressure, out to decrease pressure. Multi-Function Valve—Specification Relief Valve—Pressure Change..................................................................7000 kPa per 1/2 Turn 70 bar per 1/2 Turn 1000 psi per 1/2 Turn

e. Hold hex wrench and tighten lock nut to specification.

T158857C —UN—14JUN04

Multi-Function Valve—Specification Lock Nut—Torque.......................................................................16.3 N·m 144 lb.-in.

f. Repeat test to verify pressure, adjust as required. g. Install hex cover. 11. Turn key switch OFF to reset brake mode to NORMAL. 12. Remove test equipment. 1— Forward Multi-Function Valve

2— Reverse Multi-Function Valve

Multi-Function Valves (shown with hex covers on)

TW73308,000010E -19-30APR14-3/3

TM10721 (03SEP14)

9026-25-16

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=720

Test

Transmission Efficiency Test

A small current signal to maintain system pressure means there is very little leakage. A large current signal reading means higher internal leakage.

SPECIFICATIONS Transmission Oil Temperature

57—66°C 135—150°F

Transmission Speed Position

1.6

Engine Speed

Fast Idle

450J Pressure

36 301—38 645 kPa 363—386 bar 5265—5605 psi

550J Pressure

39 300—41 644 kPa 393—416 bar 5700—6400 psi

1. Raise machine off the ground and support with D01182AA 20-Ton Floor Stands.

650J Pressure

43 299—45 643 kPa 433—456 bar 6280—6620 psi

2. Lower blade to ground. Check if tracks are still off ground and are free to rotate in either direction.

Pump Amperage (good)

0—14 mA

Pump Amperage (marginal)

15—19 mA

Pump Amperage (bad)

Over 20 mA

Multi-Function Relief Valve

3. Stop engine. CAUTION: To avoid injury from escaping fluid under pressure, stop engine and relieve the pressure in the system before disconnecting or connecting hydraulic or other lines. Tighten all connections before applying pressure. Pressure spikes in the transmission closed loop can approach 68 950 kPa (690 bar) (10,000 psi). Use hoses and fittings rated for these pressures when checking transmission system pressures.

ESSENTIAL TOOLS JT03482 High Pressure Test Kit SERVICE EQUIPMENT AND TOOLS D01182AA 20-Ton Floor Stands JT02156A Digital Pressure/Temperature Analyzer (2 used) JT02160 70 000 kPa (700 bar) (10 000 PSI) Transducer (2 used)

The purpose of this test is to determine the amount of transmission internal leakage in the closed-loop components.

4. Install test fittings, lines, and gauge in motor test ports.

This is accomplished by determining the amount of oil the transmission pump must deliver to maintain a specified system pressure in the closed loop. This pressure is below the multi-function valve setting. Therefore, the amount of pump flow indicates the amount of internal leakage in the closed loop. The transmission controller sends a current signal to the Pressure Control Pilot (PCP) on each pump. The PCP produces a hydraulic pressure differential to the servo piston relative to the amount of current. By monitoring the current signal being sent to the PCP, the amount of leakage in the closed loop can be determined.

Each test port senses closed-loop pressure. • Use test ports (1 and 2) to check left motor (rear pump) relief setting. • Use test ports (3 and 4) to check right motor (front pump) relief setting. 5. Start engine and heat oil to specification. See Transmission Oil Warmup Procedure. (Group 9026-25.) Specification Transmission Oil—Temperature......................................................................57—66°C 135—150°F

Continued on next page

TM10721 (03SEP14)

9026-25-17

FB87413,5F5E30C -19-14AUG13-1/4

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=721

Test 3— Right Reverse (RR) 4— Right Forward (RF)

T198077A —UN—25FEB04

1— Left Forward (LF) 2— Left Reverse (LR)

Closed Loop Test Ports Continued on next page

TM10721 (03SEP14)

9026-25-18

FB87413,5F5E30C -19-14AUG13-2/4

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=722

Test

6. Remove transmission control unit (TCU) cover and adjust TCU. a. Press TCU MENU (D) until RATE appears in window (A). Press SELECT. b. Press NEXT (F) until BRAK appears. Press SELECT. TX1012349A —UN—21SEP06

c. Press NEXT until TEST appears. Press SELECT. d. Press TCU MENU until Diag appears in window (A). Press SELECT. e. Press NEXT until LPMP mAmp or RPMP mAmp appears. 7. Start engine, increase engine speed, and set transmission speed to specifications.

Transmission Control Unit (TCU)

Specification Transmission Speed—Position.................................................................................. 1.6 Engine—Speed.......................................................................... Fast Idle TX1012472A —UN—21SEP06

8. Put decelerator mode switch in transmission mode, decel function icon will come ON. 9. Fully depress decelerator pedal and pull park lock lever up. IMPORTANT: To prevent damage to multi-function valves, the test software limits the test function to 20 seconds before returning TCU to neutral. Monitor Display Unit (MDU)

The tracks must be operated between test function to prevent localized overheating of multi-function valves. Rotating the tracks will circulate some hot oil out of closed loop circuit to the hydrostatic oil reservoir for cooling.

A—Transmission Control Unit (TCU) Display Window B—STATUS Light (red) C—POWER Light (green) D—MENU Button

NOTE: Pressure should rise as the engine speed is slowly increased and then levels out. The point at which the pressure levels out is the relief valve setting. If high pressure reading is erratic (very unstable), rotate tracks slightly to reposition motor speed ring and sensor. Repeat test. If pressures remain erratic, turn tracker (Trkr) off in TCU to perform this test. Service codes will be recorded when motor speed sensor is disconnected and must be cleared when test is completed.

650J—Pressure....................................................... 43 299—45 643 kPa 433—456 bar 6280—6620 psi

• If pressure is above minimum multi-function valve specification, go to next step of test.

• If pressure is low, perform Multi-Function Relief Valve Test. (Group 9026-25.) Then proceed with this test.

NOTE: To determine mA from TCU value, move decimal point one space to the left. Example: 159 equals 15.9 mA.

10. Move transmission control lever to forward and slowly release the decelerator pedal. System pressure will increase rapidly to a maximum value. Record maximum pressure and compare reading to specifications. Multi-Function Relief Valve—Specification 450J—Pressure....................................................... 36 301—38 645 kPa 363—386 bar 5265—5605 psi 550J—Pressure....................................................... 39 300—41 644 kPa 393—416 bar 5700—6400 psi

11. Slowly release the decelerator pedal until system pressure reads 6895 kPa (68.9 bar) (1000 psi). Record Pump mA. 12. Continue releasing decelerator pedal until system pressure reads 34 474 kPa (345 bar) (5000 psi). Record Pump mA. 13. Move transmission control lever (TCL) to neutral. Return engine speed to slow idle.

Continued on next page

TM10721 (03SEP14)

E—SELECT Button F— NEXT Button G—BACK Button H—Diagnostic Trouble Code (DTC) Light

9026-25-19

FB87413,5F5E30C -19-14AUG13-3/4

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=723

Test

14. Subtract mA reading at 1000 psi from mA reading at 5000 psi. Refer to specifications to determine closed-loop condition. Specification Pump Amperage—(good)............................................................................. 0—14 mA Pump Amperage—(marginal)....................................................................................... 15—19 mA Pump Amperage—(bad)............................................................................ Over 20 mA

18. Separate the high pressure hoses between the pump and motor. Close open lines with high pressure fittings capable of withstanding 68 950 kPa (690 bar) (10 000 psi). 19. Run test as before and set to the same mA reading at 5000 psi on monitor. Record engine rpm. If engine rpm decreases, internal leakage is indicated in the motor. If engine rpm stays the same, leakage is indicated in the pump.

15. Repeat procedure for other track in forward. 16. Move transducers to Left Reverse (LR ) test port (2) and Right Reverse (RR) test port (3) to check reverse efficiency settings. 17. If any of the four readings are not within specification, continue to next step.

20. Change test connections and repeat test procedure for opposite side. 21. Turn key off to return TCU main menu to NORMAL setting. 22. Remove test equipment.

NOTE: The hydrostatic pump does not have test ports to record closed loop pressure. By setting mA the same as first part of test, we can now monitor engine rpm to determine if leakage is in pump or motor. FB87413,5F5E30C -19-14AUG13-4/4

TM10721 (03SEP14)

9026-25-20

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=724

Test

Neutral Charge Relief and Operating Charge Relief Pressure Test SPECIFICATIONS Transmission Oil Temperature

57—66°C 135—150°F

Engine Speed

Fast Idle

Transmission Charge Oil Pressure 2034—2377 kPa 20—24 bar (in neutral) 295—345 psi Transmission Operating Charge Oil Pressure (minimum)

1827 kPa 18.27 bar 265 psi

This procedure will check the combined charge pump pressure in neutral and operating charge relief pressure.

T157976B —UN—23JUL02

CAUTION: Prevent possible injury from unexpected track movement. Raise the machine off the ground and support with appropriate stands. Tracks must be free to rotate in either direction, check for objects on tracks before rotating tracks. 1. Raise machine off the ground and support with D01182AA Floor Stands. Lower blade to the ground. Tracks must be free to rotate in either direction. 2. Heat transmission oil to specification. See Transmission Oil Warmup Procedure. (Group 9026-25.) Specification Transmission Oil—Temperature......................................................................57—66°C 135—150°F

Neutral Charge Relief Valve 1— Neutral Charge Relief Valve

3. Put park lock lever UP and the transmission control lever (TCL) in neutral.

If transmission oil charge pressure in neutral is not within specification, adjust pressure by turning screw in or out.

4. Start engine.

9. Move park lock lever to DOWN position.

5. View TRANS CHARGE OIL pressure by accessing the DIAGNOSTIC / LIVE VALUES / PRESSURES submenu on the SDM. See Standard Display Monitor (SDM) Menu Structure—Service Mode. (Group 9015-16.)

IMPORTANT: If operating charge pressure drops below 1310 kPa (13 bar) (190 psi) brakes will start to engage. Adjust neutral charge pressure to the high end of specification.

6. Run engine at fast idle. Specification Engine—Speed.......................................................................... Fast Idle

7. Record transmission charge oil pressure. Specification Transmission Charge Oil—Pressure (in neutral).......................................................................... 2034—2377 kPa 20—24 bar 295—345 psi

10. Record transmission charge oil pressure while moving TCL from neutral into forward or reverse. 11. Compare reading to specifications. Specification Transmission Operating Charge Oil—Pressure (minimum)................................................................................. 1827 kPa 18.27 bar 265 psi

• Transmission charge oil pressure must drop

approximately 207 kPa (2.07 bar) (30 psi) as TCL is moved from neutral. NOTE: The neutral charge relief valve (1) is located on • Transmission operating charge oil pressure must bottom of the front hydrostatic pump. Adjustments not drop below specification. can be made from left side of machine main frame. • If pressure is below specifications, remove and inspect operating charge relief valve. Continued on next page TW73308,0000110 -19-03DEC09-1/2

TM10721 (03SEP14)

9026-25-21

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=725

Test TW73308,0000110 -19-03DEC09-2/2

TM10721 (03SEP14)

9026-25-22

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=726

Test

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

650J Crawler—Weight (approximate).............................................................................. 8958 kg 19 750 lb

SPECIFICATIONS Transmission Oil Temperature

2. Remove rubber mat and floor plate from operator's station for access to pumps.

57—66°C 135—150°F

Engine Speed

Slow Idle

PDCV Neutral Adjustment Turns

1/2 total number of turns as marked (from forward pressure rise-to-reverse pressure rise)

Adjustment Screw Nut Torque

3. Set brake mode to test. a. Enter service mode on standard display monitor (SDM), by pressing and holding MENU for approximately 5 seconds until three beeps are heard and “service mode” is temporarily displayed on the monitor screen.

7 N·m 62 lb-in.

SERVICE EQUIPMENT AND TOOLS

b. Select MACHINE SETTINGS from the SDM main menu.

D01182AA 20-Ton Floor Stands JT05598 Gauge

c. Press NEXT until BRAKE MODE appears and then press SELECT. Set the brake mode to TEST. For more information on navigation using the SDM, see Standard Display Monitor (SDM) Menu Structure—Service Mode. (Group 9015-16.)

This procedure will adjust the hydrostatic pump neutral between forward and reverse. Repeat procedure for left and right track. This procedure must be performed anytime a pump is serviced or new pump is installed. Diagnostic trouble codes (DTC) will be recorded during this test and must be cleared when completed. See Standard Display Monitor (SDM) Menu Structure—Service Mode. (Group 9015-16.)

