John Deere 3032E Tractor Compact Utility Diagnostic Repair Manual
3025E, 3032E, 3036E, and 3038E Compact Utility
ractors Diagnostic and Repair Manual For complete service information
TECHNICAL MANUAL
3025E PIN (G_XXXXXX—), 3032E, 3036E, and 3038E PIN (E_XXXXXX—) Compact Utility T ractor , Diagnostic and Repair Manual TM127919 20DEC20 (ENGLISH)
see: and 4TNV88 Diesel Engines (Final T ier 4 Stage Platform)
3TNV88F Diesel Engines (Final T ier 4 Platform) CTM144419
DOWNLOAD: John Deere 3032E 3036E Tractor Diagnostic and Repair Manual
John Deere Augusta W orks PRINTED
Introduction
Foreword
This manual written for experienced Essential tools required performing certain service work are identified this manual and are recommended for
Live with safety: Read the safety messages the introduction this manual and the cautions presented throughout the text the
This the safety - alert When you see this symbol the machine in this alert the potential for personal injury
T echnical manuals are divided in two parts: repair and operation and tests. Repair sections tell how repair the Operation and tests sections help you identify the majority routine failures quickly
Information organized groups for the various components requiring service instruction. the
beginning each group are summary listings all applicable essential service equipment and other materials needed the job, service parts specifications, wear tolerances, and torque values.
T echnical Manuals are concise guides for specific They are - the - job guides containing only the vital information needed for and repair
Fundamental service information available from other sources covering basic theory fundamentals general and basic type failures and their
Section Information
Group 05A
Group 05B References
Group 05C echnical Specific References
Group 05D and Lubricants
Group 05E Number Locations
Section 20—Engine Repair
Group Group System
Section Air Intake, and Exhaust Repair
Group Group Intake Group
Section Repair Group Connector Repair
Group , Starter , and Alternator
Group System Components
Contents
Section Operator ’ s Station Repair
Group and Support
Group Console
Group - Gard
Group Operator Station Components
Section T rouble Codes
Group References
Group ICC Cluster Control (ICC) Diagnostic T rouble Codes
Group ECU Control Unit (ECU) Diagnostic T rouble Codes
Section 212—Observable Symptoms and System Diagnostics
Group References
Group System Diagnostics
Group Air Intake, Exhaust, and Cooling System Diagnostics
Group System Diagnostics
Section 50—Drive Systems and T ransmission Repair
Group T rain
Group Front Wheel Drive
Group ferential Group O
Section Repair Group
Section Repair Group
Section Repair Group Pump and Filter Group
Group Control V alve
Group Lines
Section 80—Miscellaneous Repair
Group and Side Panels Group Group
Group Control Unit System Diagnostics
Group Systems and T ransmission System Diagnostics
Group System Diagnostics
Group System Diagnostics
Group System Diagnostics
Section 220—Engine Operation, T est, and Adjustments
Group References
Group Preliminary Checks and Operational Checks
Group Operation
Group ests and Adjustments
Section Air Intake, Exhaust, and Cooling Operation, T est, and Adjustments
Group References
Group Preliminary Checks and Operational Checks
Group Operation
Group and Connector Information
Group ests and Adjustments
Original All illustrations and specifications this manual are based the latest information available the time The right is reserved make changes any time without
Section 240A—Electrical General and Theory Operation
Group References
Group Theory Operation
Section 240B—Electrical Schematics
Group References
Group 30AA Starter and ECU (SE1A)
Group 30AB Starter and ECU (SE1B)
Group 30BA Cluster ECU (SE2A)
Group 30BB Cluster ECU (SE2B)
Group 30CA Control Unit 3038E (SE3A)
Group 30CB Control Unit (SE3B)
Group 30DA and T urn ECU (SE4A)
Group 30DB and T urn ECU (SE4B)
Group 30EA Control (SE5)
Group 30GA SCV (SE7)
Section Components and Connectors
Group References
Group 40A and Control Units
Group 40B
Group 40D and Binary Devices
Group 40E
Group 40F
Group 40G
Group 40H - W arning Devices
Group 40K
Group 40M
Group 40S
Group 40W
Group 40X
Group 40Y and Electrically Actuated Mechanical Devices
Group 40Z Points
Section T ests and Adjustments
Group References
Group ests and Adjustments
Section Control Units
Group References
Group —Calibrations, Preliminary Checks and Operational Checks
Group Operation
Group and Connector Information
Group est and Adjustments
Group ICC Cluster Control (ICC)
Group ECU Control Unit (ECU)
Section 250—Drive System and T ransmission Operation, T est, and Adjustments
Group References
Group Preliminary Checks and Operational Checks
Group Operation
Group
Group and Connector Information
Group ests and Adjustments
Section Operation, T est, and Adjustments
Group References
Group —Calibrations, Preliminary Checks and Operational Checks
Group Operation
Group
Group and Connector Information
Group ests and Adjustments
Section Operation, T est, and Adjustments
Group References
Group —Calibrations, Preliminary Checks and Operational Checks
Group Operation
Group and Connector Information
Group ests and Adjustments
Section Operation, T est, and Adjustments
Group 05A References
Group —Calibrations, Preliminary Checks and Operational Checks
This a safety - alert When you see this symbol your machine in this alert the potential for personal injury
Follow recommended precautions and safe operating
Understand Signal W ords
DANGER ; The signal word DANGER indicates a hazardous situation if not will result death serious injury
W
ARNING ; The signal word W ARNING indicates a hazardous situation not could result death serious injury
CAUTION ; The signal word CAUTION indicates a hazardous situation which, not avoided, could result minor moderate injury CAUTION may also used alert against unsafe practices associated with events which could lead personal injury
A signal W ARNING, used with the safety - alert symbol. DANGER identifies the most serious DANGER W ARNING safety signs are located near specific General
Follow Safety Instructions
Carefully read all safety messages this manual and your machine safety signs. Keep safety signs good Replace missing damaged safety sure new equipment components and repair parts include the current safety Replacement safety signs are available from your John Deere dealer
There can additional safety information contained parts and components sourced from suppliers that not reproduced this
Learn how operate the machine and how use controls properly . not let anyone operate without instruction.
