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Table of Contents tm1691 Service ADVISOR™ tm1691 Service ADVISOR™ (1) Safety Features Recognize Safety Information Follow Safety Instructions Operate Only If Qualified Wear Protective Equipment Avoid Unauthorized Machine Modifications Inspect Machine Stay Clear of Moving Parts Avoid High-Pressure Fluids Beware of Exhaust Fumes Prevent Fires Prevent Battery Explosions Handle Chemical Products Safely Dispose of Waste Properly Prepare for Emergencies Use Steps and Handholds Correctly Start Only From Operator's Seat Use and Maintain Seat Belt Prevent Unintended Machine Movement Avoid Work Site Hazards Keep Riders Off Machine Avoid Backover Accidents Avoid Machine Tipover Add and Operate Attachments Safely Use Special Care When Operating Operating or Traveling On Public Roads Inspect and Maintain ROPS Stay Clear of Rotating Drivelines Park and Prepare for Service Safely Service Cooling System Safely Remove Paint Before Welding or Heating Make Welding Repairs Safely Drive Metal Pins Safely Safety Sign General Information POWERTECH 4.5L (4045) and 6.8L (6068) John Deere Engines Engine—Sectional View General Engine Description POWERTECH 4.5L (4045) and 6.8L (6068) John Deere Engines (1) Make Visual Inspection of Engine and Supporting Systems Diagnose Engine Malfunctions tm1691

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POWERTECH 4.5L (4045) and 6.8L (6068) John Deere Engines (2) JT05801 Clamp-On Electronic Tachometer Installation Adjust Engine Speed Control Linkage (S.N. 872335—882699) Adjust Engine Speed Control Linkage (S.N. 882700— ) Adjust Slow and Fast Idle (S.N. —882699) POWERTECH 4.5L (4045) and 6.8L (6068) John Deere Engines (3) Air Intake System Leakage Test Altitude Compensator Boost Pressure Engine Performance Test Injection Pump Timing (S.N. —882699) Injection Pump Timing (S.N. 882700— ) Fuel Line Leakage Test Electrical Diagram Information Component Identification Table Fuse (Blade-Type) Color Codes Fuse Location and Specifications (S.N. —880053) Wiring and Schematic Diagrams Legend (S.N. —880053) System Functional Schematic Section Legend (S.N. —880053) System Functional Schematic (S.N. —880053) Fuse Location and Specifications (S.N. 880054—882699) Wiring and Schematic Diagrams Legend (S.N. 880054—882699) System Functional Schematic Section Legend (S.N. 880054—882699) System Functional Schematic (S.N. 880054—882699) Fuse Location and Specifications (S.N. 882700— ) Wiring and Schematic Diagrams Legend (S.N. 882700— ) System Functional Schematic Section Legend (S.N. 882700— ) System Functional Schematic (S.N. 882700— ) Main Harness (W4) Component Location (S.N. —880053) Main Harness (W4) Connectors, Wire and Pin Location (S.N. —880053) Main Harness (W4) Component Location (S.N. 880054—882699) Main Harness (W4) Connectors, Diode, Wire and Pin Location (S.N. 880054—882699) Main Harness (W4) Component Location (S.N. 882700— ) Main Harness (W4) Connectors, Diode, Wire and Pin Location (S.N. 882700— ) Transmission Diode Harness (W5) Component Location (S.N. —880053) Transmission Diode Harness (W5) Component Location (S.N. 880054— ) Differential Lock, Park Brake and MFWD Solenoid Diode Harness (W6) Component Location (S.N. —880053) Differential Lock, Park Brake and MFWD Solenoid Diode Harness (W6) Component Location (S.N. 880054— ) ROPS Harness (W7) Component Location (S.N. —880053) ROPS Harness (W7) Component Location (S.N. 880054— ) Dash Harness (W8) Component Location (S.N. —880053) Dash Harness (W8) Connector, Wire and Pin Location (S.N. —880053) Dash Harness (W8) Component Location (S.N. 880054—882699) Dash Harness (W8) Connector, Wire, and Pin Location (S.N. 880054—882699) Dash Harness (W8) Component Location (S.N. 882700— ) Dash Harness (W8) Connector, Wire, and Pin Location (S.N. 882700— ) tm1691

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10 5 10 6 10 7 11 2 11 4 11 6 11 7 11 9 12 2 12 4 12 5 12 6 13 3 13 5 13 6 13 8 14 1 14 2 14 4 14 6 14 9 15 0 15 3 15 6 16 1 16 2