4. Install JT05598 Gauge in one of the servo test ports (2 or 3). 5. Warm transmission oil to normal operating temperature. See Transmission Oil Warmup Procedure. (Group 9026-25.) Specification Transmission Oil—Temperature......................................................................57—66°C 135—150°F

6. Disconnect front and rear pump pressure control pilot (PCP) (B8 and B9) harness connectors. See Engine Harness (W6) Component Location. (Group 9015-10.)

1. Raise machine off the ground and support with D01182AA 20-Ton Floor Stands. Lower blade to the ground.

7. Set engine speed to specification. Specification Engine—Speed..........................................................................Slow Idle

Specification 450J Crawler—Weight (approximate).............................................................................. 7949 kg 17 525 lb 550J Crawler—Weight (approximate).............................................................................. 8279 kg 18 252 lb

8. Move park lock lever to the UP (locked) position.

Continued on next page

TM10721 (03SEP14)

9026-25-23

TW73308,0000111 -19-20MAY09-1/3

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=727

T198205A —UN—01MAR04

Test

1— Pressure Control Pilot (PCP) Internal Adjustment Port 2— Reverse Servo Test Port 3— Forward Servo Test Port 4— Reverse Pump Displacement Control Valve (PDCV) Test Port

5— Forward Pump Displacement Control Valve (PDCV) Test Port 6— Park Brake Quick Coupler 7— Pressure Control Pilot (PCP) Manual Override Lever 8— Drain Line To Rear Pump

Front Pump Test Ports Shown TW73308,0000111 -19-20MAY09-2/3

9. Loosen pump neutral adjustment screw lock nut (4). 10. Slowly turn adjustment screw, noting direction of turn, until pressure on gauge just rises. Stop and mark location of adjustment screw. 11. Turn machine OFF and move gauge to opposite servo test port. 12. Start machine and set engine speed to specification. Specification Engine—Speed..........................................................................Slow Idle

13. Park lock lever must be in the UP (locked) position. 14. Slowly turn the screw in the opposite direction, counting the number of turns until pressure on gauge just rises. Stop and mark location of adjustment screw.

• If adjustment screw is turned more than 1/2 turn but less than 2 turns, continue with next step.

T118976B —UN—15DEC98

NOTE: Leveling swash plate would only be considered if pump was just installed on machine, after servicing.

• If adjustment screw is turned a 1/2 turn or less,

disassemble pump and level swash plate. See Hydrostatic Pumps Disassemble. (Group 0360.) • If adjustment screw is turned more than 2 turns, disassemble pump displacement control valve and check for a worn feedback link. See Pump Displacement Control Valve (PDCV) Disassemble and Assemble. (Group 0360.) 15. Turn adjustment screw back 1/2 the total number turns and tighten locking nut. Specification PDCV Neutral Adjustment —Turns............... 1/2 total number of turns, as marked (from forward pressure rise-to-reverse pressure rise) Adjustment Screw Nut—Torque....................................................................................7 N·m 62 lb-in.

Hydrostatic Pump Null Adjustment Screw 4— Pump Neutral Adjustment Screw Lock Nut

17. Disconnect test equipment. 18. Calibrate transmission control unit (TCU). See Transmission Control Unit (TCU) Calibration. (Group 9015-20.) 19. Install floor plate and rubber mat to operator's station.

16. Repeat procedure on the other side track pump. TW73308,0000111 -19-20MAY09-3/3

TM10721 (03SEP14)

9026-25-24

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=728

Test

Pump Servo Pressure Test Fast Idle

Transmission Speed

3.0 T198205A —UN—01MAR04

SPECIFICATIONS Engine Speed

SERVICE EQUIPMENT AND TOOLS XPD361 Quick Coupler JT02156A Digital Pressure/Temperature Analyzer JT02161 3446 kPa (35 bar) (500 PSI) Transducer D01182AA 20-Ton Floor Stands JDG1932 Motor Flushing Test Harness Front Pump Test Ports Shown

The purpose of this test is to check proper operation of the pump servo control circuit and pump displacement control valve (PDCV).

1— Pressure Control Pilot (PCP) Internal Adjustment Port 2— Reverse Servo Test Port 3— Forward Servo Test Port 4— Reverse Pump Displacement Control Valve (PDCV) Test Port

Diagnostic trouble codes will be recorded during this test and must be cleared when completed. 1. Install quick couplers in servo test ports (2 and 3). Connect digital pressure/temperature analyzer and transducer or a gauge. 2. View TRANS CHARGE OIL pressure by accessing the DIAGNOSTIC / LIVE VALUES / PRESSURES submenu on the SDM. See Standard Display Monitor (SDM) Menu Structure—Service Mode. (Group 9015-16.)

5— Forward Pump Displacement Control Valve (PDCV) Test Port 6— Park Brake Quick Coupler 7— Pressure Control Pilot (PCP) Manual Override Lever 8— Drain Line To Rear Pump

CAUTION: Prevent possible injury from unexpected track movement. Tracks will rotate when transmission control lever (TCL) is moved to forward or reverse.

NOTE: TRANS CHARGE OIL will display pressure seen in the brake circuit.

a. Push decel pedal to floor. b. Put park lock lever in DOWN position.

c. Put transmission control lever (TCL) in forward. d. Slowly release decel pedal. e. Record forward servo pressure and charge pressure. 7. Repeat test using reverse servo pressure and charge pressure.

3. Raise machine off the ground and support with D01182AA Floor Stands. Lower blade to the ground. Check that tracks are free to rotate in either direction. 4. Start engine and check that forward and reverse pressures on both pumps are equal in neutral. If pressures are not OK, check neutral (null) adjustment or go to mistrack/indexes malfunctions. See Pump Displacement Control Valve (PDCV) Neutral (Null) Adjustment. (Group 9026-25.) See Mistrack/Index Malfunctions. (Group 9026-15.) 5. Set engine speed control to specification. Specification Engine—Speed.......................................................................... Fast Idle

6. Set transmission speed to specification.

Servo pressures must be approximately equal and will be less than charge pressure. • If servo pressures are not approximately equal, a problem exists in the pump displacement control valve (PDCV) such that the PDCV cannot fully activate or a leak in the servo is indicated. • If servo pressure is equal to charge pressure, a mechanical problem is indicated in the pump or pump servo. Remove displacement control valve and inspect pump servo or repair pump. See Pump Displacement Control Valve (PDCV) Disassemble and Assemble. (Group 0360.) • If pressures are still not to specification, see Mistrack/Index Malfunctions. (Group 9026-15.)

Specification Transmission—Speed......................................................................... 3.0

Continued on next page

TM10721 (03SEP14)

9026-25-25

TW73308,0000112 -19-05JUN09-1/2

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=729

Test

NOTE: During normal operation, the transmission controller regulates the mA to the PCP which will not allow the swash plate to contact the mechanical stop. When the JDG1932 test harness is installed, 5 volts are supplied directly to the PCP forcing the swash plate to the mechanical stops. 8. Install JDG1932 test harness with switch between pump PCP and left or right motor speed sensor. 9. Set brake mode to TEST by accessing the MACHINE SETTINGS / BRAKE MODE submenu on the SDM. See Standard Display Monitor (SDM) Menu Structure—Service Mode. (Group 9015-16.) NOTE: If BRAKE MODE setting is not set to TEST, brakes will apply and engine will stall 3 seconds after tracks start moving.

NOTE: If decel pedal is pressed to floor (brake position) at any time during track movement the brakes will apply and the engine will stall. 10. Repeat servo pressure test using switch to activate track in forward and reverse. Servo pressure must now equal charge pressure. 11. Clear any diagnostic trouble codes that may have appeared during procedure. NOTE: Stopping engine by turning key off will reset brake mode TEST setting back to Normal setting. 12. Stop engine.

TW73308,0000112 -19-05JUN09-2/2

TM10721 (03SEP14)

9026-25-26

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=730

Test

Hydrostatic Motor Min./Max. Angle Servo Piston Pressure Test SPECIFICATIONS Transmission Oil Temperature

57—66°C 135—150°F

Engine Speed

Fast Idle

Transmission Speed (low)

1.0

Transmission Speed (high)

3.0

SERVICE EQUIPMENT AND TOOLS JT02158 Digital Pressure/Temperature Analyzer TX1059470A —UN—13MAY09

JT02162 35 000 kPa (350 bar) (5000 PSI) Transducer

The purpose of this test is to verify that the motor shift solenoid has shifted allowing control pressure to the servo piston, swashing the motor to minimum or maximum displacement. CAUTION: Prevent possible injury from unexpected track movement. Raise the machine off the ground and support with appropriate stands. Tracks must be free to rotate in either direction, check for objects on tracks before rotating tracks. 1. Raise machine off the ground and support with floor stands. Lower blade to ground. 2. Install quick couplers in servo test ports (1 and 2). Connect JT02158 Digital Pressure/Temperature Analyzer and JT02162 35 000 kPa (350 bar) (5000 PSI) Transducer or a gauge. 3. Warm transmission oil to specification. See Transmission Oil Warmup Procedure. (Group 9026-25.) Specification Transmission Oil—Temperature......................................................................57—66°C 135—150°F

Motor Servo Piston Test Ports 1— Minimum Angle Servo Piston Pressure Test Port

2— Maximum Angle Servo Piston Pressure Test Port

8. Put transmission control lever in forward and slowly release decelerator/brake pedal . Record test port (1) and (2) pressure readings in forward. 9. Slowly increase transmission speed to high speed. Specification Transmission —Speed (high)................................................................................................... 3.0

Record test ports (1 and 2) pressure readings at high speed.

4. Set engine and transmission speed to specification.

10. Compare test port pressures to table. Track speeds must increase evenly.

Specification Transmission —Speed (low)..................................................................................................... 1.0 Engine—Speed.......................................................................... Fast Idle

Transmission Speed

Min. Angle Test Port (1)

Max. Angle Test Port (2)

In Neutral

Return Pressure

Closed Loop Pressure

5. Push decelerator/brake pedal to floor.

1.0 Low Speed

Return Pressure

Reduced Closed Loop Pressure

6. Record test port (1) and (2) pressure readings in neutral.

3.0 High Speed

Reduced Closed Loop Reduced Closed Loop Pressure Pressure

Servo Piston Pressures

7. Put park lock lever in DOWN position. WS68074,000093B -19-20MAY09-1/1

TM10721 (03SEP14)

9026-25-27

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=731

Test

Hydrostatic Motor Min. Angle Stop Adjustment

Specification Fast Idle—Speed....................................................................... 2350 rpm

SPECIFICATIONS Transmission Oil Temperature

IMPORTANT: Before testing motor min./max. angle stops, engine speed must be to specification and all diagnostic trouble codes must be cleared. After clearing codes, it may be necessary to turn key switch OFF and restart test.

57—66°C 135—150°F

Fast Idle Speed

2350 rpm

Average Motor RPM at 5 mph Speed

3230—3680 rpm

Average Motor RPM at 6 mph Speed

3950—4050 rpm

5. Check and clear all diagnostic trouble codes (DTCs). See Standard Display Monitor (SDM) Menu Structure—Service Mode. (Group 9015-16.)

ESSENTIAL TOOLS

6. Disconnect front pump PCP harness connector.

JDG1932 Test Harness

7. Install JDG1932 test harness between front pump PCP connector and left motor speed sensor (PPU) harness.

SERVICE EQUIPMENT AND TOOLS D01182AA 20-Ton Floor Stands

This procedure is used to test and adjust the min. angle motor stop. The TRACK SPEED setting for Forward and Reverse must be set to medium or high in the SDM to reach min. angle speed of 3500 rpm (5 mph) or 4000 rpm (6 mph). Motor stops generally do not need to be adjusted except after major repair or when changing maximum speed (from 5 mph to 6 mph or 6 mph to 5 mph).

NOTE: For machines without winch, remove rear access panel to access motor PPU harness. For machines with winch, route test harness through mainframe area and remove rear belly pan to make connection at motor PPU harness.

NOTE: Main harness connector with wires in pin A and B will not be used.

Diagnostic trouble codes will be recorded during this test and must be cleared when completed. NOTE: During normal operation, the transmission controller regulates the mA to the PCP which will not allow the swash plate to contact the mechanical stop. When the JDG1932 test harness is installed, 5 volts are supplied directly to the PCP forcing the swash plate to the mechanical stops. 1. Remove rubber mat and floor plate from operator's station.

CAUTION: Prevent possible injury from unexpected track movement. When test harness switch is moved out of the neutral position, tracks will rotate. Tracks must be free to rotate in either direction, check for objects on tracks before rotating tracks NOTE: Front pump supplies right motor and rear pump supplies left motor. 8. Start engine. Put park lock lever in DOWN position.

9. Test Min. Angle Stop: a. Turn MOTOR SOLENOID to ON by accessing the TCU DIAGNOSTICS / SETTINGS / MOTOR SOLENOID submenu on the SDM. See Standard Display Monitor (SDM) Menu Structure—Service Mode. (Group 9015-16.)