Keep your machine proper working Unauthorized modifications the machine may impair the function and/or safety and fect machine
precautions are listed CAUTION safety CAUTION also calls attention safety messages this
you not understand any part this manual and need contact your John Deere dealer
Prepare for Emergencies
prepared a fire
Keep a first aid kit and fire extinguisher handy
Keep emergency numbers for ambulance and fire department near your
W ear Protective Clothing
W ear close fitting clothing and safety equipment appropriate the
Operating equipment safely requires the full attention the operator . not wear radio music headphones while operating
Protect Against Noise
There are many variables that fect the sound level including machine condition and maintenance level the ground operating duty ambient and
Exposure loud noise can cause impairment loss
Always wear hearing W ear a suitable hearing protective device such earmuf earplugs protect against objectionable uncomfortable loud
Handle Fuel void Fires
Handle fuel with care: it is highly not refuel the machine while smoking when near open flame
Always stop engine before refueling Fill fuel tank
Use only approved fuel container for transporting flammable
Never fill fuel container in pickup truck with plastic bed liner Always place fuel container ground before T ouch fuel container with fuel dispenser nozzle before removing can Keep fuel dispenser nozzle contact with fuel container inlet when
Handle Starting Fluid Safely
Starting fluid highly
Keep all sparks and flame away when using Keep starting fluid away from batteries and
T o prevent accidental discharge when storing the pressurized keep the cap the container , and store a protected not incinerate puncture a starting fluid container
not use starting fluid engine equipped with glow plugs air intake heater
Fire Prevention
not store fuel container where there open flame, pilot light such within a water heater other
T o reduce the risk fire, your tractor should regularly inspected and
Operator ’ s Manual greatly reduce the risk fire and the chance costly
• not store fuel container where there open flame, spark, pilot light such within a water heater other
• Birds and other animals may build nests bring other flammable materials into the engine compartment onto the exhaust system. The tractor should inspected and cleaned prior the first use each day
• Check fuel and fittings frequently for cracks Replace necessary
• A build crop material and other debris may occur during normal This is especially true when operating in very dry conditions conditions where airborne crop material crop dust is Any such build must removed ensure proper machine function and reduce the risk fire. The tractor must inspected and cleaned periodically throughout the day
Follow all operational and safety procedures posted the machine and the Operator ’ s careful hot engine and exhaust components during inspection and Before carrying out any inspection always shut OFF the place the transmission P ARK set parking and remove the key Removal the key will prevent others from starting the tractor during inspection and cleaning.
• Regular and thorough cleaning the tractor combined with other routine maintenance procedures listed the
Case Fire
CAUTION: A void personal injury
Stop machine immediately the first sign Fire may identified the smell smoke sight flames. Because fire grows and spreads rapidly , get f the machine immediately and move safely away from the not return the machine! The number one priority safety
Call the fire A portable fire extinguisher can put out a small fire contain until the fire department arrives; but portable extinguishers have Always put the safety the operator and bystanders attempting extinguish a keep your back the wind with unobstructed escape path you can move away quickly the fire cannot extinguished.
Pull the pin. Hold the extinguisher with the nozzle pointing away from and release the locking
Read the fire extinguisher instructions and become familiar with their and operation before a fire
Aim low . Point the extinguisher the base the fire.
Local fire departments fire equipment distributors may fer fire extinguisher training and recommendations. your extinguisher does not have follow these general guidelines:
Squeeze the lever slowly and evenly
Sweep the nozzle from side -side.
Keep ROPS Installed Properly
Make certain all parts are reinstalled correctly if the roll - over protective structure (ROPS) loosened removed for any T ighten mounting bolts proper
The protection fered ROPS will impaired ROPS subjected structural involved in overturn any way altered A damaged ROPS should not
The seat part the ROPS safety Replace only with John Deere seat approved for your tractor
Any alteration the ROPS must approved the manufacturer .
Use Foldable ROPS and Seat Belt Properly
A void crushing injury death during rollover
• this machine is equipped with a foldable rollover protective structure (ROPS), keep the ROPS the fully extended and locked USE a seat belt when you operate with a ROPS in the fully extended
- Hold the latch and pull the seat belt across the body
- Insert the latch into the Listen for a
- T the seat belt make sure that the belt securely
- Snug the seat belt across the hips.
• this machine operated with the ROPS folded (for enter a low drive with extreme NOT USE a seat belt with the ROPS
• Return the ROPS the fully extended position soon the machine is operated under normal conditions.
