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John Deere Tractors 5080G, 5090G, 5090GH, 5075GL, 5085GL, 5075GF, 5085GF, 5100GF, 5075GN, 5085GN, 5100GN, 5075GV, 5085GV Repair Service Manual (TM406419)

Complete Repair Technical Manual for John Deere 5075G (F, L, N, V) , 5080G, 5085G (F, L, N, V) , 5090G(, H) , 5100G(F, N) Tractors (S.N. -00468, -,000469- (Engine F5A) T3A), with all the workshop information to maintain, repair, and rebuild like professional mechanics.

John Deere 5100GN, 5100GF, 5090GH, 5090G, 5085GV, 5085GN, 5085GL, 5085GF, 5080G, 5075GV, 5075GN, 5075GL, 5075GF workshop technical manual (repair) includes:
* Numbered table of contents easy to use so that you can find the information you need fast.
* Detailed sub-steps expand on repair procedure information
* Numbered instructions guide you through every repair procedure step by step.
* Notes, cautions and warnings throughout each chapter pinpoint critical information.
* Bold figure number help you quickly match illustrations with instructions.
* Detailed illustrations, drawings and photos guide you through every procedure.
* Enlarged inset helps you identify and examine parts in detail.

tm406419 – John Deere 5080G, 5090G,5090GH,5075GL, 5085GL,5075GF,5085GF, 5100GF,5075GN,5085GN, 5100GN,5075GV,5085GV Tractors Repair (Worldwide Edition) Technical Manual.PDF
tm406428 – Remise en état des tacteurs 5080G, 5090G, 5090GH, 5075GL, 5085GL,5075GF, 5085GF, 5100GF,5075GN, 5085GN, 5100GN,5075GV, 5085GV -: (Édition internationale) French.pdf
tm406429 – Reparatur der Traktoren 5080G, 5090G, 5090GH, 5075GL, 5085GL,5075GF, 5085GF, 5100GF,5075GN, 5085GN, 5100GN,5075GV, 5085GV -: (Weltweite Ausgabe) German.pdf
tm406439 – Riparazione dei trattori5080G, 5090G, 5090GH, 5075GL, 5085GL,5075GF, 5085GF, 5100GF,5075GN, 5085GN, 5100GN,5075GV, 5085GV -: (Edizione universale) Italian.pdf
tm406454 – Reparação de Tratores5080G, 5090G, 5090GH, 5075GL, 5085GL,5075GF, 5085GF, 5100GF,5075GN, 5085GN, 5100GN,5075GV, 5085GV -: (Edição Mundial) Portuguese.pdf

Total Pages: 1,382 pages
File Format: PDF (bookmarked, ToC, Searchable, Printable, high quality)
Language: English German etc

MAIN SECTIONS (5080G, 5090G, 5090GH, 5075GL, 5085GL, 5075GF, 5085GF, 5100GF, 5075GN, 5085GN, 5100GN, 5075GV, 5085GV)
Foreword
Safety
Safety Measures
General Information
Specifications
Tune-Up
Predelivery Inspection
Engine
Removal and Installation of Engine Components
Fuel and Air Intake Systems
Speed Control Linkage
Fuel System
Air Intake System
Electrical System
Battery, Starter Motor, and Alternator
Switches and Sensors
Drive Train (without Transmission)
Component Removal and Installation
Front-Wheel Drive Clutch – Transmission
Differential
Final Drives
Power Take-Off
Transmission Housing – Sensors
Mechanical Transmissions
Removal and Installation of Power Train Components
Clutch
Hi-Lo Clutch (24/24-Speed Transmission)
Transmission
Power Reverser Transmission (24-12)
Removal and Installation of Components – 24/12-Speed Transmission
Electro-Hydraulic Forward High/Low and Reverse Clutch – 24/12-Speed Transmission
Steering and Brake Systems
Steering System
Brake System
Hydraulic System
Hydraulic Pump and Filter
Hitch
Three-Point Hitch
Selective Control Valves
Miscellaneous
Removal and Installation of Components
Front Axle
Front and Rear Wheels
Trailer Mounting and Swinging Drawbar
Fenders
Operator`s Cab and Open Operator`s Station
Remove and Install Operator`s Cab/Open Operator`s Station
Controls and Instruments
Air-Conditioning System
Heating System
Operator`s Cab
Open Operator`s Station
Operator`s Seat
Special Tools
Special Tools (Dealer-Fabricated)
Special Tools (Available as Spare Parts)

