John Deere 2954D Processor Operation and Test Technical Manual TM10333 PDF

Introduction
Foreword
Technical Information Feedback Form
Contents
General Information
Safety
Recognize Safety Information
Follow Safety Instructions
Operate Only If Qualified
Wear Protective Equipment
Avoid Unauthorized Machine Modifications
Add Cab Guarding for Special Uses
Inspect Machine
Stay Clear of Moving Parts
Avoid High-Pressure Fluids
Avoid High-Pressure Oils
Beware of Exhaust Fumes
Prevent Fires
Prevent Battery Explosions
Handle Chemical Products Safely
Dispose of Waste Properly
Prepare for Emergencies
Use Steps and Handholds Correctly
Start Only From Operator′s Seat
Use and Maintain Seat Belt
Prevent Unintended Machine Movement
Avoid Work Site Hazards
Keep Riders Off Machine
Avoid Backover Accidents
Avoid Machine Tip Over and Machine Damage
Use Special Care When Lifting Objects
Add and Operate Attachments Safely
Keep the Operator Protective Structure (OPS) in Place
Park and Prepare for Service Safely
Service Cooling System Safely
Remove Paint Before Welding or Heating
Make Welding Repairs Safely
Drive Metal Pins Safely
Diagnostics
Main Controller (MCX) Diagnostic Trouble Codes
Main Controller (MCX) Diagnostic Trouble Codes
01— EEPROM Malfunction
02— RAM Malfunction
03— A/D Conversion Malfunction
04— Sensor Voltage Malfunction
07— Engine Speed Dial Malfunction
10— Pump 1 Delivery Pressure Sensor Malfunction
11— Pump 2 Delivery Pressure Sensor Malfunction
12— Pump 1 Control Pressure Sensor Malfunction
13— Pump 2 Control Pressure Sensor Malfunction
14— Swing Pressure Sensor Malfunction
15— Boom Up Pressure Sensor Malfunction
16— Arm In Pressure Sensor Malfunction
18— Travel Pressure Sensor Malfunction
Engine Control Unit (ECU) Diagnostic Trouble Codes
Engine Control Unit (ECU) Diagnostic Trouble Codes
28.03— Throttle #3 Out of Range High
28.04— Throttle #3 Out of Range Low
29.03— Throttle #2 Out of Range High
29.04— Throttle #2 Out of Range Low
91.03— Throttle Voltage Out of Range High
91.04— Throttle Voltage Out of Range Low
647.05— Proportional Fan Speed Solenoid Driver Open
647.31— Fan Manual Reverse Mode Input Active Too Long
1638.03— Hydraulic Oil Temperature Sensor Out of Range High
1638.04— Hydraulic Oil Temperature Sensor Out of Range Low
Information Controller (ICX) Diagnostic Trouble Codes
Information Controller (ICX) Diagnostic Trouble Codes
01— Abnormal Internal RAM
02— Abnormal Flash Memory
03— Abnormal Exterior
04— Abnormal EEPROM
06— Abnormal Time
07— Main Controller Communication Timeout
08— Monitor Communication Timeout
09— Main Controller Communication Timeout
10— Satellite Terminal Communication Timeout
Air Conditioner Controller (ACX) Diagnostic Trouble Codes
Air Conditioner Controller (ACX) Diagnostic Trouble Codes
21— Mix Door Open Circuit
-21— Mix Door Short Circuit
22— Mode Encoder Open Circuit
23— In-Cab Ambient Temperature Sensor Open Circuit
-23— In-Cab Ambient Temperature Sensor Short Circuit
24— Outdoor Ambient Temperature Sensor Open Circuit
-24— Outdoor Ambient Temperature Sensor Short Circuit
25— Coolant Temperature Sensor Open Circuit
-25— Coolant Temperature Sensor Short Circuit
26— Solar Radiation Sensor Open Circuit
-26— Solar Radiation Sensor Short Circuit
Operational Checkout Procedure
Operational Checkout Procedure
Operational Checkout
Engine
Theory of Operation
Engine Fuel System Component Location
Engine Cooling System Component Location
Cold Weather Starting Aid
Engine Speed Control System Operation (S.N. —290132)
Engine Speed Control System Operation (S.N. 290133— )
Diagnostic Information
PowerTech Plus™ 4.5 L and 6.8 L (4045 and 6068) John Deere Engines
Diagnose Engine Malfunctions
Tests
Radiator Temperature Differential Check
Electrical System
System Information
Electrical Diagram Information
System Functional Schematic Diagram
Wiring Diagram