2. Raise machine off the ground and support with D01182AA Floor Stands. Lower blade to the ground. Tracks must be free to rotate in either direction.

NOTE: This will provide a 12 volt supply to the motor solenoids. Turning machine off will reset MOTOR SOLENOID to NORMAL. Procedure to energize motor solenoids must be repeated every time key switch is cycled.

3. Heat transmission oil to specification. See Transmission Oil Warmup Procedure. (Group 9026-25.)

b. View RIGHT MOTOR RPM by accessing the DIAGNOSTIC / SPEEDS submenu on the SDM. See Standard Display Monitor (SDM) Menu Structure—Service Mode. (Group 9015-16.)

Specification Transmission Oil—Temperature......................................................................57—66°C 135—150°F

4. Increase engine speed to fast idle. Compare to specifications.

NOTE: If decel pedal is pressed to floor (brake position) at any time during track movement the brakes will apply and the engine will stall. Continued on next page

TM10721 (03SEP14)

9026-25-28

TW73308,0000113 -19-11JAN08-1/2

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=732

Test Adjust Min. Angle Stop: a. Stop engine. Remove access plate from back of machine and/or left or right floor access plate at bottom rear of machine.

c. Depress decelerator to low idle. Do not engage park brake. NOTE: If transmission control lever (TCL) is left in neutral, brakes will apply and engine will stall 3 seconds after tracks start moving.

NOTE: One turn is equal to approximately 200 rpm. b. Adjust min. angle stop (2) in to decrease speed and out to increase speed.

d. Put transmission control lever (TCL) in forward. e. Engine speed at high idle, activate test harness switch in forward (tracks will rotate). f. Release decelerator pedal and record the average rpm. g. Return test harness switch to neutral. h. Activate test harness switch in reverse (tracks will rotate) and record average rpm. i. Return test harness switch to neutral.

11. Repeat both test and adjustments on left track. 12. Set TRACK SPEED to desired setting (MEDIUM or HIGH) by accessing the MACHINE SETTINGS / TRANSMISSION / TRACK SPEED submenu on the SDM. See Standard Display Monitor (SDM) Menu Structure—Service Mode. (Group 9015-16.) NOTE: Min./max. stop adjustment settings and the transmission controller track speed settings must be the same.

NOTE: Lowest recorded average rpm (between forward and reverse) must be within specification for the machine to successfully calibrate.

• If Min. angle stops are set at 6 mph and the track

speed setting is set at medium, the maximum speed will be 5 mph but will result in low power, low torque, or machine may not calibrate. • If Min. angle stops are set at 5 mph and track speed setting is set at high, the maximum speed will be 5 mph.

10. Compare average rpm readings to specifications. Specification Average Motor RPM at 5 mph—Speed................................................................. 3230—3680 rpm Average Motor RPM at 6 mph—Speed................................................................. 3950—4050 rpm

• If average rpm readings are within specifications

switch test harness connection at motor from left to right motor and at pump PCP from front pump to rear pump. • If average rpm readings are not within specifications, stop engine and do the following adjustment procedure.

13. Clear any diagnostic trouble codes that may have appeared during procedure. 14. If min. angle stop is adjusted, calibrate transmission controller. See Transmission Control Unit (TCU) Calibration. (Group 9015-20.)

TW73308,0000113 -19-11JAN08-2/2

TM10721 (03SEP14)

9026-25-29

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=733

Test

Charge Pump Flow Test SPECIFICATIONS Transmission Oil Temperature

57—66°C 135—150°F

Engine Speed

1800 rpm

Typical Combined Flow

53—61 L/min(f) 14—16 gpm

Minimum Combined Flow

49 L/min(f) 13 gpm

Typical Single Flow

26—30 L/min(f) 7—8 gpm

Minimum Single Flow

25 L/min(f) 6.5 gpm

SERVICE EQUIPMENT AND TOOLS JT07148-2 Flow Block JT03448 Test Hose (2 used)

T116990B —UN—28AUG98

This procedure is used to determine hydrostatic pump flow and to isolate front and rear pump flow, if necessary. Charge pressures must be to specification, perform Neutral Charge Relief and Operating Charge Relief Pressure Test (Group 9026-25.), before doing this test. Combined Pump Flow 1.

Open left rear access door.

IMPORTANT: Damage to charge pumps will result if flow meter valve is not fully open. Flow control valve on flow meter must be fully open.

Flow Meter Shown Installed On Filter Inlet

2. Connect flow meter in line at the hydrostatic filter housing inlet as shown. Open flow meter valve so it does not restrict pump oil flow. 3. Heat oil to specification. See Transmission Oil Warmup Procedure. (Group 9026-25.) Specification Transmission Oil—Temperature......................................................................57—66°C 135—150°F

4. With park lock lever UP, run engine at specified RPM. Record flow meter reading. This is total flow of both pumps.

Specification Typical—Combined Flow................................................................................. 53—61 L/min(f) 14—16 gpm Minimum—Combined Flow......................................................................................... 49 L/min(f) 13 gpm

5. If flow is below minimum specification for combined flow, the front pump flow must be checked in order to determine which pump is below specification. 6. Remove test equipment.

Specification Engine—Speed......................................................................... 1800 rpm Continued on next page

TM10721 (03SEP14)

9026-25-30

WS68074,000093D -19-12JAN07-1/2

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=734

Test Single Charge Pump Flow 1. Remove rubber floor mat and floor plate from operator's station. 2. Install flow meter in line from front pump outlet fitting (1).

T157979B —UN—23JUL02

3. Heat oil to specification. See Transmission Oil Warmup Procedure. (Group 9026-25.) Specification Transmission Oil—Temperature......................................................................57—66°C 135—150°F

4. Park lock lever in UP position, run engine at specified rpm. Record flow. Specification Engine—Speed......................................................................... 1800 rpm Typical—Single Flow....................................................... 26—30 L/min(f) 7—8 gpm Minimum—Single Flow............................................................ 25 L/min(f) 6.5 gpm

Front Pump Flow Meter Installation Shown 1— Front Pump Outlet Fitting

removed to replace or repair the charge pump. See Hydrostatic Pump Remove and Install. (Group 0300.) and Hydrostatic Charge Pump Disassemble and Assemble. (Group 0360.)

5. Determine front and rear pump flow as follows:

• Subtract single pump flow from combined pump

flow. This is the flow of the rear pump, compare to specifications. • If charge pump flow is below specification, the complete hydrostatic pump assembly must be

6. Remove test equipment.

WS68074,000093D -19-12JAN07-2/2

TM10721 (03SEP14)

9026-25-31

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=735

Test

Cooler Bypass Valve Test 1800 rpm

Pump Case Pressure (Bypass Closed) Pressure

124—165 kPa 1.24—1.65 bar 18—24 psi

Pump Case Pressure (Bypass Open) Pressure

310—414 kPa 3.1—4.1 bar 45—60 psi

Bypass Valve Opening Temperature

57—63°C 135—145°F

Bypass Valve Fully Open Temperature

74°C 165°F

T8438AA —UN—10MAR95

SPECIFICATIONS Engine Speed

Left Side Rear Pump Shown

ESSENTIAL TOOLS XPD361 Quick Coupler (9/16-20UN M ORB)

1— Test Port

SERVICE EQUIPMENT AND TOOLS D01182AA 20-Ton Floor Stands

a. Depress and hold decelerator pedal to lower stop.

JT03448 Test Hose (2 used) JT02156A Digital Pressure/Temperature Analyzer

b. Pull park lock lever to up position.

JT02162 3446 kPa (35 bar) (500 PSI) Transducer

c. Push transmission control lever (TCL) to forward detent.

The purpose of this test is to determine if the cooler bypass valve is opening and closing at specified temperatures. 1. Loosen reservoir cap. DO NOT tighten until test is completed. CAUTION: Prevent possible injury from unexpected track movement. Raise the machine off the ground and support with appropriate stands. Tracks must be free to rotate in either direction, check for objects on tracks before rotating tracks.

IMPORTANT: To prevent damage to multi-function valves, the test software limits the test function to 20 seconds before returning TCU to neutral. The tracks must be operated between test function to prevent localized overheating of multi-function valves. Rotating the tracks will circulate hot oil out of closed loop circuit through the case drain filter, hydrostatic oil cooler, and to reservoir for cooling. d. Slowly release decelerator pedal and run until TCU returns to neutral, approximately 20 seconds.

2. Raise machine off the ground and support with D01182AA stands. Lower blade to ground. Tracks must be free to rotate in either direction.

e. Go to next step and circulate oil. 8. Oil Circulate Cycle:

IMPORTANT: To get accurate results, hydrostatic oil temperature must be below 50°C (122°F) before starting this test.

a. Depress and hold decelerator pedal to lower stop. b. Push park lock lever to down position. c. Push transmission control lever (TCL) to forward detent.

3. Install quick coupler in servo test port on left side of rear pump (1). Connect digital pressure/temperature analyzer and transducer or a gauge.

d. Slowly release decelerator pedal and run for fifteen seconds in forward.

4. Start engine. 5. Set brake mode to TEST by accessing the MACHINE SETTINGS / BRAKE MODE submenu on the SDM. See Standard Display Monitor (SDM) Menu Structure—Service Mode. (Group 9015-16.) 6. Set engine speed to specification. Specification Engine—Speed......................................................................... 1800 rpm

e. Shift TCL to reverse and run for fifteen seconds. NOTE: As temperature increases to opening temperature, pressure will also start to increase. This indicates the bypass valve is opening. 9. Alternate heating and circulating cycles while monitoring pump case pressure and temperature until bypass is open.

7. Oil Heating Cycle:

Continued on next page

TM10721 (03SEP14)

9026-25-32

TW73308,0000114 -19-29APR08-1/2

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=736

Test

Compare readings to specification. Specification Pump Case Pressure (Bypass Closed)—Pressure............................................................ 124—165 kPa 1.24—1.65 bar 18—24 psi Pump Case Pressure (Bypass Open)—Pressure.............................................................. 310—414 kPa 3.1—4.1 bar 45—60 psi Bypass Valve Opening—Temperature.............................................................57—63°C 135—145°F

Bypass Valve Fully Open—Temperature......................................................................... 74°C 165°F

10. If bypass valve does not meet specializations, remove and inspect. Repair or replace as required. NOTE: Stopping engine by turning key off will reset brake mode TEST setting back to Normal setting. 11. Stop engine.

TW73308,0000114 -19-29APR08-2/2

TM10721 (03SEP14)

9026-25-33

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=737

Test

TM10721 (03SEP14)

9026-25-34

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=738

Section 9031 Heating and Air Conditioning Contents Page

Group 05—Theory of Operation Air Conditioning System Cycle Of Operation............................................... 9031-05-1 Group 15—Diagnostic Information Air Conditioning System Diagnose Malfunctions ..........................................9031-15-1 Air Conditioning System Does Not Operate Diagnostic Procedure..............................................9031-15-1 Air Conditioner Does Not Cool Interior of Cab Diagnostic Procedure ................9031-15-3 Air Conditioner Runs Constantly, Too Cold Diagnostic Procedure ...................9031-15-5 Interior Windows Continue To Fog Diagnostic Procedure............................9031-15-6 Heater System Diagnose Malfunctions ..........................................9031-15-6 Heater System Does Not Operate Diagnostic Procedure............................9031-15-6 Heater Does Not Warm Interior of Cab Diagnostic Procedure............................9031-15-7 Interior Windows Continue To Fog Diagnostic Procedure............................9031-15-8 Group 25—Test Proper Refrigerant Handling...................... 9031-25-1 R134a Refrigerant Cautions ...................... 9031-25-1 R134a Oil Charge Capacity....................... 9031-25-1 R134a Refrigerant Charge Capacity................................................. 9031-25-1 Refrigerant Hoses And Tubing Inspection .............................................. 9031-25-2 Operating Pressure Diagnostic Chart...................................................... 9031-25-3 Air Conditioner High/Low Pressure (Binary) Switch Test............................... 9031-25-5 Freeze Control Switch Test........................ 9031-25-6 Leak Testing .............................................. 9031-25-6

TM10721 (03SEP14)

9031-1

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=1

Contents

TM10721 (03SEP14)

9031-2

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=2

Group 05

Theory of Operation Air Conditioning System Cycle Of Operation

7 6

T142307 —UN—28JUN13

8 9 10 11 T142307 1— Evaporator Core 2— Compressor 3— Condenser Core 4— Circulation Blower Motor

5— Expansion Valve 6— Receiver-Dryer 7— High Pressure Liquid

8— High Pressure Gas 9— Low Pressure Liquid 10— Low Pressure Gas

The compressor is belt driven and engaged by an electromagnetic clutch. The air conditioning circuit automatically controls compressor engagement or disengagement when system is in operation. See System Functional Schematic and Section Legend. (Group 9015-10.) Compressor draws low pressure gas from evaporator and compresses it into high pressure gas. This causes temperature of refrigerant to rise higher than that of outside air. High pressure gas leaves compressor and flows through condenser where heat is removed and transferred to outside air being drawn through condenser core by fan. Cooling refrigerant causes it to condense and refrigerant leaves condenser as high pressure liquid. High pressure liquid flows into receiver-dryer where moisture and contaminants (acid, solids, etc.) are

removed. Receiver-dryer may contain a color moisture indicator. (Blue) indicates no moisture is present. (Pink) indicates moisture is present. Should moisture be combined with refrigerant, hydrofluoric and hydrochloric acids are formed. These acids are very corrosive to metal surfaces and leakage will eventually develop. Receiver-dryer also stores refrigerant allowing a longer period of time before additional refrigerant is needed. Refrigerant hoses allow a small amount of refrigerant to migrate through their walls. Refrigerant flows from receiver-dryer through expansion valve to evaporator. Expansion valve senses refrigerant temperature and pressure to modulate refrigerant flow. Expansion valve changes refrigerant to low pressure liquid entering evaporator. Actual cooling and drying of cab air takes place at evaporator. Heat absorbed by evaporator and transferred to refrigerant causes refrigerant to vaporize into low pressure gas. Low pressure gas is drawn from evaporator by compressor and cycle is repeated.