TABLE OF CONTENTS…………….1
Section 05: Safety…………….23
Group 05: Safety Measures…………….23
Recognize Safety Information…………….25
Understand Signal Words…………….26
“Important” – Information…………….27
”Note” Information…………….28
Follow Safety Instructions…………….29
Handle Fluids Safely—Avoid Fires…………….30
Prevent Battery Explosions…………….31
Prepare for Emergencies…………….32
Prevent Acid Burns…………….33
Service Cooling System Safely…………….35
Avoid High-Pressure Fluids…………….36
Park Machine Safely…………….37
Support Machine Properly…………….38
Wear Protective Clothing…………….39
Work in Clean Area…………….40
Service Machines Safely…………….41
Work In Ventilated Area…………….42
Illuminate Work Area Safely…………….43
Replace Safety Signs…………….44
Use Proper Lifting Equipment…………….45
Keep ROPS Installed Properly…………….46
Service Tires Safely…………….47
Avoid Harmful Asbestos Dust…………….48
Avoid Heating Near Pressurized Fluid Lines…………….49
Remove Paint Before Welding or Heating…………….50
Use Proper Tools…………….51
Dispose of Waste Properly…………….52
Use Safety Lights and Devices…………….53
Practice Safe Maintenance…………….54
Service Front-Wheel Drive Tractor Safely…………….55
Live With Safety…………….56
Section 10: General Information…………….57
Group 05: Specifications…………….1228
Summary of References – Specifications…………….1228
Engine…………….64
Transmission…………….66
Front-Wheel Drive Clutch…………….67
Hydraulic System…………….68
Electrical System…………….69
Capacities…………….70
Sound Level…………….71
Fuel System…………….72
Brakes…………….73
Three-Point Hitch…………….74
Loads and Weights…………….75
Towable Loads…………….76
Shipping Weights…………….77
Maximum Permissible Axle Loads and Total Weights…………….79
Load Capacity of Tires…………….81
Load Capacity of Tires With Front Loader…………….93
Observe Rear Wheel Tread Width Limitations…………….94
Metric Bolt and Screw Torque Values…………….97
Unified Inch Bolt and Screw Torque Values…………….99
Diesel Fuel…………….102
Handling and Storing Diesel Fuel…………….103
Do Not Use Galvanized Containers…………….104
Fill Fuel Tank…………….105
Diesel Engine Break-In Oil — Non-Emissions Certified and Certified Tier 1, Tier 2, Tier 3, Stage I, Stage II, and Stage III…………….107
Diesel Engine Oil — Tier 2 and Stage II…………….109
Transmission and Hydraulic Oil…………….111
Front-Wheel Drive Axle and Rear Drop Axle Oil…………….112
Grease…………….113
Oil Filters…………….114
Lubricant Storage…………….115
Mixing of Lubricants…………….116
Diesel Engine Coolant…………….117
Operating in Warm Temperature Climates…………….118
Alternative and Synthetic Lubricants…………….119
Serial Number Plates…………….120
Product Identification Number Location…………….121
Engine Serial Number…………….122
Fuel Injection Pump Serial Number Location…………….124
Power Steering Valve Serial Number Location…………….125
Air-Conditioning Compressor Serial Number Location…………….126
Transmission Serial Number Location…………….127
Front Axle (2WD) Serial Number Location…………….128
Front-Wheel Drive Serial Number…………….129
Group 10: Tune-Up…………….58
Summary of References – Tune-Up…………….131
Using High-Pressure Washers…………….132
Preliminary engine test…………….133
Clean Radiator and Oil Cooler…………….134
Clean Air-Conditioning System Condenser…………….136
Check Hoses and Hose Clamps…………….138
Clean Engine Crankcase Vent Tube…………….140
Clean the Dust Unloading Valve…………….141
Engine Air Filter…………….142
Cleaning the Primary Filter Element…………….144
Cleaning a Dusty Element…………….145
Secondary (Safety) Element…………….146
Clean Cab Air Filters…………….147
Check Belt Wear and Tension…………….337
Check Engine Oil Level…………….149
Check Brake System Oil Level…………….150
Check Coolant Level…………….152
Check Transmission/Hydraulic System Oil Level…………….153
Check the Fuel Filter…………….154
Bleed Fuel System…………….293
Starting Motor…………….160
Battery – Checking Specific Gravity…………….161
Check Neutral Start System…………….162
Check Setting of Head Lights and Work Lights…………….164
Check Lights…………….165
Final Engine Check…………….166
Tractor Operation Check…………….167
Group 15: Predelivery Inspection…………….169
Predelivery Inspection…………….169
Section 20: Engine…………….170
Group 00: Removal and Installation of Engine Components…………….170
Summary of References – Remove and Install Engine Components…………….172
Engine Repair…………….173
Specifications…………….1228
Remove Engine…………….175
Install Engine…………….188
Water Pump Repair…………….199
Remove and Inspect Radiator…………….200
Remove and Inspect Radiator (5G Remove and Inspect Radiator (5G & 5GH){pgNO}170 5GH)…………….201
Remove and Inspect Radiator (5GL)…………….212
Remove and Inspect Radiator (5GV, 5GN Remove and Inspect Radiator (5GV, 5GN & 5GF){pgNO}170 5GF)…………….218
Install Radiator…………….228
Remove Oil Cooler…………….229
Replace Thermostat…………….231
Remove engine side panels…………….233
Install engine side panels…………….236
Vertical Exhaust Pipe Disassembly…………….237
Horizontal Exhaust Pipe Disassembly…………….240
Remove Muffler Cover…………….241
Separate Engine from Front Support…………….243
Section 30: Fuel and Air Intake Systems…………….245
Group 05: Speed Control Linkage…………….245
Summary of References – Speed Control Linkage…………….247
Adjust Hand Throttle Lever and Accelerator Pedal…………….248
Recondition Hand Throttle Lever and Accelerator Pedal…………….257
Group 10: Fuel System…………….72
Fuel System – Summary of References…………….260
Injection Pump, Nozzle and Governor Repair…………….261
Drain Fuel Tank…………….262
Remove, Inspect and Install Fuel Tank…………….263
Remove, Inspect and Install Fuel Tank (5G Remove, Inspect and Install Fuel Tank (5G & 5GH){pgNO}245 5GH)…………….264
Remove, Inspect and Install Fuel Tank (5GL)…………….270
Remove, Inspect, and Install Fuel Tank (5GV, 5GN, 5GF)…………….274
Remove, Inspect, and Install Additional Fuel Tank (5GV, 5GN, 5GF)…………….280
Remove, Inspect and Install Fuel Tank Protection…………….285
Replace Fuel Filter…………….287
Replace Fuel Filter (5G Replace Fuel Filter (5G & 5GH){pgNO}245 5GH)…………….288
Replace Fuel Filter (5GL, 5GV, 5GN Replace Fuel Filter (5GL, 5GV, 5GN & 5GF){pgNO}245 5GF)…………….290
Replace Fuel Transfer Pump…………….292
Bleed Fuel System…………….293
Group 15: Air Intake System…………….245
Summary of References – Air Intake System…………….297
Turbocharger Repair…………….298
Remove and Install the Air Cleaner Element…………….299
Remove and Install the Air Cleaner Element (5G Remove and Install the Air Cleaner Element (5G & 5GH){pgNO}245 5GH)…………….300
Remove and Install the Air Cleaner Element (5GL)…………….301
Remove and Install the Air Cleaner Element (5GV, 5GN Remove and Install the Air Cleaner Element (5GV, 5GN & 5GF){pgNO}245 5GF)…………….302
Remove and Install Air Intake Hoses…………….305
Remove and Install Air Intake Hoses (5G Remove and Install Air Intake Hoses (5G & 5GH){pgNO}245 5GH)…………….306
Remove and Install Air Intake Hoses (5GL, 5GV, 5GN Remove and Install Air Intake Hoses (5GL, 5GV, 5GN & 5GF){pgNO}245 5GF)…………….311
Section 40: Electrical System…………….314
Group 05: Battery, Starter Motor, and Alternator…………….314
Battery, Starter Motor and Alternator – Summary of References…………….317
Starting Motor Repair…………….318
Disconnect Battery…………….319
Connect Battery…………….320
Remove Battery…………….321
Install Battery…………….322
Remove and Install Battery (5G Remove and Install Battery (5G & 5GH){pgNO}314 5GH)…………….323
Remove and Install Battery (5GL)…………….325
Remove and Install Battery (5GV, 5GN Remove and Install Battery (5GV, 5GN & 5GF){pgNO}314 5GF)…………….327
Remove and Install Starter Motor…………….330
Alternator/Regulator Repair…………….332
Replace Alternator/Regulator…………….333
Check Belt Wear and Tension…………….337
Group 10: Switches and Sensors…………….314
Summary of References – Switches and Sensors…………….341
Replace Air Filter Restriction Switch B02…………….342
Replace Fuel Level Sensor B03…………….343
Replace Engine Oil Pressure Switch B04…………….347
Replace Park Brake Switch B05…………….348
Replace Transmission Speed Sensor B06…………….350
Replace PTO Speed Selection Switch B07/A…………….352
Replace PTO Speed Selection Switch B07/B…………….354
Replace PTO Safety Switch B08…………….356
Replace Air-Conditioning Pressure Switch B15…………….358
Replace Neutral Start Switch B36…………….359
Replace Coolant Temperature Sensor B56…………….360
Replace Brake Oil Level Sensor B69…………….361
Replace Engine Speed Sensor B72…………….362
Replace Brake Pedal Switches B112…………….363
Replace Thermostat B150…………….364
Replace Resistor B151…………….365
Replace Position Sensor B200 (EHS II)…………….366
Replace Draft Sensor B201 (EHS II)…………….367
Replace Pressostat B304…………….368
Replace Main Switch S01…………….369
Replace Light/Horn Switch S09…………….371
Replace PTO Mode Switch S21/A (Independent PTO)…………….374
Replace PTO Mode Switch S21/B (Ground Drive PTO)…………….375
Replace Hazard Warning Light Switch S106…………….376
Replace Raise Limit Switch S200 (EHS II)…………….378
Replace Fuel Shut-Off Solenoid Valve Y13…………….379
Replace Dashboard…………….380
Replace Instrument Panel…………….383
Remove and Install Dashboard Cowls…………….384
Section 50A: Drive Train (without Transmission)…………….393
Group 00: Component Removal and Installation…………….393
Drive Systems – Component Removal and Installation, Summary of References…………….396
Specifications…………….1228
Remove and Install Front-Wheel Drive Clutch…………….398
Remove and Install Differential Assembly…………….400
Remove and Install Final Drive Assembly…………….403
Remove Rear PTO Cover…………….407
Install Rear PTO Cover…………….409
Group 15: Front-Wheel Drive Clutch – Transmission…………….66
Summary of References – Front-Wheel Drive Clutch…………….413
Specifications…………….1228
Disassemble and Inspect Front-Wheel Drive Clutch…………….415
Front-Wheel Drive Clutch Cross Section…………….422
Assemble Front-Wheel Drive Clutch…………….424
Group 20: Differential…………….393
Summary of References – Differential…………….434
Essential Tools…………….936
Service Equipment and Tools…………….436
Specifications…………….1228
Disassemble, Inspect and Assemble Four Pinion Differential Assembly…………….438
Four Pinion Differential Backlash Adjustment…………….442
Four Pinion Differential Bearing Preload Adjustment…………….444
Inspect and Repair Differential Lock Pedal and Linkage…………….446
Inspect and Repair Hydraulic Differential Lock and Linkage…………….448
Remove, Inspect and Install Differential Lock Assembly…………….450
Group 25: Final Drives…………….393
Summary of References – Final Drives…………….457
Specifications…………….1228
Remove and Inspect Planetary Drive Assembly…………….459
Install Planetary Drive Assembly…………….463
Remove, Inspect and Install Axle Shaft Assembly…………….468
Disassemble, Inspect and Assemble Gears and Shafts of Final Drive (HighCrop Tractors)…………….472
Group 30: Power Take-Off…………….394
Power Take-Off – Summary of References…………….476
Power Take-Off – Special Tools…………….477
Inspect and Repair Rear PTO Clutch Lever and Linkage…………….478
Remove, Inspect and Install Hydraulic PTO Clutch Cylinder Assembly…………….482
Inspect and Repair Rear PTO Engagement Lever and Linkage…………….484
Disassemble, Inspect and Assemble PTO Shift Leverage Assembly…………….487
Disassemble, Inspect and Assemble Rear PTO Engagement Control…………….490
Disassemble, Inspect and Assemble Rear PTO Drive Shaft Assembly…………….492
Disassemble, Inspect and Assemble Rear PTO Engagement Sleeve…………….495
Remove and Install Rear PTO Drive Shaft…………….498
Disassemble Electro-Hydraulic Rear PTO Cover…………….500
Assemble Electro-Hydraulic Rear PTO Cover…………….503
Disassemble Electro-Hydraulic Rear PTO Clutch Drive Shaft…………….507
Assemble Electro-Hydraulic Rear PTO Clutch Drive Shaft…………….511
Remove Electro-Hydraulic Rear PTO Drive Shaft…………….516
Disassemble Electro-Hydraulic Rear PTO Drive Shaft…………….517
Assemble Electro-Hydraulic Rear PTO Drive Shaft…………….520
Install Electro-Hydraulic Rear PTO Drive Shaft…………….524
Remove Electro-Hydraulic Rear PTO Input Shaft…………….525
Disassemble and Assemble Electro-Hydraulic Rear PTO Input Shaft…………….526
Install Electro-Hydraulic Rear PTO Input Shaft…………….527
Remove Electro-Hydraulic Rear PTO Brake…………….528
Disassemble Electro-Hydraulic Rear PTO Brake…………….530
Assemble Electro-Hydraulic Rear PTO Brake…………….534
Install Electro-Hydraulic Rear PTO Brake…………….539
Group 35: Transmission Housing – Sensors…………….394
Remove, Inspect and Install Housing Sensors…………….544
Section 50B: Mechanical Transmissions…………….547
Group 00: Removal and Installation of Power Train Components…………….547
Remove and Install Power Train Components – Summary of References…………….550
Remove and Install Power Train Components – Specifications…………….1228
Separate Engine from Clutch Housing…………….552
Install Engine on Clutch Housing…………….565
Separate Clutch Housing from Transmission…………….575
Install Clutch Housing on Transmission…………….576
Separate Clutch Housing from Transmission – not for 24/12 Speed Transmission…………….577
Install Clutch Housing on Transmission – not for 24/12 Speed Transmission…………….583
Replace Clutch Housing Seal – 12/12 Speed Transmission…………….589
Replace Clutch Housing Seal – 24/24 Speed Transmission…………….590
Group 05: Clutch…………….547
Summary of References – Clutch…………….595
Specifications…………….1228
Inspect and Repair Clutch Pedal and Linkage…………….597
Remove and Install Clutch Assembly…………….599
Disassemble and Inspect Clutch Assembly…………….602
Assemble Clutch Assembly…………….611
Traction Clutch Finger Adjustment…………….617
PTO Clutch Finger Adjustment…………….619
Remove and Inspect Clutch Release Mechanism…………….621
Install Clutch Release Mechanism…………….624
Group 10: Hi-Lo Clutch (24/24-Speed Transmission)…………….547
Summary of References – Hi-Lo Clutch (24/24-Speed Transmission)…………….629
Specifications…………….1228
Remove and Inspect Mechanical Hi-Lo Drive…………….631
Install Mechanical Hi-Lo Drive…………….634
Disassemble, Inspect and Assemble Mechanical Hi-Lo Shift Shaft Assembly…………….637
Disassemble, Inspect and Assemble Mechanical Hi-Lo Synchronizer…………….639
Disassemble, Inspect and Assemble Mechanical Hi-Lo Drive Shaft…………….641
Disassemble, Inspect and Assemble Mechanical Hi-Lo Reduction Shaft…………….643
Inspect and Repair Mechanical Hi-Lo Shift Lever…………….645
Seal Ring Replacement of Hydraulic Hi-Lo Clutch Drive Shaft…………….647
Remove and Inspect Hydraulic Hi-Lo Clutch Assembly…………….652
Install Hydraulic Hi-Lo Clutch Assembly…………….655
Disassemble, Inspect and Assemble Hydraulic Hi-Lo Clutch…………….659
Disassemble, Inspect and Assemble Hydraulic Hi-Lo Drive Shaft…………….663
Group 20: Transmission…………….66
Transmission – Summary of References…………….666
Transmission – Specifications…………….1228
Remove and Install Transmission…………….668
Inspect and Repair Gear and Range Shift Levers…………….670
Remove, Inspect and Install Range Shaft…………….674
Range Shaft End Play Adjustment…………….680
Remove, Inspect and Install Primary and Reverse Shafts…………….681
Primary Shaft End Play Adjustment…………….694
Remove, Inspect and Install Pinion Shaft…………….696
Pinion Shaft Cone Point Adjustment…………….703
Pinion Bearing Preload Adjustment…………….705
Remove, Inspect and Install Secondary Shaft…………….708
Secondary Shaft End Play Adjustment…………….720
Section 50C: Power Reverser Transmission (24-12)…………….724
Group 00: Removal and Installation of Components – 24/12-Speed Transmission…………….66
Removal and Installation of Components – 24/12-Speed Transmission, Summary of References…………….727
Removal and Installation of Components – 24/12-Speed Transmission, Specifications…………….1228
Removal and Installation of Components – 24/12-Speed Transmission, Special Tools…………….729
Separate Clutch Housing from Transmission – 24/12-Speed Transmission…………….730
Install Clutch Housing on Transmission – 24/12-Speed Transmission…………….735
Guide of Forward High Clutch Drive Shaft and Cover of Forward Low/Reverse Clutch Drive Shaft – 24/12-Speed Transmission…………….741
Remove Guide of Forward High Clutch Drive Shaft – 24/12-Speed Transmission…………….743
Replace Seal Rings of Forward High Clutch Drive Shaft – 24/12-Speed Transmission…………….745
Install Guide of Forward High Clutch Drive Shaft – 24/12-Speed Transmission…………….746
Remove Cover of Forward Low/Reverse Clutch Drive Shaft – 24/12-Speed Transmission…………….750
Replace Seal Rings of Forward Low/Reverse Clutch Drive Shaft – 24/12-Speed Transmission…………….752
Install Cover of Forward Low/Reverse Clutch Drive Shaft – 24/12-Speed Transmission…………….754
Remove Air Pump – 24/12-Speed Transmission…………….757
Install Air Pump – 24/12-Speed Transmission…………….759
Group 15: Electro-Hydraulic Forward High/Low and Reverse Clutch – 24/12-Speed Transmission…………….66
Electro-Hydraulic Forward High/Low and Reverse Clutch – 24/12-Speed Transmission, Summary of References…………….762
Electro-Hydraulic Forward High/Low and Reverse Clutch – 24/12-Speed Transmission, Specifications…………….1228
Remove Electro-Hydraulic Forward High/Low and Reverse Clutch Assembly – 24/12-Speed Transmission…………….764
Install Electro-Hydraulic Forward High/Low and Reverse Clutch Assembly – 24/12-Speed Transmission…………….766
Disassemble, Inspect and Assemble Electro-Hydraulic Forward High Clutch – 24/12-Speed Transmission…………….769
Disassemble, Inspect and Assemble Electro-Hydraulic Forward Low Clutch – 24/12-Speed Transmission…………….775
Disassemble, Inspect and Assemble Electro-Hydraulic Reverse Clutch – 24/12-Speed Transmission…………….781
Remove Secondary Shaft Assembly – 24/12-Speed Transmission…………….788
Disassemble, Inspect and Assemble Secondary Shaft Assembly – 24/12-Speed Transmission…………….789
Install Secondary Shaft Assembly – 24/12-Speed Transmission…………….794
Remove Drive Shaft Assembly – 24/12-Speed Transmission…………….795
Replace Clutch Housing Seal – 24/12-Speed Transmission…………….796
Disassemble, Inspect and Assemble Drive Shaft Assembly – 24/12-Speed Transmission…………….797
Install Drive Shaft Assembly – 24/12-Speed Transmission…………….801
Section 60: Steering and Brake Systems…………….802
Group 05: Steering System…………….802
Summary of References – Steering System…………….805
Specifications…………….1228
Remove and Install Steering Column and Valve…………….808
Disassemble and Inspect Steering Valve…………….823
Assemble Steering Valve…………….827
Remove and Install Steering Cylinder…………….832
Remove and Install Steering Cylinder (Two-Wheel Drive F and V Tractors)…………….834
Remove and Install Steering Cylinder (Two-Wheel Drive HighCrop Tractors)…………….836
Disassemble, Inspect and Assemble Steering Cylinder…………….838
Disassemble, Inspect and Assemble Steering Cylinder (5GV, 5GN, 5GF and 5GL Tractors)…………….841
Disassemble, Inspect and Assemble Steering Cylinder (Two-Wheel Drive HighCrop Tractors)…………….845
Remove, Inspect and Install Tie Rod Assembly (Standard Tractors)…………….847
Remove, Inspect and Install Tie Rod Assembly (5GV, 5GN, 5GF and 5GLTractors)…………….851
Remove, Inspect and Install Tie Rod Assembly (Two-Wheel Drive HighCrop Tractors)…………….856
Group 10: Brake System…………….802
Summary of References – Brake System…………….859
Specifications…………….1228
Change Brake System Oil…………….861
Remove and Install Brake Cylinders and Pedals…………….864
Remove and Install Brake Cylinders and Pedals (5G Remove and Install Brake Cylinders and Pedals (5G & 5GH){pgNO}802 5GH)…………….865
Remove and Install Brake Cylinders and Pedals (5GL)…………….868
Remove and Install Brake Cylinders and Pedals (5GV, 5GN Remove and Install Brake Cylinders and Pedals (5GV, 5GN & 5GF){pgNO}802 5GF)…………….871
Disassemble and Inspect Brake Pedals…………….874
Brake Cylinders Cross Section…………….876
Remove and Inspect Brakes…………….877
Install Brakes…………….880
Trailer Brake Valve System Components…………….883
Remove and Install Trailer Brake Valve…………….884
Disassemble and Inspect Trailer Brake Valve…………….886
Inspect and Replace Brake Hydraulic Lines…………….890
Remove, Inspect and Install Brake Linkage…………….892
Remove, Inspect and Install Park Brake Lever…………….895
Remove, Inspect and Install Park Brake Linkage…………….897
Remove Brake Pump…………….903
Install Brake Pump…………….906
Section 70: Hydraulic System…………….907
Group 05: Hydraulic Pump and Filter…………….907
Summary of References – Hydraulic Pump and Filter…………….910
Specifications…………….1228
Remove and Install Hydraulic Pump…………….912
Remove and Install Third Hydraulic Pump (If Equipped)…………….914
Remove Hydraulic Pump External Components…………….917
Install Hydraulic Pump External Components…………….924
Remove and Install Hydraulic Filter/Manifold…………….926
Remove Hydraulic Filter…………….927
Inspect and Replace Hydraulic Suction Lines…………….928
Inspect and Replace Third Hydraulic Pump Suction Lines (If Equipped)…………….930
Inspect and Replace Hydraulic Supply Lines…………….931
Group 10: Hitch…………….907
Summary of References – Hitch…………….935
Essential Tools…………….936
Specifications…………….1228
Inspect and Repair Hitch Control Lever and Linkage…………….938
Remove, Inspect and Install Hitch Valve…………….941
Safety and Relief Valve Adjustment…………….945
Remove, Inspect and Install EHS II…………….947
Remove, Inspect and Install Draft and Position Sensing Linkage…………….951
Sensing Spring Adjustment…………….954
Remove and Install Rockshaft Assembly…………….955
Remove and Install Rockshaft Assembly (5G Remove and Install Rockshaft Assembly (5G & 5GH){pgNO}907 5GH)…………….956
Remove and Install Rockshaft Assembly (5GL)…………….959
Remove, Inspect and Install Lift Arms and Cylinder of Rockshaft Assembly…………….963
Remove Hitch Control Linkage (Standard Tractors)…………….966
Remove Hitch Control Linkage (F and V Tractors)…………….969
Inspect and Repair Hitch Control Linkage…………….972
Install Hitch Control Linkage (Standard Tractors)…………….976
Install Hitch Control Linkage (F and V Tractors)…………….980
Remove, Inspect and Install Draft and Position Sensing Linkage (EHS II)…………….983
Hitch Sensitivity Adjustment…………….987
Rockshaft Position Control Lever Adjustment…………….988
Rockshaft Draft Control Lever Adjustment…………….989
Distributor Control Valve Adjustment…………….991
Group 15: Three-Point Hitch…………….74
Summary of References – Three-Point Hitch…………….994
Inspect and Repair Draft Links (Standard Tractors)…………….995
Inspect and Repair Draft Links (F and V Tractors)…………….997
Inspect and Repair Adjustable Lift Link…………….1000
Inspect and Repair Hydraulically Adjustable Lift Link…………….1003
Inspect and Repair Center Link…………….1005
Group 20: Selective Control Valves…………….908
Summary of References – Selective Control Valves…………….1008
Selective Control Valve and Lever Assembly (5G Selective Control Valve and Lever Assembly (5G & 5GH){pgNO}908 5GH)…………….1009
Selective Control Valve and Lever Assembly (5 GL)…………….1012
Remove and Install Selective Control Valve (SCV)…………….1014
Remove and Install Selective Control Valve (SCV) – Tractors With Mid-Mounted Couplers…………….1016
Disassemble, Inspect and Assemble Selective Control Valve Lever…………….1019
Selective Control Valve Levers – Exploded View…………….1022
Section 80: Miscellaneous…………….1025
Group 00: Removal and Installation of Components…………….1025
Summary of References – Removal and Installation of Components (Miscellaneous)…………….1028
Specifications…………….1228
Remove Hood…………….1030
Remove Hood (5G Remove Hood (5G & 5GH){pgNO}1025 5GH)…………….1031
Remove Hood (5GL)…………….1034
Remove Hood (5GV, 5GN Remove Hood (5GV, 5GN & 5GF){pgNO}1025 5GF)…………….1035
Install Hood…………….1037
Remove and Install Front Axle – Two-Wheel Drive Standard Tractors…………….1038
Remove and Install Front Axle – Two-Wheel Drive V, N and F Tractors…………….1041
Remove and Install Front Axle – Two-Wheel Drive HighCrop Tractors…………….1045
Remove, Inspect and Install Front Axle Drive Shaft…………….1048
Remove and Install Front Axle – Four-Wheel Drive Standard, HighCrop and F Tractors…………….1057
Remove and Install Front Axle – Four-Wheel Drive V and N Tractors…………….1059
Group 10: Front Axle…………….1025
Summary of References – Front Axle…………….1063
Specifications…………….1228
Inspect and Replace Pivot Pin and Bushings…………….1065
Remove and Install Spindle Assembly (Standard Tractors)…………….1067
Remove and Install Spindle Assembly (F and V Tractors)…………….1070
Remove and Install Spindle Assembly (HighCrop Tractors)…………….1073
Inspect and Replace Spindle Shaft Bushings…………….1075
Inspect and Replace Front-Wheel Bearings (Standard Tractors)…………….1077
Inspect and Replace Front-Wheel Bearings (F and V Tractors)…………….1079
Inspect and Replace Front-Wheel Bearings (HighCrop Tractors)…………….1082
Group 15: Front and Rear Wheels…………….1025
Remove and Install Front or Rear Wheels…………….1088
Group 20: Trailer Mounting and Swinging Drawbar…………….1108
Summary of References – Trailer Mounting and Swinging Drawbar…………….1108
Check the Manually – Operated Hitch (EEC Type) for Wear…………….1094
Check the Manually-Operated Hitch (CUNA Type) for Wear…………….1097
Check the Manually-Operated Hitch (CUNA D2 Type) for Wear…………….1099
Check the Tow Hook for Wear (F and V Tractors)…………….1101
Check the Swinging Drawbar for Wear…………….1102
Remove Guide Rails for Height-Adjustable Trailer Hitch…………….1104
Install Guide Rails for Height-Adjustable Trailer Hitch…………….1106
Swinging Drawbar…………….1108
Group 25: Fenders…………….1026
Summary of References – Fenders…………….1111
Remove and Install Fenders (5G Remove and Install Fenders (5G & 5GH){pgNO}1026 5GH)…………….1112
Remove and Install Fenders (5GL)…………….1116
Section 90: Operator's Cab and Open Operator's Station…………….1120
Group 00: Remove and Install Operator's Cab/Open Operator's Station…………….1120
Summary of References – Remove and Install Operator's Cab/Open Operator's Station…………….1123
Remove Operator's Cab…………….1124
Install Operator's Cab…………….1139
Remove Open Operator's Station…………….1140
Install Open Operator's Station…………….1156
Group 05: Controls and Instruments…………….1120
Summary of References – Controls and Instruments…………….1158
Remove Control Lever Moldings…………….1159
Remove Instrument Panel…………….1171
Remove and Install EHS II Control Panel…………….1174
Group 15: Air-Conditioning System…………….1120
Air-Conditioning System – Summary of References…………….1177
Air-Conditioning System – Special Tools…………….1178
Air-Conditioning System – Specifications…………….1228
Torques for Tightening Refrigerant Hoses…………….1180
Air-Conditioning System – Safety at Work…………….1181
Storage of Refrigerant Containers…………….1183
Air-Conditioning – Important…………….1184
Service Work on Air-Conditioning System…………….1185
Fill with Refrigerant Oil…………….1190
Discharging the System…………….1192
Evacuating the System…………….1193
Filling With Refrigerant Oil…………….1194
Filling the System…………….1195
Topping Up a Partly Discharged System…………….1196
Leakage Test…………….1197
Replace Air-Conditioning Receiver-Drier…………….1198
Remove, Inspect, and Install Air-Conditioning Condenser…………….1200
Remove, Inspect and Install Air-Conditioning Compressor…………….1202
Check Level in the Compressor…………….1204
Air-Conditioning Evaporator – Parts…………….1205
Remove and Install Air-Conditioning Evaporator…………….1207
Air Conditioning Control Unit Disassembly…………….1213
Group 20: Heating System…………….1121
Summary of References – Heating System…………….1216
Remove, Inspect and Install Cab Heater Valve…………….1217
Remove, Inspect and Install Cab Heater Core…………….1219
Remove, Inspect and Install Cab Air-Conditioning Core…………….1221
Remove, Inspect and Install Blower Motor…………….1224
Group 25: Operator's Cab…………….1121
Summary of References – Operator's Cab…………….1227
Specifications…………….1228
Remove and Install Sun Visor…………….1229
Remove and Install Windshield…………….1230
Windshield – Exploded View…………….1234
Remove and Install Lower Front Windows…………….1236
Lower Front Windows – Exploded View…………….1238
Remove and Install Cab Door…………….1240
Remove and Install Inner Handle…………….1242
Cab Door – Exploded View…………….1244
Remove and Install Rear Side Cab Windows…………….1246
Rear Side Cab Windows, Exploded View…………….1248
Remove and Install Rear Window…………….1249
Rear Window – Exploded View…………….1252
Remove and Install Cab Recirculating/Fresh Air Filter…………….1254
Cab Roof Disassembly…………….1256
Post-Cover Disassembly…………….1267
Group 30: Open Operator's Station…………….1121
Summary of References – Open Operator's Station…………….1274
Remove and Install 2-post ROPS (Standard Tractors)…………….1275
Remove and Install 2-post ROPS (F and V Tractors)…………….1278
Group 35: Operator's Seat…………….1121
Remove and Install Operator's Seat and Support…………….1287
Section 99: Special Tools…………….1291
Group 05: Special Tools (Dealer-Fabricated)…………….1291
Summary of References — Dealer-Manufactured Tools…………….1296
Adapter…………….1297
Cone Point Adjustment Tools…………….1298
Draft Control Adjusting Tool…………….1300
Seal Ring Replacement Kit – Tool 1…………….1301
Seal Ring Replacement Kit – Tool 2…………….1302
Group 10: Special Tools (Available as Spare Parts)…………….1291
Summary of References – Special Tools and Test Equipment…………….1305
D01019AA – Single-Speed Hydraulic Hand Pump Assembly…………….1307
D01072AA – Bushing, Bearing, and Seal Driver Set…………….1308
D01210AA – Slide Hammer Puller…………….1309
FKM10436 – Oil Injector…………….1310
FKM10443 – Charging Valve…………….1311
FKM10475 – Adjusting Tool…………….1312
JDE83 – Flywheel Turning Tool…………….1313
JDG19 – Lifting Eyes…………….1314
JDG1337 – Clutch Repair Fixture…………….1315
JDG1375 – Clutch Finger Height Gauge…………….1316
JDG10974EU – Air-Conditioning Service Unit…………….1317
KJD10447 – Oil Seal Installer…………….1318
KJD10494 – Tensioning Tool…………….1319
KJD10567 – Lifting Device for Operator's Cab…………….1320
KJD119029 – Bearing Cup Driver…………….1321
KJD119034 – Seal Ring Driver…………….1322
KJD119183 – Cover Installation Tool…………….1323
KJD677629 – Final Drive Assembly Removal Tool…………….1324
KJD715004 – Bearing Cone Driver…………….1325
KJD715082 – Bearing Cone Driver…………….1326
KJD715093 – Bearing Cone Driver…………….1327
KJD715243 – Bearing Cone Driver…………….1328
KJD715583 – Bearing Cup Driver…………….1329
KJD715600 – Bearing Cup Driver…………….1330
KJD715665 – Bushing Driver…………….1331
KJD715667 – Bushing Driver…………….1332
KJD715668 – Seal Driver…………….1333
KJD715669 – Bearing Cup Driver…………….1334
KJD10570 – Safety Equipment (Air-Conditioning Service)…………….1335
KJD10571 – Protective Cover for Air-Conditioning Service Unit…………….1336
KJD10572 – Standard Flushing Kit (Air-Conditioning Service)…………….1337
KJD10573 – UV Contrast Agent (Air-Conditioning Service)…………….1338
KJD10574 – Hose Extensions (2.5 m) (Air-Conditioning Service)…………….1339
KJD10575 – PAG Oil (Air-Conditioning Service)…………….1340
KJD10576UV – Lamp and Safety Goggles (Air-Conditioning Service)…………….1341
KJD10577 – Filter/Receiver-Drier Cartridge for Air-Conditioning Service Unit…………….1342
KJD715800 – Dummy Pinion Shaft…………….1343
KJD715801 – Plug Driver…………….1344
KJD715802 – Bearing Driver…………….1345
KJD715804 – Seal Driver…………….1346
KJD715805 – Alignment Tool…………….1347
KJD715808 – Bearing Cup Driver…………….1348
KJD715810 – Dummy Differential Assembly…………….1349
KJD715815 – Pin Installation Tool…………….1350
KJD715821 – Bearing Driver and Alignment Tool…………….1351
KJD715824 – Seal Ring Driver…………….1352
KJD715825 – Bearing Driver…………….1353
KJD715826 – Seal Ring Driver…………….1354
KJD715827 – Bearing Cup Driver…………….1355
KJD715829 – Bushing Driver…………….1356
KJD715830 – Bearing Driver and Alignment Tool…………….1357
KJD715836 – Seal Ring Driver…………….1358
KJD715837 – Bearing Driver…………….1359
KJD715838 – Bearing Driver…………….1360
KJD715843 – Bearing Driver…………….1361
KJD715844 – Bearing Cup Driver…………….1362
KJD715845 – Shaft Installation Tool…………….1363
KJD715848 – Bearing and Gear Assembly Driver…………….1364
KJD715887 – Seal Ring Replacement Kit – Tool 2…………….1365
KJD715888 – Seal Ring Replacement Kit – Tool 1…………….1366
KJD716105 – Spacer…………….1367
KJD716106 – Seal Driver…………….1368
KJD716107 – Seal Driver…………….1369
KJD716108 – Bearing Driver…………….1370
KJD716110 – Bearing Support Driver…………….1371
KJD716111 – Bearing Driver…………….1372
KJD716133 – Seal Ring Driver…………….1373
KJD716134 – Seal Ring Driver…………….1374
KJD716138 – Bushing Driver…………….1375
KJD716139 – Bearing Driver…………….1376
KJD716140 – Bearing Driver…………….1377
KJD716143 – Bearing Driver…………….1378
KJD716144 – Alignment Tool…………….1379
KJD716156 – Bearing Cone Driver…………….1380
KJD716157 – Bearing Driver…………….1381
KJD716170 – Seal Ring Driver…………….1382
KJD716171 – Bearing Cone Driver…………….1383
KJD716202 – Shaft Holding Tool…………….1384
KJD716211 – Bearing Driver…………….1385
KJD716216 – Seal Ring Driver…………….1386
KJD716217 – Bushing Driver…………….1387
KJD716218 – Seal Ring Driver…………….1388
KJD716219 – Bearing Driver…………….1389
KJD716220 – Seal Ring Driver…………….1390
KJD716300 – Bushing Driver…………….1391
KJD716302 – Bearing Cup Driver…………….1392
KJD716303 – Bearing Cup Driver…………….1393
KJD716304 – Seal Driver…………….1394
KJD716305 – Bushing Driver…………….1395
OTC7062A – Holder…………….1396

John Deere Tractors 5080G, 5090G, 5090GH, 5075GL, 5085GL, 5075GF, 5085GF, 5100GF, 5075GN, 5085GN, 5100GN, 5075GV, 5085GV Repair Service Manual (TM406419)

INSTANT DOWNLOAD

Posted on February 22, 2024 by admin

John Deere Tractors 5100GN, 5100GF, 5090GH, 5090G, 5085GV, 5085GN, 5085GL, 5085GF, 5080G, 5075GV, 5075GN, 5075GL, 5075GF Diagnosis & Tests Service Technical Manual (TM406319)

INSTANT DOWNLOAD

Complete Diagnosis & Tests Technical Manual with electrical wiring diagrams for John Deere Tractors 5080G, 5090G, 5090GH, 5075G(L,F,V,N), 5085G(L,F,V,N), 5100GF, 5100GN (S.N. -00468, -,000469- (Engine F5A) T3A) (Worldwide Edition), with all the workshop information to maintain, diagnose, and rebuild like professional mechanics.

John Deere 5080G, 5090G, 5090GH, 5075GL, 5085GL, 5075GF, 5085GF, 5100GF, 5075GN, 5085GN, 5100GN, 5075GV, 5085GV Tractors workshop Diagnosis & Tests technical manual includes:
* Numbered table of contents easy to use so that you can find the information you need fast.
* Detailed sub-steps expand on repair procedure information
* Numbered instructions guide you through every repair procedure step by step.
* Troubleshooting and electrical service procedures are combined with detailed wiring diagrams for ease of use.
* Notes, cautions and warnings throughout each chapter pinpoint critical information.
* Bold figure number help you quickly match illustrations with instructions.
* Detailed illustrations, drawings and photos guide you through every procedure.
* Enlarged inset helps you identify and examine parts in detail.