Stay Clear Rotating Drivelines
Entanglement rotating driveline can cause serious injury
Keep tractor master shield and driveline shields in place all Make sure rotating shields turn freely
Only use power take - f driveshafts with adequate guards and
W ear close fitting Stop the engine and sure that PT O driveline is stopped before making cleaning out O driven
not install any adapter device between the tractor and the primary implement O driveshaft that will allow a 1000 rpm tractor shaft power a 540 rpm implement speeds higher than 540
not install any adapter device that results in a portion the rotating implement tractor the adapter
The tractor master shield shall overlap the end the splined shaft and the added adaptor device outlined the
The angle which the primary implement O driveshaft can inclined may reduced depending the shape and size the tractor master shield and the shape and size the guard the primary implement O
not raise implements high enough damage the tractor master shield guard primary implement O Detach the O driveline shaft if it is necessary increase implement (See Attching/Detaching O Driveline)
When using T ype 3/4 inclination and turning angles may reduced depending type O master shield and coupling
Use Steps and Handholds Correctly
Prevent falls facing the machine when getting and Maintain 3 - point contact with and
Use extra care when snow , moisture present slippery conditions. Keep steps clean and free grease Never jump when exiting Never mount dismount a moving
Read Operator ’ s Manuals for ISOBUS Controllers
addition GreenStar ™ this display can used a display device for any ISOBUS Controller that meets ISO 1 1783 This includes capability control ISOBUS implements. When used this manner , information and control functions placed the display are provided the ISOBUS Controller and are the responsibility the ISOBUS Controller manufacturer
GreenStar a trademark Deere & Company
Use Seat Belt Properly
A void crushing injury death during rollover
This machine equipped with a rollover protective structure USE a seat belt when you operate with a
• Hold the latch and pull the seat belt across the body .
• Insert the latch into the Listen for a
• T the seat belt latch make sure that the belt securely
• Snug the seat belt across the
Replace entire seat belt if mounting retractor show signs
Inspect seat belt and mounting hardware least once a year . Look for signs loose hardware belt such extreme unusual wear ,
Some these functions could pose a hazard either the operator a bystander Read the Operator ’ s Manual provided the ISOBUS Controller manufacturer and observe all safety messages manual and ISOBUS Controller product prior
NOTE: ISOBUS refers the ISO Standard 1 1783
Replace only with replacement parts approved for your See your John Deere dealer .
Operating the T ractor Safely
Y can reduce the risk accidents following these simple precautions:
• Pump brakes when stopping slippery
• Regularly clean fenders and fender valances (mud flaps) Remove dirt before driving public
• Use your tractor only for jobs was designed perform, for and carrying a variety interchangeable equipment designed conduct agricultural
• Operators must mentally and physically capable accessing the operator ’ s station and/or and operating the machine properly and safely
• Never operate machine when distracted, fatigued, Proper machine operation requires the operator ’ s full attention and
Heated and V entilated Operator ’ s Seat
• overheated seat heater can cause a burn injury damage the T o reduce the risk use caution when using the seat heater for extended periods especially the operator cannot feel temperature change pain the not place objects the such a cover , similar which can cause the seat heater
• This tractor not intended used a recreational
T owing Loads
• Read this operator ’ s manual before operating the tractor and follow operating and safety instructions the manual and the tractor .
• Follow operation and ballasting instructions found the operator ’ s manual for your such front
• careful when towing and stopping heavy Stopping distance increases with speed and weight towed and T owed loads with without brakes that are too heavy for the tractor are towed too fast can cause loss
• Consider the total weight the equipment and its
• Follow the instructions outlined in the operator ’ s manual any mounted trailed machinery trailer not operate a combination tractor - machine tractor - trailer unless all instructions have been followed.
• Hitch towed loads only approved couplings avoid rearward
• Make sure that everyone is clear attached and work area before starting engine
• Stay clear the three - point linkage and pickup hitch (if equipped) when controlling
• Keep hands, feet, and clothing away from power - driven parts.
Driving Concerns
• Never get f a moving tractor
• Complete any required training prior operating
Parking and Leaving the T ractor
• Before shut f disengage stop lower implements/attachments place implement/attachment control devices and securely engage park mechanism, including the park pawl and park the tractor left remove key
• Leaving transmission gear with engine f will NOT prevent the tractor from
• Never near operating O operating
• W ait for all movement stop before servicing machinery
• Keep all children and nonessential personnel f tractors and all equipment.
• Never ride a tractor unless seated a John Deere approved seat with a seat
• Keep all shields/guards
• Use appropriate visual and audible signals when operating public
• Move side road before stopping.
Common Accidents
Unsafe operation misuse the tractor can result alert hazards tractor
The most common accidents involving tractors are:
• T ractor rollover
• Reduce speed when turning, applying individual brakes, operating around hazards rough ground steep
• Stability degrades when attached implements are high
• Couple brake pedals together for road
• Collisions with motor vehicles
• Improper starting procedures
• Entanglement O shafts
• Falling from tractor
• Crushing and pinching during hitching
A void Backover Accidents
Before moving sure that all persons are clear machine T urn around and look directly for best visibility Use a signal person when backing if view obstructed when in close not rely a camera determine if personnel obstacles are behind the The system can limited many factors including maintenance environmental and operating
Limited Use Forestry Operation
The intended use John Deere tractors when used forestry operations is limited tractor - specific applications like stationary work such log operating implements with electrical
These are applications where normal operation does not present a risk falling penetrating Any forestry applications beyond these such forwarding and requires fitment application - specific components including Falling Object Protective Structure (FOPS) and/or Operative Protective Structures
Contact John Deere dealer for special components.
Operating the Loader T ractor Safely
When operating a machine with a loader reduce speed required ensure good tractor and loader stability .