Wiring Diagram
Component Location Diagram
Connector End View Diagram
Electrical Schematic Symbols
System Diagrams
Explanation of Wire Markings
Fuse and Relay Specifications
System Functional Schematic, Component Location, Wiring Diagram, and Master Legend
System Splice Master Legend
System Functional Schematic
Cab Harness (W1) Component Location
Cab Harness (W1) Wiring Diagram
Machine Harness (W2) Component Location
Machine Harness (W2) Component Location (S.N. —290236)
Machine Harness (W2) Component Location (S.N. 290237— )
Machine Harness (W2) Wiring Diagram
Monitor Harness (W3) Component Location
Monitor Harness (W3) Wiring Diagram
Engine Harness (W5) Component Location—Tier 3
Engine Harness (W5) Component Location—Stage II
Engine Harness (W5) Wiring Diagram—Tier 3
Engine Harness (W5) Wiring Diagram—Stage II
Engine Interface Harness (W6) Component Location
Engine Interface Harness (W6) Wiring Diagram
Frame Harness (W7) Component Location
Frame Harness (W7) Wiring Diagram
Pump Harness (W8) Component Location
Pump Harness (W8) Wiring Diagram
Load Center Harness—Non-Valve-In-Head (W9) Component Location
Load Center Harness—Non-Valve-In-Head (W9) Wiring Diagram
Upper Cab Harness—Side Entry Cab (W10) Component Location
Upper Cab Harness—Side Entry Cab (W10) Wiring Diagram
Front Cab Work Light Harness (W16) Component Location
Front Cab Work Light Harness (W16) Wiring Diagram
Rear Cab Work Light Harness (W17) Component Location
Rear Cab Work Light Harness (W17) Wiring Diagram
Front Attachment Work Light Boom Harness (W18) Component Location
Front Attachment Work Light Boom Harness (W18) Wiring Diagram
Work Light Arm Harness—Processor (W19) Component Location
Work Light Arm Harness—Processor (W19) Wiring Diagram
Reversing Fan Switch Harness (W21) Component Location
Reversing Fan Switch Harness (W21) Wiring Diagram
Information Controller (ICX) Sub Harness (W22) Component Location
Information Controller (ICX) Sub Harness (W22) Wiring Diagram
Power Converter Harness (W23) Component Location
Power Converter Harness (W23) Wiring Diagram
Travel Alarm Harness (W24) Component Location
Travel Alarm Harness (W24) Wiring Diagram
Fuel Fired Coolant Heater Timer Harness (W26) Component Location
Fuel Fired Coolant Heater Timer Harness (W26) Wiring Diagram
Fuel Fired Coolant Heater Harness (W27) Component Location
Fuel Fired Coolant Heater Harness (W27) Wiring Diagram
Fuel Fired Coolant Heater Extension Harness (W28) Component Location
Fuel Fired Coolant Heater Extension Harness (W28) Wiring Diagram
Auxiliary Oil Cooler Harness (W29) Component Location
Auxiliary Oil Cooler Harness (W29) Wiring Diagram
Powered Condenser Harness (W30) Component Location
Powered Condenser Harness (W30) Wiring Diagram
Oil Transfer Pump Harness (W31) Component Location
Oil Transfer Pump Harness (W31) Wiring Diagram
Processor Power Harness (W44) Component Location
Processor Power Harness (W44) Wiring Diagram
Bail Lock Harness (W45) Component Location
(S.N. —290028)
(S.N. 290029—)
Bail Lock Harness (W45) Wiring Diagram
(S.N. —290028)
(S.N. 290029—)
Solenoid Harness (W46) Component Location
Solenoid Harness (W46) Wiring Diagram
Alternator Harness (W48) Component Location
Alternator Harness (W48) Wiring Diagram
Air Conditioner Compressor Clutch Harness (W49) Component Location (S.N. —290236)
Air Conditioner Compressor Clutch Harness (W49) Wiring Diagram (S.N. —290236)
Heater and Air Conditioner Harness—Side Entry Cab (W51) Component Location
Heater and Air Conditioner Harness—Side Entry Cab (W51) Wiring Diagram
Processor Controller Power Harness (W52) Component Location
Processor Controller Power Harness (W52) Wiring Diagram
(S.N. —290028)
(S.N. 290029—)
Processor Filter Harness (W53) Component Location
Processor Filter Harness (W53) Wiring Diagram
Processor Cable—LogRite (W54) Component Location