TM406319 – John Deere Tractors 5075GF, 5075GL, 5075GN, 5075GV, 5080G, 5085GL, 5085GF, 5085GN, 5085GV, 5090G, 5090GH, 5100GF, 5100GN (Worldwide Edition) Technical Manual (Diagnosis & Tests).pdf
tm406328 – Diagnostic des tracteurs 5080G, 5090G, 5090GH, 5075GL, 5085GL, 5075GF, 5085GF, 5100GF5075GN, 5085GN, 5100GN5075GV, 5085GV -: (Édition internationale) French.pdf
tm406329 – Diagnose der Traktoren5080G, 5090G, 5090GH,5075GL, 5085GL, 5075GF,5085GF, 5100GF, 5075GN,5085GN, 5100GN,5075GV, 5085GV -: (Weltweite Ausgabe) German.pdf
tm406339 – Diagnosi trattori5080G, 5090G, 5090GH, 5075GL, 5085GL, 5075GF, 5085GF, 5100GF5075GN, 5085GN, 5100GN5075GV, 5085GV -: (Edizione universale) Italian.pdf
tm406354 – Diagnósticos de Tratores5080G, 5090G, 5090GH, 5075GL, 5085GL, 5075GF, 5085GF, 5100GF5075GN, 5085GN, 5100GN5075GV, 5085GV -: (Edição Mundial) Portuguese.pdf

Total Pages: 3,491 pages
File Format: PDF (bookmarked, ToC, Searchable, Printable, high quality)
Language: English etc.

MAIN SECTIONS
Foreword
General Information
Safety Measures
General References
Diagnostic Trouble Codes
Engine Control Unit (FPT F34 (F5D) Diesel Engine
Electronic Hitch Sensing
Transmission Control Unit
E-SCV Control Unit
Vehicle Control Unit
Observable Symptoms
Fuel and Air Intake System
Electrical System
Electronic Control Units
Power Train
Steering and Brakes
Hydraulic System
Front-Wheel Drive
Air-Conditioning System
Engine
Engine – General Information
Engine – Operational Checks
Engine – Diagnostic Tests/Adjustments
Fuel, Air Intake and Cooling Systems
Fuel, Air Intake and Cooling System – Theory of Operation
Fuel, Air Intake and Cooling Systems – Diagnostic Tests/Adjustments
Electrical System
Diagnostic Schematics (5G/GH)
Diagnostic Schematics (5GL)
Diagnostic Schematics (5G VNF)
Electronic Control Units
Operation and General Information on Diagnostics
Information on How to Reprogram Control Units
ECU – Engine Control Unit
EHS II – Electronic Hitch Sensing
TCU – Transmission Control Unit
TVC – E-SCV Control Unit
VCU – Vehicle Control Unit
Electrical System (5G/GH) – Component Information
Summary of Electrical (5G/GH) Components and Harnesses
Electrical Components – Assemblies (5G/GH)
Electrical Components – Sensors (5G/GH)
Electrical Components – Lights (5G/GH)
Electrical Components – Fuses, Relays and Diodes (5G/GH)
Electrical Components – Power Supply and Alternator (5G/GH)
Electrical Components – Monitoring and Signalling Devices (5G/GH)
Electrical Components – Electrical Motors (5G/GH)
Electrical Components – Resistors (5G/GH)
Electrical Components – Switches (5G/GH)
Wiring Harnesses (5G/GH)
Wiring Diagrams (5G/GH)
Connector Information (5G/GH)
Ground Points (5G/GH)
Electrical Components – Solenoids and Solenoid Valves (5G/GH)
Electrical Components – Other (5G/GH)
Electrical System (5GL) – Component Information
Summary of Electrical Components and Harnesses (5GL)
Electrical Components – Assemblies (5GL)
Electrical Components – Sensors (5GL)
Electrical Components – Lights (5GL)
Electrical Components – Fuses, Relays and Diodes (5GL)
Electrical Components – Power Supply and Alternator (5GL)
Electrical Components – Monitoring and Signaling Devices (5GL)
Electrical Components – Electrical Motors (5GL)
Electrical Components – Resistors (5GL)
Electrical Components – Switches (5GL)
Wiring Harnesses (5GL)
Wiring Diagrams (5GL)
Connector Information (5GL)
Ground Points (5GL)
Electrical Components – Solenoids and Solenoid Valves (5GL)
Electrical System (5G VNF) – Component Information
Summary of Electrical Components and Harnesses (5G VNF)
Electrical Components – Assemblies (5G VNF)
Electrical Components – Sensors (5G VNF)
Electrical Components – Lights (5G VNF)
Electrical Components – Fuses, Relays and Diodes (5G VNF)
Electrical Components – Power Supply and Alternator (5G VNF)
Electrical Components – Monitoring and Signaling Devices (5G
VNF)
Electrical Components – Electrical Motors (5G VNF)
Electrical Components – Resistors (5G VNF)
Electrical Components – Switches (5G VNF)
Wiring Harnesses (5G VNF)
Wiring Diagrams (5G VNF)
Connector Information (5G VNF)
Ground Points (5G VNF)
Electrical Components – Solenoids and Solenoid Valves (5G VNF)
Electrical Components – Other (5G VNF)
Drive Train (without Transmission)
Front-Wheel Drive – Theory of Operation
Differential – Theory of Operation
Final Drives – Theory of Operation
Rear PTO – Theory of Operation
Drive Train (without Transmission) – Component Information
Drive Train (without transmisson) – Diagnostic Tests/Adjustments
Mechanical Transmissions
Mechanical Transmissions – Theory of Operation
Mechanical Transmissions – Component Information
Drive Train (without transmisson) – Diagnostic Tests/Adjustments
Power Reverser Transmission (24/12)
Power Reverser Transmission (24-12) – Operational Checks
Power Reverser Transmission (24-12) – Theory of Operation
Power Reverser Transmission (24-12) – Diagnostic Tests/Adjustments
Steering and Brake Systems
Steering and Brake Systems – Theory of Operation
Steering and Brake Systems – Component Information
Steering and Brake Systems – Diagnostic Tests/Adjustments
Hydraulic System
Hydraulic System – Theory of Operation
Hydraulic System – Schematics
Hydraulic System – Component Information
Hydraulic System – Diagnostic Tests/Adjustments
Miscellaneous
Operational Checks
Cab and Open Operator’s Station
Cab and Open Operator’s Station – Theory of Operation
Cab and Open Operator’s Station – Component Information
Cab and Open Operator’s Station – Diagnostic Tests/Adjustments
Special Tools
Special Tools (Dealer-Fabricated)John Deere Tractors 5100GN, 5100GF, 5090GH, 5090G, 5085GV, 5085GN, 5085GL, 5085GF, 5080G, 5075GV, 5075GN, 5075GL, 5075GF Diagnosis & Tests Service Technical Manual (TM406319)

TM406319 – John Deere Tractors 5100GN, 5100GF, 5090GH, 5090G, 5085GV, 5085GN, 5085GL, 5085GF, 5080G, 5075GV, 5075GN, 5075GL, 5075GF Technical Manual (Diagnosis & Tests).PDF

Complete Diagnosis & Tests Technical Manual with electrical wiring diagrams for John Deere Tractors 5080G, 5090G, 5090GH, 5075G(L,F,V,N), 5085G(L,F,V,N), 5100GF, 5100GN (S.N. -00468, -,000469- (Engine F5A) T3A) (Worldwide Edition), with all the shop information to maintain, diagnostic, repair, refurbish/rebuild like professional mechanics.

Total Pages: 3,391 pages
File Format: PDF (bookmarked, ToC, Searchable, Printable, high quality)
Language: English