T o avoid tractor rollover and damage front tires and tractor , not carry load with your loader a speed over km/h
T o avoid tractor damage not use a front loader a sprayer tank the tractor is equipped with a 3 Meter Front
Never allow anyone walk work under a raised loader . not use loader a work not lift carry anyone loader , in bucket, implement
Lower loader ground before leaving operators
The Rollover Protective Structure (ROPS) cab may not provide suf ficient protection from load
falling onto the operators T o prevent loads from falling onto the operators always use appropriate implements for specific applications (that manure round bale round bale and
Ballast tractor accordance Ballast Recommendations PREP ARE TRACT
Keep Riders Off Machine
Only allow the operator the Keep riders Riders machine are subject injury such being struck foreign objects and being thrown f the Riders also obstruct the operator ’ s view resulting the machine being operated in unsafe manner
Instructional Seat
The instructional if has been provided only for training operators diagnosing machine
Use Safety Lights and Devices
Prevent collisions between other road slow moving tractors with attachments towed and self - propelled machines public Frequently check for traf fic from the rear , especially in and use turn signal lights.
Use flashing warning and turn signals day and Follow local regulations for equipment lighting and Keep lighting and marking and good working order Replace repair lighting and marking that has been damaged lost. implement safety lighting kit is available from your John Deere dealer
Use a Safety Chain
A safety chain will help control drawn equipment should accidentally separate from the drawbar
Using the appropriate adapter parts, attach the chain the tractor drawbar support other specified anchor Provide only enough slack in the chain permit
See your John Deere dealer for a chain with a strength rating equal greater than the gross weight the towed machine. not use safety chain for towing.
Transport T owed Equipment Safe Speeds
not exceed the maximum transport This towing unit may capable operating transport speeds that exceed the maximum allowable transport speed for towed
Before transporting a towed determine from signs the implement information provided the operator manual the maximum transport Never transport speeds that exceed the maximum transport Exceeding the maximum transport speed can result in:
• Loss control the towing unit/implement combination
• Reduced ability stop during braking
• Implement tire failure
• Damage the implement structure its components
Implements shall equipped with brakes if the maximum fully loaded weight greater than 1500 (3307 lbs) and greater than times the weight the towing
Example: Implement mass 1600 (3527 lbs) and towing unit mass 1600 (3527 lbs), example implement not required have brakes.
• When transporting speeds between km/h mph) the fully loaded implement must weigh less than times the towing unit
Implements without brakes: not transport speeds greater than km/h (20
Implements with brakes:
• the manufacturer does not specify a maximum transport not tow speeds greater than km/h (25
• When transporting speeds km/h (25 mph) the fully loaded implement must weigh less than times the towing unit
When towing a trailer , become familiar with the braking characteristics and ensure the compatibility the tractor/trailer combination regard the deceleration
T owing T railers/Implements Safely
Stopping distance increases with speed and mass and when transporting
T owed mass with without brakes that is too heavy for the tractor towed too fast can cause loss
Consider the total weight the equipment and its load.
When towing a trailer , become familiar with the braking characteristics and ensure the compatibility the tractor/trailer combination in regard the deceleration
Stay clear area between tractor and trailed
T railer/Implement Brake System T Speed
Unbraked
Independent . .
Overrun brake .
km/h mph)
km/h mph)
km/h mph)
Single - line hydraulic brake km/h mph)
Dual - line hydraulic brake km/h (25 mph)
Single - line air brake km/h mph)
Maximum design speed
There may legal limits force that restrict travel speeds figures lower than those quoted
Use additional caution when towing loads under adverse surface when and
Dual - line air brake
Use Caution Slopes, Uneven T errain, and Rough Ground
A void and obstructions which cause the tractor especially A void sharp uphill
Driving forward out a mired a steep slope could cause the tractor tip over Back out these situations if
Danger overturn increases greatly with narrow tread high
Not all conditions that can cause a tractor overturn are Be alert for any situation which stability may compromised.
Slopes are a major factor related loss - - control and tip - over which can result in severe injury Operation all slopes requires extra
Uneven terrain rough ground can cause loss - - control and tip - over which can result in severe injury Operation uneven terrain rough ground requires extra
Never drive near the edge a gully , drop - steep a body water The machine could suddenly roll over if a wheel goes over the edge the ground caves
Choose a low ground speed you will not have stop shift while a
A void turning a the tires lose disengage the O and proceed slowly , straight down the
Keep all movement slopes slow and gradual. not make sudden changes speed which could cause the machine roll over
Freeing a Mired Machine
Attempting free a mired machine can involve safety hazards such the mired tractor tipping the towing tractor and the tow chain tow bar cable not recommended) failing and recoiling from its stretched condition.
Back your tractor out if gets mired down in Unhitch any towed Dig mud from behind the rear
Place boards behind the wheels provide a solid base and try back out slowly necessary , dig mud from the front all wheels and drive slowly ahead.
necessary tow with another use a tow bar a long chain cable not Inspect the chain for Make sure all parts towing devices are adequate size and strong enough handle the load.
Always hitch the drawbar the towing not hitch the front pushbar attachment Before clear the area Apply power smoothly take the slack: a sudden pull could snap any towing device causing whip recoil dangerously .
