Table of Contents tm1691 Service ADVISOR™ tm1691 Service ADVISOR™ (1) Safety Features Recognize Safety Information Follow Safety Instructions Operate Only If Qualified Wear Protective Equipment Avoid Unauthorized Machine Modifications Inspect Machine Stay Clear of Moving Parts Avoid High-Pressure Fluids Beware of Exhaust Fumes Prevent Fires Prevent Battery Explosions Handle Chemical Products Safely Dispose of Waste Properly Prepare for Emergencies Use Steps and Handholds Correctly Start Only From Operator's Seat Use and Maintain Seat Belt Prevent Unintended Machine Movement Avoid Work Site Hazards Keep Riders Off Machine Avoid Backover Accidents Avoid Machine Tipover Add and Operate Attachments Safely Use Special Care When Operating Operating or Traveling On Public Roads Inspect and Maintain ROPS Stay Clear of Rotating Drivelines Park and Prepare for Service Safely Service Cooling System Safely Remove Paint Before Welding or Heating Make Welding Repairs Safely Drive Metal Pins Safely Safety Sign General Information POWERTECH 4.5L (4045) and 6.8L (6068) John Deere Engines Engine—Sectional View General Engine Description POWERTECH 4.5L (4045) and 6.8L (6068) John Deere Engines (1) Make Visual Inspection of Engine and Supporting Systems Diagnose Engine Malfunctions tm1691
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8 9 11 12 13 14 15 16 17 18 19 20 21 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 42 44 45 46 47 48 50 83 84 86 87 88 90
POWERTECH 4.5L (4045) and 6.8L (6068) John Deere Engines (2) JT05801 Clamp-On Electronic Tachometer Installation Adjust Engine Speed Control Linkage (S.N. 872335—882699) Adjust Engine Speed Control Linkage (S.N. 882700— ) Adjust Slow and Fast Idle (S.N. —882699) POWERTECH 4.5L (4045) and 6.8L (6068) John Deere Engines (3) Air Intake System Leakage Test Altitude Compensator Boost Pressure Engine Performance Test Injection Pump Timing (S.N. —882699) Injection Pump Timing (S.N. 882700— ) Fuel Line Leakage Test Electrical Diagram Information Component Identification Table Fuse (Blade-Type) Color Codes Fuse Location and Specifications (S.N. —880053) Wiring and Schematic Diagrams Legend (S.N. —880053) System Functional Schematic Section Legend (S.N. —880053) System Functional Schematic (S.N. —880053) Fuse Location and Specifications (S.N. 880054—882699) Wiring and Schematic Diagrams Legend (S.N. 880054—882699) System Functional Schematic Section Legend (S.N. 880054—882699) System Functional Schematic (S.N. 880054—882699) Fuse Location and Specifications (S.N. 882700— ) Wiring and Schematic Diagrams Legend (S.N. 882700— ) System Functional Schematic Section Legend (S.N. 882700— ) System Functional Schematic (S.N. 882700— ) Main Harness (W4) Component Location (S.N. —880053) Main Harness (W4) Connectors, Wire and Pin Location (S.N. —880053) Main Harness (W4) Component Location (S.N. 880054—882699) Main Harness (W4) Connectors, Diode, Wire and Pin Location (S.N. 880054—882699) Main Harness (W4) Component Location (S.N. 882700— ) Main Harness (W4) Connectors, Diode, Wire and Pin Location (S.N. 882700— ) Transmission Diode Harness (W5) Component Location (S.N. —880053) Transmission Diode Harness (W5) Component Location (S.N. 880054— ) Differential Lock, Park Brake and MFWD Solenoid Diode Harness (W6) Component Location (S.N. —880053) Differential Lock, Park Brake and MFWD Solenoid Diode Harness (W6) Component Location (S.N. 880054— ) ROPS Harness (W7) Component Location (S.N. —880053) ROPS Harness (W7) Component Location (S.N. 880054— ) Dash Harness (W8) Component Location (S.N. —880053) Dash Harness (W8) Connector, Wire and Pin Location (S.N. —880053) Dash Harness (W8) Component Location (S.N. 880054—882699) Dash Harness (W8) Connector, Wire, and Pin Location (S.N. 880054—882699) Dash Harness (W8) Component Location (S.N. 882700— ) Dash Harness (W8) Connector, Wire, and Pin Location (S.N. 882700— ) tm1691
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105 106 107 112 114 116 117 119 122 124 125 126 133 135 136 138 141 142 144 146 149 150 153 156 161 162 165 166 167 169 175 177 180 181 182 183 184 185 186 188 190 192 197 199