TABLE OF CONTENTS…………….1
Section 210: General Information…………….3434
Group 05: Safety Measures…………….66
General Information – Safety – Summary of References…………….70
Recognize Safety Information…………….72
Understand Signal Words…………….73
Follow Safety Instructions…………….74
Prevent Machine Runaway…………….75
Operating the Tractor Safely…………….76
Operating the Loader Tractor Safely…………….78
Passenger Seat…………….79
Use Safety Lights and Devices…………….80
Towing Trailers/Implements Safely (Mass)…………….81
Use Caution On Slopes and Uneven Terrain…………….82
Freeing a Mired Machine…………….83
Avoid Backover Accidents…………….84
Handle Fluids Safely—Avoid Fires…………….85
Handling Batteries Safely…………….86
Prepare for Emergencies…………….88
Avoid High-Pressure Fluids…………….89
Service Cooling System Safely…………….90
Remove Paint Before Welding or Heating…………….91
Avoid Heating Near Pressurized Fluid Lines…………….92
Work In Ventilated Area…………….93
Avoid Contact with Agricultural Chemicals…………….94
Handle Agricultural Chemicals Safely…………….95
Stay Clear of Rotating Drivelines…………….97
Wear Protective Clothing…………….99
Protect Against Noise…………….100
Practice Safe Maintenance…………….101
Avoid Hot Exhaust…………….102
Exhaust Filter Cleaning…………….103
Clean Exhaust Filter Safely…………….104
Read Operator Manuals for ISOBUS Implements…………….107
Use Steps and Handholds Correctly…………….108
Use Seat Belt Properly…………….109
Park Machine Safely…………….110
Use Proper Lifting Equipment…………….111
Construct Dealer-Made Tools Safely…………….112
Support Machine Properly…………….113
Work in Clean Area…………….114
Illuminate Work Area Safely…………….115
Service Machines Safely…………….116
Service Accumulator Systems Safely…………….117
Service Tires Safely…………….118
Use Proper Tools…………….119
Service Front-Wheel Drive Tractor Safely…………….120
Avoid Eye Contact With Radar…………….121
Keep ROPS Installed Properly…………….122
Replace Safety Signs…………….124
Replace Safety Signs…………….124
Dispose of Waste Properly…………….125
Live With Safety…………….890
Safety Measures on Electronic Control Units…………….127
Servicing Electronic Control Units…………….903
Welding Near Electronic Control Units…………….904
Keep Electronic Control Unit Connectors Clean…………….902
Safety Instructions for Replacing a Halogen Bulb…………….131
Safety Instructions for Replacing Xenon (HID) Bulbs and Ballast Units…………….133
Group 10: General References…………….67
General Information – General References, Summary of References…………….136
General Information – Electrical System, Approach to Tabular Diagnostic Procedures…………….137
General Information – Electrical System, Troubleshooting Unsolved Problems…………….139
General Information – Electrical System, Worksheet for Circuit/Harness Test…………….140
General Information – Electrical System, Visual Check…………….142
General Information – Electrical System, Electrical Circuit Malfunctions…………….143
Section 211: Diagnostic Trouble Codes…………….148
Group ECU: Engine Control Unit (FPT F34 (F5D) Diesel Engine…………….148
ECU 004151.12 – Fuel Rail Pressure Relief Valve (PRV) Fault…………….148
ECU 065564.03 – Water-in-Fuel detected…………….148
ECU 065585.03 – Coolant Temperature Sensor, Voltage Too High…………….148
ECU 065585.04 – Coolant Temperature Sensor, Voltage Too Low…………….148
ECU 065587.03 – Manifold Air Temperature Sensor (High-Pressure Pump), Voltage Too High…………….148
ECU 065587.04 – Manifold Air Temperature Sensor (High-Pressure Pump), Voltage Too Low…………….148
ECU 065588.00 – Manifold Air Pressure Sensor (High-Pressure Pump) Fault…………….148
ECU 065588.01 – Manifold Air Pressure Sensor (High-Pressure Pump) Fault…………….148
ECU 065588.03 – Manifold Air Pressure Sensor (High-Pressure Pump), Voltage Too High…………….148
ECU 065588.04 – Manifold Air Pressure Sensor (High-Pressure Pump), Voltage Too Low…………….148
ECU 065589.03 – Fuel Temperature Sensor, Voltage Too High…………….148
ECU 065589.04 – Fuel Temperature Sensor, Voltage Too Low…………….148
ECU 065590.03 – Fuel Rail Pressure Sensor, Voltage Too High…………….148
ECU 065590.04 – Fuel Rail Pressure Sensor, Voltage Too Low…………….148
ECU 065591.02 – Fuel Rail Pressure Relief Valve (PRV), Opens Too Often…………….148
ECU 065591.03 – Fuel Rail Pressure Relief Valve (PRV) Fault…………….148
ECU 065591.04 – Fuel Rail Pressure Relief Valve (PRV) is forced to open by system test…………….148
ECU 065596.03 – Ambient Temperature Sensor, Voltage Too High…………….148
ECU 065596.04 – Ambient Temperature Sensor, Voltage Too Low…………….148
ECU 065601.02 – Crankshaft Position Sensor Fault…………….148
ECU 065601.04 – Camshaft Position Sensor Signal Invalid…………….148
ECU 065603.02 – Camshaft Position Sensor Fault…………….148
ECU 065603.04 – Camshaft Position Sensor Fault…………….148
ECU 065604.03 – Engine Speed Sensor Signal Mismatch…………….148
ECU 065609.02 – Fuel Filter Heater Fault…………….148
ECU 065609.03 – Fuel Filter Heater, Voltage Too High…………….148
ECU 065609.04 – Fuel Filter Heater, Voltage Too Low…………….148
ECU 065609.12 – Fuel Filter Heater, Temperature too High…………….148
ECU 065617.03 – High Pressure Fuel System Fault…………….148
ECU 065619.03 – High Pressure Fuel System Fault…………….148
ECU 065619.03 – High Pressure Fuel System Fault…………….148
ECU 065621.03 – High Pressure Fuel Control Valve Fault…………….149
ECU 065623.03 – High Pressure Fuel Control Valve Fault…………….149
ECU 065624.03 – Leakage in Fuel System…………….149
ECU 065625.02 – High Pressure Fuel Control Valve Fault…………….149
ECU 065629.03 – Diesel Particulate Filter Fault (Derate Level 1)…………….149
ECU 065630.03 – EGR Valve Fault (Derate Level 1)…………….149
ECU 065633.02 – Injector No. 1, Short Circuit…………….149
ECU 065634.02 – Injector No. 2, Short Circuit…………….149
ECU 065635.02 – Injector No. 3, Short Circuit…………….149
ECU 065636.02 – Injector No. 4, Short Circuit…………….149
ECU 065639.02 – Injector No. 1 Fault…………….149
ECU 065640.02 – Injector No. 2 Fault…………….149
ECU 065641.02 – Injector No. 3 Fault…………….149
ECU 065642.02 – Injector No. 4 Fault…………….149
ECU 065649.03 – Injector Wiring Bank 1, Short Circuit…………….149
ECU 065651.03 – Injector Wiring Bank 2, Short Circuit…………….149
ECU 065660.12 – Control Software Internal Fault…………….149
ECU 065662.02 – Control Software Internal Fault…………….149
ECU 065662.03 – Control Software Internal Fault…………….149
ECU 065662.04 – Control Software Internal Fault…………….149
ECU 065662.12 – Fuel Injection Limited…………….149
ECU 065663.12 – Injector No. 1, Incorrect Calibration Code…………….149
ECU 065679.02 – Oxygen Sensor Fault…………….149
ECU 065679.03 – Oxygen Sensor, Voltage Too High…………….149
ECU 065679.04 – Oxygen Sensor, Voltage Too Low…………….149
ECU 065689.02 – Turbocharger Wastegate Fault…………….149
ECU 065693.04 – Engine Power Derate Condition Exists…………….149
ECU 065694.04 – Engine Power Derate Condition Exists…………….149
ECU 065713.03 – CAN Bus Voltage Too High…………….149
ECU 065713.04 – CAN Bus Voltage Too Low…………….149
ECU 065719.02 – Incorrect CAN Bus Message…………….149
ECU 065736.03 – Incorrect CAN Bus Message…………….149
ECU 065745.03 – Control Software Internal Fault…………….149
ECU 065746.02 – Control Software Internal Fault…………….150
ECU 065746.03 – Control Software Internal Fault…………….150
ECU 065746.04 – Control Software Internal Fault…………….150
ECU 065746.12 – Control Software Internal Fault…………….150
ECU 065747.12 – Control Software Internal Fault…………….150
ECU 065748.12 – Control Software Internal Fault…………….150
ECU 065752.12 – Control Software Internal Fault…………….150
ECU 065753.02 – Control Software Internal Fault…………….150
ECU 065753.03 – Control Software Internal Fault…………….150
ECU 065753.12 – Control Software Internal Fault…………….150
ECU 065754.12 – Control Software Internal Fault…………….150
ECU 065763.03 – Control Software Internal Fault…………….150
ECU 065764.03 – Control Software Internal Fault…………….150
ECU 065766.12 – ECU Supply Voltage No. 1 Fault…………….150
ECU 065767.03 – ECU Supply Voltage No. 2 Fault…………….150
ECU 065768.03 – ECU Supply Voltage No. 2 Fault…………….150
ECU 065771.03 – Barometric Air Pressure, Voltage Too High…………….150
ECU 065771.04 – Barometric Air Pressure, Voltage Too Low…………….150
ECU 065777.03 – DPF Differential Pressure Sensor, Voltage Too High…………….150
ECU 065777.04 – DPF Differential Pressure Sensor, Voltage Too Low…………….150
ECU 065779.12 – DPF Differential Pressure Sensor Fault…………….150
ECU 065783.00 – DOC Outlet Temperature Sensor Fault…………….150
ECU 065783.03 – DOC Outlet Temperature Sensor, Voltage Too High…………….150
ECU 065783.04 – DOC Outlet Temperature Sensor, Voltage Too Low…………….150
ECU 065791.02 – Engine Oil Viscosity Too Low…………….150
ECU 065791.04 – Engine Oil Viscosity Low…………….150
ECU 131109.03 – Main Relay, Voltage Too High…………….150
ECU 131109.04 – Main Relay, Voltage Too Low…………….150
ECU 131110.03 – Unswitched Battery Voltage Too High…………….150
ECU 131110.04 – Unswitched Battery Voltage Too Low…………….150
ECU 131127.03 – Fuel Rail Pressure Relief Valve (PRV), Opens Too Often…………….150
ECU 131127.04 – Fuel Rail Pressure Relief Valve (PRV) is forced to open by system test…………….150
ECU 131127.12 – Fuel Rail Pressure Relief Valve (PRV) is forced to open by system test…………….150
ECU 131128.03 – Engine Oil Pressure Sensor Fault…………….151
ECU 131128.04 – Engine Oil Pressure Low…………….151
ECU 131158.03 – Engine Power Derate Condition Exists…………….151
ECU 131161.03 – High Pressure Fuel Control Valve, Voltage Too High…………….151
ECU 131162.03 – Injector No. 1, Calibration Fault…………….151
ECU 131162.04 – Injector No. 1, Calibration Fault…………….151
ECU 131165.03 – Diesel Particulate Filter Fault (Derate Level 3)…………….151
ECU 131166.03 – EGR Valve Fault (Derate Level 3)…………….151
ECU 131183.04 – Fuel Rail Pressure Fault…………….151
ECU 131199.12 – Injector No. 2, Incorrect Calibration Code…………….151
ECU 131225.04 – Turbocharger Wastegate Fault…………….151
ECU 131227.03 – Turbocharger Inlet Temperature, Voltage Too High…………….151
ECU 131227.04 – Turbocharger Inlet Temperature, Voltage Too Low…………….151
ECU 131252.02 – Incorrect CAN Bus Message…………….151
ECU 131281.03 – Control Software Internal Fault…………….151
ECU 131283.12 – Control Software Internal Fault…………….151
ECU 131284.04 – Control Software Internal Fault…………….151
ECU 196651.02 – Indicator Light for Glow Plug Fault…………….151
ECU 196651.03 – Glow Plug, Voltage Too High…………….151
ECU 196651.04 – Glow Plug, Voltage Too Low…………….151
ECU 196651.12 – Glow Plug System, Temperature Too High…………….151
ECU 196697.04 – High Pressure Fuel Control Valve, Voltage Too Low…………….151
ECU 196698.03 – Injector No. 2, Calibration Fault…………….151
ECU 196698.04 – Injector No. 2, Calibration Fault…………….151
ECU 196735.12 – Injector No. 3, Incorrect Calibration Code…………….151
ECU 196755.02 – Turbocharger Wastegate Valve Fault…………….151
ECU 196755.03 – Turbocharger Wastegate Valve, Voltage Too High…………….151
ECU 196755.04 – Turbocharger Wastegate Valve, Voltage Too Low…………….151
ECU 196755.12 – Turbocharger Wastegate Valve, Temperature Too High…………….151
ECU 196765.04 – Engine Power Derate Condition Exists…………….151
ECU 196766.04 – Engine Power Derate Condition Exists…………….151
ECU 196808.02 – Incorrect CAN Bus Message…………….151
ECU 196817.12 – Control Software Internal Fault…………….151
ECU 196820.02 – Control Software Internal Fault…………….152
ECU 196820.03 – Control Software Internal Fault…………….152
ECU 196820.04 – Control Software Internal Fault…………….152
ECU 196820.12 – Control Software Internal Fault…………….152
ECU 196835.00 – Control Software Internal Fault…………….152
ECU 196835.01 – Control Software Internal Fault…………….152
ECU 196835.02 – Control Software Internal Fault…………….152
ECU 196835.03 – Control Software Internal Fault…………….152
ECU 196835.04 – Control Software Internal Fault…………….152
ECU 196835.12 – Control Software Internal Fault…………….152
ECU 196849.04 – Diesel Particulate Filter Fault…………….152
ECU 196851.12 – DPF Differential Pressure Sensor Fault…………….152
ECU 196854.03 – DOC Inlet Temperature Sensor, Voltage Too High…………….152
ECU 196854.04 – DOC Inlet Temperature Sensor, Voltage Too Low…………….152
ECU 196857.03 – Diesel Particulate Filter Fault…………….152
ECU 262182.03 – Engine Control Unit, Voltage Too High…………….152
ECU 262182.04 – Engine Control Unit, Voltage Too Low…………….152
ECU 262194.03 – Engine Temperature Too High…………….152
ECU 262197.12 – Fuel Rail Pressure Sensor Fault…………….152
ECU 262229.03 – High Pressure Fuel System Fault…………….152
ECU 262233.03 – High Pressure Fuel Control Valve Fault…………….152
ECU 262234.03 – Injector No. 3, Calibration Fault…………….152
ECU 262234.04 – Injector No. 3, Calibration Fault…………….152
ECU 262271.12 – Injector No. 4, Incorrect Calibration Code…………….152
ECU 262281.03 – EGR Valve Fault…………….152
ECU 262285.02 – Actuator for Throttle Fault…………….152
ECU 262285.12 – Actuator for Throttle, Temperature Too High…………….152
ECU 262299.03 – Turbocharger Pressure Sensor, Voltage Too High…………….152
ECU 262299.04 – Turbocharger Pressure Sensor, Voltage Too Low…………….152
ECU 262301.04 – Engine Power Derate Condition Exists…………….152
ECU 262302.04 – Engine Power Derate Condition Exists…………….152
ECU 262356.03 – Control Software Internal Fault…………….152
ECU 262356.04 – Control Software Internal Fault…………….152
ECU 262371.03 – Control Software Internal Fault…………….153
ECU 262371.04 – Control Software Internal Fault…………….153
ECU 262371.12 – Control Software Internal Fault…………….153
ECU 262393.03 – Diesel Particulate Filter Fault…………….153
ECU 327724.01 – Glow Plug Control Unit Fault…………….153
ECU 327730.03 – Engine Temperature Too High…………….153
ECU 327733.03 – Fuel Rail Pressure Sensor, Pressure Too High…………….153
ECU 327756.03 – Engine Speed Extremely High…………….153
ECU 327769.12 – High Pressure Fuel Control Valve, Temperature Too High…………….153
ECU 327770.03 – Injector No. 4, Calibration Fault…………….153
ECU 327770.04 – Injector No. 4, Calibration Fault…………….153
ECU 327817.03 – EGR Valve Fault…………….153
ECU 327817.04 – EGR Valve Fault…………….153
ECU 327819.02 – EGR Valve Fault…………….153
ECU 327819.12 – EGR Valve, Temperature Too High…………….153
ECU 327820.03 – Actuator for Throttle Fault…………….153
ECU 327820.04 – Actuator for Throttle Fault…………….153
ECU 327821.03 – Actuator for Throttle, Voltage Too High…………….153
ECU 327821.04 – Actuator for Throttle, Voltage Too Low…………….153
ECU 327890.03 – Control Software Internal Fault…………….153
ECU 327892.02 – Control Software Internal Fault…………….153
ECU 327892.03 – Control Software Internal Fault…………….153
ECU 327892.04 – Control Software Internal Fault…………….153
ECU 327892.12 – Control Software Internal Fault…………….153
ECU 327907.03 – Control Software Internal Fault…………….153
ECU 327907.04 – Control Software Internal Fault…………….153
ECU 327907.12 – Control Software Internal Fault…………….153
ECU 327925.12 – Diesel Particulate Filter Fault…………….153
ECU 393217.02 – Oxygen Sensor Fault…………….153
ECU 393218.02 – Oxygen Sensor Fault…………….153
ECU 393221.03 – Oxygen Sensor Wiring, Short Circuit…………….153
ECU 393222.02 – Oxygen Sensor Fault…………….153
ECU 393223.03 – Oxygen Sensor Fault…………….153
ECU 393223.04 – Oxygen Sensor Fault…………….154
ECU 393225.02 – Control Software Internal Fault…………….154
ECU 393226.04 – Oxygen Sensor, Voltage Too High…………….154
ECU 393227.03 – Oxygen Sensor, Voltage Too High…………….154
ECU 393227.04 – Oxygen Sensor, Voltage Too Low…………….154
ECU 393228.03 – Oxygen Sensor, Temperature Too High…………….154
ECU 393228.04 – Oxygen Sensor, Temperature Too Low…………….154
ECU 393355.00 – EGR Valve, Voltage Too High…………….154
ECU 393355.01 – EGR Valve, Voltage Too Low…………….154
ECU 393355.02 – EGR Valve Fault…………….154
ECU 393355.03 – EGR Valve, Voltage Too High…………….154
ECU 393355.04 – EGR Valve, Voltage Too Low…………….154
ECU 393355.07 – EGR Valve Fault…………….154
ECU 393357.03 – Actuator for Throttle, Voltage Too High…………….154
ECU 393357.04 – Actuator for Throttle, Voltage Too Low…………….154
ECU 393374.04 – Engine Power Derate Condition Exists…………….154
ECU 393428.02 – Control Software Internal Fault…………….154
ECU 393428.03 – Control Software Internal Fault…………….154
ECU 393428.04 – Control Software Internal Fault…………….154
ECU 393428.12 – Control Software Internal Fault…………….154
ECU 393460.12 – Regeneration Fault…………….154
ECU 458796.00 – Glow Plug No.1, Current Too Low…………….154
ECU 458796.01 – Glow Plug No.3, Current Too Low…………….154
ECU 458796.02 – Glow Plug No.4, Current Too Low…………….154
ECU 458796.03 – Glow Plug No.2, Current Too Low…………….154
ECU 458889.00 – EGR Valve (Position Sensor), Voltage Too High…………….154
ECU 458889.01 – EGR Valve (Position Sensor), Voltage Too Low…………….154
ECU 458891.03 – Actuator for Throttle, Voltage Too High…………….154
ECU 458891.04 – Actuator for Throttle, Voltage Too Low…………….154
ECU 458893.03 – Actuator for Throttle, Voltage Too High…………….154
ECU 458893.04 – Actuator for Throttle, Voltage Too Low…………….154
ECU 458938.02 – Incorrect CAN Bus Message…………….154
ECU 458995.12 – Diesel Particulate Filter Fault…………….154
Group EHS2: Electronic Hitch Sensing…………….155
EHS01 – Position Sensor Fault…………….155
EHS02 – Draft Sensor Fault…………….155
EHS04 – Electronic Hitch Sensing Control Unit Internal Failure…………….155
EHS08 – Electronic Hitch Sensing Control Unit, Supply Voltage too Low…………….155
EHS16 – Electronic Hitch Sensing Control Unit, Supply Voltage too High…………….155
EHS32 – Lowering Solenoid Valve Fault…………….155
EHS64 – Raising Solenoid Valve Fault…………….155
Group TCU: Transmission Control Unit…………….155
TCU 000126.02 – Oil Filter Restricted Sensor, Fault…………….155
TCU 000126.31 – Transmission Oil Filter Restricted…………….155
TCU 000127.02 – Transmission Oil Pressure Detected with Engine Off…………….155
TCU 000127.07 – Transmission Oil Pressure Detected with Shut-Off Solenoid Valve Not Activated…………….155
TCU 000127.31 – Transmission Oil Pressure too Low…………….155
TCU 000158.00 – Transmission Control Unit, Supply Voltage too High…………….155
TCU 000158.01 – Transmission Control Unit, Supply Voltage too Low…………….155
TCU 000161.02 – Top Shaft Speed Sensor, Out Of Range…………….155
TCU 000161.08 – Top Shaft Speed Sensor, Fault…………….155
TCU 000177.00 – Transmission Oil Temperature too High…………….155
TCU 000177.01 – Transmission Oil Temperature too Low…………….155
TCU 000177.05 – Transmission Oil Temperature Sensor, Signal Voltage too High…………….155
TCU 000177.06 – Transmission Oil Temperature Sensor, Signal Voltage too Low…………….155
TCU 000190.09 – Incorrect CAN Bus Message, Engine Speed from ECU…………….155
TCU 000598.02 – Clutch Pedal Potentiometer and Clutch Pedal Switch, Signals Mismatch…………….155
TCU 000629.09 – Control Unit Internal Fault…………….155
TCU 000629.10 – Control Unit Internal Fault…………….155
TCU 000629.11 – Control Unit Internal Fault…………….155
TCU 000629.12 – Control Unit Internal Fault…………….155
TCU 000629.14 – Control Unit Internal Fault…………….155
TCU 000629.31 – Control Unit Internal Fault…………….155
TCU 000630.02 – Calibration Parameters Out of Range…………….155
TCU 000630.31 – Calibration Parameters Saving Fault…………….155
TCU 000639.31 – CAN Bus, High Error Rate…………….156
TCU 000788.06 – Forward High Clutch or Reverse Clutch, Current too High…………….156
TCU 000976.31 – PTO Switch Fault…………….156
TCU 001565.00 – INFORMATION FOR OPERATOR: Move Reverse Drive Lever to Neutral…………….156
TCU 003509.00 – 5-Volt Supply Voltage too Low…………….156
TCU 003509.01 – 5-Volt Supply Voltage too High…………….156
TCU 003593.06 – Current too High at All Outputs to Solenoid Valve…………….156
TCU 003596.06 – PTO Mode Indicator Lights, Current too High…………….156
TCU 003599.06 – PTO Shut-Off Solenoid Valve, Current too High…………….156
TCU 521215.00 – PTO Pressure Detected with PTO Shut-Off Solenoid Valve not Activated…………….156
TCU 521215.15 – PTO Pressure Detected with PTO Solenoid Valve not Activated…………….156
TCU 521215.16 – PTO Pressure Detected with PTO Switched Off…………….156
TCU 521215.18 – PTO Pressure not Detected with PTO Switched On…………….156
TCU 521216.31 – INFORMATION FOR OPERATOR: Stop Tractor, System Check in Process…………….156
TCU 521221.00 – Forward Low Clutch, Unexpected Slip…………….156
TCU 521221.06 – Forward Low Clutch, Current too High…………….156
TCU 521221.31 – Forward Low Clutch, Unexpected Slip…………….156
TCU 521222.00 – Forward High Clutch, Unexpected Slip…………….156
TCU 521222.31 – Forward High Clutch, Unexpected Slip…………….156
TCU 521230.02 – Reverse Drive Lever Switch Fault…………….156
TCU 521230.07 – Reverse Drive Lever Switch Fault…………….156
TCU 521230.12 – Reverse Drive Lever Switch Fault…………….156
TCU 521230.14 – Reverse Drive Lever Switch Fault…………….156
TCU 521230.31 – Reverse Drive Lever Switch Fault…………….156
TCU 521233.00 – Forward High Clutch Solenoid Valve, Feedback Current Present with Solenoid Valve Not Activated…………….156
TCU 521233.01 – Forward High Clutch Solenoid Valve, Feedback Current Not Present with Solenoid Valve Activated…………….156
TCU 521233.31 – Forward High Clutch Solenoid Valve, Measured and Reference Current Mismatch…………….156
TCU 521234.00 – Forward Low Clutch Solenoid Valve, Feedback Current Present with Solenoid Valve Not Activated…………….156
TCU 521234.01 – Forward Low Clutch Solenoid Valve, Feedback Current Not Present with Solenoid Valve Activated…………….156
TCU 521234.31 – Forward Low Clutch Solenoid Valve, Measured and Reference Current Mismatch…………….156
TCU 521235.00 – Reverse Clutch Solenoid Valve, Feedback Current Present with Solenoid Valve Not Activated…………….157
TCU 521235.01 – Reverse Clutch Solenoid Valve, Feedback Current Not Present with Solenoid Valve Activated…………….157
TCU 521235.31 – Reverse Clutch Solenoid Valve, Measured and Reference Current Mismatch…………….157
TCU 521236.06 – Main Ring Valve Solenoid Valve, Current too High or Shorted to Ground…………….157
TCU 521236.31 – Main Ring Valve Solenoid Valve, Feedback Current too High…………….157
TCU 521237.00 – Forward High Clutch, Pressure too High…………….157
TCU 521237.01 – Forward High Clutch, Pressure too Low…………….157
TCU 521237.03 – Forward High Clutch Pressure Sensor, Signal Voltage too High…………….157
TCU 521237.04 – Forward High Clutch Pressure Sensor, Signal Voltage too Low…………….157
TCU 521237.14 – Forward High Clutch, Pressure Difference too High…………….157
TCU 521237.31 – Forward High Clutch Solenoid Valve, Fault…………….157
TCU 521238.00 – Forward Low Clutch, Pressure too High…………….157
TCU 521238.01 – Forward Low Clutch, Pressure too Low…………….157
TCU 521238.03 – Forward Low Clutch Pressure Sensor, Signal Voltage too High…………….157
TCU 521238.04 – Forward Low Clutch Pressure Sensor, Signal Voltage too Low…………….157
TCU 521238.14 – Forward Low Clutch, Pressure Difference too High…………….157
TCU 521238.31 – Forward Low Clutch Solenoid Valve, Fault…………….157
TCU 521239.00 – Reverse Clutch, Pressure too High…………….157
TCU 521239.01 – Reverse Clutch, Pressure too Low…………….157
TCU 521239.03 – Reverse Clutch Pressure Sensor, Signal Voltage too High…………….157
TCU 521239.04 – Reverse Clutch Pressure Sensor, Signal Voltage too Low…………….157
TCU 521239.14 – Reverse Clutch, Pressure Difference too High…………….157
TCU 521239.31 – Reverse Clutch Solenoid Valve, Fault…………….157
TCU 522202.09 – Incorrect CAN Bus Message, Information from VCU…………….157
TCU 522383.00 – Reverse Clutch, Unexpected Slip…………….157
TCU 522383.31 – Reverse Clutch, Unexpected Slip…………….157
TCU 522402.02 – Transmission Speed Sensor, Signal Faulty…………….157
TCU 522402.08 – Transmission Speed Sensor, Fault…………….157
TCU 523666.00 – Control Unit, Supply Voltage too High…………….157
TCU 523666.01 – Control Unit, Supply Voltage too Low…………….157
TCU 523735.14 – Driving Clutch Solenoid Valves Activated without Signal from Reverse Drive Lever…………….157
TCU 523735.31 – Driving Clutch Solenoid Valves Activated with Reverse Drive Lever in Neutral or Clutch Pedal Completely Depressed…………….158
TCU 524173.00 – Clutch Pedal Potentiometer, Value too High…………….158
TCU 524173.01 – Clutch Pedal Potentiometer, Value too Low…………….158
TCU 524173.03 – Clutch Pedal Potentiometer, Output Voltage too High…………….158
TCU 524173.04 – Clutch Pedal Potentiometer, Output Voltage too Low…………….158
Group TVC: E-SCV Control Unit…………….158
TVC 053248 – Potentiometer for E-SCV 4 Oil Flow Rate Fault…………….158
TVC 053249 – Multi-function lever Fault (E-SCV Valve 4)…………….158
TVC 053250 – E-SCV Valve 4 Fault…………….158
TVC 053251 – Potentiometer for E-SCV 3 Oil Flow Rate Fault…………….158
TVC 053252 – Multi-function lever Fault (E-SCV Valve 3)…………….158
TVC 053253 – E-SCV Valve 3 Fault…………….158
TVC 053254 – Potentiometer for E-SCV 1 Oil Flow Rate Fault…………….158
TVC 053255 – E-SCV 1 Control Lever Fault…………….158
TVC 053256 – E-SCV Valve 2 Fault…………….158
TVC 053257 – Potentiometer for E-SCV 2 Oil Flow Rate Fault…………….158
TVC 053258 – E-SCV 2 Control Lever Fault…………….158
TVC 053259 – E-SCV Valve 1 Fault…………….158
TVC 053260 – E-SCV Transport Lock Switch Fault…………….158
TVC 053261 – Control Unit Unswitched Supply Voltage High…………….158