A void Contact with Agricultural Chemicals
This enclosed cab does not protect against inhaling vapor , aerosol pesticide use instructions require respiratory wear appropriate respirator inside the
Before leaving the cab, wear personal protective equipment required the pesticide use
When - entering the remove protective equipment and store either outside the cab in a closed box some other type sealable container inside the cab a pesticide resistant container , such a plastic
Clean your shoes boots remove soil other contaminated particles prior entering the
Handle Agricultural Chemicals Safely
Chemicals used agricultural applications such and fertilizers can harmful your health the environment if not used carefully
Always follow all label directions for and legal use agricultural
Reduce risk exposure and injury:
• W ear appropriate personal protective equipment recommended the manufacturer the absence follow these general guidelines:
- Chemicals labeled : Most toxic. Generally require use respirator , and skin
- Chemicals labeled : Less Generally require use and skin
- Chemicals labeled : Least Generally require use gloves and skin protection.
• A void inhaling vapor , aerosol dust.
• Always have water , and towel available when working with chemical contacts wash immediately with soap and water chemical gets into flush immediately with water
• W ash hands and face after using chemicals and before eating, drinking, smoking, urination.
• not smoke eat while applying chemicals.
• After handling always bathe shower and change W ash clothing before wearing
• Seek medical attention immediately if illness occurs during shortly after use
• Store chemicals a locked area away from human livestock Keep children away
• Always dispose containers properly T riple rinse empty containers and puncture crush containers and dispose properly
• Keep chemicals original not transfer chemicals unmarked containers containers used for food drink.
Handling Batteries Safely
Battery gas can Keep sparks and flames away from Use a flashlight check battery electrolyte
Never check battery charge placing a metal object across the Use a voltmeter hydrometer
Always remove grounded ( battery clamp first and replace grounded clamp last.
Sulfuric acid battery electrolyte poisonous and strong enough burn eat holes in and cause blindness splashed into
A void hazards by:
• Filling batteries a well - ventilated area
• W earing eye protection and rubber gloves
• A voiding use air pressure clean batteries
• A voiding breathing fumes when electrolyte added
• A voiding spilling dripping electrolyte
• Using correct battery booster charger
acid spilled skin eyes:
Flush skin with water
Apply baking soda lime help neutralize the Flush eyes with water for Get medical attention immediately .
acid swallowed: not induce vomiting. Drink large amounts water but not exceed 2 L
Get medical attention immediately W
ARNING: Battery posts, terminals, and related accessories contain lead and lead compounds, chemicals known the State California cause cancer and reproductive W ash hands after handling.
A void Heating Near Pressurized Fluid Lines
Flammable spray can generated heating near pressurized fluid resulting severe burns yourself and bystanders. not heat welding, soldering, using a torch near pressurized fluid lines other flammable Pressurized lines can accidentally burst when heat goes beyond the immediate flame
Remove Paint Before W elding Heating
A void potentially toxic fumes and
Hazardous fumes can generated when paint is heated welding, soldering, using a torch.
Remove paint before heating:
• Remove paint a minimum 100 in.) from area fected paint cannot wear approved respirator before heating
• you sand grind avoid breathing the W ear approved respirator
• you use solvent paint stripper , remove stripper with soap and water before welding. Remove solvent paint stripper containers and other flammable material from Allow fumes disperse least minutes before welding
not use a chlorinated solvent areas where welding will take place.
all work area that well ventilated carry toxic fumes and dust away
Dispose paint and solvent properly
Handle Electronic Components and Brackets
Safely
Falling while installing removing electronic components mounted equipment can cause serious injury Use a ladder platform easily reach each mounting
Use sturdy and secure footholds and not install remove components in wet icy
installing servicing a R base station a tower other tall use a certified climber
installing servicing a global positioning receiver mast used implement, use proper lifting techniques and wear proper protective equipment. The mast is heavy and can awkward T people are required when mounting locations are not accessible from the ground from a service
Practice Safe Maintenance
Understand service procedure before doing Keep area clean and dry
Never lubricate, service, adjust machine while Keep and clothing away from power - driven Disengage all power and operate controls relieve Lower equipment the Stop the Remove the key Allow machine
Securely support any machine elements that must raised for service
Keep all parts good condition and properly installed. Fix damage immediately . Replace worn broken parts. Remove any buildup
self - propelled disconnect battery ground cable ( before making adjustments electrical systems welding machine.
towed disconnect wiring harnesses from tractor before servicing electrical system components welding
Falling while cleaning working height can cause serious injury Use a ladder platform easily reach each Use sturdy and secure footholds and
A void Hot Exhaust
Servicing machine attachments with engine running can result serious personal injury . A void exposure and skin contact with hot exhaust gases and components.
Exhaust parts and streams become very hot during Exhaust gases and components reach temperatures hot enough burn melt common materials.
Clean Exhaust Filter Safely
During exhaust filter cleaning the engine may run elevated idle and hot temperatures for extended period Exhaust gases and exhaust filter components reach temperatures hot enough burn people, ignite melt common materials.
Keep machine away from structures which may susceptible harm damage from hot exhaust gases A void potential fire explosion hazards from flammable materials and vapors near the exhaust. Keep exhaust outlet away from people and anything that can
Closely monitor machine and surrounding area for smoldering debris during and after exhaust filter
Adding fuel while engine is running can create a fire explosion Always stop engine before refueling machine and clean any spilled
Always make sure that engine is stopped while hauling machine a truck trailer
Contact with exhaust components while still hot can result serious personal injury .