Processor Cable—LogRite (W54) Wiring Diagram
Processor Cable—TimberRite™ (W55) Component Location
Processor Cable—TimberRite™ (W55) Wiring Diagram
Horn Switch Harness (W56) Component Location
Horn Switch Harness (W56) Wiring Diagram
Fuel Filter Harness (W59) Component Location
(S.N. 290031—)
Fuel Filter Harness (W59) Wiring Diagram
(S.N. 290031—)
Engine Sub-Harness (W60) Component Location—Stage II
Engine Sub-Harness (W60) Wiring Diagram—Stage II
Air Conditioning Interlock Harness (W61) Component Location (S.N. 290237— )
Air Conditioner Interlock Harness (W61) Wiring Diagram (S.N. 290237— )
JDLink™ Modular Telematics Gateway (MTG) Harness (W6002) Component Location—If Equipped
JDLink™ Modular Telematics Gateway (MTG) Harness (W6002) Wiring Diagram—If Equipped
Sub-System Diagnostics
Controller Area Network (CAN) Theory of Operation
Starting and Charging Circuit Theory of Operation
Monitor Controller Circuit Theory of Operation
Engine Control Unit (ECU) Circuit Theory of Operation
Main Controller (MCX) Circuit Theory of Operation
Information Controller (ICX) Circuit Theory of Operation
Travel Alarm Circuit Theory of Operation
Windshield Wiper and Washer Circuit Theory of Operation
Auxiliary Oil Cooler Circuit Theory of Operation
JDLink™ Circuit Theory of Operation—If Equipped
Monitor Operation
Monitor Service Mode Operation
Diagnostic Display Unit (DDU) Operation
Processor Monitor Operation
References
Reading Diagnostic Trouble Codes With Monitor Display
Reading Diagnostic Trouble Codes With Diagnostic Display Unit (DDU)
Service ADVISOR™ Diagnostic Application
Service ADVISOR™ Connection Procedure To 9-Pin Diagnostic Connector
Reading Engine Diagnostic Trouble Codes With Service ADVISOR™ Diagnostic Application
Service ADVISOR™ Interactive Tests
JDLink™ Connection Procedure—If Equipped
Fuse Test
Relay Test
Pressure Sensor Test
Solenoid Test
Proportional Solenoid Test
Temperature Sensor Test
Engine Speed (N) Sensor Test
Alternator Test
Electrical Component Checks
Battery Remove and Install
Rear Cover Remove and Install—Side Entry Cab
Main Controller (MCX) Remove and Install—Side Entry Cab
Engine Control Unit (ECU) Remove and Install
Information Controller (ICX) Remove and Install—Side Entry Cab
Monitor Controller Remove and Install—Side Entry Cab
Key Switch Remove and Install—Side Entry Cab
Switch Panel Remove and Install—Side Entry Cab
Travel Alarm Remove and Install—Side Entry Cab
Left Console Remove and Install
Right Console Remove and Install—Side Entry Cab
Disconnect Tab Retainer Connectors
Disconnecting Spring Wire Clip Connectors
Replace DEUTSCH™ Connectors
Replace DEUTSCH™ Rectangular or Triangular Connectors
Install DEUTSCH™ Contacts
Replace WEATHER PACK™ Connector
Install WEATHER PACK™ Contacts
Replace (Pull Type) Metri-Pack™ Connectors
Replace (Push Type) Metri-Pack™ Connectors
Replace CINCH™ Connectors
Install CINCH™ Contact
Repair 32 and 48 Way CINCH™ Connectors
Remove Connector Body from Blade Terminals
Power Train
Theory of Operation
Track Adjuster and Recoil Spring Operation
Travel Gearbox Operation
Diagnostic Information
Diagnose Undercarriage Components Malfunctions
Measure Swing Bearing Wear
Hydraulic System
Theory of Operation
Hydraulic System Operation
Fan Drive System Operation
Pilot System Operation
Pilot Pump, Pressure Regulating Valve and Filter Operation
Pilot Control Shutoff Valve Operation
Bail Lock Valve Operation
Pilot Control Valve Operation
Travel Pilot Control Valve Operation
Auxiliary Pilot Valve Operation
Auxiliary Tandem Pilot Pump Hydraulic Circuit
Pilot Operation of Control Valve Operation
Pilot Signal Manifold Operation
Pump 1, Pump 2 and Drive Gearbox Operation
Pump 1 and Pump 2 Regulator Operation
Engine Speed Sensing Control Circuit Operation
Control Valve Operation
Control Valve Check Valves Identification and Operation