Continued on next page

TM10721 (03SEP14)

11— Air Flow

9031-05-1

AA95137,000121B -19-07JAN08-1/2

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=741

Theory of Operation

A freeze control switch senses temperature of evaporator coil through a capillary tube. This prevents the evaporator from becoming cold enough to freeze moisture that condenses on evaporator coil. Condensed moisture is drained away through drain tubes connected to drain pan under evaporator. System pressure is monitored by high and low pressure switch, located on high pressure side of expansion valve. If pressure becomes too high or too low the switch opens and stops compressor, interrupting the cycle.

Accumulator is located between evaporator and compressor in low pressure gas hose to retain a quantity of oil to protect compressor from a dry start after long periods of not being used. See A/C Harness (W8) Component Location (Group 9015-10) for location of machine heater and A/C components.

AA95137,000121B -19-07JAN08-2/2

TM10721 (03SEP14)

9031-05-2

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=742

Group 15

Diagnostic Information Air Conditioning System Diagnose Malfunctions TW73308,0000101 -19-12MAY09-1/34

Air Conditioning System Does Not Operate Diagnostic Procedure TW73308,0000101 -19-12MAY09-2/34

• 1

Heater Blower 15-Amp Check heater blower 15-amp fuse (F8). see Fuse and Relay Specifications. (Group Fuse (F8) Check 9015-10.)

Is fuse blown?

YES: Replace fuse (F8).

NOTE: If the heater blower switch and all work lights do not operate, check accessory relay (K6). See Accessory Relay Check.

NO: Go to Heater Blower Switch Check. TW73308,0000101 -19-12MAY09-3/34

• 2

Heater Blower Switch Check

Check heater blower switch (S7). See Cab Roof Harness (W4) Component Location. (Group 9015-10.)

Switch Position

Continuity Between Pins

Off

No Continuity

Low

1 and Battery Power

Medium

1, 2 and Battery Power

High

1, 2, 3 and Battery Power

Maximum

1, 2, 3, 4 and Battery Power

Is switch functioning properly?

YES: Go to Cab Heater Blower Resistor Check.

NO: Switch malfunction. Replace heater blower switch (S7). TW73308,0000101 -19-12MAY09-4/34

• 3

Cab Heater Blower Resistor Check

Check cab heater blower resistor (R2). See A/C Harness (W8) Component Location. (Group 9015-10.)

YES: Go to Heater Blower Motor Check.

Is resistor within specifications?

NO: Resistor malfunction. Replace cab heater blower resistor (R2).

Specification R2—Cab Heater Blower Resistor—Low Speed Resistance (X12 pins 2 and 6)......................................................2.2—2.7 ohms Medium Low Speed Resistance (X12 pins 3 and 6) ............................................................................................1.3—1.9 ohms Medium Speed Resistance (X12 pins 5 and 6).......................................................................................................0.5—0.9 ohms

TW73308,0000101 -19-12MAY09-5/34

• 4

Heater Blower Motor Check

Disconnect heater blower motor (M2) and supply 24 volts to motor. See A/C Harness (W8) Component Location. (Group 9015-10.)

YES: Go to Accessory Relay Check.

Does motor run?

NO: Motor malfunction. Replace heater blower motor (M2). Continued on next page

TM10721 (03SEP14)

9031-15-1

TW73308,0000101 -19-12MAY09-6/34

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=743

Diagnostic Information

• 5

Accessory Relay Check

Remove accessory relay (K6). See Main Cab/Canopy Harness (W5) Component Location. (Group 9015-10.)

Install a good relay in place of accessory relay.

YES: Relay malfunction. Replace accessory relay.

Does A/C system operate?

NO: Go to Air Conditioning On/Off Switch Check. TW73308,0000101 -19-12MAY09-7/34

• 6

Air Conditioning On/Off Switch Check

Put switch in both ON positions and measure continuity between pins 2B and 3 or in other ON position between pins 2B and 1. See Main Cab/Canopy Harness (W5) Component Location. (Group 9015-20.)

YES: Go to Air Conditioning Freeze Switch Check.

Is there continuity in both switch ON positions?

NO: Switch malfunction. Replace air conditioning on/off switch (S19). TW73308,0000101 -19-12MAY09-8/34

• 7

Air Conditioning Freeze Switch Check

Check air conditioning freeze switch (B22). Perform Freeze Control Switch Test. (Group 9031-25.)

YES: Go to A/C Binary Pressure Switch Check.

Is switch functioning properly?

NO: Switch malfunction. Replace air conditioning freeze switch (B22). TW73308,0000101 -19-12MAY09-9/34

• 8

A/C Binary Pressure Switch Check

Check A/C binary pressure switch (B50). Perform Air Conditioner High/Low Pressure (Binary) Switch Test. (Group 9031-25.)

YES: Go to Air Conditioning Compressor Clutch Solenoid Check.

Is switch functioning properly?

NO: Pressure switch malfunction. Replace A/C binary pressure switch (B50). TW73308,0000101 -19-12MAY09-10/34

• 9

Air Conditioning Compressor Clutch Solenoid Check

Check resistance of air conditioning compressor clutch solenoid (Y5). See Engine Harness (W6) Component Location. (Group 9015-10.)

YES: Go to Air Conditioning Compressor Clutch 5-Amp Diode Check.

Is solenoid within specifications?

NO: Solenoid malfunction. Repair or replace air conditioning compressor clutch solenoid (Y5).

Specification Y5—Air Conditioning Compressor Clutch Solenoid—Resistance..................................................................................3.5—6 ohms

TW73308,0000101 -19-12MAY09-11/34

•

10 Air Conditioning Compressor Clutch 5-Amp Diode Check

Check air conditioning compressor clutch diode (V6). See Engine Harness (W6) Component Location. (Group 9015-10.)

YES: Go to Air Conditioning Harness Check.

Is diode functioning properly?

NO: Diode malfunction. Replace diode. Continued on next page

TM10721 (03SEP14)

9031-15-2

TW73308,0000101 -19-12MAY09-12/34

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=744

Diagnostic Information

•

11 Air Conditioning Harness Check

Check wiring and connections to components. See A/C Harness (W8) Wiring Diagram and see Cab Roof Harness (W4) Wiring Diagram. (Group 9015-10.)

Check for open and short circuits.

YES: Harness malfunction. Repair or replace harness. See A/C Harness (W8) Wiring Diagram and see Cab Roof Harness (W4) Wiring Diagram. (Group 9015-10.)

Do any shorts or opens exist?

NO: Checks complete. TW73308,0000101 -19-12MAY09-13/34

Air Conditioner Does Not Cool Interior of Cab Diagnostic Procedure TW73308,0000101 -19-12MAY09-14/34

• 1

Fresh Air Filter Component Check

Check fresh air filter for debris or air flow restrictions.

YES: Replace fresh air filter.

Is fresh air filter clogged?

NO: Go to Condenser Restriction Check. TW73308,0000101 -19-12MAY09-15/34

• 2

Condenser Restriction Check condenser fins for air flow restrictions. Check

YES: Clean condenser fins.

Are condenser fins clogged with debris?

NO: Go to Recirculating Air Filter Restriction Check. TW73308,0000101 -19-12MAY09-16/34

• 3

Recirculating Air Filter Check recirculating air filter for flow restrictions. Restriction Check

YES: Clean or replace recirculating air filter.

Is recirculating air filter dirty or clogged with debris?

NO: Go to Refrigerant Hose Restriction Check. TW73308,0000101 -19-12MAY09-17/34

• 4

Refrigerant Hose Restriction Check

Check refrigerant hoses.

YES: Re-route or re-index hoses. Replace kinked or collapsed hoses.

Are any hoses kinked, pinched or collapsed?

NO: Go to Condenser Core and Evaporator Core Air Flow Restriction Check.

Continued on next page

TM10721 (03SEP14)

9031-15-3

TW73308,0000101 -19-12MAY09-18/34

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=745

Diagnostic Information

• 5

Condenser Core and Evaporator Core Air Flow Restriction Check

Check condenser core and evaporator core fins for debris.

YES: Clean condenser core and evaporator core fins.

Are the condenser core or evaporator core fins clogged with debris?

NO: Go to Heater Blower Motor and Cab Heater Blower Resistor Check. TW73308,0000101 -19-12MAY09-19/34

• 6

Heater Blower Motor Check heater blower motor (M2) by applying 24 volts to the motor. Check to see if and Cab Heater Blower motor is running when voltage is applied. See A/C Harness (W8) Component Location. Resistor Check (Group 9015-10.)

Check cab heater blower resistor (R2). See A/C Harness (W8) Wiring Diagram. (Group 9015-10.) For specifications, see Electrical Component Specifications. (Group 9015-20.)

YES: Go to Compressor Belt Check.

Are heater blower motor and cab heater blower resistor both functioning properly?

NO: Replace heater blower motor and/or resistor. TW73308,0000101 -19-12MAY09-20/34

• 7

Compressor Belt Check

Check engine serpentine belt. See Inspect Serpentine Belt. (Operator's Manual.)

YES: Go to Operator's Station Seals Check.

Is belt tension ok?

NO: Adjust or replace belt. TW73308,0000101 -19-12MAY09-21/34

• 8

Operator's Station Seals Check

Check windows and doors to make sure seals are good.

YES: Go to Condenser Fan Motor 1 Relay Check.

Are seals on all windows and doors functioning properly?

NO: Repair or replace malfunctioning seals. TW73308,0000101 -19-12MAY09-22/34

• 9

Condenser Fan Motor 1 Relay Check

Check A/C relay (K5). see Fuse and Relay Specifications. (Group 9015-10.)

YES: Go to Condenser Fan Motor 1 10-Amp Fuse Check.

Is relay functioning properly?

NO: Relay malfunction. Replace condenser fan motor 1 relay (K2). TW73308,0000101 -19-12MAY09-23/34

•

10 Condenser Fan Motor 1 10-Amp Fuse Check

Check condenser fan motor 1 10-amp fuse (F23). see Fuse and Relay Specifications. (Group 9015-10.)

YES: Replace condenser fan motor 1 10-amp fuse (F23).

Is fuse blown?

NO: Go to Condenser Fan Motor 2 10-Amp Fuse Check. Continued on next page

TM10721 (03SEP14)

9031-15-4

TW73308,0000101 -19-12MAY09-24/34

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=746

Diagnostic Information

•

11 Condenser Fan Motor 2 10-Amp Fuse Check

Check condenser fan motor 2 10-amp fuse (F24). see Fuse and Relay Specifications. (Group 9015-10.)

YES: Replace condenser fan motor 2 10-Amp fuse (F24).

Is fuse blown?

NO: Go to Heater Valve Motor Check. TW73308,0000101 -19-12MAY09-25/34

•

12 Heater Valve Motor Check

Check heater valve motor (M2) to make sure heater valve is not staying open.

YES: Go to System Refrigerant (R134a) Charge Low Check.

Is heater valve motor functioning properly?

NO: Heater valve motor (M2) malfunction. Replace motor. TW73308,0000101 -19-12MAY09-26/34

•

13 System Refrigerant (R134a) Charge Low Check

Check for leaks in refrigerant system and recharge. See Charge R134a System. (Group 1830.)