TVC 053262 – Control Unit Unswitched Supply Voltage Low…………….158
TVC 053263 – Control Unit 5 V Supply Fault…………….158
TVC 053264 – Safety Valve Fault…………….158
TVC 053265 – CAN bus Message Problem (E-SCV Valve 4)…………….158
TVC 053266 – CAN bus Message Problem (E-SCV Valve 4)…………….158
TVC 053267 – Incorrect CAN bus Message (E-SCV Valve 4)…………….158
TVC 053268 – Incorrect CAN bus Message (E-SCV Valve 4)…………….158
TVC 053270 – Incorrect EEPROM Value (E-SCV Valve 4)…………….158
TVC 053271 – Setpoint not Neutral (E-SCV Valve 4)…………….158
TVC 053272 – Supply Voltage Low (E-SCV Valve 4)…………….158
TVC 053273 – Supply Voltage High (E-SCV Valve 4)…………….158
TVC 053274 – Setpoint not Reached (E-SCV Valve 4)…………….158
TVC 053275 – Setpoint not Reached (E-SCV Valve 4)…………….159
TVC 053276 – Setpoint not Reached (E-SCV Valve 4)…………….159
TVC 053277 – Unexpected Movement (E-SCV Valve 4)…………….159
TVC 053278 – Supply Voltage Low (E-SCV Valve 4)…………….159
TVC 053279 – Supply Voltage High (E-SCV Valve 4)…………….159
TVC 053280 – Supply Voltage High (E-SCV Valve 4)…………….159
TVC 053281 – E-SCV Valve 4 Fault…………….159
TVC 053282 – E-SCV Valve 4 Fault…………….159
TVC 053283 – E-SCV Valve 4 Stuck Open…………….159
TVC 053284 – E-SCV Valve 4 Not NEUTRAL…………….159
TVC 053285 – E-SCV Valve 4 Fault…………….159
TVC 053286 – CAN bus Message Problem (E-SCV Valve 3)…………….159
TVC 053287 – CAN bus Message Problem (E-SCV Valve 3)…………….159
TVC 053288 – Incorrect CAN bus Message (E-SCV Valve 3)…………….159
TVC 053289 – Incorrect CAN bus Message (E-SCV Valve 3)…………….159
TVC 053291 – Incorrect EEPROM Value (E-SCV Valve 3)…………….159
TVC 053292 – Setpoint not Neutral (E-SCV Valve 3)…………….159
TVC 053293 – Supply Voltage Low (E-SCV Valve 3)…………….159
TVC 053294 – Supply Voltage High (E-SCV Valve 3)…………….159
TVC 053295 – Setpoint not Reached (E-SCV Valve 3)…………….159
TVC 053296 – Setpoint not Reached (E-SCV Valve 3)…………….159
TVC 053297 – Setpoint not Reached (E-SCV Valve 3)…………….159
TVC 053298 – Unexpected Movement (E-SCV Valve 3)…………….159
TVC 053299 – Supply Voltage Low (E-SCV Valve 3)…………….159
TVC 053300 – Supply Voltage High (E-SCV Valve 3)…………….159
TVC 053301 – Supply Voltage High (E-SCV Valve 3)…………….159
TVC 053302 – E-SCV Valve 3 Fault…………….159
TVC 053303 – E-SCV Valve 3 Fault…………….159
TVC 053304 – E-SCV Valve 3 Stuck Open…………….159
TVC 053305 – E-SCV Valve 3 Not NEUTRAL…………….159
TVC 053306 – E-SCV Valve 3 Fault…………….159
TVC 053307 – CAN bus Message Problem (E-SCV Valve 2)…………….159
TVC 053308 – CAN bus Message Problem (E-SCV Valve 2)…………….159
TVC 053309 – Incorrect CAN bus Message (E-SCV Valve 2)…………….160
TVC 053310 – Incorrect CAN bus Message (E-SCV Valve 2)…………….160
TVC 053312 – Incorrect EEPROM Value (E-SCV Valve 2)…………….160
TVC 053313 – Setpoint not Neutral (E-SCV Valve 2)…………….160
TVC 053314 – Supply Voltage Low (E-SCV Valve 2)…………….160
TVC 053315 – Supply Voltage High (E-SCV Valve 2)…………….160
TVC 053316 – Setpoint not Reached (E-SCV Valve 2)…………….160
TVC 053317 – Setpoint not Reached (E-SCV Valve 2)…………….160
TVC 053318 – Setpoint not Reached (E-SCV Valve 2)…………….160
TVC 053319 – Unexpected Movement (E-SCV Valve 2)…………….160
TVC 053320 – Supply Voltage Low (E-SCV Valve 2)…………….160
TVC 053321 – Supply Voltage High (E-SCV Valve 2)…………….160
TVC 053322 – Supply Voltage High (E-SCV Valve 2)…………….160
TVC 053323 – E-SCV Valve 2 Fault…………….160
TVC 053324 – E-SCV Valve 2 Fault…………….160
TVC 053325 – E-SCV Valve 2 Stuck Open…………….160
TVC 053326 – E-SCV Valve 2 Not NEUTRAL…………….160
TVC 053327 – E-SCV Valve 2 Fault…………….160
TVC 053328 – CAN bus Message Problem (E-SCV Valve 1)…………….160
TVC 053329 – CAN bus Message Problem (E-SCV Valve 1)…………….160
TVC 053330 – Incorrect CAN bus Message (E-SCV Valve 1)…………….160
Section 212: Observable Symptoms…………….643
Group 30: Fuel and Air Intake System…………….643
Fuel and Air Intake Problems…………….643
Group 40: Electrical System…………….643
Electrical System (Summary of References)…………….647
Starting System Diagnostics…………….643
Charging System Diagnostics…………….643
Lighting System Diagnostics…………….643
Group 45: Electronic Control Units…………….643
Vehicle CAN Bus Check…………….660
Group 50: Power Train…………….643
Drive System Diagnostics…………….643
Group 60: Steering and Brakes…………….643
Problems with the Brakes…………….643
Problems with the Steering System…………….643
Problems with the Trailer Brakes…………….643
Group 70: Hydraulic System…………….643
Problems with the Hydraulic System…………….643
Group 80: Front-Wheel Drive…………….643
Problems with the Front-Wheel Drive…………….643
Group 90: Air-Conditioning System…………….643
Problems with the Air-Conditioning System…………….643
Section 220: Engine…………….681
Group 05: Engine – General Information…………….3434
General Information – Engine Overview…………….684
Group 10: Engine – Operational Checks…………….681
Operational Check-Out (Summary of References)…………….687
Safety…………….712
Preliminary Engine Tests…………….689
Group 50: Engine – Diagnostic Tests/Adjustments…………….681
Tests and Adjustments (Summary of References)…………….691
Dynamometer Test…………….692
Section 230: Fuel, Air Intake and Cooling Systems…………….693
Group 20: Fuel, Air Intake and Cooling System – Theory of Operation…………….693
Summary of References – Theory of Operation…………….3420
Fuel System – Description – 5G Fuel System – Description – 5G & 5GH Models{pgNO}693 5GH Models…………….696
Fuel System – Description – 5GL, 5GV, 5GN Fuel System – Description – 5GL, 5GV, 5GN & 5GF Models{pgNO}693 5GF Models…………….697
Fuel System – Description – Auxiliary Fuel Tank (Optional) – 5GN Fuel System – Description – Auxiliary Fuel Tank (Optional) – 5GN & 5GF Models{pgNO}693 5GF Models…………….698
Air Intake System – Theory of Operation…………….699
Engine Cooling System Operation…………….701
Cooling System Radiator — Description…………….703
Viscous Clutch of Fan — Theory of Operation…………….704
Automatic Drive Belt Tensioner — Theory of Operation…………….706
Cold Weather Starting Aid — Theory of Operation…………….707
Group 50: Fuel, Air Intake and Cooling Systems – Diagnostic Tests/Adjustments…………….693
Summary of References – Tests and Adjustments…………….709
General Information…………….3434
Explanation of Checks…………….711
Safety…………….712
Special Tools…………….3448
Specifications…………….3350
Test Air Intake System…………….715
Test the Low-Pressure Switch in Air Intake System…………….717
Check the Cooling System for Leaks…………….719
Testing the Temperature at which the Thermostat opens…………….721
Checking the Viscous Clutch of the Fan…………….723
Check the Fuel Transfer Pump…………….724
Hand Throttle Lever and Accelerator Pedal Adjustment – 5G Hand Throttle Lever and Accelerator Pedal Adjustment – 5G & 5GH Models{pgNO}693 5GH Models…………….726
Hand Throttle Lever and Accelerator Pedal Adjustment – 5GL, 5GV, 5GN Hand Throttle Lever and Accelerator Pedal Adjustment – 5GL, 5GV, 5GN & 5GF Models{pgNO}693 5GF Models…………….735
Section 240: Electrical System…………….737
Group 30A: Diagnostic Schematics (5G/GH)…………….737
Diagnostic Schematics (5G/GH), Summary of References…………….741
50AA – Starting Motor and Charging System (5G/GH), Diagnostic Schematic…………….742
50BA – Hood Lighting System (5G/GH), Diagnostic Schematic…………….744
50BA – Head Lights (5G/GH), Diagnostic Schematic…………….746
50BA – Clearance and Tail Lights (5G/GH), Diagnostic Schematic…………….748
50BB – Work Lights (Tractors with Cab) (5G/GH), Diagnostic Schematic…………….750
50BC – Hazard Warning Lights (5G/GH), Diagnostic Schematic…………….752
50BC – Turn Signal Lights (5G/GH), Diagnostic Schematic…………….754
50CA – Horn (5G/GH), Diagnostic Schematic…………….756
50CB – Rear Window Wiper and Washer System (5G/GH), Diagnostic Schematic…………….758
50CB – Windshield Wiper (5G/GH), Diagnostic Schematic…………….760
50CC – Fan Motor and Backlights (5G/GH), Diagnostic Schematic…………….762
50CE – Radio and Dome Light (5G/GH), Diagnostic Schematic…………….764
50CF – Beacon Light (Open Operator Platform) (5G/GH), Diagnostic Schematic…………….766
50CF – Beacon Light (Cab) (5G/GH), Diagnostic Schematic…………….768
50CG – Trailer Socket (5G/GH), Diagnostic Schematic…………….770
50FA – Cruise Control (5G/GH), Diagnostic Schematic…………….772
50GA – Transmission Control Unit (5G/GH), Diagnostic Schematic…………….774
50FA – Electronic Engine Control (5G/GH), Diagnostic Schematic…………….776
50FA – Foot Throttle Control (5G/GH), Diagnostic Schematic…………….778
50FA – Hand Throtle Control (5G/GH), Diagnostic Schematic…………….780
50GA – Hi Lo Shifting (5G/GH), Diagnostic Schematic…………….782
50GD – Differential Lock (5G/GH), Diagnostic Schematic…………….784
50GE – Front Wheel Drive (5G/GH), Diagnostic Schematic…………….786
50GF – Rear PTO System (5G/GH), Diagnostic Schematic…………….788
50GG – Brakes (5G/GH), Diagnostic Schematic…………….790
50HA – Electronic Hitch Sensing (EHS II) (5G/GH), Diagnostic Schematic…………….792
50HB – Electronic Hitch Sensing (EHS II) with E-SCV (5G/GH), Diagnostic Schematic…………….794
50HC – E-SCV Control Unit (5G/GH), Diagnostic Schematic…………….797
50IA – Instrument Unit (5G/GH), Diagnostic Schematic…………….799
50JA – Vehicle CAN Bus System (5G/GH), Diagnostic Schematic…………….801
Group 30B: Diagnostic Schematics (5GL)…………….738
Diagnostic Schematics (5GL), Summary of References…………….804
50AA – Intake Air Heater Circuit (5GL), Diagnostic Schematic…………….805
50BA – Clearance Light and Tail Light Circuit (5GL), Diagnostic Schematic…………….807
50BA – Hood Lighting System (5GL), Diagnostic Schematic…………….809
50BC – Hazard Warning Lights Circuit (5GL), Diagnostic Schematic…………….811
50BC – Turn Signal Lights Circuit (5GL), Diagnostic Schematic…………….813
50CA – Horn Circuit (5GL), Diagnostic Schematic…………….815
50CF – Beacon Light Circuit (5GL), Diagnostic Schematic…………….817
50CG – Trailer Socket Circuit (5GL), Diagnostic Schematic…………….819
50GD – Differential Lock Circuit (5GL), Diagnostic Schematic…………….821
50GE – Brake System Circuit (5GL), Diagnostic Schematic…………….823
50GE – Front Wheel Drive and Park Brake Circuit (5GL), Diagnostic Schematic…………….825
Group 30C: Diagnostic Schematics (5G VNF)…………….738
Diagnostic Schematics (5G VNF), Summary of References…………….828
50AA – Starting Motor and Charging System (5G VNF), Diagnostic Schematic…………….829
50AB – Electrical Starting Aid Circuit (5G VNF), Diagnostic Schematic…………….831
50BA – Headlights (5G VNF), Diagnostic Schematic…………….833
50BB – Clearance and Tail Lights (5G VNF), Diagnostic Schematic…………….835
50BC – Worklights (Tractors with Cab) (5G VNF), Diagnostic Schematic…………….837
50BD – Hazard Warning Lights (5G VNF), Diagnostic Schematic…………….839
50BE – Turning-Signal Lights (5G VNF), Diagnostic Schematic…………….841
50CA – Horn (5G VNF), Diagnostic Schematic…………….843
50CB – Air-Conditioning Condenser (5G VNF), Diagnostic Schematic…………….845
50CC – Air-Conditioning System (5G VNF), Diagnostic Schematic…………….847
50CD – Windshield Wiper and Washer System (5G VNF), Diagnostic Schematic…………….849
50CE – Rear Window Wiper and Washer System (5G VNF), Diagnostic Schematic…………….851
50CF – Radio and Dome Light (5G VNF), Diagnostic Schematic…………….853
50CG – Beacon Light (Cab) (5G VNF), Diagnostic Schematic…………….855
50CH – Beacon Light (ROPS) (5G VNF), Diagnostic Schematic…………….857
50CI – Trailer Socket (5G VNF), Diagnostic Schematic…………….859
50GA – Transmission Control Unit (5G VNF), Diagnostic Schematic…………….861
50GB – Differential Lock (5G VNF), Diagnostic Schematic…………….863
50GC – Brakes (5G VNF), Diagnostic Schematic…………….865
50GD – Hi/Lo System (5G VNF), Diagnostic Schematic…………….867
50GE – Front-Wheel Drive and Park Brake (5G VNF), Diagnostic Schematic…………….869
50HA – Electronic Hitch Sensing (EHS II) (5G VNF), Diagnostic Schematic…………….871
50HB – Hydraulically Adjustable Stabilizer Bar and Lift Link (5G VNF), Diagnostic Schematic…………….872
50HC – E-SCV Control Unit (5G VNF), Diagnostic Schematic…………….873
50IA – Instrument Unit (5G VNF), Diagnostic Schematic…………….875
50JA – Vehicle CAN Bus System (5G VNF), Diagnostic Schematic…………….877
Section 245: Electronic Control Units…………….878
Group 05: Operation and General Information on Diagnostics…………….878
Operation and General Information on Diagnostics (Summary of References)…………….882
Procedure for Dealing with Diagnostic Trouble Codes…………….883
Digital Display Onboard Functionality (5G/GH)…………….885
Digital Display Onboard Functionality (5G VNF)…………….886
Group 10C: Information on How to Reprogram Control Units…………….878
Information on How to Reprogram Control Units – Summary of References…………….888
General Information on How to Reprogram Control Units…………….889
Live With Safety…………….890
Software Data Files Available for Downloading (5G/GH)…………….891
Software Data Files Available for Downloading (5G VNF)…………….893
Procedure When Replacing Control Units…………….895
Important Notes on Programming…………….896
Procedure When Programming Control Units…………….897
Procedure in the Event of a Programming Problem…………….899
Group ECU: ECU – Engine Control Unit…………….878
ECU – Engine Control Unit, Summary of References…………….901
Keep Electronic Control Unit Connectors Clean…………….902
Servicing Electronic Control Units…………….903
Welding Near Electronic Control Units…………….904
Control Unit Information and Overview Test…………….905
Engine Control Unit Replacement…………….906
Engine Replacement…………….907
Service ADVISOR Readings (Datapoint) list for FPT F34 (F5D) Diesel Engine…………….908
ECU Diagnostic Trouble Codes (DTC) Overview (sorted by P-Code)…………….911
Engine Oil and Filter Replacement Calibration…………….924
DPF Differential Pressure Sensor Calibration…………….925
Oxygen Sensor Calibration…………….926
DPF Calibration…………….927
DOC Calibration…………….928
DPF Ash Service Calibration…………….929
Injector Calibration…………….930
Fuel Rail Pressure Relief Valve Counter Reset…………….932
EGR Valve Calibration…………….933
Glow Plug System Test…………….934
Service Regeneration…………….935
Cylinder Cutout Test…………….936
Group EHS: EHS II – Electronic Hitch Sensing…………….879
EHS II – Electronic Hitch Sensing (Summary of References)…………….939
Calibration of the EHS II System…………….940
EHS II Diagnostic Trouble Codes…………….942
Electronic Hitch Sensing, System Information…………….943
Electronic Hitch Sensing (EHS II), Operational Check…………….944
Group TCU: TCU – Transmission Control Unit…………….879
TCU – Transmission Control Unit – Summary of References…………….946
Transmission Control Unit – On-Board Configuration (5G/GH)…………….947
Transmission Control Unit – On-Board Configuration – Vehicle type configuraton (5G/GH)…………….951
Transmission Control Unit – On-Board Configuration – Clutch pedal calibration (5G/GH)…………….954
Transmission Control Unit – On-Board Configuration – Clutches pressure sensors calibration (5G/GH)…………….957
Transmission Control Unit -On-Board Configuration – FNR lever comfort parameterization (5G/GH)…………….960
Transmission Control Unit – On-Board Configuration – Hi Lo comfort parameterization (5G/GH)…………….963
Transmission Control Unit – On-Board Configuration – Clutch pedal comfort parameterization (5G/GH)…………….966
Transmission Control Unit – On-Board Configuration – Limp home mode activation (5G/GH)…………….969
Transmission Control Unit – On-Board Configuration – On board diagnostic (5G/GH)…………….972
Transmission Control Unit – On-Board Configuration and Calibration Values (5G/GH)…………….974
Digital Display – TCU Message and Diagnostic Trouble Code (DTC) Overview (5G/GH)…………….975
Transmission Control Unit – On-Board Configuration (5G VNF)…………….980
Digital Display – TCU Message and Diagnostic Trouble Code (DTC) Overview (5G VNF)…………….987
Transmission Control Unit – On-Board Configuration and Calibration Values (5G VNF)…………….991
Transmission Control Unit – Software Information…………….992
Clutch Pedal, Operational Check…………….993
Reverse Drive Lever, Operational Check…………….994
Forward High Clutch, Operational Check…………….995
Forward Low Clutch, Operational Check…………….996
Reverse Clutch, Operational Check…………….997
TCU Main Ring Pressure, Operational Check…………….998
Power Take-Off (PTO) (5G VNF), Operational Check…………….999
Group TVC: TVC – E-SCV Control Unit…………….880
TVC – E-SCV Control Unit – Summary of References…………….1001
Service ADVISOR Readings (Datapoint) list for TVC E-SCV Control Unit…………….1002
TVC Diagnostic Trouble Codes…………….1004
E-SVC – Configuration of Replacement Valve…………….1006
E-SVC – Changing E-SCV Configuration…………….1007
E-SVC – Diagnostic LED Output Test Mode…………….1008
E-SVC – End Cover Valve Test Mode…………….1009
Group VCU: VCU – Vehicle Control Unit…………….880
Digital Display – User Interface…………….1014
Digital Display – Display Properties (Basic Settings)…………….1018
Digital Display – Initial Setup (Matching with Tractor)…………….1025
Oil Service Message Reset…………….1035
Displaying Diagnostic Trouble Codes…………….1037
Digital Display – Message and Diagnostic Trouble Code (DTC) Overview (5G/GH)…………….1039
Section 249A: Electrical System (5G/GH) – Component Information…………….1049
Group 40: Summary of Electrical (5G/GH) Components and Harnesses…………….1049
Summary of Electrical Components (5G/GH), Summary of References…………….1071
Summary of Wiring Harnesses (5G/GH), Summary of References…………….1077
Summary of Wiring Diagrams (5G/GH), Summary of References…………….1078
Summary of Connector Information (5G/GH), Summary of References…………….1079
Summary of Ground Points (5G/GH), Summary of References…………….1084
Group 40A: Electrical Components – Assemblies (5G/GH)…………….1049
A05 – Right Speaker (5G/GH), Component Information…………….1087
A06 – Left Speaker (5G/GH), Component Information…………….1089
A010 – Radio (5G/GH), Component Information…………….1091
A050 – CAN Bus Terminator 1 (Vehicle CAN Bus) (Mechanical Transmission) (5G/GH), Component Information…………….1094
A050 – CAN Bus Terminator 1 (Vehicle CAN Bus) (Power Reverser Transmission) (5G), Component Information…………….1096
A051 – CAN Bus Terminator (E-SCV CAN Bus) (5G/GH), Component Information…………….1098
A210 – EHS II Control Unit (5G/GH), Component Information…………….1100
A320 – Transmission Control Unit (Power Reverser Transmission) (5G/GH), Component Information…………….1108
A330 – Instrument Unit (Power Reverser Transmission) (5G), Component Information…………….1111
A330 – Instrument Unit (Mechanical Transmission) (5G/GH), Component Information…………….1115
A500 – Engine Control Unit (ECM) (5G/GH), Component Information…………….1119
A510 – Glow Plug Control Unit (GCU) (5G/GH), Component Information…………….1126
A520 – High Pressure Pump (5G/GH), Component Information…………….1128
A530 – Actuator for Throttle (5G/GH), Component Information…………….1130
A997 – E-SCV Control Unit (TVC) (5G/GH), Component Information…………….1132
Group 40B: Electrical Components – Sensors (5G/GH)…………….1049
B02 – Air Filter Restriction Sensor, Component Information…………….1139
B03 – Fuel Level Sensor (Mechanical Transmission) (5G/GH), Component Information…………….1141
B03 – Fuel Level Sensor (Power Reverser Transmission) (5G), Component Information…………….1143
B05 – Parking Brake Switch (Mechanical Transmission) (5G/GH), Component Information…………….1145
B05 – Parking Brake Switch (Power Reverser Transmission) (5G), Component Information…………….1147
B06 – Transmission Speed Sensor (Mechanical Transmission) (5G/GH), Component Information…………….1149
B06 – Transmission Speed Sensor (Power Reverser Transmission) (5G), Component Information…………….1151
B07A – PTO Switch (540E/1000 rpm) (Mechanical Transmission) (5G/GH), Component Information…………….1153
B07A – PTO Switch (540E/1000 rpm) (Power Reverser Transmission) (5G), Component Information…………….1155
B07B – PTO Switch (540 rpm) (Mechanical Transmission) (5G/GH), Component Information…………….1157
B07B – PTO Switch (540 rpm) (Power Reverser Transmission) (5G), Component Information…………….1159
B08 – PTO Neutral Start Switch (Mechanical Transmission) (5G/GH), Component Information…………….1161
B08 – PTO Neutral Start Switch (Power Reverser Transmission) (5G), Component Information…………….1164
B15 – Air Conditioning Pressure Switch, Component Information…………….1167
B31 – Trailer Brake Pressure Switch, Component Information…………….1169
B36 – Neutral Start Switch (Mechanical Transmission) (5G/GH), Component Information…………….1171
B36 – Neutral Start Switch (Power Reverser Transmission) (5G), Component Information…………….1173
B60 – Transmission Oil Temperature Sensor (Power Reverser Transmission) (5G), Component Information…………….1175
B63 – High Range/Low Range Switch on Transmission (Power Reverser Transmission) (5G), Component Information…………….1177
B64 – Reverse Drive Lever Switch (Power Reverser Transmission) (5G), Component Information…………….1179
B65 – Clutch Pedal Potentiometer (Power Reverser Transmission) (5G), Component Information…………….1181
B69 – Brake Oil Level Sensor (Power Reverser Transmission) (5G), Component Information…………….1183
B69 – Brake Oil Level Sensor (Mechanical Transmission) (5G/GH), Component Information…………….1185
B73 – Oil Filter Restriction Sensor (Power Reverser Transmission) (5G), Component Information…………….1187
B104 – Top Shaft Speed Sensor (Power Reverser Transmission) (5G), Component Information…………….1189
B112R – Brake Pedal Switch (Power Reverser Transmission) (5G), Component Information…………….1191
B112L – Brake Pedal Switch (Power Reverser Transmission) (5G), Component Information…………….1194
B112R – Brake Pedal Switch (Mechanical Transmission) (5G/GH), Component Information…………….1197
B112L – Brake Pedal Switch (Mechanical Transmission) (5G/GH), Component Information…………….1199
B150 – Thermostat, Component Information…………….1201
B151 – Fan Resistor (5G/GH), Component Information…………….1203
B200 – Hitch Position Sensor (5G/GH), Component Information…………….1205
B201 – Draft Sensor (5G/GH), Component Information…………….1207
B300 – Forward High Clutch Pressure Sensor (Power Reverser Transmission) (5G), Component Information…………….1209
B301 – Forward Low Clutch Pressure Sensor (Power Reverser Transmission) (5G), Component Information…………….1211
B302 – Reverse Clutch Pressure Sensor (Power Reverser Transmission) (5G), Component Information…………….1213
B303 – TCU Pressure Sensor (Power Reverser Transmission) (5G), Component Information…………….1215
B350 – PTO Pressure Sensor (Mechanical Transmission) (5G/GH), Component Information…………….1217
B350 – PTO Pressure Sensor (Power Reverser Transmission) (5G), Component Information…………….1219
B500 – Coolant Temperature Sensor (5G/GH), Component Information…………….1221
B501 – Oxygen Sensor (5G/GH), Component Information…………….1223
B502 – Camshaft Position Sensor (5G/GH), Component Information…………….1225
B503 – Fuel Temperature Sensor (5G/GH), Component Information…………….1227
B504 – Turbocharger Pressure Sensor (5G/GH), Component Information…………….1229
B505 – Engine Oil Pressure Sensor (5G/GH), Component Information…………….1231
B506 – Fuel Rail Pressure Sensor (5G/GH), Component Information…………….1233
B507 – Turbocharger Air Intake Temperature Sensor, Component Information…………….1235
B508 – Crankshaft Position Sensor (5G/GH), Component Information…………….1237
B509 – Ambient Temperature Sensor (5G/GH), Component Information…………….1239
B510 – Water in Fuel Sensor (5G/GH), Component Information…………….1241
B511 – DPF Differential Pressure Sensor (5G/GH), Component Information…………….1243
B512 – DOC Inlet Temperature Sensor (5G/GH), Component Information…………….1245
B513 – DOC Outlet Temperature Sensor (5G/GH), Component Information…………….1247
B980 – PTO Shaft Output Speed Sensor 1 with IPM (PTO Clutch Side Sensor) (5G/GH), Component Information…………….1249
B981 – Potentiometer for E-SCV 2 Oil Flow Rate (5G/GH), Component Information…………….1251
B982 – Potentiometer for E-SCV 2 Shut-Off Time (5G/GH), Component Information…………….1253
B983 – Potentiometer for E-SCV 4 Oil Flow Rate (5G/GH), Component Information…………….1255
B984 – Potentiometer for E-SCV 3 Oil Flow Rate (5G/GH), Component Information…………….1257
B985 – Potentiometer for E-SCV 1 Oil Flow Rate (5G/GH), Component Information…………….1259
B986 – Potentiometer for E-SCV 1 Shut-Off Time (5G/GH), Component Information…………….1261
B987 – Differential Lock Pressure Switch (Mechanical Transmission) (5G/GH), Component Information…………….1263
B987 – Differential Lock Pressure Switch (Power Reverser Transmission) (5G), Component Information…………….1265
B988 – Front Wheel Drive Pressure Switch (Mechanical Transmission) (5G/GH), Component Information…………….1267
B988 – Front Wheel Drive Pressure Switch (Power Reverser Transmission) (5G), Component Information…………….1269
B989 – PTO Shaft Output Speed Sensor 2 with IPM (Engine Side Sensor) (Mechanical Transmission) (5G/GH), Component Information…………….1271
B989 – PTO Shaft Output Speed Sensor 2 with IPM (Engine Side Sensor) (Power Reverser Transmission) (5G), Component Information…………….1273
B990 – PTO Shaft Output Speed Sensor 1 (Mechanical Transmission) (5G/GH), Component Information…………….1275