Engine Harness (W9) Component Location (S.N. 882700— ) Engine Harness (W9) Connector, Wire, and Pin Location (S.N. 882700— ) Power Shift Transmission Harness (W10) Component Location Power Shift Transmission Harness (W10) Connector, Wire, and Pin Location 12-Volt Power Outlet Harness (W11) Component Location—Optional (S.N. 882700— ) Power Circuit Operational Information (S.N. —880053) Power Circuit Theory of Operation (S.N. —880053) Power Circuit Schematic (S.N. —880053) Power Circuit Operational Information (S.N. 880054— ) Power Circuit Theory of Operation (S.N. 880054— ) Power Circuit Schematic (S.N. 880054— ) Power Circuit Sub-System Diagnostics Start Circuit Operational Information Start Circuit Theory of Operation (S.N. —880053) Start Circuit Schematic (S.N. —880053) Start Circuit Theory of Operation (S.N. 880054— ) Start Circuit Schematic (S.N. 880054— ) Start Circuit Sub-System Diagnostics Charging Circuit Operational Information Charging Circuit Theory of Operation Charging Circuit Schematic (S.N. —880053) Charging Circuit Schematic (S.N. 880054— ) Charging Circuit Sub-System Diagnostics PTO Circuit Operational Information—If Equipped PTO Circuit Theory of Operation—If Equipped PTO Circuit Schematic—If Equipped PTO Circuit Sub-System Diagnostics—If Equipped Display Monitor and Warning Indicator Switches Circuit Specifications Display Monitor and Warning Indicator Switches Circuit Operational Information Display Monitor and Warning Indicator Switches Circuit Theory of Operation (S. N. —880053) Display Monitor and Warning Indicator Switches Circuit Schematic (S.N. —880053) Display Monitor and Warning Indicator Switches Circuit Theory of Operation (S.N. 880054—882699) Display Monitor and Warning Indicator Switches Circuit Schematic (S.N. 880054—882699) Display Monitor and Warning Indicator Switches Circuit Theory of Operation (S. N. 882700— ) Display Monitor and Warning Indicator Switches Circuit Schematic (S.N. 882700— ) Display Monitor and Warning Indicator Switches Circuit Sub-System Diagnostics Neutral Disconnect Circuit Specifications—Manual Shift Neutral Disconnect Circuit Operational Information—Manual Shift Neutral Disconnect Circuit Theory of Operation—Manual Shift Neutral Disconnect Circuit Schematic—Manual Shift (S.N. —880053) Neutral Disconnect Circuit Schematic—Manual Shift (S.N. 880054— ) Neutral Disconnect Circuit Sub-System Diagnostics—Manual Shift tm1691
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204 206 209 211 215 217 218 219 220 221 222 223 240 241 242 243 244 245 259 260 261 262 263 273 274 275 276 281 282 283 285 286 289 290 294 295 318 319 320 323 324 325
Range Shift Circuit Theory Of Operation—Power Shift Range Shift Circuit Schematic—Power Shift Range Shift Circuit Sub-System Diagnostics—Power Shift Engine Control Unit Circuit Theory of Operation and Circuit Schematic (S.N. 882700— ) Alternators and Starting Motors Access Engine Diagnostic Trouble Codes Using Blink Method (S.N. 882700— ) Engine Diagnostic Trouble Codes (S.N. 882700— ) Throttle Position Sensor Test (S.N. 882700— ) Engine Coolant Temperature Sensor Test Battery Operation Battery Specifications Diagnose Battery Malfunctions Check Battery Electrolyte Level And Terminals Using Booster Batteries—12 Volt System Alternator Operation—65 Amp Bosch Forward, Reverse, Low Range Forward and Third Speed Clutch Pack Operation Power Shift High Range Forward, First Speed and Second Speed Clutch Packs Manual Shift Power Train Overview Torque Converter Operation Manual Shift Synchronizer Operation Transmission Pump Operation Transmission Filter Operation Manual Shift Transmission Operation—First Gear Forward Manual Shift Transmission Operation—Third Gear Reverse Power Shift Power Train Overview Power Shift Transmission Gear Flow Mechanical Front Wheel Drive (MFWD) Operation Manual Shift Transmission Control Valve Operation Manual Shift Transmission Control Circuit—Neutral with Park Brake Off Manual Shift Transmission Control Circuit—Forward Manual Shift Transmission Control Circuit—Reverse Power Shift Transmission Clutch Engagement And Solenoids Activated Power Shift Transmission Control Circuit—Neutral With Park Brake Off Power Shift Transmission Control Valve and Shift Valve Operation—Neutral Power Shift Transmission Control Circuit—First Forward Power Shift Transmission Control Valve and Shift Valve—First Forward Power Shift Transmission Control Circuit—High Range (Fourth) Forward Power Shift Transmission Control Valve and Shift Valve—High Range (Fourth) Forward Power Shift Transmission Control Circuit—First Reverse Power Shift Transmission Control Valve and Shift Valve—First Reverse Manual Shift Modulation Valve Operation Power Shift Modulation Valve Operation Differential Operation Differential Lock Operation Brake Valve Operation (S.N. —880907) tm1691