A void contact with these components until cooled safe
service procedure requires engine running:
• Only engage power - driven parts required service procedure
• Ensure that other people are clear operator station and machine
Keep and clothing away from power - driven
Always disable movement set the parking brake mechanism and disconnect power attachments tools before leaving the operator ’ s
Shut f engine and remove key (if equipped) before leaving the machine
W ork V
entilated Area
Engine exhaust fumes can cause sickness necessary run engine in enclosed remove the exhaust fumes from the area with exhaust pipe you not have exhaust pipe open the doors and get outside air into the
Support Machine Properly
Always lower the attachment implement the ground before you work the the work requires that the machine attachment provide secure support for left a raised hydraulically supported devices can settle leak not support the machine cinder hollow props that may crumble under continuous not work under a machine that is supported solely a Follow recommended procedures in this
When implements attachments are used with a always follow safety precautions listed the implement attachment
Prevent Machine Runaway
A void possible injury death from machinery runaway . not start engine shorting across starter Machine will start in gear normal circuitry is NEVER start engine while standing Start engine only from operator ’ s with transmission neutral
Park Machine Safely
Before working the machine:
• Lower all equipment the
• Stop the engine and remove the key .
• Disconnect the battery ground
• Hang a "DO NOT OPERA TE" tag in operator
T ransport T ractor Safely
A disabled tractor best transported a flatbed carrier
Use chains secure the tractor the carrier The axles and tractor frame are suitable attachment
Before transporting the tractor a low - loader truck flatbed rail make sure that the hood is secured over the tractor engine and that roof hatch (if equipped) and windows are properly
Never tow a tractor a speed greater than km/h
An operator must steer and brake the tractor under tow
Service Cooling System Safely
Explosive release fluids from pressurized cooling system can cause serious
Shut f Only remove filler cap when cool enough touch with bare hands. Slowly loosen cap first stop relieve pressure before removing completely .
Service Accumulator Systems Safely
Escaping fluid gas from systems with pressurized accumulators that are used air and air brake systems can cause serious injury Extreme heat can cause the accumulator and pressurized lines can accidentally cut. not weld use a torch near a pressurized accumulator pressurized line.
Relieve pressure from the pressurized system before removing accumulator
Relieve pressure from the hydraulic system before removing accumulator Never attempt relieve hydraulic system accumulator pressure loosening a
Accumulators cannot repaired.
Service T ires Safely
Explosive separation a tire and rim parts can cause serious injury
not attempt mount a tire unless you have the proper equipment and experience perform the
Always maintain the correct tire not inflate the tires above the recommended pressure. Never weld heat a wheel and tire assembly The heat can cause increase air pressure resulting in a tire W elding can structurally weaken deform the
When inflating tires, use a clip - chuck and extension hose long enough allow you stand one side and NOT front over the tire assembly Use a safety cage
Wheels and tires are heavy . When handling wheels and tires use a safe lifting device get assistant help
Check wheels for low cuts, damaged rims, missing lug bolts and nuts.
Service Front-Wheel Drive T ractor Safely
When servicing front - wheel drive tractor with the rear wheels supported f the ground and rotating wheels engine power , always support front wheels in a similar manner . Loss electrical power transmission hydraulic system pressure will engage the front driving pulling the rear wheels f the support front wheels are not Under these front drive wheels can engage even with switch in disengaged
T
ightening Wheel Retaining Bolts/Nuts
T orque wheel retaining bolts/nuts the intervals specified section Break - Period and
A void High-Pressure Fluids
Inspect hydraulic hoses periodically – least once per year – for
exposed wire braid any other signs wear
Replace worn damaged hose assemblies immediately with John Deere approved replacement
Escaping fluid under pressure can penetrate the skin causing serious injury .
A void the hazard relieving pressure before disconnecting hydraulic other T ighten all connections before applying
Search for leaks with a piece Protect hands and body from high - pressure
with this type injury should reference a knowledgeable medical Such information available English from Deere & Company Medical Department calling 1 - 800 - 822 - 8262
accident occurs, see a doctor immediately . Any fluid injected into the skin must surgically removed within a few hours gangrene may Doctors unfamiliar
309 - 748 -
Not Open
High-Pressure Fuel System
High - pressure fluid remaining in fuel lines can cause serious injury not disconnect attempt repair fuel lines, sensors, any other components between the high - pressure fuel pump and nozzles engines with High Pressure Common Rail (HPCR) fuel
Only technicians familiar with this type system can perform repairs. (See your John Deere dealer
Store Attachments Safely
Stored attachments such dual cage and loaders can fall and cause serious injury
Securely store attachments and implements prevent Keep playing children and bystanders away from storage
Decommissioning Proper Recycling and Disposal Fluids and Components
Safety and environmental stewardship measures must taken into account when decommissioning a machine and/or component. These measures include the following:
• Use appropriate tools and personal protective equipment such face shields during the removal handling objects and materials.
• Follow instructions for specialized
• Release stored energy lowering suspended machine relaxing disconnecting the battery other electrical power , and releasing pressure hydraulic and other similar
• Minimize exposure components which may have residue from agricultural such fertilizers and Handle and dispose these components appropriately
• Carefully drain fuel hydraulic and lines before recycling components. Use leak - proof containers when draining fluids. not use food beverage containers.