YES: Repair or replace hoses and recharge system.

Does refrigerant system have any leaks?

NO: Go to Evaporator Core Fins Check. TW73308,0000101 -19-12MAY09-27/34

•

14 Evaporator Core Fins Check

Check evaporator core fins for frosting or freezing.

YES: Thermostat switch not positioned correctly in evaporator core. Reposition switch.

Is there any ice or frost on evaporator fins?

NO: Checks complete. TW73308,0000101 -19-12MAY09-28/34

Air Conditioner Runs Constantly, Too Cold Diagnostic Procedure TW73308,0000101 -19-12MAY09-29/34

• 1

Evaporator Core Component Check

Check evaporator core fins for frosting or freezing.

YES: Thermostat switch not positioned correctly in evaporator core. Reposition switch in evaporator core.

Is there any ice or frost on evaporator fins?

NO: Compressor clutch running constantly. Go to Freeze Control Switch Check. TW73308,0000101 -19-12MAY09-30/34

• 2

Freeze Control Switch Check

Check freeze control switch (B22). See A/C Harness (W8) Component Location. (Group 9015-10.)See Freeze Control Switch Test. (Group 9031-25.)

YES: Checks complete.

Is freeze control switch functioning properly?

NO: Switch malfunction. Replace air conditioning freeze switch (B22).

Continued on next page

TM10721 (03SEP14)

9031-15-5

TW73308,0000101 -19-12MAY09-31/34

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=747

Diagnostic Information Interior Windows Continue To Fog Diagnostic Procedure TW73308,0000101 -19-12MAY09-32/34

• 1

Fresh Air Filter Check

Check fresh air filter for debris or air flow restrictions.

YES: Replace fresh air filter.

Is fresh air filter clogged?

NO: Go to Air Conditioning On/Off Switch Check. TW73308,0000101 -19-12MAY09-33/34

• 2

Air Conditioning On/Off Switch Check

Check status of air conditioning on/off switch (S19). See Cab Roof Harness (W4) Component Location. (Group 9015-10.)

YES: Replace air conditioning on/off switch (S19).

Is switch in the on position?

NO: Turn switch on. TW73308,0000101 -19-12MAY09-34/34

Heater System Diagnose Malfunctions TW73308,0000102 -19-12MAY09-1/18

Heater System Does Not Operate Diagnostic Procedure TW73308,0000102 -19-12MAY09-2/18

• 1

Under-Seat Heater 20-Amp Fuse Check

Check under-seat heater 20-amp fuse (F27). see Fuse and Relay Specifications. (Group 9015-10.)

YES: Replace under-seat heater 20-amp fuse (F27).

Is fuse blown?

NO: Go to Heater Blower 10-Amp Fuse Check. TW73308,0000102 -19-12MAY09-3/18

• 2

Heater Blower 15-Amp Check heater blower 15-amp fuse (F8). see Fuse and Relay Specifications. (Group Fuse Check 9015-10.)

Is fuse blown?

YES: Replace heater blower 15-amp fuse (F8).

NO: Go to Under-Seat Heater Blower Switch Check. TW73308,0000102 -19-12MAY09-4/18

• 3

Under-Seat Heater Blower Switch Check

Check for continuity between pins 3 and 6 of under-seat heater blower switch (S13), when switch is in ON position. See Main Cab/Canopy Harness (W5) Component Location. (Group 9015-10.)

YES: Go to Heater Blower Switch Check.

Is switch functioning properly?

NO: Switch malfunction. Replace under-seat heater blower switch (S13). Continued on next page

TM10721 (03SEP14)

9031-15-6

TW73308,0000102 -19-12MAY09-5/18

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=748

Diagnostic Information

• 4

Heater Blower Switch Check

Check heater blower switch (S7). See Cab Roof Harness (W4) Component Location. (Group 9015-10.)

Switch Position

Continuity Between Pins

Off

No Continuity

Low

1 and Battery Power

Medium

1, 2 and Battery Power

High

1, 2, 3 and Battery Power

Maximum

1, 2, 3, 4 and Battery Power

Is switch functioning properly?

YES: Go to Accessory Relay #1 Check.

NO: Switch malfunction. Replace heater blower switch (S7). TW73308,0000102 -19-12MAY09-6/18

• 5

Accessory Relay #1 Check

Remove accessory relay #1 (K2). See Main Cab/Canopy Harness (W5) Component Location. (Group 9015-10.)

Install identical relay in place of accessory relay #1.

YES: Relay malfunction. Replace accessory relay #1.

Does A/C system operate?

NO: Go to Heater Wiring Harness Check. TW73308,0000102 -19-12MAY09-7/18

• 6

Heater Wiring Harness Check air conditioning, operator's station and cab roof wiring harnesses for Check short-circuits and/or open-circuits. See Cab Roof Harness (W4) Wiring Diagram, see Main Cab/Canopy Harness (W5) Wiring Diagram and see A/C Harness (W8) Wiring Diagram. (Group 9015-10.) Is wiring ok?

YES: Checks complete.

NO: Harness malfunction. Repair or replace harness. See Main Cab/Canopy Harness (W5) Wiring Diagram and see A/C Harness (W8) Wiring Diagram. (Group 9015-10.) TW73308,0000102 -19-12MAY09-8/18

Heater Does Not Warm Interior of Cab Diagnostic Procedure TW73308,0000102 -19-12MAY09-9/18

• 1

Fresh Air Filter Check

Check fresh air filter for debris or air flow restrictions.

YES: Replace fresh air filter.

Is fresh air filter clogged?

NO: Go to Recirculating Air Filter Check. TW73308,0000102 -19-12MAY09-10/18

• 2

Recirculating Air Filter Check

Check recirculating air filter for flow restrictions.

YES: Clean or replace recirculating air filter.

Is recirculating air filter dirty or clogged with debris?

NO: Go to Heater Hose Restriction Check.

Continued on next page

TM10721 (03SEP14)

9031-15-7

TW73308,0000102 -19-12MAY09-11/18

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=749

Diagnostic Information

• 3

Heater Hose Restriction Check

Check heater hoses.

YES: Re-route or re-index hoses. Replace kinked or collapsed hoses.

Are any hoses kinked, pinched or collapsed?

NO: Go to Heater Core Air Flow Restriction Check. TW73308,0000102 -19-12MAY09-12/18

• 4

Heater Core Air Flow Restriction Check

Check heater core fins for debris.

YES: Clean heater core fins.

Are the heater core fins clogged with debris?

NO: Go to Heater Blower Motor and Cab Heater Blower Resistor Check. TW73308,0000102 -19-12MAY09-13/18

• 5

Heater Blower Motor Check heater blower motor (M2) and cab heater blower resistor (R2). See A/C Harness YES: Go to Heater Valve and Cab Heater Blower (W8) Wiring Diagram. (Group 9015-10.) For specifications, see Electrical Component Check. Resistor Check Specifications. (Group 9015-20.)

Are heater blower motor and cab heater blower resistor both functioning properly?

NO: Replace heater blower motor and/or resistor. TW73308,0000102 -19-12MAY09-14/18

• 6

Heater Valve Check

Check heater valve for proper operation.

YES: Checks complete.

Is heater valve operating properly?

NO: Replace heater valve. TW73308,0000102 -19-12MAY09-15/18

Interior Windows Continue To Fog Diagnostic Procedure TW73308,0000102 -19-12MAY09-16/18

• 1

Fresh Air Filter Check

Check fresh air filter for debris or air flow restrictions.

YES: Replace fresh air filter.

Is fresh air filter clogged?

NO: Go to Air Conditioning On/Off Switch Check. TW73308,0000102 -19-12MAY09-17/18

• 2

Air Conditioning On/Off Switch Check

Check status of air conditioning on/off switch (S19). See Cab Roof Harness (W4) Component Location. (Group 9015-10.)

YES: Replace air conditioning on/off switch (S19).

Is switch in the on position?

NO: Turn switch on. TW73308,0000102 -19-12MAY09-18/18

TM10721 (03SEP14)

9031-15-8

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=750

Group 25

Test Proper Refrigerant Handling The U.S. Environmental Protection Agency prohibits discharge of any refrigerant into the atmosphere, and requires that refrigerant be recovered using the approved recovery equipment. IMPORTANT: Use correct refrigerant recovery, recycling and charging stations. Do not use refrigerant, hoses, fittings, components

or refrigerant oils intended for use with R12 refrigerant. Recovery, recycling and charging stations for R12 and R134a refrigerants must not be interchanged. Systems containing R12 refrigerant use a different oil than systems using R134a. Certain seals are not compatible with both types of refrigerants. MODTX9031QQ2009 -19-06MAY04-1/1

R134a Refrigerant Cautions SPECIFICATIONS Maximum Amount To Heat Refrigerant In Closed Container Temperature

Do not heat refrigerant over 52°C (125°F) in a closed container. Heated refrigerant will develop high pressure which can burst the container.

52°C 125°F

CAUTION: Do not allow liquid refrigerant to contact eyes or skin. Liquid refrigerant will freeze eyes or skin on contact. Wear goggles, gloves and protective clothing.

Specification Maximum Amount To Heat Refrigerant In Closed Container—Temperature............................................................................................ 52°C 125°F

If liquid refrigerant contacts eyes or skin, do not rub the area. Splash large amounts of cool water on affected area. Go to a physician or hospital immediately for treatment.

Keep refrigerant containers away from heat sources. Store refrigerant in a cool place.

Do not allow refrigerant to contact open flames or very hot surfaces such as electric welding arc, electric heating element, and lighted smoking materials.

Do not handle damp refrigerant container with your bare hands. Skin may freeze to container. Wear gloves. If skin freezes to container, pour cool water over container to free the skin. Go to a physician or hospital immediately for treatment. TX,9031,JC1705 -19-01AUG12-1/1

R134a Oil Charge Capacity Item

Measurement

Specification

System

Capacity

239.5 mL 8.1 fl oz

Condenser

Capacity

32.5 mL 1.1 fl oz

Evaporator

Capacity

32.5 mL 1.1 fl oz

Receiver-Dryer

Capacity

30.0 mL 1.0 fl oz TX14826,000009E -19-21AUG03-1/1

R134a Refrigerant Charge Capacity Item

Measurement

Specification

Refrigerant Charge

Capacity

1.47 kg 3.25 lb TX14826,000009F -19-31AUG04-1/1

TM10721 (03SEP14)

9031-25-1

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=751

Test

Refrigerant Hoses And Tubing Inspection When a component is disconnected from the system, special care should be given to inspecting hoses and tubing for moisture, grease, dirt, rust, or other foreign material. If such contamination is present in hoses, tubing, or fittings and cannot be removed by cleaning, then replace parts.

tube connections. Dip O-rings in correct viscosity oil before assembling. IMPORTANT: Hose used for air conditioning systems contains special barriers in its walls to prevent migration of refrigerant gas.

Fittings that have grease or dirt on them should be wiped clean with a cloth dampened with alcohol. Chlorinated solvents (such as trichloroethylene) are contaminants, and must not be used for cleaning.

Do not use hydraulic hoses as replacement hoses in the air conditioning system. Use only certified hose meeting SAE J51B requirements.

To assist in making leak proof joints, use a small amount of clean correct viscosity refrigerant oil on all hose and MODTX9031QQ1882 -19-06MAY04-1/1

TM10721 (03SEP14)

9031-25-2

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=752

Test

Operating Pressure Diagnostic Chart NOTE: Inspection of the sight glass will not give proper indicators of air conditioning concerns on R134a systems. OPERATING PRESSURE DIAGNOSTIC CHART Low Side Pressure

High Side Pressure

Problem

Solution

Low

Low or Normal

Loss of refrigerant.

Leak in system. Do leak test. Add refrigerant. Normal migration through hoses. Add refrigerant.

Low

Low or Normal

Loss of refrigerant.

Leak in system. Do leak test. Repair leak. Add refrigerant in this group.

Low

Low or Normal

Loss of refrigerant.

Normal migration through hoses. Add refrigerant in this group

Low

Low or Normal

Restriction in system:

Inspect for bent, kinked, or dented lines. Feel lines for a temperature change. Remove refrigerant by recovery method. Inspect and clean each component.

1. 2. 3. 4.

Between compressor and condenser. Inside condenser. Between condenser and receiver-dryer. Inside receiver-dryer.

Low

Low or Normal

Blower motor running too slow.

Check for motor shaft binding or defective electrical connections.

Low

Low or Normal

Evaporator core dirty or air flow through evaporator restricted.

Clean evaporator and straighten fins.

Low

Low or Normal

Expansion valve malfunction. Replace expansion valve.

Low

Low or Normal

Restriction in system: 1. 2. 3.