B990 – PTO Shaft Output Speed Sensor 1 (Power Reverser Transmission) (5G), Component Information…………….1277
B998 – Hand Throttle Sensor (5G/GH), Component Information…………….1279
B999 – Foot Throttle Potentiometer (Mechanical Transmission) (5G/GH), Component Information…………….1281
B999 – Foot Throttle Potentiometer (Power Reverser Transmission) (5G), Component Information…………….1283
Group 40E: Electrical Components – Lights (5G/GH)…………….1052
E01 – Right-Hand Headlight (5G/GH), Component Information…………….1287
E02 – Left-Hand Headlight (5G/GH), Component Information…………….1289
E03 – Right Hand Clearance (Tractors with Cab) (Mechanical Transmission) (5G/GH), Component Information…………….1291
E03 – Right Hand Clearance (Tractors with Cab) (Power Reverser Transmission) (5G), Component Information…………….1293
E04 – Left-Hand Clearance (Tractors with Cab) (Mechanical Transmission) (5G/GH), Component Information…………….1295
E04 – Left-Hand Clearance (Tractors with Cab) (Power Reverser Transmission) (5G), Component Information…………….1297
E05 – Cigarette Lighter (Mechanical Transmission) (5G/GH), Component Information…………….1299
E05 – Cigarette Lighter (Power Reverser Transmission) (5G/GH), Component Information…………….1301
E07 – Left-Hand H4 Farm Headlight (5G/GH), Component Information…………….1303
E08 – Right-Hand H4 Farm Headlight (5G/GH), Component Information…………….1305
E11/L – Left-Hand Work Light (Rear) (5G/GH), Component Information…………….1307
E11/R – Right-Hand Work Light (Rear) (5G/GH), Component Information…………….1309
E12 – Dome Light (5G/GH), Component Information…………….1311
E13 – Left-Hand Tail Light (5G/GH), Component Information…………….1313
E14 – Right-Hand Tail Light (5G/GH), Component Information…………….1315
E18/1L – Front Left-Hand Work Light (5G/GH), Component Information…………….1317
E18/1R – Front Right-Hand Work Light (5G/GH), Component Information…………….1319
E21 – License Plate Light (ROPS) (5G/GH), Component Information…………….1321
E21 – License Plate Light (5G/GH), Component Information…………….1323
E27 – Beacon Light (5G/GH), Component Information…………….1325
E28 – Heater and Air Conditioning Control Panel Backlighting (5G/GH), Component Information…………….1327
Group 40F: Electrical Components – Fuses, Relays and Diodes (5G/GH)…………….1052
F1-F16 and K1-K7 (Fuse and Relay Box) (5G-GH), Component Information…………….1330
F1-F6 Fuse Box (R.H. Cab Post)…………….1331
F1 – ECU Sensor Fuse (7.5A) (5G/GH), Component Information…………….1335
F1 – Fuse for E-SCV Power Supply (30A) (5G/GH), Component Information…………….1337
F2 – ECU Protection Fuse (20A) (5G/GH), Component Information…………….1339
F3 – ECU Protection Fuse (7.5A) (5G/GH), Component Information…………….1341
F4 – Fuel Heater Fuse (20A) (5G/GH), Component Information…………….1343
F5 – Glow Plug Fuse (60A) (5G/GH), Component Information…………….1345
F6 – ECU Main Protection Fuse (60A) (5G/GH), Component Information…………….1347
F24 – Electronic Hitch Sensing Fuse (EHS II) (60A) (5G/GH), Component Information…………….1349
K1 – ECU Main Relay (5G/GH), Component Information…………….1351
K2 – Fuel Heater Relay (5G/GH), Component Information…………….1353
F3 – Maxi Fuse (70A) (5G/GH), Component Information…………….1355
K01 – Starter Relay (Power Reverser Transmission) (5G), Component Information…………….1357
K01 – Starter Relay (Mechanical Transmission) (5G/GH), Component Information…………….1359
K08 – Flasher Unit (Power Reverser Transmission) (5G), Component Information…………….1361
K08 – Flasher Unit (Mechanical Transmission) (5G/GH), Component Information…………….1363
K18 – Relay of Electronic Hitch Sensing (EHS II) (5G/GH), Component Information…………….1365
K22 – Power Supply Relay (5G/GH), Component Information…………….1367
K23 – Front Work Light Relay (5G/GH), Component Information…………….1369
K24 – Rear Work Light Relay (5G/GH), Component Information…………….1371
K25 – A/C Clutch Relay (5G/GH), Component Information…………….1373
K28 – Fan Speed Relay (5G/GH), Component Information…………….1375
X8.FW11/5A – Fuse Box F1—F6 (E-SCV) (5G/GH)…………….1377
X8.RW11/5A – Relay Box K1—K4 (E-SCV) (5G/GH)…………….1379
Group 40G: Electrical Components – Power Supply and Alternator (5G/GH)…………….1053
G01 – Battery (5G/GH), Component Information…………….1383
G02 – Alternator (5G/GH), Component Information…………….1385
Group 40H: Electrical Components – Monitoring and Signalling Devices (5G/GH)…………….1053
H01 – Horn (5G/GH), Component Information…………….1391
H80 – Trailer Brake Warning Light (Power Reverser Transmission) (5G/GH), Component Information…………….1393
H80 – Trailer Brake Warning Light (Mechanical Transmission) (5G/GH), Component Information…………….1395
Group 40M: Electrical Components – Electrical Motors (5G/GH)…………….1054
M01- Starting Motor (5G/GH), Component Information…………….1401
M02 – Air Conditioning Compressor Clutch (5G/GH), Component Information…………….1405
M03 – Front Wiper Motor (5G/GH), Component Information…………….1407
M04 – Rear Wiper Motor with Switch (5G/GH), Component Information…………….1409
M05 – Pump of Washer System (5G/GH), Component Information…………….1411
M06 – Air Suspension Seat Compressor Motor (Mechanical Transmission) (5G/GH), Component Information…………….1413
M06 – Air Suspension Seat Compressor Motor (Power Reverser Transmission) (5G/GH), Component Information…………….1415
M07- Fan Motor (5G/GH), Component Information…………….1417
Group 40R: Electrical Components – Resistors (5G/GH)…………….1054
R501 – Glow Plug for Cylinder 1 (5G/GH), Component Information…………….1421
R502 – Glow Plug for Cylinder 2 (5G/GH), Component Information…………….1423
R503 – Glow Plug for Cylinder 3 (5G/GH), Component Information…………….1425
R504 – Glow Plug for Cylinder 4 (5G/GH), Component Information…………….1427
R505 – Fuel Filter Heater (5G/GH), Component Information…………….1429
Group 40S: Electrical Components – Switches (5G/GH)…………….1054
S01 – Main Switch (Mechanical Transmission) (5G/GH), Component Information…………….1433
S01 – Main Switch (Power Reverser Transmission) (5G), Component Information…………….1435
S09 – Multi-Function Lever (Mechanical Transmission) (5G-GH), Component Information…………….1437
S09 – Multi-Function Lever (Power Reverser Transmission) (5G-GH), Component Information…………….1440
S11 – H4 Farm Headlight Switch (5G/GH), Component Information…………….1443
S14 – Fan Switch (5G/GH), Component Information…………….1445
S15 – Switch for Windshield Wiper and Pump of Washer System (5G/GH), Component Information…………….1447
S20 – Calibration Switch of Instrument Unit (Power Reverser Transmission) (5G), Component Information…………….1449
S21A – Ground Speed PTO Selector Speed (Mechanical Transmission) (5G/GH), Component Information…………….1451
S21A – Ground Speed PTO Selector Switch (Power Reverser Transmission) (5G), Component Information…………….1453
S21B – Independent Rear PTO Selector Switch (Mechanical Transmission) (5G/GH), Component Information…………….1455
S21B – Independent Rear PTO Selector Switch (Power Reverser Transmission) (5G), Component Information…………….1457
S22 – Differential Lock Switch (Mechanical Transmission) (5G/GH), Component Information…………….1459
S22 – Differential Lock Switch (Power Reverser Transmission) (5G/GH), Component Information…………….1461
S36 – Beacon Light Switch (Power Reverser Transmission) (5G), Component Information…………….1463
S36 – Beacon Light Switch (Mechanical Transmission) (5G/GH), Component Information…………….1465
S40 – Presence Sensor Switch (Power Reverser Transmission) (5G/GH), Component Information…………….1467
S61 – Rear Work Light with Switch (Mechanical Transmission) (5G/GH), Component Information…………….1469
S61 – Rear Work Light with Switch (Power Reverser Transmission) (5G), Component Information…………….1471
Section 249B: Electrical System (5GL) – Component Information…………….1992
Group 40: Summary of Electrical Components and Harnesses (5GL)…………….1992
Summary of Electrical Components (5GL), Summary of References…………….1999
Summary of Wiring Harnesses (5GL), Summary of References…………….2001
Summary of Wiring Diagrams (5GL), Summary of References…………….2002
Summary of Connector Information (5GL), Summary of References…………….2003
Summary of Ground Points (5GL), Summary of References…………….2005
Group 40A: Electrical Components – Assemblies (5GL)…………….1992
A050 – CAN Bus Terminator 1 (Vehicle CAN BUS) (Not Used) (5GL), Component Information…………….2008
A330 – Instrument Unit (5GL), Component Information…………….2010
A540 – Injection Pump (5GL), Component Information…………….2013
A999 – Air Intake Heater Control Unit (5GL), Component Information…………….2015
Group 40B: Electrical Components – Sensors (5GL)…………….1992
B02 – Air Filter Restriction Sensor (5GL), Component Information…………….2019
B03 – Fuel Level Sensor (5GL), Component Information…………….2021
B04 – Engine Oil Pressure Switch (5GL), Component Information…………….2023
B05 – Parking Brake Switch (5GL), Component Information…………….2025
B06 – Transmission Speed Sensor (5GL), Component Information…………….2027
B07A – PTO Switch (540E/1000 rpm) (5GL), Component Information…………….2029
B07B – PTO Switch (540 rpm) (5GL), Component Information…………….2031
B08 – PTO Neutral Start Switch (5GL), Component Information…………….2033
B31 – Trailer Brake Pressure Switch (5GL), Component Information…………….2036
B36 – Neutral Start Switch (without Front PTO) (5GL), Component Information…………….2038
B36 – Neutral Start Switch (with Front PTO) (5GL), Component Information…………….2040
B56 – Coolant Temperature Sensor (5GL), Component Information…………….2042
B69 – Brake Oil Level Sensor (5GL), Component Information…………….2044
B72 – Engine Speed Sensor (5GL), Component Information…………….2046
B112 – Brake Pedal Switches (5GL), Component Information…………….2048
Group 40E: Electrical Components – Lights (5GL)…………….1992
E01 – Right-Hand Headlight (5GL), Component Information…………….2054
E02 – Left-Hand Headlight (5GL), Component Information…………….2056
E03 – Left-Hand Clearance Light (5GL), Component Information…………….2058
E04 – Right-Hand Clearance Light (5GL), Component Information…………….2060
E05 – Cigarette Lighter, Component Information…………….2062
E13 – Left-Hand Tail Light, Component Information (5GL)…………….2064
E14 – Right-Hand Tail Light (5GL), Component Information…………….2066
E21 – License Plate Light (5GL), Component Information…………….2068
E27 – Beacon Light (5GL), Component Information…………….2070
Group 40F: Electrical Components – Fuses, Relays and Diodes (5GL)…………….1993
F1–F16 and K1–K7 (Fuse and Relay Box) (5GL), Component Information…………….2074
F00, K01 and K08 (Fuses and Relays) (5GL), Component Information…………….2076
D4 – Diode (5GL), Component Information…………….2077
F00 – 50 Amp Main Fuse (5GL), Component Information…………….2079
F999 – Air Heater Fuse (5GL), Component Information…………….2081
K01 – Starter Relay (5GL), Component Information…………….2083
K08 – Flasher (5GL), Component Information…………….2085
K10 – Air Heater Relay (5GL), Component Information…………….2087
Group 40G: Electrical Components – Power Supply and Alternator (5GL)…………….1993
G01 – Battery (5GL), Component Information…………….2093
G02 – Alternator (5GL), Component Information…………….2095
Group 40H: Electrical Components – Monitoring and Signaling Devices (5GL)…………….1993
H01 – Horn (5GL), Component Information…………….2099
H01 – Horn (Not Used) (5GL), Component Information…………….2101
H80 – Trailer Brake Valve Warning Light (5GL), Component Information…………….2103
Group 40M: Electrical Components – Electrical Motors (5GL)…………….1993
M01 – Starting Motor (5GL), Component Information…………….2109
M02 – Air Conditioning Compressor Clutch (5GL), Component Information…………….2113
M06 – Air Suspension Seat Compressor Motor (5GL), Component Information…………….2115
Group 40R: Electrical Components – Resistors (5GL)…………….1993
R015 – Intake Air Heater (5GL), Component Information…………….2119
Group 40S: Electrical Components – Switches (5GL)…………….1993
S01 – Main Switch (5GL), Component Information…………….2123
S09 – Multi-Function Lever (5GL), Component Information…………….2125
S20 – Calibration Switch of Instrument Panel (5GL), Component Information…………….2128
S21A – Ground Drive PTO Mode Switch (5GL), Component Information…………….2130
S21B – Independent Rear PTO Mode Switch (5GL), Component Information…………….2132
S22 – Differential Lock Switch (5GL), Component Information…………….2134
S36 – Beacon Light Switch (5GL), Component Information…………….2136
S51 – Calibration Switch of Instrument Unit (5GL), Component Information…………….2138
S61 – Rear Work Light with Switch (5GL), Component Information…………….2140
S63 – Front Wheel Drive Switch (5GL), Component Information…………….2142
S106 – Hazard Warning Light Switch (5GL), Component Information…………….2144
S999 – Front PTO Switch (5GL), Component Information…………….2146
Group 40WA: Wiring Harnesses (5GL)…………….1994
W01B – Main Wiring Harness (5GL)…………….2153
W02B – Engine Wiring Harness (5GL)…………….2157
W05B – Hood Wiring Harness (5GL)…………….2160
W06B – Trailer Brake Valve Wiring Harness (5GL)…………….2161
W12B – Tail Light Wiring Harness (Left and Right) (5GL)…………….2162
W14/1B – License Plate Wiring Harness (5GL)…………….2164
W17B – Beacon Light Wiring Harness (5GL)…………….2165
W18B – Air Intake Heater Wiring Harness (5GL)…………….2166
W21B – Positive Battery Cable (5GL)…………….2168
W22B – Negative Battery Cable (5GL)…………….2169
W33B – Front PTO Main Wiring Harness (5GL)…………….2170
W34B – Front PTO/EH Valve Wiring Harness (5GL)…………….2172
W37B – Multi-Function Lever Wiring Harness (5GL)…………….2173
W42B – Alternator (D+) Wiring Harness (5GL)…………….1994
Group 40WB: Wiring Diagrams (5GL)…………….1994
W01B – Main Wiring Diagram (5GL)…………….2178
W02B – Engine Wiring Diagram (5GL)…………….2181
W05B – Hood Wiring Diagram (5GL)…………….2183
W06B – Trailer Brake Wiring Diagram (5GL)…………….2184
W18B – Air Intake Heater Wiring Diagram (5GL)…………….2185
W33B – Front PTO Main Wiring Diagram (5GL)…………….2186
W37B – Multi-Function Lever Wiring Diagram (5GL)…………….2187
Group 40X: Connector Information (5GL)…………….1994
X1W01B – Connection point between harnesses W01B and W02B (5GL)…………….2190
X1W02B – Connection point between harnesses W02B and W01B (5GL)…………….2192
X1W05B – Connection point between harnesses W05B and W02B (5GL)…………….2194
X1W06B – Connection point between harnesses W06B and W01B (5GL)…………….2196
X1W12LHB – Connection point between harnesses W12LHB and W01B (5GL)…………….2198
X1W12RHB – Connection point between harnesses W12RHB and W01B (5GL)…………….2200
X1W17B – Connection point between harnesses W01B and W17B (5GL)…………….2202
X1W18/1B – Connection point between harnesses W18/1B and W01B (5GL)…………….2204
X1W21B – Connection to the Battery G01 (5GL)…………….2206
X1W22B – Connection to the Battery G01 (5GL)…………….2208
X1W33B – Connection point between harnesses W33B and W01B (5GL)…………….2210
X2W02B – Connection point between harnesses W02B and W05B (5GL)…………….2212
X2W14/1B – Connection point between harnesses W14/1B and W14/2B (5GL)…………….2214
X2W21B – Connection to the Starting Motor M01 (5GL)…………….2216
X2W22B – Connection to the Ground GNDX2W22 (5GL)…………….2218
X2W42B – Connection point between harnesses W02B and W42B (5GL)…………….2220
X3W33B – Connection point between harnesses W33B and W01B (5GL)…………….2222
X4W02B – Connection point between harnesses W02B and W42B (5GL)…………….2224
X4W33B – Connection point between harnesses W33B and W34B (5GL)…………….2226
X5W01B – Connection to Diode D4 (5GL)…………….2228
X5W34B – Connection point between harnesses W34B and W33B (5GL)…………….2230
X6W33B – Connection point between harnesses W33B and W01B (5GL)…………….2232
X10W01B – Connection point between harnesses W01B and W12LHB (5GL)…………….2234
X10W02B – Connection point between harnesses W02B and W11/4B (5GL)…………….2236
X11W01B – Connection point between harnesses W01B and W14/1B (5GL)…………….2238
X12W01B – Connection point between harnesses W01B and W12RHB (5GL)…………….2240
X13W01B – Connection point between harness W01B and 7-terminal power outlet socket (not used) (5GL)…………….2242
X32W01B – Connection point between harness W01B and diagnostic socket (5GL)…………….2244
X33W01B – Connection point between harnesses W01B and W18/1B (5GL)…………….2246
X39W01B – Connection point between harnesses W01B and JW01B (5GL)…………….2248
X39.JW01B – Connection point between harnesses W01B and Light Wiring Jumper Harness (5GL)…………….2250
X42.1W01B – Connection point between harness W01B and 3-terminal power outlet socket (not used) (5GL)…………….2252
X42.2W01B – Connection point between harness W01B and 3-terminal power outlet socket (not used) (5GL)…………….2254
X42.3W01B – Connection point between harness W01B and 3-terminal power outlet socket (not used) (5GL)…………….2256
X44W01B – Connection point between harnesses W01B and W17B (5GL)…………….2258
X45.1W01B – Connection point between harnesses W01B and W37B (5GL)…………….2260
X45.2W01B – Connection point between harnesses W01B and W37B (5GL)…………….2262
X49W01B – Connection point between harnesses W01B and W09B (5GL)…………….2264
X51W01B – Connection point to EHS II Control Unit (Not Used) (5GL)…………….2266
X53W01B – Connection point between harnesses W01B and Cab Wiring Harness (not used) (5GL)…………….2268
X55W01B – Connection point between harnesses W01B and W33B (with front PTO) (5GL)…………….2270
X58W01B – Connection to HI-LO gear lever switch wiring harness W25 (not used) (5GL)…………….2272
X62W01B – Connection point between harnesses W01B and W33B (5GL)…………….2274
X65W01B – Connection point between harnesses W01B and W06B (5GL)…………….2276
X68W01B – Connection point between harnesses W01B and W33B (5GL)…………….2278
X69W01B – Connection point between harnesses W01B and EH SCV Wiring Harness (5GL)…………….2280
X70W01B – Connection point between harness W01B and HI-LO valve (not used) (5GL)…………….2282
Group 40XGND: Ground Points (5GL)…………….1996
GNDX13W02B – Ground Point…………….2286
GNDX2W22B – Ground Point…………….2288
GNDX67W01B – Ground Point…………….2289
Group 40Y: Electrical Components – Solenoids and Solenoid Valves (5GL)…………….1996
Y03 – Front Wheel Drive Solenoid Valve (5GL), Component Information…………….2293
Y05 – Differential Lock Solenoid Valve (5GL), Component Information…………….2295
Y31 – Trailer Brake Solenoid Valve (5GL), Component Information…………….2297
Y999 – Front PTO EH Valve Solenoid (5GL), Component Information…………….2299
Section 249C: Electrical System (5G VNF) – Component Information…………….2301
Group 05: Summary of Electrical Components and Harnesses (5G VNF)…………….2301
Summary of Electrical Components (5G VNF), Summary of References…………….2315
Summary of Wiring Harnesses (5G VNF), Summary of References…………….2319
Summary of Wiring Diagrams (5G VNF), Summary of References…………….2320
Summary of Connector Information (5G VNF), Summary of References…………….2321
Summary of Ground Points (5G VNF), Summary of References…………….2324
Group 40A: Electrical Components – Assemblies (5G VNF)…………….2301
A005 – Right Speaker (5G VNF), Component Information…………….2327
A006 – Left Speaker (5G VNF), Component Information…………….2329
A010 – Radio (5G VNF), Component Information…………….2331
A050 – CAN Bus Terminator (Vehicle CAN BUS) (5G VNF), Component Information…………….2333
A051 – CAN Bus Terminator (E-SCV CAN Bus) (5G VNF), Component Information…………….2335
A210 – EHS Control Unit (5G VNF), Component Information…………….2337
A320 – Transmission Control Unit (5G VNF), Component Information…………….2340
A330 – Instrument Unit (5G VNF), Component Information…………….2344
A540 – Fuel Injection Pump (5G VNF), Component Information…………….2347
A997 – E-SCV Control Unit (TVC) (5G VNF), Component Information…………….2349
A999 – Intake Air Heater Control Unit (5G VNF), Component Information…………….2354
Group 40B: Electrical Components – Sensors (5G VNF)…………….2301
B02 – Air Filter Restriction Sensor (5G VNF), Component Information…………….2358
B03 – Fuel Level Sensor (5G VNF), Component Information…………….2360
B04 – Engine Oil Pressure Switch (5G VNF), Component Information…………….2362
B05 – Park Brake Switch (5G VNF), Component Information…………….2364
B06 – Transmission Speed Sensor (5G VNF), Component Information…………….2366
B07/1 – PTO Switch (540 rpm) (5G VNF), Component Information…………….2368
B07/2 – PTO Switch (540E rpm) (5G VNF), Component Information…………….2370
B08 – PTO Neutral Start Switch (5G VNF), Component Information…………….2372
B31 – Trailer Brake Pressure Switch (5G VNF), Component Information…………….2374
B36/1 – Neutral Start Switch (5G VNF), Component Information…………….2376
B36/2 – Neutral Start Switch (5G VNF), Component Information…………….2378
B56 – Coolant Temperature Sensor (5G VNF), Component Information…………….2380
B60 – Transmission Oil Temperature Sensor (5G VNF), Component Information…………….2382
B63 – Hi/Lo Switch on Transmission (5G VNF), Component Information…………….2384
B64 – Reverse Drive Lever Switch (5G VNF), Component Information…………….2386
B65 – Clutch Pedal Potentiometer (5G VNF), Component Information…………….2388
B69 – Brake Oil Level Sensor (5G VNF), Component Information…………….2390
B72 – Engine Speed Sensor (5G VNF), Component Information…………….2392
B73 – Transmission Oil Filter Restriction Sensor (5G VNF), Component Information…………….2394
B104 – Transmission Top Shaft Speed Sensor (5G VNF), Component Information…………….2396
B112/1 – Right Brake Pedal Switch (5G VNF), Component Information…………….2398
B112/2 – Left Brake Pedal Switch (5G VNF), Component Information…………….2400
B150 – Thermostat (5G VNF), Component Information…………….2402
B151 – Fan Resistor (5G VNF), Component Information…………….2404
B200 – Hitch Position Sensor (5G VNF), Component Information…………….2406
B201 – Draft Sensor (5G VNF), Component Information…………….2408
B300 – Forward High Clutch Pressure Sensor (5G VNF), Component Information…………….2410
B301 – Forward Low Clutch Pressure Sensor (5G VNF), Component Information…………….2412
B302 – Reverse Clutch Pressure Sensor (5G VNF), Component Information…………….2414
B303 – Transmission Oil Pressure Switch (5G VNF), Component Information…………….2416
B304 – Refrigerant Pressure Sensor (5G VNF), Component Information…………….2418
B350 – PTO Pressure Sensor (5G VNF), Component Information…………….2420
B979 – Fuel Level Sensor (Auxiliary Fuel Tank) (5G VNF), Component Information…………….2422
B981 – Potentiometer for E-SCV 2 Oil Flow Rate (5G VNF), Component Information…………….2424
B982 – Potentiometer for E-SCV 2 Shut-Off Time (5G VNF), Component Information…………….2426
B983 – Potentiometer for E-SCV 4 Oil Flow Rate (5G VNF), Component Information…………….2428
B984 – Potentiometer for E-SCV 3 Oil Flow Rate (5G VNF), Component Information…………….2430
B985 – Potentiometer for E-SCV 1 Oil Flow Rate (5G VNF), Component Information…………….2432
B986 – Potentiometer for E-SCV 1 Shut-Off Time (5G VNF), Component Information…………….2434
Group 40E: Electrical Components – Lights (5G VNF)…………….2302
E01 – Right Headlight (5G VNF), Component Information…………….2438
E02 – Left Headlight (5G VNF), Component Information…………….2440
E03 – Right Clearance Light (5G VNF), Component Information…………….2442
E04 – Left Clearance Light (5G VNF), Component Information…………….2444
E11/1L – Left Rear Worklight (5G VNF), Component Information…………….2446
E11/1R – Right Rear Worklight (5G VNF), Component Information…………….2448
E12 – Dome Light (5G VNF), Component Information…………….2450
E13 – Left Tail Light (5G VNF), Component Information…………….2452
E14 – Right Tail Light (5G VNF), Component Information…………….2454
E18/1L – Left Front Work Light (5G VNF), Component Information…………….2456
E18/1R – Right Front Work Light (5G VNF), Component Information…………….2458
E21 – License Plate Light (OOS) (5G VNF), Component Information…………….2460
E21 – License Plate Light (Cab) (5G VNF), Component Information…………….2462
E27 – Beacon Light (ROPS) (5G VNF), Component Information…………….2464
E27 – Beacon Light (Cab) (5G VNF), Component Information…………….2466
E28 – Heater and Air-Conditioning Control Panel Backlighting (5G VNF), Component Information…………….2468
Group 40F: Electrical Components – Fuses, Relays and Diodes (5G VNF)…………….2303
X6W01C – Fuse Box F1—F16 (Mechanical Transmission) (5G VNF)…………….2472
X6W01C – Fuse Box F1—F16 (Power Reverser Transmission) (5G VNF)…………….2474
X4W04C – Fuse Box F1—F6 (Cab Wiring Harness) (5G VNF)…………….2476
X8.FW41C – Fuse Box F1—F6 (E-SCV) (5G VNF)…………….2478
X5.1W01C – Diodes D4—D6 (5G VNF), Component Information…………….2480
X21.1W01C – Diodes D7—D9 (5G VNF), Component Information…………….2483
X6.1W01C – Relay Box K1—K7 (Mechanical Transmission) (5G VNF)…………….2485
X6.1W01C – Relay Box K1—K7 (Power Reverser Transmission) (5G VNF)…………….2487
X8.RW41C – Relay Box K1—K4 (E-SCV) (5G VNF)…………….2489
F00 – 50 Amp Main Fuse (5G VNF), Component Information…………….2491
F3 – 70 Amp Main Fuse (5G VNF), Component Information…………….2493
F24 – Electronic Hitch Sensing Fuse (EHS II) (5G VNF), Component Information…………….2495