• not pour waste fluids onto the down a into any water
• Observe all and local ordinances governing the handling disposal waste fluids (example: brake fluid);
filters; batteries; other substances Burning flammable fluids components other than specially designed incinerators may prohibited law and could result exposure harmful fumes
• Service and dispose air conditioning systems appropriately Government regulations may require a certified service center recover and recycle air conditioning refrigerants which could damage the atmosphere allowed
• Evaluate recycling options for rubber , and electronic components which may part completely
• Contact your local environmental recycling center , your John Deere dealer for information the proper way recycle dispose
The best method for delivering self - propelled and most implements attachments a flatbed truck trailer . Secure loads with tie down chains, and aware height and width restrictions avoid collision with bridge other road
Check with local authorities regarding oversized load transport restrictions and
When remember that towed loads can upset cause loss control when towed with undersized towing unit.
Never tow implement behind a truck other motor The ability maintain control and brake the implement and vehicle mass is The ability properly attach the implement hitch and safety chain the motor vehicle may marginal. With most motor vehicles not possible properly operate the tail and turn signal lights the and most cases the implement tires are not rated for highway
T drawn implements only with a properly sized and weighted tractor equipped with a stationary drawbar (See tractor manual for ballast
the proper size rear tires and the sway blocks should the down not transport unless the tractor front end ballasted the weight levels specified the tractor manual for the correct implement
Before attach a properly sized safety tow chain between the implement and tractor
Stopping distance increases with speed and weight towed and when transporting Observe these recommended maximum road local speed limits that may lower:
• towed equipment does not have not transport speeds above km/h (20 mph) and not tow loads that weigh more than times the weight the tractor
• the towed equipment has not transport speeds above km/h (25 mph) and not tow loads more than times the weight the tractor
Use additional caution and reduce speed when towing under adverse surface when and when inclines.
Attach the implement lighting harness the tractor and make sure that the warning and taillights both the tractor and implement are and functioning properly
Integral and semi - integral implements should attached a tractor with a three - point hitch specified the implement The tractor should have
Make sure that the SMV and other markings the implement are clean and
Information A vailable Sections, Groups and Subgroups
IMPORT ANT : T roubleshoot the equipment one problem a Repairing one system problem could solve a problem several
• Observable Symptoms/System Diagnostics
• Calibration Procedures
• Preliminary Checks
• Operational Checks
NOTE: determined that a problem is not in a specific section the diagnostic procedure references another , more appropriate
• T ests and Adjustments
Groups contain THEOR Y OPERA The theory operation gives a quick look what the system does and more detailed information about how the system
Each section identifies a major category Sections ending the number nine contain connector information, component identification, and location photographs for the various For Section 249 contains electrical connector and component information and Section 279 contains hydraulic component identification and
Within each section, the manual is divided into groups and subgroups with blocks
Groups contain SCHEMA The schematic a graphical representation the and Each component represented the schematic has a unique name and designator used for identifying parts the diagnostic These names could dif ferent than the names used conversation marketing
Groups contain general standard other information not associated with a specific system.
Groups contain reference material utilized in diagnostic contain the following information:
Groups contain DIAGNOSTIC The diagnostic procedures provide detailed step - - step instructions help isolate failed components.
ITEM
Glossary T erms
ABBREVIA TION
Accessory ACC
Air Conditioning A/C
Alternating Current AC
DESCRIPTION
Secondary electrical system
System used for cooling the air the cab
Electrical current that reverses its direction regularly recurring intervals
Battery Bat A device used furnish electrical current
Brakes BR
Abbreviation
Charge Air Cooler CAC A device used for cooling compressed intake air
Controller Area Network CAN A
Chassis Control Unit CCU
Circuit CCT A
Clockwise
Cold Cranking Amperes CCA
communication system linking - board electronics
Computerized system for tractor monitoring
complete path electrical current
Direction which the hands a clock rotate
measured capability perform during cold - weather operation
Component T echnical Manual CTM T echnical manual developed for the servicing major components
Counterclockwise CCW
Direction opposite the rotation the hands a clock
Diagnostic Receptacle A connection where hydraulic pressure can measured
Digital Multimeter DMM electrical multi - functional measuring device
Direct Current Electrical current flowing one direction only
Diesel Particulate Filter DPF
Engine Control Unit ECU
Portion the exhaust filter
Electronic device used house computerized system that controls engine functions
Exhaust Gas Recirculation EGR Engine emission
Electrohydraulic EH
Hydraulic valve function that controlled electrically
Electronic Components Relay ELX Relay powering most the electronic components
Open Operator Station OOS
Abbreviation
Forward FWD Direction movement
Forward - Neutral - Reverse FNR
Gallons per Minute gpm
V and Air
Conditioning AC
High - Pressure Common Rail HPCR
Hitch Control Unit HCU
Housing Hsg
Hydrostatic T ransmission HST
Hydraulic T railer Brake HTB
Ignition IGN
Inside Diameter
Instrument Cluster Control Unit ICC
International Standards Organization ISO
Joint Industry Council Organization JIC
Left - Hand L - H
Abbreviation
Amount fluid displaced over a period one minute
Abbreviation
Abbreviation
Computerized system used control hitch functions
Abbreviation