Main Relief and Power Boost Valve Circuit Operation
Circuit Relief and Anticavitation Valve Operation
Travel Flow Combiner Valve Operation
Boom Lower Meter-In Cut Valve Operation
Boom Regenerative Valve Circuit Operation
Arm Regenerative Valve Circuit Operation
Front Attachment Regenerative Valve Circuit Operation
Boom and Arm Reduced Leakage Valves Operation
Arm 1 Flow Rate Control Valve Circuit Operation
Arm 2 Flow Rate Control Valve Circuit Operation
Front Attachment Flow Rate Control Valve Circuit Operation
Boom Flow Rate Control Valve Circuit Operation
Swing Reduction Gearbox Operation
Swing Motor, Crossover Relief Valve, and Make-Up Check Valve Operation
Swing Motor Dampener Valve Operation
Swing Motor Park Brake Release Circuit Operation
Center Joint Operation
Travel Motor and Park Brake Valve Operation
Travel Motor Speed Circuit Operation
Cylinder Operation
Return Filter Operation
Diagnostic Information
Diagnose Hydraulic System Malfunctions
Diagnose Pilot Circuit Malfunctions
Diagnose Front End Circuit Malfunctions
Diagnose Swing Circuit Malfunctions
Diagnose Travel Circuit Malfunctions
Pump 1, Pump 2 and Pilot Pumps Line Identification
Control Valve Line Identification
Swing Motor Line Identification
Pilot Control Valve-to-Pilot Signal Manifold Component Location
Pilot Signal Manifold-to-Control Valve Line Connection
Travel System Component Location
Travel Hydraulic System Line Connection
Hydraulic System Schematic
Pilot Valve Schematic (S.N. —290022)
Pilot Valve Schematic (S.N. 290022—290028)
Pilot Valve Schematic (S.N. 290029—)
Control Valve Schematic
Swing Device Schematic
Travel Motor Schematic
Pump 1 and Pump 2 Schematic
Hydraulic System Component Location
Hydraulic System Line Connection
Fan Drive System Component Location
Tests
Hydraulic Oil Sampling Port Location
JT05800 Digital Thermometer Installation
JT02156A Digital Pressure/Temperature Analyzer Installation
Hydraulic Oil Cleanup Procedure Using Portable Filter Caddy
Hydraulic Oil Warm-Up Procedure
Pilot Pressure Regulating Valve Test and Adjustment
Control Valve Spool Actuating Pilot Pressure Test
Arm Regenerative Solenoid Valve Test and Adjustment
Power Boost Solenoid Valve Test and Adjustment
Travel Speed Solenoid Valve Test and Adjustment
Torque Control Solenoid Valve Test and Adjustment
Pump Control Pilot Pressure Signal Test
Main Relief and Power Boost Valve Test and Adjustment
Circuit Relief Valve Test and Adjustment
Swing Motor Crossover Relief Valve Test and Adjustment
Travel Motor Crossover Relief Valve Test and Adjustment
Pump Regulator Test and Adjustment—Minimum Flow
Pump Regulator Test and Adjustment—Maximum Flow
Pump Flow Test
Swing Motor Leakage Test
Travel Motor Leakage Test
Cylinder Drift Test—Boom and Arm
Fan Drive Pump Flow Test
Fan Speed Test
9031A – Heating and Air Conditioning – Side Entry Cab
Theory of Operation
Air Conditioning System Cycle of Operation
Diagnostic Information – Standard Condenser
Diagnose Air Conditioning System Malfunctions
Diagnose Heating System Malfunctions
Heater and Air Conditioner Diagnostic Trouble Code Check
Side Entry Cab Heater and Air Conditioner Component Location
Diagnostic Information – Powered Condenser
Diagnose Air Conditioning System Malfunctions
Diagnose Heating System Malfunctions
Heater and Air Conditioner Diagnostic Trouble Code Check
Side Entry Cab Heater and Air Conditioner Component Location With Powered Condenser
Tests
Refrigerant Cautions and Proper Handling
Heater and Air Conditioner Operational Checks
Air Conditioner Compressor Clutch Test
Refrigerant Leak Test
Refrigerant Hoses and Tubing Inspection
Air Conditioner Compressor Belt Check and Adjustment
Air Conditioner Freeze Control Switch Test
Air Conditioner High/Low-Pressure Switch Test
Operating Pressure Diagnostic Chart
Dealer Fabricated Tools
Dealer Fabricated Tools
DFT1218 Split Flange Hose Cap