Between receiver-dryer and expansion valve. Between expansion valve and evaporator. Between evaporator and compressor.

Inspect for bent, kinked, or dented lines. Feel lines for a temperature change. Remove refrigerant by recovery method. Inspect and clean each component.

Low

Low or Normal

Moisture in system.

Remove refrigerant using recovery method, evacuate and charge the system. See Recover R134a SystemSee Evacuate R134a System See Charge R134a System. (Group 1830.)

Low

High

Restriction in system:

Inspect for bent, kinked, or dented lines. Feel lines for a temperature change. Remove refrigerant by recovery method. Inspect and clean each component.

1. 2. 3. 4. 5.

Between compressor and condenser. Inside condenser. Between condenser and receiver-dryer. Inside receiver-dryer. Between receiver-dryer and expansion valve.

Normal

Heater valve not closing.

Normal

Expansion valve malfunction. Replace expansion valve.

Normal

Moisture in system (intermittent cooling below 27°C [80°F] ambient).

Remove refrigerant using recovery method, evacuate and charge the system. See Recover R134a System. See Evacuate R134a System. See Charge R134a System. (Group 1830.)

Normal

Loss of refrigerant.

Leak in system. Do leak test. Repair leak. Add refrigerant.

Normal

Loss of refrigerant

Normal migration through hoses. Add refrigerant in this group.

Normal

Air is system.

Remove refrigerant using recovery method, evacuate and charge the system. See Recover R134a System. See Evacuate R134a System. See Charge R134a System. (Group 1830.)

Normal

High

Restricted air flow through condenser or radiator.

Inspect for debris. Straighten fins.

Normal

High

Overcharge of refrigerant.

Start engine and run at fast idle. Operate air conditioner at maximum cooling. Remove refrigerant from low-side of system using recovery operation until bubbles appear in sight glass. Add 0.7 kg (1.5 lb) of refrigerant through low-side valve.

Normal

High

Expansion valve malfunction. Replace expansion valve.

Close heater shut-off valve on engine block or clamp heater hoses shut

Continued on next page

TM10721 (03SEP14)

9031-25-3

AA95137,000121A -19-07JAN08-1/2

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=753

Test OPERATING PRESSURE DIAGNOSTIC CHART Low Side Pressure

High Side Pressure

Problem

Solution

Normal

High

Restriction in system:

Inspect for bent, kinked, or dented lines. Feel lines for a temperature change. Remove refrigerant by recovery method. Inspect and clean each component.

1. 2. 3. 4. Normal

High

Between compressor and condenser. Inside condenser. Between condenser and receiver-dryer. Inside receiver-dryer.

Restriction in system: 1. 2. 3. 4.

Between compressor and condenser. Inside condenser. Between condenser and receiver-dryer. Inside receiver-dryer.

Inspect for bent, kinked, or dented lines. Feel lines for a temperature change. Remove refrigerant by recovery method. Inspect and clean each component.

High

Low

Compressor belt loose.

Tighten belt.

High

Low

Compressor clutch slipping.

Check for battery voltage at compressor clutch with clutch engaged. Clean electrical connections or replace relay.

High

Low

Compressor clutch slipping.

Inspect and repair clutch.

High

Low

Compressor failure.

Test compressor efficiency. (Group 1830.)

High

Normal

Expansion valve malfunction. Replace expansion valve.

High

Restricted air flow through condenser or radiator.

High

Expansion valve malfunction. Replace expansion valve.

High

Overcharge of refrigerant.

Start engine and run at fast idle. Operate air conditioner at maximum cooling. Remove refrigerant from low-side of system using refrigerant recovery method until bubbles appear in sight glass. Add 0.7 kg (1.5 lb) of refrigerant through low-side valve.

High

Restriction in system:

Inspect for bent, kinked, or dented lines. Feel lines for a temperature change. Remove refrigerant by recovery method. Inspect and clean each component.

High

Air in system.

Remove refrigerant using recovery method, evacuate and charge the system. See Recover R134a System.See Evacuate R134a System. See Charge R134a System. (Group 1830.)

High

Restriction in system:

Inspect for bent, kinked, or dented lines. Feel lines for a temperature change. Remove refrigerant by recovery method. Inspect and clean each component.

1. 2. 3. 4.

Between compressor and condenser. Inside condenser. Between condenser and receiver-dryer. Inside receiver-dryer.

Inspect for debris. Straighten fins.

AA95137,000121A -19-07JAN08-2/2

TM10721 (03SEP14)

9031-25-4

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=754

Test

Air Conditioner High/Low Pressure (Binary) Switch Test 138—228 kPa 1.4—2.3 bar 20—33 psi

Low Pressure (Normally Open) Closing Pressure

159—255 kPa 1.6—2.6 bar 23—37 psi

High Pressure Opening Pressure

2620—2895 kPa 26—29 bar 380—420 psi

High Pressure (Normally Closed) Closing Pressure

1379—2068 kPa 13.8—20.7 bar 200—300 psi

T8426AD —UN—06MAR95

SPECIFICATIONS Low Pressure Opening Pressure

• The actual pressure setting of switch can be checked by

ESSENTIAL TOOLS JT02148 Straight Connector For Switch Testing SERVICE EQUIPMENT AND TOOLS Multimeter

NOTE: Low pressure switch is normally open when removed from machine. When installed the switch becomes closed because of normal system pressure.

• Turn key switch on but do not start engine. Turn blower switch on. Turn temperature control switch to the maximum cooling position. • Disconnect and connect low pressure switch at harness connector. Compressor clutch must engage and disengage (click). NOTE: The line that attaches the low pressure switch has a valve to prevent discharging the air conditioning system when switch is removed.

• Disconnect harness from switch and remove switch from line. Connect low pressure switch to harness. Specification Low Pressure—Opening Pressure............................................................................ 138—228 kPa 1.4—2.3 bar 20—33 psi Low Pressure (Normally Open)—Closing Pressure............................................................................ 159—255 kPa 1.6—2.6 bar 23—37 psi

connecting it to a pressure source such as a regulated air supply or dry nitrogen. • Switch must not have continuity between terminals until pressure increases to switch closing pressure specification. Slowly release pressure. Switch must have continuity until pressure decreases to switch opening pressure specification.

• Connect a portable pressure source, such as dry nitrogen, to switch.

Specification High Pressure—Opening Pressure........................................................................ 2620—2895 kPa 26—29 bar 380—420 psi High Pressure (Normally Closed)—Closing Pressure........................................................................ 1379—2068 kPa 13.8—20.7 bar 200—300 psi

• Switch must have continuity between terminals

until pressure increases to switch opening pressure specification. • Slowly release pressure. Switch must not have continuity until pressure decreases to switch closing pressure specification. • The switch can also be checked when installed in air conditioning system, however, pressure is slow to increase to test specification. Connect an air conditioning gauge set to service fittings at compressor. Cover condenser with paper or plastic to stop air flow. Operate air conditioner on maximum cooling. Note high-side pressure when high pressure switch opens and then closes.

Compressor clutch must not engage (click). WS68074,0000940 -19-12JAN07-1/1

TM10721 (03SEP14)

9031-25-5

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=755

Test

Freeze Control Switch Test -1.4—0.28°C 29.5—32.5°F

Freeze Control Switch (Normally Closed) Closes as Temperature rises Closing Temperature

1.38—3.06°C 34.5—37.5°F

T7199EZ —UN—13NOV90

SPECIFICATIONS Freeze Control Switch (Normally Closed) Opens As Temperature Drops Opening Temperature

• Remove freeze control switch from evaporator. • Connect ohmmeter to switch terminals. Switch must be closed at room temperature.

• Put switch into a freezer (temperature must be below -0.56 ± 0.84°C [31 ± 1.5°F]). Switch must open, and continuity must not be read.

Specification Freeze Control Switch (Normally Closed) Opens As Temperature Drops—Opening Temperature........................................................................ -1.4—0.28°C 29.5—32.5°F

Specification Freeze Control Switch (Normally Closed) Closes As Temperature Rises—Closing Temperature........................................................................1.38—3.06°C 34.5—37.5°F

• Remove switch from freezer. Put sensing tube into a

• If switch does not open and close during testing, install new switch.

glass of warm water. Switch must close, and continuity must be read.

TX18076,0000016 -19-14NOV00-1/1

Leak Testing

• If a leak detector is used, move the leak detector probe

SPECIFICATIONS Move Leak Detector Speed

under the hoses and around the connections at a rate of 25 mm (1 in.) per second.

25 mm per second 1 in. per second

• Inspect all lines, fittings, and components for oily or

dusty spots. When refrigerant leaks from the system, a small amount of oil is carried out with it. • A soap and water solution can be sprayed on the components in the system to form bubbles at the source of the leak.

Specification Move Leak Detector—Speed........................................................ 25 mm per second 1 in .per second

• Some refrigerant manufacturers add dye to refrigerant to aid in leak detection.

MODTX9031QQ1881 -19-19AUG94-1/1

TM10721 (03SEP14)

9031-25-6

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314 PN=756

Index Page Page

A A/C harness (W8) Component location ................................... 9015-10-162 Wiring diagram........................................... 9015-10-165 Adjustment, auxiliary linkage ............................. 9025-20-3 Adjustment, T-bar .............................................. 9025-20-1 Adjustments Brake pedal to brake valve linkage adjustment.................................................. 9015-20-42 Hydrostatic motor min./max. angle stop adjustment.................................................. 9026-25-28 Pressure control pilot (PCP) internal adjustment test........................................... 9026-25-12 Pump displacement control valve neutral (null) adjustment......................................... 9026-25-23 Transmission Control Lever (TCL) adjustment.................................................. 9015-20-45 Air conditioner High/low pressure (Binary) switch test ............................................................... 9031-25-5 Operational check ........................................ 9005-10-11 Air conditioning Diagnose malfunctions................................... 9031-15-1 Freeze control switch test .............................. 9031-25-6 Hoses and tubing inspection.......................... 9031-25-2 Leak testing.................................................... 9031-25-6 R134a oil charge capacity.............................. 9031-25-1 R134a Refrigerant charge capacity ............... 9031-25-1 Refrigerant cycle ............................................ 9031-05-1 Refrigerant handling....................................... 9031-25-1 Refrigerant R134a caution ............................. 9031-25-1 Air restriction indicator Operational check .......................................... 9005-10-7 Alternator Operational check .......................................... 9005-10-6 Alternator test .................................................... 9015-20-9 Auxiliary lever linkage adjustment ..................... 9025-20-3

B Backup alarm Operational check .......................................... 9005-10-3 Battery Explosions, prevent........................................ 9000-01-4 Operational check .......................................... 9005-10-2 Battery disconnect switch Operational check .......................................... 9005-10-3 Binary (A/C) switch Test ................................................................ 9031-25-5 Blade angle valve ............................................ 9025-05-18 Blade controls Operational check .......................................... 9005-10-9 Blade float Operational check ........................................ 9005-10-10 Blade lift valve operation ...........9025-05-14, 9025-05-16

Blade tilt valve ................................................. 9025-05-20 Brake Brake pedal to brake valve linkage adjustment.................................................. 9015-20-42 Park brake theory of operation....................... 9026-05-8 Releasing park brake to tow the machine........................................................ 9026-25-3 Brake pedal Operational check .......................................... 9005-10-8

C Calibration Transmission Control Unit (TCU) ................. 9015-20-19 CAN circuit Test .............................................................. 9015-20-10 Change units Standard display Monitor (SDM).................... 9015-16-4 Charging circuit Theory of operation........................................ 9015-15-1 Chemical products Handling......................................................... 9000-01-5 Cinch connector (32 and 48 Way) Repair .......................................................... 9015-20-52 Circuit relief Test with remote pump................................... 9025-25-5 Circuit Theory of Operation JDLink .......................................................... 9015-15-25 Clean-up procedure Oil................................................................... 9025-25-8 Component location A/C harness (W8) ...................................... 9015-10-162 Cab roof harness (W4)................................. 9015-10-55 Canopy Auxiliary Light Harness (W11)........................................................ 9015-10-172 Electrical, GlobalTRACS® terminal (GTT) harness (W31).......................................... 9015-10-194 Electrical, JDLink™ ground harness (W32) ....................................................... 9015-10-194 Electrical, machine information gateway harness (MIG) (W30) ............................... 9015-10-194 Engine cooling system ................................... 9010-15-2 Engine fuel system......................................... 9010-15-3 Engine harness (W6) ................................. 9015-10-123 Engine intake and exhaust............................. 9010-15-9 Grill harness (W13) .................................... 9015-10-177 Hydraulic ........................................................ 9025-15-7 Hydraulic, IGC.............................................. 9025-15-14 Hydrostatic system......................................... 9026-15-5 IGC cab harness (W22) ............................. 9015-10-188 IGC machine harness (W21) ..................... 9015-10-182 Information ..................................................... 9015-05-1 Integrated grade control cab harness (W22) ....................................................... 9015-10-188 Integrated grade control machine harness (W21) ....................................................... 9015-10-182 Continued on next page