Computerized system used control hydrostatic transmission functions
Abbreviation
Control for starting and stopping the tractor
Abbreviation
Computerized system used control instrument cluster functions
Standards organization
Standards organization
Abbreviation
Liquid Crystal Display LCD A technology used for displaying information
Manifold Air Pressure MAP Air Pressure measured engine air intake
Mechanical Mech MECH Abbreviation
Mechanical Front Wheel Drive MFWD A mechanically powered front axle
ITEM
ABBREVIA TION
DESCRIPTION
Negative Neg Electrical Ground Circuit
Abbreviation
Number
Nitrogen Oxide NOx Engine emission
O - ring Face Seal ORFS ORS A type seal used hydraulic connections
Outside Diameter
Open Operator Station OOS
Performance Monitor Perf Mon PrF
Positive Pos (+)
Abbreviation
Abbreviation
Abbreviation
Charged part electrical circuit
Potentiometer POT A device used vary electrical voltage
Power T ake - f PT O
Power T rain Reverser PTR
Abbreviation
Computerized system used control power reverse transmission functions
Pressure Control V alve PCV V alve used control pressure within a system
Pressure Regulating V alve PR V A device used regulate pressure a system
Selective Control V alve SCV Device used control remote hydraulic functions
Slow Moving V ehicle SMV W arning sign the rear the tractor
Society Automotive Engineers SAE
Specification Spec
Switch SW
T achometer T ach
T ail Light
Engineering Standards Organization
Abbreviation
Abbreviation
Abbreviation
Abbreviation T emperature T emp
Three - Point Hitch 3PT
T ransmission T rans
Abbreviation
Abbreviation
Abbreviation
T ransient V oltage Protection TVP electrical device used protect a circuit from voltage surge
User Interface Module UIM
V oltage olts) V
V oltage Detector V Det
W arning Lamp
Abbreviation
Abbreviation
Abbreviation
Abbreviation Without W/O
Abbreviation
Wide - Open Throttle WOT Full throttle
T - Wheel Drive 2WD V ehicle where only one pair wheels powered
AMP®
AutoT rac™
BioGard™
BIO - GREASEGARD™
BreakPlus™
BreakIn™
CINCH®
COOLGARD™
COOLSCAN PLUS™
rademarks
rademark T yco Electronics
rademark Deere & Company
rademark Deere & Company
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rademark Cinch
rademark Deere & Company
rademark Deere & Company CoolScan™
Custom Performance™
Deere™
DEUTSCH®
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rademark Deere & Company
rademark DeutschGard™
rademark Deere & Company
John Deere™
rademark Deere & Company Loctite®
rademark Henkel Corporation
Metri - Pack®
rademark Delphi Connection Systems PowrReverser™
RollGard™
Service ADVISOR™
SER VICEGARD™
rademark Deere & Company
rademark Deere & Company
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rademark Deere & Company TEFLON®
WEA THER P ACK®
rademark Pont
rademark Packard Electric
The nominal torque values listed are for general use only with the assumed wrenching accuracy such a manual torque NOT use these values a dif ferent torque value tightening procedure given for a specific
For lock for stainless steel for nuts U - see the tightening instructions for the specific
• Make sure that fastener threads are
strength the
• Apply a thin coatGard™ equivalent oil under the head and the threads the fastener , shown the following
• conservative with the amount oil reduce the potential for hydraulic lockup blind holes due excessive
• Properly start thread
TS1741 Y18 a Hex
b Hex flange
Unified Inch Bolt and Screw T orque V alues
TS1671 Y03
1 - 3/8
The nominal torque values listed are for general use only with the assumed wrenching accuracy such a manual torque NOT use these values a dif ferent torque value tightening procedure given for a specific For lock for stainless steel for nuts U - see the tightening instructions for the specific Replace fasteners with the same higher property higher property class fasteners are tighten these the strength the
• Make sure that fastener threads are
• Apply a thin coatGard™ equivalent oil under the head and the threads the fastener , shown the following
• Be conservative with the amount oil reduce the potential for hydraulic lockup blind holes due excessive
• Properly start thread TS1741 Y18
a Grade 1 applies for hex cap screws over 6 (152 mm) and for all other types bolts and screws any
b Grade 2 applies for hex cap screws (not hex bolts) 6 (152 mm)
c Hex head column values are valid for ISO 4014 and ISO 4017 hex ISO 4162 hex socket and ISO 4032 hex
d Hex flange column values are valid for ASME ISO 1665 hex flange
Metric Cap Screw T orque V 7
NOTE: When bolting aluminum tighten 80% torque specified in
Gasket Sealant Application
Clean both surfaces that will joined using 100% isopropyl alcohol. Wipe excess f with a clean Cleaner/degreaser can substituted for isopropyl
How Apply , and Assemble Gasket
providing complete This can judged the appearance the joint once put together Excessive amounts material will cause incorrect bearing end play , extend cure and will cause runof f the A small bead buildup the joint permissible and indicates good dispersion through the Excess can wiped from the Joining should take place within three minutes after sealant
Dispence approximately 1 2 oz. flexible form - - place gasket a clean sheet table A void using excess amounts that may exposed for long periods This will help prevent contamination from surrounding atmosphere such dust with metal
Using ink roller similar apply one surface the joint loading the roller from a plastic sheet and transferring the material in a thin film the The application should the thinnest film but
Apply proper cap screw torque and sequence applicable. Allow a minimum minutes before air test adding oil for test stand
Cured material can removed with a wire brush scraper . Chemical cleaners are available for use, should they deemed necessary .
Service Recommendations For Flat Face
O-Ring Seal Fittings
Inspect the fitting sealing surfaces and O - They must free dirt defects.
Lubricate O - rings and install into grove using petroleum jelly hold
Index angle fittings and tighten hand pressing joint together insure O - ring remains T ighten fitting nut torque value shown the not allow hoses twist when tightening fittings, use backup wrench straight hose couplings.
IMPORT ANT : T ighten fittings 150% listed torque value indexing necessary fitting attached actuating
ighten fittings 50% listed torque value used aluminum housing.