F25 – Fan Motor I Fuse (5G VNF), Component Information…………….2497
F26 – Fan Motor I and II Fuse (5G VNF), Component Information…………….2499
F999 – Intake Air Heater Fuse (5G VNF), Component Information…………….2501
K01 – Starter Motor Relay (5G VNF), Component Information…………….2503
K08 – Turn-Signal Relay (5G VNF), Component Information…………….2505
K10 – Intake Air Heater Relay (5G VNF), Component Information…………….2507
K15 – Declutch Relay (5G VNF), Component Information…………….2511
K18 – Relay of Electronic Hitch Sensing (EHS II) (5G VNF), Component Information…………….2513
K22 – Power Supply Relay (5G VNF), Component Information…………….2515
K23 – Front Work Light Relay (5G VNF), Component Information…………….2517
K24 – Rear Work Light Relay (5G VNF), Component Information…………….2519
K25 – Air-Conditioning Compressor Clutch Relay (5G VNF), Component Information…………….2521
K28 – Fan Speed Relay (5G VNF), Component Information…………….2523
K29 – Relay for Air-Conditioning Condenser Fan Motor I (5G VNF), Component Information…………….2525
K30 – Relay for Air-Conditioning Condenser Fan Motor I and II (5G VNF), Component Information…………….2527
K31 – Relay for Air-Conditioning Condenser Fan Motor I and II (5G VNF), Component Information…………….2529
K999 – Fuel Pump Relay (Auxiliary Fuel Tank) (5G VNF), Component Information…………….2531
Group 40G: Electrical Components – Power Supply and Alternator (5G VNF)…………….2304
G01 – Battery (5G VNF), Component Information…………….2535
G02 – Alternator (5G VNF), Component Information…………….2537
Group 40H: Electrical Components – Monitoring and Signaling Devices (5G VNF)…………….2304
H01 – Horn (5G VNF), Component Information…………….2542
H80 – Trailer Brake Warning Light (5G VNF), Component Information…………….2544
Group 40M: Electrical Components – Electrical Motors (5G VNF)…………….2304
M01 – Starting Motor (5G VNF), Component Information…………….2550
M02 – Air Conditioning Compressor Clutch (5G VNF), Component Information…………….2554
M03 – Windshield Wiper Motor (5G VNF), Component Information…………….2556
M04 – Rear Wiper Motor with Switch (5G VNF), Component Information…………….2558
M05 – Pump of Washer System (5G VNF), Component Information…………….2560
M06 – Air Suspension Seat Compressor Motor (5G VNF), Component Information…………….2562
M07 – Cab Blower Motor (5G VNF), Component Information…………….2564
M08 – Air-Conditioning Condenser Fan Motor I (5G VNF), Component Information…………….2566
M09 – Air-Conditioning Condenser Fan Motor II (5G VNF), Component Information…………….2568
Group 40R: Electrical Components – Resistors (5G VNF)…………….2304
R015 – Heating Element of Intake Air Heater (5G VNF), Component Information…………….2572
Group 40S: Electrical Components – Switches (5G VNF)…………….2304
S01 – Main Switch (5G VNF), Component Information…………….2576
S09 – Multi-Function Lever (5G VNF), Component Information…………….2578
S14 – Fan Switch (5G VNF), Component Information…………….2580
S15 – Switch for Windshield Wiper and Pump of Washer System (5G VNF), Component Information…………….2582
S20 – Calibration Switch of Instrument Unit (5G VNF), Component Information…………….2584
S21/1 – Ground Drive PTO Selector Switch (5G VNF), Component Information…………….2586
S21/2 – Independent Rear PTO Selector Switch (5G VNF), Component Information…………….2588
S22 – Differential Lock Switch (5G VNF), Component Information…………….2590
S36 – Beacon Light Switch (5G VNF), Component Information…………….2592
S50 – Calibration Switch of Instrument Unit (5G VNF), Component Information…………….2594
S51 – Calibration Switch of Instrument Unit (5G VNF), Component Information…………….2596
S61 – Rear Worklight Switch (5G VNF), Component Information…………….2598
S63 – Front-Wheel Drive Switch (5G VNF), Component Information…………….2600
S68/1A – Hitch Remote Control Switch (Right Side Up) (5G VNF), Component Information…………….2602
S68/1B – Hitch Remote Control Switch (Right Side Down) (5G VNF), Component Information…………….2604
S68/2A – Hitch Remote Control Switch (Left Side Up) (5G VNF), Component Information…………….2606
S68/2B – Hitch Remote Control Switch (Left Side Down) (5G VNF), Component Information…………….2608
S72 – Clutch Pedal Switch (5G VNF), Component Information…………….2610
S92/1 – Front Worklight Switch (5G VNF), Component Information…………….2612
S92/2 – Rear Worklight Switch (5G VNF), Component Information…………….2614
S93 – Heating and Air-Conditioning System Switch (5G VNF), Component Information…………….2616
S106 – Hazard Warning Light Switch (5G VNF), Component Information…………….2618
S200 – Raise Limit Switch (5G VNF), Component Information…………….2620
S201 – Raise/Lower Switch (5G VNF), Component Information…………….2622
S300-1 – Hi/Lo Switch (Hi) (5G VNF), Component Information…………….2624
S300-2 – Hi/Lo Switch (Lo) (5G VNF), Component Information…………….2626
S300-3 – Declutch Switch on Range-Shift Lever (5G VNF), Component Information…………….2628
S350 – PTO Switch (5G VNF), Component Information…………….2630
S987 – Implement Side Sway Disable Switch (5G VNF), Component Information…………….2632
S988 – Implement Lateral Positioning Switch (5G VNF), Component Information…………….2634
S989 – Implement Tilt Angle Switch (5G VNF), Component Information…………….2636
S995 – E-SCV Transport Lock Switch (5G VNF), Component Information…………….2638
S996 – E-SCV 1 Control Lever (5G VNF), Component Information…………….2641
S997 – E-SCV 2 Control Lever (5G VNF), Component Information…………….2643
S998 – Multi-Function Lever (E-SCV) (5G VNF), Component Information…………….2645
S999 – Front PTO Switch (5G VNF), Component Information…………….2647
Group 40WA: Wiring Harnesses (5G VNF)…………….2305
W01C/1 (W12C, W14C, W44C) – Main Wiring Harness (Mechanical Transmission) (5G VNF)…………….2653
W01C/2 (W12C, W14C, W44C) – Main Wiring Harness (Power Reverser Transmission) (5G VNF)…………….2656
W02C (W42C) – Engine Wiring Harness (5G VNF)…………….2660
W04C (W19C, W35C) – Cab Wiring Harness (5G VNF)…………….2663
W05C – Hood Wiring Harness (5G VNF)…………….2666
W06C – Wiring Harness for Trailer Brake Valve (5G VNF)…………….2667
W09C – Wiring Harness for Hydraulically Adjustable Stabilizer Bar and Lift Link (5G VNF)…………….2668
W11C – EHS Wiring Harness (5G VNF)…………….2670
W17C – Beacon Light Wiring Harness (2 Post ROPS) (5G VNF)…………….2672
W18C – Wiring Harness for Electrical Starting Aid (5G VNF)…………….2673
W26C – Wiring Harness for Auxiliary Fuel Tank (5G VNF)…………….2674
W33C and W34C – Wiring Harness for Front PTO (5G VNF)…………….2675
W36C – Wiring Harness for Air-Conditioning System (5G VNF)…………….2676
W37C – Wiring Harness for Multi-Function Lever (5G VNF)…………….2678
W40C – Wiring Harness for E-SCV Valves and Sensors (5G VNF)…………….2679
W41C – Wiring Harness for E-SCV Control Unit (5G VNF)…………….2681
W43C – Wiring Harness for Air-Conditioning Condenser (5G VNF)…………….2682
Group 40WB: Wiring Diagrams (5G VNF)…………….2306
W01C/1 (W12C, W14C, W17C, W44C) – Main Wiring Diagram (Mechanical Transmission) (5G VNF)…………….2687
W01C/2 (W12C, W14C, W17C, W44C) – Main Wiring Diagram (Power Reverser Transmission) (5G VNF)…………….2690
W02C (W42C) – Engine Wiring Diagram (5G VNF)…………….2693
W04C (W19, W35C) – Cab Wiring Diagram (5G VNF)…………….2695
W05C – Hood Wiring Diagram (5G VNF)…………….2697
W06C – Wiring Diagram for Trailer Brake Valve (5G VNF)…………….2698
W09C – Wiring Diagram for Hydraulic Sway, Alignment and Slope Adjustment (Rear Hitch) (5G VNF)…………….2699
W11C – EHS Wiring Diagram (5G VNF)…………….2701
W18C – Wiring Diagram for Electrical Starting Aid (5G VNF)…………….2705
W26C – Wiring Diagram for Auxiliary Fuel Tank (5G VNF)…………….2707
W33C and W34C – Wiring Diagram for Front PTO (5G VNF)…………….2708
W36C – Wiring Diagram for Air-Conditioning System (5G VNF)…………….2709
W37C – Wiring Diagram for Multi-Function Lever (5G VNF)…………….2711
W40C – Wiring Diagram for E-SCV Valves and Sensors (5G VNF)…………….2712
W41C – Wiring Diagram E-SCV Control Unit (5G VNF)…………….2713
W43C – Wiring Diagram Air-Conditioning Condenser (5G VNF)…………….2714
Group 40X: Connector Information (5G VNF)…………….2307
X1W01C – Connection point between harnesses W01C and W02C (5G VNF)…………….2717
X1W02C – Connection point between harnesses W02C and W01C (5G VNF)…………….2719
X1W05C – Connection point between harnesses W05C and W02C (5G VNF)…………….2721
X1W06C – Connection point between harnesses W06C and W01C (5G VNF)…………….2723
X1W11/2C – Connection point between harnesses W11/2C and W11/1C (5G VNF)…………….2725
Section 250A: Drive Train (without Transmission)…………….2944
Group 20A: Front-Wheel Drive – Theory of Operation…………….2944
Front-Wheel Drive – Theory of Operation, Summary of References…………….2947
Front-Wheel Drive Operation – Electro-Hydraulically Shifted…………….2948
Group 20B: Differential – Theory of Operation…………….2944
Differential – Theory of Operation, Summary of References…………….2953
Differential Power Flow…………….2954
Differential Lock Operation (Hydraulic Version)…………….2956
Group 20C: Final Drives – Theory of Operation…………….2944
Final Drives – Theory of Operation, Summary of References…………….2959
Final Drive Operation…………….2960
Final Drive Operation (HighCrop Tractor)…………….2962
Group 20D: Rear PTO – Theory of Operation…………….2944
Rear PTO – Theory of Operation, Summary of References…………….2965
Operation of PTO Dry Clutch…………….2966
Electro-Hydraulic Rear PTO – Description…………….2967
Electro-Hydraulic Rear PTO – PTO Solenoid Valves…………….2969
Electro-Hydraulic Rear PTO – PTO Clutch and PTO Brake…………….2974
Ground Drive PTO and Electro-Hydraulic Rear PTO – Power Flow…………….2977
540/540E and 540/1000 rpm Rear PTO Operation…………….2979
Ground Drive and Independent Rear PTO Operation…………….2981
Group 40: Drive Train (without Transmission) – Component Information…………….2944
Drive Systems – Component Location, Summary of References…………….2984
Drive Systems – Component Location Information…………….3328
Front-Wheel Drive Components – Electro-Hydraulically Shifted (5G-5GH Models)…………….2986
Differential Components…………….2988
Differential Lock Components (Hydraulic Version)…………….2989
Final Drive Components…………….2990
Final Drive Components (HighCrop Tractor)…………….2991
Hydraulic PTO Clutch Components…………….3068
Rear PTO Components—540 and 540E/1000 RPM…………….2994
Ground Drive PTO Components…………….2995
Group 50: Drive Train (without transmisson) – Diagnostic Tests/Adjustments…………….2945
Drive Systems – Tests and Adjustments, Summary of References…………….2997
Connect SensoControl Test Equipment…………….3127
Drive Systems – Tests and Adjustments, Test Ports and Test Equipment…………….2999
Pressure Relief Valve – Pressure Check…………….3001
Hydraulic Front-Wheel Drive Clutch – Pressure Check…………….3003
Hydraulic Differential Lock – Pressure Check…………….3005
Hydraulic Rear PTO Clutch – Pressure Check…………….3007
Hydraulic Rear PTO Brake – Pressure Check…………….3009
Lube Oil Pressure Check…………….3010
Drive Systems – Tests and Adjustments, Test Result Table…………….3012
Front-Wheel Drive Lever Will Not Stay in Off Position…………….3013
Problem with Noises when Driving with Front-Wheel Drive Engaged…………….2945
Unusual Vibrations when Driving with Front-Wheel Drive Engaged…………….2945
Excessive Differential Noise…………….3023
Differential Does Not Work…………….3024
Differential Lock Does Not Work…………….3025
Differential Chatters…………….3026
Axle Noise…………….3027
Axle Shaft Will Not Turn…………….3028
PTO Noisy…………….3029
PTO Will Not Operate…………….3030
PTO Will Not Stay Engaged…………….3032
PTO Clutch Lever Adjustment…………….3033
Section 250B: Mechanical Transmissions…………….3035
Group 20: Mechanical Transmissions – Theory of Operation…………….3035
Summary of References – Theory of Operation…………….3420
Theory of Operation Information…………….3421
Clutch Operation…………….3040
Transmission Power Flow – Mechanical High-Low…………….3047
Transmission Power Flow – Electrohydraulic High-Low…………….3049
Transmission Synchronizer Operation – Mechanical High-Low…………….3051
Clutch Operation – Electrohydraulic High-Low…………….3053
Transmission Power Flow – Reverse Speed Gears…………….3055
Transmission Power Flow – Forward Speed Gears…………….3057
Transmission Synchronizer Operation – Reverse, Forward, 1st, 2nd, 3rd and 4th Gear…………….3059
Transmission Power Flow – Range Shift…………….3061
Group 40: Mechanical Transmissions – Component Information…………….3035
Summary of References – Component Location…………….3327
Component Location Information…………….3328
Mechanical Power Train Components…………….3066
Clutch Components…………….3068
Transmission Components — 12/12-Speed Transmission…………….3070
Transmission Components — 24/24-Speed Transmission (Mechanical High-Low Version)…………….3072
Transmission Components — 24/24-Speed Transmission (Hydraulic High-Low Version)…………….3074
Group 50: Drive Train (without transmisson) – Diagnostic Tests/Adjustments…………….3035
Summary of References – Diagnosis, Tests and Adjustments…………….3190
Specifications…………….3350
Diagnostic Information…………….3450
Jerky or Rough Transmission…………….3080
Major Transmission Check…………….3081
Low Transmission Oil Level (Excessive Oil Leakage)…………….3086
Gears Clash, Shift Hard, or Will Not Engage…………….3087
Two Speeds Engage Together…………….3088
Transmission Will Not Stay in Gear…………….3089
Transmission Noisy…………….3090
Clutch Pedal Free Play Adjustment…………….3091
Section 250C: Power Reverser Transmission (24/12)…………….3094
Group 10: Power Reverser Transmission (24-12) – Operational Checks…………….3094
Transmission – Introductory Checks…………….3099
24/12-Speed Transmission – Operational Checks…………….3103
Group 20: Power Reverser Transmission (24-12) – Theory of Operation…………….3094
24/12-Speed Transmission – Theory of Operation, Summary of References…………….3109
24/12-Speed Transmission – Theory of Operation, Layout of Valves and Components…………….3110
24/12-Speed Transmission – Theory of Operation, Power Flow…………….3112
24/12-Speed Transmission – Theory of Operation, Hydraulic Schematic…………….3115
24/12-Speed Transmission – Theory of Operation, EHM III Valves…………….3117
24/12-Speed Transmission – Theory of Operation, Additional Valves…………….3119
24/12-Speed Transmission – Theory of Operation, Cooling and Lube Circuit…………….3120
24/12-Speed Transmission – Theory of Operation, Air Pump…………….3122
Group 50: Power Reverser Transmission (24-12) – Diagnostic Tests/Adjustments…………….3094
24/12-Speed Transmission, Tests and Adjustments – Summary of References…………….3124
Hydraulic System – Safety Measures for Hydraulic Checks…………….3125
Connect SensoControl Test Equipment…………….3127
24/12-Speed Transmission, Tests and Adjustments – Test Ports…………….3128
24/12-Speed Transmission, Tests and Adjustments – System Check…………….3131
24/12-Speed Transmission, Tests and Adjustments – EHM III Circuit Pressure Check…………….3137
24/12-Speed Transmission, Tests and Adjustments – EHM III Pressure Relief Valve Check…………….3139
24/12-Speed Transmission, Tests and Adjustments – Forward High Clutch Pressure Check…………….3140
24/12-Speed Transmission, Tests and Adjustments – Forward Low Clutch Pressure Check…………….3142
24/12-Speed Transmission, Tests and Adjustments – Reverse Clutch Pressure Check…………….3144
24/12-Speed Transmission, Tests and Adjustments – Oil Cooler Flow Test…………….3146
24/12-Speed Transmission, Tests and Adjustments – Lube Relief Valve Check…………….3148
24/12-Speed Transmission, Tests and Adjustments – Oil Cooler Bypass Valve Check…………….3150
24/12-Speed Transmission, Tests and Adjustments – Clutch Leakage Check…………….3152
24/12-Speed Transmission, Tests and Adjustments – Test Result Table…………….3155
Hydraulic System – Heat Up the Hydraulic Oil…………….3157
Section 260: Steering and Brake Systems…………….3158
Group 20: Steering and Brake Systems – Theory of Operation…………….3158
Summary of References – Theory of Operation…………….3420
General Information…………….3434
Steering System Operation…………….3163
Steering Valve Operation – Neutral and Manual Turning…………….3166
Steering Valve Operation – Power Turning…………….3169
Brake System Operation…………….3171
Brake Cylinder Operation – Brake Pedal Depressed…………….3173
Brake Cylinder Operation – Brake Pedal Released…………….3174
Trailer Brake System Operation…………….3175
Trailer Brake Valve Operation…………….3177
Group 40: Steering and Brake Systems – Component Information…………….3158
Summary of References – Component Location…………….3327
Component Location Information…………….3328
Steering System Components…………….3183
Brake System Components…………….3186
Trailer Brake System Components…………….3188
Group 50: Steering and Brake Systems – Diagnostic Tests/Adjustments…………….3158
Summary of References – Diagnosis, Tests and Adjustments…………….3190
Essential Tools…………….3191
Specifications…………….3350
Diagnostic Information…………….3450
Steering System Operational Check…………….3195
Steering System Diagnosis…………….3196
Steering Sluggish or Loss of Steering…………….3201
Brake System Operational Check…………….3202
Brake System Diagnosis…………….3203
Excessive Brake Pedal Leak-Down…………….3205
Excessive Brake Chatter…………….3206
Trailer Brake Valve Operational Check…………….3207
Trailer Brake Valve Troubleshooting…………….3208
Steering Pump Flow Test…………….3376
Steering Valve Relief Test…………….3213
Steering Cylinder Leakage Test…………….3215
Steering Valve Leakage Test…………….3216
Toe-In Check and Adjustment…………….3218
Toe-In Check and Adjustment (Front-Wheel Drive Axle)…………….3221
Steering Stop Adjustment…………….3223
Steering Stop Adjustment (Front-Wheel Drive Axle)…………….3225
Brake Pedal Adjustment…………….3227
Park Brake Adjustment…………….3229
Bleed Brake System…………….3231
Section 270: Hydraulic System…………….3234
Group 20: Hydraulic System – Theory of Operation…………….3234
Summary of References—Theory of Operation…………….3238
General Information…………….3434
Hydraulic System Operation…………….3240
Oil Cooler Operation…………….3243
Hydraulic Filter Operation…………….3245
Hydraulic Pump Operation…………….3246
Hydraulic System Operation – Steering and Front-Wheel Drive (12/12-Speed Transmission)…………….3248
Hydraulic System Operation – Steering and Front-Wheel Drive with Mechanical Hi-Lo (24/24-Speed Transmission)…………….3250
Hydraulic System Operation – Steering and Front-Wheel Drive with Hydraulic Hi-Lo (24/24-Speed Transmission)…………….3253
Hydraulic System Operation – Steering and Front-Wheel Drive with Power Reverser (24/12 – Speed Transmission)…………….3336
Rockshaft Control Valve Operation – Neutral Position…………….3260
Rockshaft Control Valve Operation – Raise Position…………….3262
Rockshaft Control Valve Operation – Lower Position…………….3264
Rockshaft Draft – Sensing Operation…………….3266
Electro-Hydraulic Hitch Sensing II Operation – Neutral Phase…………….3268
Electro-Hydraulic Hitch Sensing II Operation – Loading Phase…………….3270
Electro-Hydraulic Hitch Sensing II Operation – Discharge Phase…………….3272
Double-Acting Selective Control Valve – Neutral Position…………….3274
Double-Acting Selective Control Valve – Position 1…………….3276
Double-Acting Selective Control Valve – Position 2…………….3278
Double-Acting Selective Control Valve – Float Position…………….3280
Double-Acting Selective Control Valve – DUAL ACTING/SINGLE CONVERSION…………….3282
Double-Acting Sleeve Coupler Operation…………….3284
Flow Divider Valve without Solenoid Valve Operation…………….3286
Electro-Hydraulic Selective Control Valve…………….3288
Three-Point hitch leveling system (5GV, 5GN Three-Point hitch leveling system (5GV, 5GN & 5GF){pgNO}3234 5GF)…………….3300
Group 30: Hydraulic System – Schematics…………….3234
Summary of References – Hydraulic System Schematics…………….3309
Hydraulic Symbols…………….3310
12/12-Speed Transmission – Steering System without Front-Wheel Drive…………….3313
24/24-Speed Transmission – Steering System and Front-Wheel Drive with Mechanical Hi-Lo…………….3314
24/24-Speed Transmission – Steering System and Front-Wheel Drive with Electro-Hydraulic Hi-Lo…………….3315
Base transmission hydraulic scheme Power Reverser 24+12…………….3235
SCV and Hitch with Flow Divider…………….3318
Group 40: Hydraulic System – Component Information…………….3235
Summary of References – Component Location…………….3327
Component Location Information…………….3328
Hydraulic System Components – Steering and Front-Wheel Drive (12/12-Speed Transmission)…………….3329
Hydraulic System Components – Steering and Front-Wheel Drive with Mechanical Hi-Lo (24/24-Speed Transmission)…………….3331
Hydraulic System Components – Steering and Front-Wheel Drive with Hydraulic Hi-Lo (24/24-Speed Transmission)…………….3333
Hydraulic System Operation – Steering and Front-Wheel Drive with Power Reverser (24/12 – Speed Transmission)…………….3336
Hitch Control Lever Linkage Components…………….3340
SCVs with Levers and Flow Divider Valve…………….3342
Group 50: Hydraulic System – Diagnostic Tests/Adjustments…………….3235
Summary of References – Diagnostic Tests/Adjustments…………….3347
Safety Precautions…………….3349
Specifications…………….3350
Diagnostic Information…………….3450
Hydraulic Oil Warm-Up Procedure…………….3352
Hydraulic System Diagnosis…………….3353
Insufficient Pump Delivery…………….3359
Hydraulic Functions Too Slow…………….3360
Excessive Pump Pressure…………….3361
Slow Hydraulic Pump Response…………….3362
Excessive Pump Noise During Operation…………….3363
Rockshaft Does Not Lift or Lifts Slowly…………….3364
Rockshaft Does Not Lower or Lowers Slowly…………….3365
Neutral Position Unstable, Rockshaft Drops After Engine Shut-Down…………….3366
SCV Control Lever Does Not Return to Neutral Position…………….3367
SCV Does Not Return to Neutral Position – SCV With Detent Position…………….3368
SCV Does Not Remain In Detent Position – SCV With Detent Position…………….3369
Remote Cylinder Does Not Extend or Retract…………….3370
Remote Cylinder Settles Under Load…………….3371
Remote Cylinder Operates Too Fast or Too Slow…………….3372
Hydraulic System Tests – with SCV…………….3373
Hydraulic System Tests…………….3374
Transmission Hydraulic System…………….3375
Pump Flow Test…………….3376
SCV Relief Valve Test…………….3378
SCV Leakage Test…………….3379
EHS II Leakage Test…………….3380
E-SCV Hydraulic System Test…………….3381
Rockshaft Lift Cycle Test…………….3387
Rockshaft Control Lever Friction Adjustment…………….3389
Hitch Sensitivity Adjustment…………….3390
Rockshaft Position Control Adjustment…………….3392
Rockshaft Draft Control Adjustment…………….3394
Electro-Hydraulic Hitch Sensing II Adjustment – Draft Sensor Rod Adjustment…………….3396
Rockshaft Safety and Relief Valve Adjustment…………….3398
Electro-Hydraulic Hitch Sensing Adjustment – Electro-Hydraulic Valve Adjustment…………….3400
Electro-Hydraulic Hitch Sensing Adjustment – Backstop Limit Switch Adjustment…………….3402
SCV Relief Valve Adjustment…………….3404
Flow Divider Valve Adjustment…………….3405
Section 280: Miscellaneous…………….3407
Group 10: Operational Checks…………….3407
Operational Test on Front-Wheel Drive Axle…………….3411
Checking Positive Front-Wheel Lead on Front-Wheel Drive Axle…………….3414
Section 290: Cab and Open Operator’s Station…………….3418
Group 20: Cab and Open Operator’s Station – Theory of Operation…………….3418
Summary of References – Theory of Operation…………….3420
Theory of Operation Information…………….3421
Principle of Heat Exchange…………….3422
R134a Refrigerant…………….3445
Operation of Air-Conditioning System – Air Flow…………….3424
Air-Conditioning System Operation…………….3426
Compressor…………….3428
Condenser…………….3429
Receiver-Drier…………….3430
Expansion Valve…………….3432
Group 40: Cab and Open Operator’s Station – Component Information…………….3418
General Information…………….3434
Air-Conditioning System Components…………….3435
Heating System Components…………….3438
Group 50: Cab and Open Operator’s Station – Diagnostic Tests/Adjustments…………….3418
Summary of References — Diagnosis, Tests and Adjustments…………….3441
Safety Equipment…………….3442
In an Emergency…………….3443
Storage of Refrigerant Containers…………….3444
R134a Refrigerant…………….3445
Important Note…………….3446
Special or Essential Tools…………….3447
Special Tools…………….3448
Diagnostic Information…………….3450
Air-Conditioning System Diagnosis…………….3451
Pressure Deviations…………….3460
Air-Conditioning System Troubleshooting…………….3462
Failure Of Mechanical Type…………….3466
Section 299: Special Tools…………….3468
Group 05: Special Tools (Dealer-Fabricated)…………….3468
Summary of References — Dealer-Manufactured Tools…………….3470
Draft Control Adjusting Tool…………….3471
Group 10: Special Tools (Available as Spare Parts)…………….3468
Special Tools (Available as Spare Parts) – Summary of References…………….3473
D01019AA – Single-Speed Hydraulic Hand Pump Assembly…………….3474
FKM10475 – Adjusting Tool…………….3475
JT05791A – Multimeter…………….3476
JT05800 – Digital Thermometer…………….3477
KJD10491—Diagnostic Interface Cable…………….3478
JT02153—Current Clamp-On Probe…………….3479
JDG10555 – Air-Conditioning Service Unit…………….3480
FKM10470 – Pressure Measuring System (Stage 1)…………….3481
FKM10471 – Pressure Measuring System (Stage 2)…………….3482
FKM10472 – Flow Measurement System…………….3483
FKM10472-4 – Temperature Sensor…………….3484
KJD10589 – Hydraulic Test Kit for Transmission Diagnostics…………….3485