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351 354 355 373 375 376 379 386 389 390 391 392 393 397 399 401 403 405 407 409 411 413 414 416 418 420 422 424 426 429 431 433 435 438 440 443 445 448 450 453 455 457 460 462 464
Brake Valve Operation—General Information (S.N. 880908— ) Brake Valve Operation—Neutral, Engine Operating (S.N. 880908— ) Brake Valve Operation—One Pedal Applied, Engine Operating (S.N. 880908— ) Brake Valve Operation—Both Pedals Applied, Engine Operating (S.N. 880908— ) Brake Valve Operation—Both Pedals Applied, Engine Stopped (S.N. 880908— ) Service Brake Operation Park Brake Operation MFWD Differential Operation—Unequal Traction (If Equipped) MFWD Differential Operation—Equal Traction (If Equipped) Diagnose Power Train Malfunction Diagnose MFWD Malfunction—If Equipped Diagnose Rear Axle Malfunction Hydraulic Circuit Symbols Adjust Brake Pedals and Equalizing Valves (S.N. —880907) Adjust Brake Pedals (S.N. 880908— ) Bleed Service Brakes (S.N. —880907) Bleed Service Brakes (S.N. 880908— ) Tracking Angle Check and Adjust—MFWD Axle Toe-In Check and Adjust Steering Angle Check and Adjust—MFWD Axle Transmission Oil Warm-Up Procedure Manual Shift Transmission Overall Test Connections, Ports, and Locations Power Shift Transmission Overall Test Connections, Ports, and Locations Torque Converter Stall Speed Test Converter-In Relief Valve Test Brake Valve Leakage Test Park Brake Release Pressure Test Transmission System Pressure Test Manual Shift Forward and Reverse Clutch Pressure Test Power Shift Low Range Forward, High Range Forward, Reverse and Speed Clutch Pressure Test Reducing Valve Pressure Test Modulation Valve Pressure Test Differential Lock Pressure Test MFWD Pressure Test—If Equipped Transmission Cooler In and Cooler Out Pressure Test Solenoid Circuit Leakage Test Transmission Pump Flow Test Open-Center Hydraulic System Hydraulic System Component Location (S.N. —872334) Hydraulic System Component Location (S.N. 872335—880907) Hydraulic System Component Location (S.N. 880908–882034) Hydraulic System Component Location (S.N. 882035—882699) Hydraulic System Component Location (S.N. 882700—883904) Hydraulic System Component Location (S.N. 883905— ) Hydraulic tm1691 System Schematic (S.N. —883904) 5
466 467 470 473 476 478 480 482 484 485 504 505 512 513 517 519 521 524 526 530 532 535 537 539 542 545 548 551 554 558 561 564 568 571 574 578 579 582 584 586 588 590 592 594 597
Hydraulic System Schematic (S.N. 883905— ) Hydraulic Control Valve Component Locations (S.N.883905— ) Hydraulic Pump Operation Hydraulic Filter Operation Steering Valve Operation Priority Valve Operation (S.N. —883904) Priority Valve Section Operation —Steering Actuated (S.N. 883905— ) Relief Valve Operation With Anticavitation (S.N. 883905— ) Relief Valve Without Anticavitation (S.N. 883905— ) Outlet Plate (S.N. —883904) Control Valve—Bucket Section (S.N. —883904) Control Valve—Boom Section—Raise (S.N. —883904) Control Valve—Boom Section—Lower (S.N. —883904) Control Valve—Boom Section—Float (S.N. —883904) Control Valve—Flow Control Section (S.N. —883904) Control Valve—Hitch Lift Section (S.N. —883904) Control Valve—Hitch Pitch Section (S.N. —883904) Control Valve—Hitch Tilt and Auxiliary Sections (S.N. —883904) Control Valve—Inlet Section with System Relief Valve (S.N. 883905— ) Control Valve—Bucket Section—Dump (S.N. 883905— ) Control Valve—Boom Section—Raise (S.N. 883905— ) Control Valve—Flow Control Section (S.N. 883905— ) Control Valve—Boom Section—Float (S.N. 883905— ) Control Valve—Hitch Pitch Section (S.N. 883905— ) Control Valve—Hitch Lift Section—Raise (S.N. 883905— ) Control Valve—Hitch Tilt and Auxiliary