TM10721 (03SEP14)

Index-1

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314

Index

Page

JDLink™ harnesses (W6002 and W6003)—if equipped (S.N. 196418— ) ................................................................ 9015-10-198 Main cab/canopy harness (W5) ................... 9015-10-67 Power and ground cables (W1) ................... 9015-10-54 Radio harness (W9) ................................... 9015-10-168 Transmission harness (W7) ....................... 9015-10-146 Component location—MIG/GTT JDLink™ system ........................................ 9015-10-194 Component location—MTG/SAT JDLink™ .................................................... 9015-10-198 Connection procedure JDLink ............................................................ 9015-20-8 Control valve Hydraulic, operation ....................................... 9025-05-9 Hydraulic-IGC, operation ............................. 9025-05-22 Control valve lift check Operational check ........................................ 9005-10-10 Control valve outlet.......................................... 9025-05-21 Controller area network (CAN) Theory of operation........................................ 9015-15-3 Controls Transmission Control Lever (TCL) adjustment.................................................. 9015-20-45 Cooling system Service safely................................................. 9000-01-9 Cycle time Operational check ........................................ 9005-10-10 Cylinder drift test................................................ 9025-25-6 Cylinder leakage test ......................................... 9025-25-7

Function drifts down diagnostic procedure ................................................... 9025-15-35 Hydraulic functions slow diagnostic procedure ................................................... 9025-15-31 Hydraulic power low diagnostic procedure ................................................... 9025-15-34 No hydraulic functions diagnostic procedure ................................................... 9025-15-30 Oil overheats diagnostic procedure ............. 9025-15-36 One hydraulic function does not work diagnostic procedure.................................. 9025-15-33 Diagnostic chart, pressure................................. 9031-25-3 Diagnostic information Hydrostatic low charge pressure malfunctions ............................................... 9026-15-25 Hydrostatic machine full speed malfunctions ............................................... 9026-15-33 Hydrostatic Mistrack/Indexes malfunctions ............................................... 9026-15-28 hydrostatic overheating malfunctions............................................................ 9026-15-23 Hydrostatic schematic—neutral (park brake on) ...................................................... 9026-15-1 Hydrostatic system component location......................................................... 9026-15-5 Hydrostatic system diagram - forward (slow speed)............................................... 9026-15-17 Hydrostatic system diagram - park brake on (neutral)................................................. 9026-15-13 Hydrostatic system diagram - reverse (fast speed) ........................................................ 9026-15-21 Hydrostatic TCU calibration malfunctions ............................................... 9026-15-44 Hydrostatic track malfunctions ..................... 9026-15-40 Hydrostatic, low power malfunctions............................................................ 9026-15-35 Diagnostic touble codes (DTC) Electrohydraulic controller.............................. 9001-40-1 Transmission control unit (TCU) .................... 9001-30-1 Diagnostic trouble code check........................... 9005-10-1 Diagnostic trouble codes Reading, Service ADVISOR .......................... 9015-20-3 Diagnostic Trouble Codes Service ADVISOR.......................................... 9015-20-1 Digital Thermometer Installation........................ 9026-25-1 Display and clear trouble codes ........................ 9005-10-1

D Decelerator sensor Remove and install ...................................... 9015-20-44 Decelerator/brake pedal Operational check .......................................... 9005-10-8 Diagnose hydraulic system malfunctions Blade float does not work diagnostic procedure ................................................... 9025-15-25 Function drifts down diagnostic procedure ................................................... 9025-15-26 Hydraulic functions slow diagnostic procedure ................................................... 9025-15-22 Hydraulic pump noisy diagnostic procedure ................................................... 9025-15-24 No hydraulic functions diagnostic procedure ................................................... 9025-15-22 Oil overheats diagnostic procedure ............. 9025-15-27 One hydraulic function does not work diagnostic procedure.................................. 9025-15-25 Diagnose hydraulic system malfunctionsIGC Blade float does not work diagnostic procedure ................................................... 9025-15-33 Blade response not smooth diagnostic procedure ................................................... 9025-15-37

E ECU connector Repair .......................................................... 9015-20-52 Electrical Component specifications............................ 9015-20-16 Schematic, wiring diagram, and component location information ................... 9015-05-1 System functional schematic and section legend .......................................................... 9015-10-9 Continued on next page

TM10721 (03SEP14)

Index-2

450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314

Index

Page

Emergencies Prepare for ..................................................... 9000-01-5 Engine Cooling system component location......................................................... 9010-15-2 Diagnose malfunctions................................... 9010-15-1 Fuel system component location ................... 9010-15-3 Idle check....................................................... 9010-25-5 Intake and exhaust component location......................................................... 9010-15-9 Theory of operation........................................ 9010-05-1 Engine control unit (ECU) Theory of operation........................................ 9015-15-5 Engine speed..................................................... 9010-25-5 Engine speed control Remove and install ...................................... 9015-20-43 Equipment, protective Wear .............................................................. 9000-01-2

F Filter Hydraulic ........................................................ 9025-05-5 Hydrostatic filter theory of operation ............................................................... 9026-05-4 Fires, prevent..................................................... 9000-01-4 FLC connector Repair .......................................................... 9015-20-52 Flow chart Transmission control circuit operation (flow chart) ................................................... 9026-05-2 Fluid sample Procedure ...................................................... 9010-25-1 Flushing procedure Hydraulic oil cleanup procedure..................... 9026-25-1 Hydrostatic pump flushing procedure .............................................................. 9026-25-8 FNR sensor Remove and install ...................................... 9015-20-44 Fuel System Test ............................................... 9010-25-6 Fumes, exhaust Beware........................................................... 9000-01-4 Fuse Location ......................................................... 9015-10-1 Specifications................................................. 9015-10-1

G General precautions Avoid high pressure oils................................. 9000-01-3 GlobalTRACS® terminal (GTT) harness (W31) Component location ................................... 9015-10-194 Wiring diagram........................................... 9015-10-200

H Heater blower motor Operational check .......................................... 9005-10-6 Heater system Diagnose malfunctions................................... 9031-15-6 Hide/unhide main menu Standard display monitor (SDM).................... 9015-16-4 High/low (A/C) pressure switch Test ................................................................ 9031-25-5 Horn Operational check .......................................... 9005-10-2 Hydraulic Component location ....................................... 9025-15-7 Component location-IGC ............................. 9025-15-14 Control valve operation-IGC ........................ 9025-05-22 Control valve, operation ................................. 9025-05-9 Schematic ...................................................... 9025-15-1 System schematic, IGC ................................. 9025-15-4 Hydraulic controls Operational check .......................................... 9005-10-9 Hydraulic cylinder operation ............................ 9025-05-26 Hydraulic filter operation Theory of operation........................................ 9025-05-5 Hydraulic oil warm-up procedure....................... 9025-25-1 Hydraulic pump.................................................. 9025-05-2 Hydraulic pump and reservoir operation Theory of operation........................................ 9025-05-3 Hydraulic system Diagnose IGC malfunctions ......................... 9025-15-30 Diagnose malfunctions................................. 9025-15-22 Hydraulic system operation Theory of operation........................................ 9025-05-1 Hydraulic system relief valve test .................................................9025-25-3, 9025-25-4 Hydrostatic system Brake pedal to brake valve linkage adjustment.................................................. 9015-20-42 Charge pump flow test ................................. 9026-25-30 Charge pump operation ................................. 9026-05-3 Cooler bypass valve test.............................. 9026-25-32 Flushing valve and operating charge relief valve operation........................................... 9026-05-16 Hydraulic oil cleanup procedure..................... 9026-25-1 Hydrostatic filter operation ............................. 9026-05-4 Hydrostatic motor min./max. angle control piston pressure test.................................... 9026-25-27 Hydrostatic motor min./max. angle stop adjustment.................................................. 9026-25-28 Hydrostatic motor operation......................... 9026-05-18 Hydrostatic pump and motor initial start-up procedure ..................................................... 9026-25-6 Hydrostatic pump flushing procedure .............................................................. 9026-25-8 Hydrostatic pump operation ......................... 9026-05-15 JDG1770 Ultra clean hand launcher ....................................................... 9026-25-1 Continued on next page

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450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314

Index

Page

JT05800 Digital Thermometer Installation .................................................... 9026-25-1 Multi-function relief valve test....................... 9026-25-14 Multi-function valve operation ...................... 9026-05-10 Neutral charge relief pressure test............... 9026-25-21 Neutral charge relief valve operation ...................................................... 9026-05-7 Oil cooler bypass valve operation ................ 9026-05-12 Operating charge relief pressure test ............................................................. 9026-25-21 overheating malfunctions ............................. 9026-15-23 Park brake operation...................................... 9026-05-8 Pressure control pilot (PCP) internal adjustment test........................................... 9026-25-12 Pressure control pilot (PCP) manual override test ................................................. 9026-25-9 Pressure control pilot (PCP) test.................. 9026-25-10 Pump displacement control valve (PDCV) operation .................................................... 9026-05-14 Pump displacement control valve neutral (null) adjustment......................................... 9026-25-23 Pump pressure control pilot (PCP) operation .................................................... 9026-05-13 Pump servo pressure test ............................ 9026-25-25 Releasing park brake to tow the machine........................................................ 9026-25-3 Theory of operation........................................ 9026-05-1 Transmission Control Lever (TCL) adjustment.................................................. 9015-20-45 Transmission efficiency test ......................... 9026-25-17 Transmission Oil Warm-up Procedure .............................................................. 9026-25-2 Hydrostatic System Component location ....................................... 9026-15-5 Hydrostatic schematic—neutral (park brake on) ...................................................... 9026-15-1 Hydrostatic system diagram - forward (slow speed)............................................... 9026-15-17 Hydrostatic system diagram - park brake on (neutral)................................................. 9026-15-13 Hydrostatic system diagram - Reverse (fast speed) ................................................ 9026-15-21 Transmission control circuit operation (flow chart) ................................................... 9026-05-2

All blade functions operate normally in manual mode, but not in auto mode .......................................................... 9015-20-28 Blade lift and angle operate normally, but blade incr/decr does not............................. 9015-20-36 Blade lift and tilt operate normally in auto mode, but not in manual mode................... 9015-20-33 Blade lift and tilt operate normally, but blade angle does not.................................. 9015-20-34 Blade moves quickly (jumps) to one side, then slowly comes back on grade .............. 9015-20-40 Blade response is not smooth...................... 9015-20-37 Waves in graded surface ............................. 9015-20-41 IGC system troubleshooting ............................ 9015-20-24 Integrated grade control (IGC) Theory of operation...................................... 9015-15-22

I Idle check .......................................................... 9010-25-5 IGC Hydraulic control valve operation................. 9025-05-22 IGC observable symptoms All blade functions are slow or sluggish ...................................................... 9015-20-39 All blade functions do not operate in manual or auto modes ............................... 9015-20-24 All blade functions operate normally in auto mode, but not in manual mode................... 9015-20-31

J JDLink Circuit Theory of Operation.......................... 9015-15-25 JDLink™ Component location—MTG/SAT................ 9015-10-198 Wiring Diagrams—MIG/GTT...................... 9015-10-200 Wiring Diagrams—MTG/SAT ..................... 9015-10-213 JDLink™ ground harness (W32) Component location ................................... 9015-10-194 Wiring diagram........................................... 9015-10-212 JDLink™ harnesses (W6002 and W6003) Component location—if equipped (S.N. 196418— ) ............................................... 9015-10-198 JDLink system Connection procedure.................................... 9015-20-8 JDLink™ system Component location—MIG/GTT ................ 9015-10-194 Identification................................................... 9015-20-5 Machine information gateway (MIG) harness (W30) wiring diagram ................. 9015-10-200

L Legend Component location ....................................... 9015-10-5 System Functional Schematic........................ 9015-10-5 Wiring diagram............................................... 9015-10-5 Linkage adjustment, auxiliary ............................ 9025-20-3 Linkage adjustment, T-bar................................. 9025-20-1 Loader inlet section operation ......................... 9025-05-12 Low charge pressure malfunctions Hydrostatic ................................................... 9026-15-25 Low power malfunctions Hydrostatic ................................................... 9026-15-35

M Machine full speed malfunctions Hydrostatic ................................................... 9026-15-33 Continued on next page

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450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314