John Deere Tractors 5100GN, 5100GF, 5090GH, 5090G, 5085GV, 5085GN, 5085GL, 5085GF, 5080G, 5075GV, 5075GN, 5075GL, 5075GF Diagnosis & Tests Service Technical Manual (TM406319)

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Posted on February 22, 2024 by admin

John Deere FPT F32 (F5A) Diesel Engine Repair Service Manual (CTM408119)

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Complete service repair manual with Electrical Wiring Diagrams for John Deere FPT F32 (F5A) Diesel Engine (Tier 3_Stage III A platform), with all the technical information to maintain, diagnose, repair, and rebuild like professional mechanics.

John Deere FPT F32 (F5A) Diesel Engine workshop service repair manual includes:
* Numbered table of contents easy to use so that you can find the information you need fast.
* Detailed sub-steps expand on repair procedure information
* Numbered instructions guide you through every repair procedure step by step.
* Troubleshooting and electrical service procedures are combined with detailed wiring diagrams for ease of use.
* Notes, cautions and warnings throughout each chapter pinpoint critical information.
* Bold figure number help you quickly match illustrations with instructions.
* Detailed illustrations, drawings and photos guide you through every procedure.
* Enlarged inset helps you identify and examine parts in detail.

ctm408119 – FPT F32 (F5A) Diesel Engine (Tier 3_Stage III A platform) Component Technical Manual (EN).pdf
ctm408128 – Moteur diesel FPT F32 (F5A) (plate-forme Tier 3/phase III A) French.pdf
ctm408129 – FPT F32 (F5A) Dieselmotor (Tier 3/Stufe III A-Plattform) German.pdf
ctm408139 – Motore diesel FPT F32 (F5A) (Piattaforma Tier3/fase III A) Italian.pdf
ctm408153 – Silnik wysokoprężny FPT F32 (F5A) (platforma Tier 3/Stage III A) Polish.pdf
ctm408154 – Motor Diesel FPT F32 (F5A) (Plataforma Tier 3/Fase III A) Portuguese.pdf

PRODUCT DETAILS:
Total Pages: 381 pages
File Format: PDF (Internal Links, Bookmarked, Table of Contents, Searchable, Printable, high quality)
Language: English

TABLE OF CONTENTS
TABLE OF CONTENTS…………….1
Section 01: General Information…………….7
Group 000: Safety…………….7
Understand Signal Words…………….10
Avoid Heating Near Pressurized Fluid Lines…………….11
Avoid High-Pressure Fluids…………….12
Avoid Hot Exhaust…………….13
Construct Dealer-Made Tools Safely…………….14
Dispose of Waste Properly…………….15
Exhaust Filter Cleaning…………….16
Follow Safety Instructions…………….17
Handle Fluids Safely—Avoid Fires…………….18
Handling Batteries Safely…………….19
Illuminate Work Area Safely…………….21
Install All Guards…………….22
Live With Safety…………….23
Practice Safe Maintenance…………….24
Precautions for Welding…………….25
Prepare for Emergencies…………….27
Prevent Acid Burns…………….28
Prevent Battery Explosions…………….30
Prevent Machine Runaway…………….31
Protect Against High Pressure Spray…………….32
Protect Against Noise…………….33
Recognize Safety Information…………….34
Remove Paint Before Welding or Heating…………….35
Replace Safety Signs…………….36
Service Cooling System Safely…………….37
Service Machines Safely…………….38
Stay Clear of Rotating Drivelines…………….39
Support Machine Properly…………….40
Use Proper Lifting Equipment…………….41
Use Proper Tools…………….42
Wait Before Opening High-Pressure Fuel System…………….43
Wear Protective Clothing…………….44
Work in Clean Area…………….45
Work In Ventilated Area…………….46
Group 001: Engine Identification Information…………….8
Engine Serial Number Plate Information…………….49
Group 002: Fuels, Lubricants, and Coolants…………….8
Diesel Engine Oil — Tier 3, Stage III…………….53
Engine Oil and Filter Service Intervals…………….55
John Deere Break-In Plus™ Engine Oil…………….56
Transmission and Hydraulic Oil…………….57
Front-Wheel Drive Axle Oil…………….58
Multiluber Grease…………….60
Mixing of Lubricants…………….61
Lubricant Storage…………….62
Alternative and Synthetic Lubricants…………….63
Diesel Engine Coolant…………….64
Operating in Warm Temperature Climates…………….66
Testing Diesel Engine Coolant…………….67
Storing Fuel…………….68
Handling and Storing Diesel Fuel…………….70
Diesel Fuel…………….70
Minimizing the Effect of Cold Weather on Diesel Engines…………….72
Lubricity of Diesel Fuel…………….74
BioDiesel Fuel…………….75
Testing Diesel Fuel…………….77
Oilscan™ and CoolScan™…………….78
Section 02: Repair and Adjustments…………….79
Group 010: Engine Rebuild…………….79
Engine Disassembly…………….111
Engine Assembly…………….142
Final Checks…………….213
Group 020: Cylinder Head and Valves Repair and Adjustment…………….79
Rocker Arm Cover Blow-by Filter Disassembly/Assembly Procedure…………….227
Group 090: Electronic Fuel System Repair and Adjustment…………….79
Injection Pump Disassembly/Assembly Procedure…………….251
Group 100: Maintenance…………….79
Servicing Plan…………….263
Engine Oil Level Check…………….264
Check of Fuel System…………….266
Cooling System Check…………….267
Lubricating System Check…………….268
Check of Water Presence within Fuel Filter or Pre-Filter…………….269
Check of Belt’s Tear and Wear Status…………….270
Check and Setting of Rocker Arm Clearance…………….271
Engine Oil and Filter Replacement…………….273
Fuel Filter Replacement…………….275
Bleeding Procedure…………….276
Drive Belt Replacement…………….277
Section 03: Theory of Operation…………….279
Group 123: Cooling System…………….279
Engine Cooling System…………….283
Group 126: Lubrication System…………….279
Engine Oil Vapor Recirculation…………….287
Engine Lubrication System…………….288
Group 130: Electronic Fuel System…………….279
Fuel System Operation…………….302
Fuel Filter Operation…………….312
Group 135: Air Intake and Exhaust System…………….279
Turbocharger System…………….314
EGR Exhaust Gas Recycle System…………….315
Section 04: Diagnostics…………….317
Group 150: Observable Diagnostics and Tests…………….317
Troubleshooting Procedure…………….319
Engine Does Not Start…………….317
Engine Stops…………….317
Engine Overheating…………….317
Engine Power And Irregular Functioning…………….317
Engine Is Running Noisy…………….317
Engine Smokes Abnormally…………….317
Section 05: Tools and Other Materials…………….330
Group 170: Special Tools…………….330
99322205…………….332
JDG99340025…………….333
JDG99346259…………….334
JDG99346262…………….335
99360076…………….336
99360183…………….337
99360268…………….338
JDG99360288…………….339
JDG99360292…………….340
JDG99360339…………….341
JDG99360362…………….342
99360500…………….343
99360605…………….344
JDG99360612…………….345
JDG99361043…………….346
99370006…………….347
JDG99370415…………….348
JDG99395100…………….349
JDG99395216…………….350
99395603…………….351
Section 06: Specifications…………….352
Group 190: Repair and Diagnostic Specifications…………….352
Metric Bolt and Screw Torque Values…………….355
Unified Inch Bolt and Screw Torque Values…………….357
Torque Specifications…………….360
Main Engine Specifications…………….366
Cylinder Head Technical Specifications…………….369
Cylinder Block, Pistons, and Connecting Rods Technical Specifications…………….371
Crankshaft, Main Bearings, and Flywheel Technical Specifications…………….373
Electrical Specifications…………….375

John Deere FPT F32 (F5A) Diesel Engine Repair Service Manual (CTM408119)

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