Sections (S.N. 883905— ) Use These Seven Basic Steps to Diagnose and Test the Hydraulic System Make a Pretest Inspection and an Operation Check of the Machine Hydraulic System Pretest Diagnose Hydraulic System Problems Loader Bucket Self-Leveling Linkage Indicator Adjustment (S.N. —870948) Loader Bucket Self-Leveling Linkage Indicator Adjustment (S.N. 870949— ) Return-to-Dig Switch Adjustment JT05800 Digital Thermometer Installation Hydraulic Oil Warm-Up Procedure Hydraulic Pump Flow Test (S.N. —880053) Hydraulic Pump Flow Test (S.N. 880054—883904) Hydraulic Pump Flow Test (S.N. 883905— ) Priority Relief Valve Pressure Test (S.N. —888053) Priority Relief Valve Pressure Test (S.N. 880054—883904 ) Priority Relief Valve Pressure Test (S.N. 883905— ) System Relief Valve Pressure Test (S.N. —883904) System Relief Valve Pressure Test (S.N. 883905— ) Hydraulic Oil Cooler Restriction Test (S.N. —883904) Hydraulic Oil Cooler Restriction Test (S.N. 883905— ) tm1691
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598 600 602 603 605 613 619 621 623 624 625 627 629 631 633 635 637 639 641 643 645 647 649 651 653 655 657 658 659 660 674 678 681 685 686 687 689 692 695 698 701 703 705 707 710
Circuit Relief Valve Test—With Remote Pump (S.N. —883904) Circuit Relief Valve Test—With Remote Pump (S.N. 883905— ) Steering System Leakage Test Steering Cylinder Leakage Test Hydraulic Cylinder Drift Test Procedure Function Drift Test Cylinder Leakage Test Cycle Time Specifications (S.N. —883904) Cycle Time Specifications (S.N. 883905— ) Hydrostatic PTO System Component Location (S.N. —882699) Hydrostatic PTO System Component Location (S.N. 882700—) Hydrostatic PTO System Schematic—If Equipped Hydrostatic PTO Pump Operation—If Equipped Hydrostatic PTO Pump Control Circuit Operation—Actuated Hydrostatic PTO High Pressure Relief Valve Operation Hydrostatic PTO Motor Operation—If Equipped Diagnose Hydrostatic PTO System Problems Before Performing Hydrostatic PTO Tests and Adjustments Hydrostatic PTO Pump Servo Piston Neutral Adjustment—If Equipped Before Performing Hydrostatic PTO Tests and Adjustments (1) Hydrostatic PTO Pump Neutral Charge Relief Valve Pressure Test and Adjustment—If Equipped Hydrostatic PTO Pump High Pressure Relief Valve and Pressure Override Valve Tests and Adjustments—If Equipped PTO Oil Cooler Restriction Test (S.N. —882699) PTO Oil Cooler Restriction Test (S.N. 882700—)
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Foreword This manual is wri en for an experienced technician. Essen al tools required in performing certain service work are iden fied in this manual and are recommended for use. Live with safety: Read the safety messages in the introduc on of this manual and the cau ons presented throughout the text of the manual.
This is the safety-alert symbol. When you see this symbol on the machine or in this manual, be alert to the poten al for personal injury. Technical manuals are divided in two parts: repair and opera on and tests. Repair sec ons tell how to repair the components. Opera on and tests sec ons help you iden fy the majority of rou ne failures quickly. Informa on is organized in groups for the various components requiring service instruc on. At the beginning of each group are summary lis ngs of all applicable essen al tools, service equipment and tools, other materials needed to do the job, service parts kits, specifica ons, wear tolerances, and torque values. Technical Manuals are concise guides for specific machines. They are on-the-job guides containing only the vital informa on needed for diagnosis, analysis, tes ng, and repair. Fundamental service informa on is available from other sources covering basic theory of opera on, fundamentals of troubleshoo ng, general maintenance, and basic type of failures and their causes. To order a technical manual, see DB1990 Service Publica ons Catalog. A complete Opera on and Test manual includes the following sec ons: Sec on 9000 General Informa on Sec on 9005 Opera onal Checkout Procedure Sec on 9010 Engine Sec on 9015 Electrical System Sec on 9020 Power Train Sec on 9025 Hydraulic System Sec on 9026 Hydrosta c PTO System
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