Index

Page

Machine information gateway (MIG) harness (W30) Component location ................................... 9015-10-194 Wiring diagram........................................... 9015-10-200 Machine modifications Avoid .............................................................. 9000-01-2 Machine, inspect................................................ 9000-01-2 Main hydraulic pump flow test ........................... 9025-25-1 Malfunctions Low charge pressure hydrostatic ................. 9026-15-25 Low power, hydrostatic ................................ 9026-15-35 Machine full speed, hydrostatic.................... 9026-15-33 Mistrack/Indexes hydrostatic........................ 9026-15-28 overheating .................................................. 9026-15-23 TCU calibration ............................................ 9026-15-44 Tracks .......................................................... 9026-15-40 Mistrack/Indexes malfunctions Hydrostatic ................................................... 9026-15-28 Modular Telematics Gateway (MTG) Harness (W6002) Wiring Diagram .......................................... 9015-10-213 Monitor Operational check .......................................... 9005-10-3 Motor Hydrostatic motor min./max. angle control piston pressure test.................................... 9026-25-27 Hydrostatic motor min./max. angle stop adjustment.................................................. 9026-25-28 Hydrostatic motor theory of operation .................................................... 9026-05-18 Hydrostatic pump and motor initial start-up procedure ...................................9026-25-6, 9026-25-8

Hydrostatic pump and motor initial start-up procedure ..................................................... 9026-25-6 Hydrostatic pump flushing procedure .............................................................. 9026-25-8 Hydrostatic pump theory of operation .................................................... 9026-05-15 Pump servo pressure test ............................ 9026-25-25 Pump, flow test .................................................. 9025-25-1 Pump, hydraulic................................................. 9025-05-2

O Oil Hydraulic oil cleanup procedure..................... 9026-25-1 Oil clean-up procedure ...................................... 9025-25-8 Operation qualification....................................... 9000-01-1 Operational checkout......................................... 9005-10-1

P Park brake Operational check .......................................... 9005-10-8 Park brake valve leakage Operational check .......................................... 9005-10-7 Parts, moving Stay clear ....................................................... 9000-01-2 Pressure diagnostic chart .................................. 9031-25-3 Prevent unintended detonation of explosive devices............................................................. 9000-01-9 Pump Charge pump flow test ................................. 9026-25-30 Hydraulic ........................................................ 9025-05-3 Hydrostatic charge pump theory of operation ...................................................... 9026-05-3

R Reading diagnostic trouble codes Service ADVISOR.......................................... 9015-20-3 Recognize Safety, information ......................................... 9000-01-1 Relay Location ......................................................... 9015-10-1 Specifications................................................. 9015-10-1 Relief valve Hydraulic system, operation......................... 9025-05-10 Reservoir Hydraulic ........................................................ 9025-05-3 Ripper hydraulic Component location ..................................... 9025-15-20

S Safety Add cab guarding for special uses................. 9000-01-6 Avoid backover accidents .............................. 9000-01-8 Avoid machine tip over................................... 9000-01-8 Drive metal pins safely................................. 9000-01-10 Instructions, follow ......................................... 9000-01-1 Keep riders off machine ................................. 9000-01-7 Make welding repairs safely......................... 9000-01-10 Park and prepare for service safely ............... 9000-01-9 Prevent unintended machine movement .................................................... 9000-01-6 Start only from operator's seat....................... 9000-01-6 Safety, Avoid High-Pressure Fluids Avoid High-Pressure Fluids ........................... 9000-01-3 Safety, information Recognize ...................................................... 9000-01-1 Sample Fluid, procedure ............................................. 9010-25-1 Satellite (SAT) Harness (W6003) Wiring Diagram .......................................... 9015-10-213 Schematic Electrical, system functional........................... 9015-10-9 Hydraulic ........................................................ 9025-15-1 Hydraulic, IGC................................................ 9025-15-4 Hydrostatic schematic—neutral (park brake on) ...................................................... 9026-15-1 Hydrostatic system diagram - forward (slow speed)............................................... 9026-15-17

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450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314

Index

Page

Hydrostatic system diagram - park brake on (neutral)................................................. 9026-15-13 Hydrostatic system diagram - reverse (fast speed) ........................................................ 9026-15-21 Information ..................................................... 9015-05-1 SDM Menu structure (service mode) ...................... 9015-16-1 Seat control Operational check .......................................... 9005-10-2 Service ADVISOR Overview ........................................................ 9015-20-1 Reading diagnostic trouble codes.................. 9015-20-3 Service ADVISOR™ Connection Procedure ........................................................ 9015-20-1 Servo Pump servo pressure test ............................ 9026-25-25 Slow and fast idle Operational check .......................................... 9005-10-7 Specifications Electrical components.................................. 9015-20-16 Fuse ............................................................... 9015-10-1 Relay.............................................................. 9015-10-1 Standard display monitor (SDM) Change units.................................................. 9015-16-4 Hide/unhide main menu ................................. 9015-16-4 Menu structure (service mode) ...................... 9015-16-1 Setting hour meter (new monitor install)........................................................... 9015-16-5 Theory of operation...................................... 9015-15-15 Start-up procedure Hydrostatic pump and motor initial start-up procedure ..................................................... 9026-25-6 Starting Aid Operation ....................................... 9010-05-1 Starting circuit Theory of operation........................................ 9015-15-1 Steer sensor Remove and install ...................................... 9015-20-44 System functional schematic Information ..................................................... 9015-05-1

Hydrostatic motor min./max. angle control piston pressure test.................................... 9026-25-27 Hydrostatic motor min./max. angle stop adjustment.................................................. 9026-25-28 Hydrostatic pump and motor initial start-up procedure ..................................................... 9026-25-6 Hydrostatic pump flushing procedure .............................................................. 9026-25-8 JDG1770 Ultra clean hand launcher ....................................................... 9026-25-1 JT05800 Digital Thermometer Installation .................................................... 9026-25-1 Multi-function relief valve test....................... 9026-25-14 Neutral charge relief pressure test............... 9026-25-21 Operating charge relief pressure test ............................................................. 9026-25-21 Pressure control pilot (PCP) internal adjustment test........................................... 9026-25-12 Pressure control pilot (PCP) manual override test ................................................. 9026-25-9 Pressure control pilot (PCP) test.................. 9026-25-10 Pump displacement control valve neutral (null) adjustment......................................... 9026-25-23 Pump servo pressure test ............................ 9026-25-25 Releasing park brake to tow the machine........................................................ 9026-25-3 Transmission efficiency test ......................... 9026-25-17 Transmission Oil Warm-up Procedure .............................................................. 9026-25-2 Turbocharger Boost Pressure........................ 9010-25-7 Theory of operation Charging circuit .............................................. 9015-15-1 Controller area network (CAN)....................... 9015-15-3 Engine control unit (ECU) .............................. 9015-15-5 Hydraulic system operation............................ 9025-05-1 Hydrostatic system......................................... 9026-05-1 Hydrostatic system - charge pump operation ...................................................... 9026-05-3 Hydrostatic system - flushing valve and operating charge relief valve operation .................................................... 9026-05-16 Hydrostatic system - hydrostatic filter operation ...................................................... 9026-05-4 Hydrostatic system - hydrostatic motor operation .................................................... 9026-05-18 Hydrostatic system - hydrostatic pump operation .................................................... 9026-05-15 Hydrostatic system - multi-function valve operation .................................................... 9026-05-10 Hydrostatic system - neutral charge relief valve operation............................................. 9026-05-7 Hydrostatic system - oil cooler bypass valve operation........................................... 9026-05-12 Hydrostatic system - park brake operation ...................................................... 9026-05-8 Hydrostatic system - pump displacement control valve (PDCV) operation.................. 9026-05-14

T T-bar linkage adjustment ................................... 9025-20-1 TCL Operational check .......................................... 9005-10-8 TCU calibration malfunctions Hydrostatic ................................................... 9026-15-44 Test Circuit reliefs with remote pump..................... 9025-25-5 Test, cylinder leakage ........................................ 9025-25-7 Test, main pump flow......................................... 9025-25-1 Test, system relief............................9025-25-3, 9025-25-4 Tests Charge pump flow test ................................. 9026-25-30 Cooler bypass valve test.............................. 9026-25-32 Fuel System ................................................... 9010-25-6 Hydraulic oil cleanup procedure..................... 9026-25-1

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450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314

Index

Page

Hydrostatic system - pump pressure control pilot (PCP) operation ...................... 9026-05-13 Integrated grade control (IGC) ..................... 9015-15-22 Standard display monitor (SDM).................. 9015-15-15 Starting circuit ................................................ 9015-15-1 Transmission control circuit operation (flow chart) ................................................... 9026-05-2 Transmission Control Unit (TCU) ................. 9015-15-19 Thermometer Installation, Digital....................... 9026-25-1 Throttle control Remove and install ...................................... 9015-20-43 Towing Releasing park brake to tow the machine........................................................ 9026-25-3 Track malfunctions Hydrostatic ................................................... 9026-15-40 Tracking and maximum speed Operational check .......................................... 9005-10-9 Transmission Transmission control circuit operation (flow chart) ................................................... 9026-05-2 Transmission efficiency test ......................... 9026-25-17 Transmission Control Unit (TCU) Calibration.................................................... 9015-20-19 Theory of operation...................................... 9015-15-19 Transmission speed Operational check .......................................... 9005-10-8 Turbocharger Boost Pressure Test.................... 9010-25-7

Pressure control pilot (PCP) test.................. 9026-25-10 Pump displacement control valve neutral (null) adjustment......................................... 9026-25-23 Valve, blade angle ........................................... 9025-05-18 Valve, blade tilt ................................................ 9025-05-20 Valve, control valve inlet .................................. 9025-05-12 Valve, control valve outlet................................ 9025-05-21 Valve, lift ......................................9025-05-14, 9025-05-16 Valve, system relief..........................9025-25-3, 9025-25-4

V Valve Cooler bypass valve test.............................. 9026-25-32 Hydraulic control, operation ........................... 9025-05-9 Hydraulic control-IGC, operation.................. 9025-05-22 Hydraulic system relief, operation................ 9025-05-10 Hydrostatic flushing valve and operating charge relief valve operation ...................... 9026-05-16 Hydrostatic multi-function valve theory of operation .................................................... 9026-05-10 Hydrostatic neutral charge relief valve theory of operation ....................................... 9026-05-7 Hydrostatic oil cooler bypass valve theory of operation ................................................ 9026-05-12 Hydrostatic pump displacement control valve (PDCV) operation ............................. 9026-05-14 Hydrostatic pump pressure control pilot (PCP) operation ......................................... 9026-05-13 Multi-function relief valve test....................... 9026-25-14 Neutral charge relief pressure test............... 9026-25-21 Operating charge relief pressure test ............................................................. 9026-25-21 Pressure control pilot (PCP) internal adjustment test........................................... 9026-25-12 Pressure control pilot (PCP) manual override test ................................................. 9026-25-9

TM10721 (03SEP14)

W Washer motor, front and rear Operational check .......................................... 9005-10-4 Washer motor, left and right Operational check .......................................... 9005-10-5 Waste Dispose of properly ........................................ 9000-01-5 Wiper, front and rear Operational check .......................................... 9005-10-4 Wiper, left and right Operational check .......................................... 9005-10-5 Wiring diagram A/C harness (W8) ...................................... 9015-10-165 Cab roof harness (W4)................................. 9015-10-57 Canopy Auxiliary Light Harness (W11)........................................................ 9015-10-175 Engine harness (W6) ................................. 9015-10-131 GlobalTRACS® terminal (GTT) harness (W31) ....................................................... 9015-10-200 Grill harness (W13) .................................... 9015-10-179 IGC cab harness (W22) ............................. 9015-10-190 IGC machine harness (W21) ..................... 9015-10-185 Information ..................................................... 9015-05-1 Integrated grade control cab harness (W22) ....................................................... 9015-10-190 Integrated grade control machine harness (W21) ....................................................... 9015-10-185 JDLink™ ground harness (W2).................. 9015-10-212 Machine information gateway (MIG) harness (W30).......................................... 9015-10-200 Main cab/canopy harness (W5) ................... 9015-10-75 Radio harness (W9) ................................... 9015-10-170 Transmission harness (W7) ....................... 9015-10-151 Wiring Diagram Charge Pressure Sensor Harness (W25) ....................................................... 9015-10-194 Modular Telematics Gateway (MTG) Harness (W6002) ..................................... 9015-10-213 Satellite (SAT) Harness (W6003)............... 9015-10-213 Wiring Diagrams—MIG/GTT JDLink™ .................................................... 9015-10-200 Wiring Diagrams—MTG/SAT JDLink™ .................................................... 9015-10-213

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450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314

Index

TM10721 (03SEP14)

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450J (S.N. 159987—216242), 550J and 650J (S.N. 159987— ) Crawler Dozer Operation and Test 090314