Engine Harness (W9) Component Location (S.N. 882700— ) Engine Harness (W9) Connector, Wire, and Pin Location (S.N. 882700— ) Power Shift Transmission Harness (W10) Component Location Power Shift Transmission Harness (W10) Connector, Wire, and Pin Location 12-Volt Power Outlet Harness (W11) Component Location—Optional (S.N. 882700— ) Power Circuit Operational Information (S.N. —880053) Power Circuit Theory of Operation (S.N. —880053) Power Circuit Schematic (S.N. —880053) Power Circuit Operational Information (S.N. 880054— ) Power Circuit Theory of Operation (S.N. 880054— ) Power Circuit Schematic (S.N. 880054— ) Power Circuit Sub-System Diagnostics Start Circuit Operational Information Start Circuit Theory of Operation (S.N. —880053) Start Circuit Schematic (S.N. —880053) Start Circuit Theory of Operation (S.N. 880054— ) Start Circuit Schematic (S.N. 880054— ) Start Circuit Sub-System Diagnostics Charging Circuit Operational Information Charging Circuit Theory of Operation Charging Circuit Schematic (S.N. —880053) Charging Circuit Schematic (S.N. 880054— ) Charging Circuit Sub-System Diagnostics PTO Circuit Operational Information—If Equipped PTO Circuit Theory of Operation—If Equipped PTO Circuit Schematic—If Equipped PTO Circuit Sub-System Diagnostics—If Equipped Display Monitor and Warning Indicator Switches Circuit Specifications Display Monitor and Warning Indicator Switches Circuit Operational Information Display Monitor and Warning Indicator Switches Circuit Theory of Operation (S. N. —880053) Display Monitor and Warning Indicator Switches Circuit Schematic (S.N. —880053) Display Monitor and Warning Indicator Switches Circuit Theory of Operation (S.N. 880054—882699) Display Monitor and Warning Indicator Switches Circuit Schematic (S.N. 880054—882699) Display Monitor and Warning Indicator Switches Circuit Theory of Operation (S. N. 882700— ) Display Monitor and Warning Indicator Switches Circuit Schematic (S.N. 882700— ) Display Monitor and Warning Indicator Switches Circuit Sub-System Diagnostics Neutral Disconnect Circuit Specifications—Manual Shift Neutral Disconnect Circuit Operational Information—Manual Shift Neutral Disconnect Circuit Theory of Operation—Manual Shift Neutral Disconnect Circuit Schematic—Manual Shift (S.N. —880053) Neutral Disconnect Circuit Schematic—Manual Shift (S.N. 880054— ) Neutral Disconnect Circuit Sub-System Diagnostics—Manual Shift tm1691

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Range Shift Circuit Theory Of Operation—Power Shift Range Shift Circuit Schematic—Power Shift Range Shift Circuit Sub-System Diagnostics—Power Shift Engine Control Unit Circuit Theory of Operation and Circuit Schematic (S.N. 882700— ) Alternators and Starting Motors Access Engine Diagnostic Trouble Codes Using Blink Method (S.N. 882700— ) Engine Diagnostic Trouble Codes (S.N. 882700— ) Throttle Position Sensor Test (S.N. 882700— ) Engine Coolant Temperature Sensor Test Battery Operation Battery Specifications Diagnose Battery Malfunctions Check Battery Electrolyte Level And Terminals Using Booster Batteries—12 Volt System Alternator Operation—65 Amp Bosch Forward, Reverse, Low Range Forward and Third Speed Clutch Pack Operation Power Shift High Range Forward, First Speed and Second Speed Clutch Packs Manual Shift Power Train Overview Torque Converter Operation Manual Shift Synchronizer Operation Transmission Pump Operation Transmission Filter Operation Manual Shift Transmission Operation—First Gear Forward Manual Shift Transmission Operation—Third Gear Reverse Power Shift Power Train Overview Power Shift Transmission Gear Flow Mechanical Front Wheel Drive (MFWD) Operation Manual Shift Transmission Control Valve Operation Manual Shift Transmission Control Circuit—Neutral with Park Brake Off Manual Shift Transmission Control Circuit—Forward Manual Shift Transmission Control Circuit—Reverse Power Shift Transmission Clutch Engagement And Solenoids Activated Power Shift Transmission Control Circuit—Neutral With Park Brake Off Power Shift Transmission Control Valve and Shift Valve Operation—Neutral Power Shift Transmission Control Circuit—First Forward Power Shift Transmission Control Valve and Shift Valve—First Forward Power Shift Transmission Control Circuit—High Range (Fourth) Forward Power Shift Transmission Control Valve and Shift Valve—High Range (Fourth) Forward Power Shift Transmission Control Circuit—First Reverse Power Shift Transmission Control Valve and Shift Valve—First Reverse Manual Shift Modulation Valve Operation Power Shift Modulation Valve Operation Differential Operation Differential Lock Operation Brake Valve Operation (S.N. —880907) tm1691

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Brake Valve Operation—General Information (S.N. 880908— ) Brake Valve Operation—Neutral, Engine Operating (S.N. 880908— ) Brake Valve Operation—One Pedal Applied, Engine Operating (S.N. 880908— ) Brake Valve Operation—Both Pedals Applied, Engine Operating (S.N. 880908— ) Brake Valve Operation—Both Pedals Applied, Engine Stopped (S.N. 880908— ) Service Brake Operation Park Brake Operation MFWD Differential Operation—Unequal Traction (If Equipped) MFWD Differential Operation—Equal Traction (If Equipped) Diagnose Power Train Malfunction Diagnose MFWD Malfunction—If Equipped Diagnose Rear Axle Malfunction Hydraulic Circuit Symbols Adjust Brake Pedals and Equalizing Valves (S.N. —880907) Adjust Brake Pedals (S.N. 880908— ) Bleed Service Brakes (S.N. —880907) Bleed Service Brakes (S.N. 880908— ) Tracking Angle Check and Adjust—MFWD Axle Toe-In Check and Adjust Steering Angle Check and Adjust—MFWD Axle Transmission Oil Warm-Up Procedure Manual Shift Transmission Overall Test Connections, Ports, and Locations Power Shift Transmission Overall Test Connections, Ports, and Locations Torque Converter Stall Speed Test Converter-In Relief Valve Test Brake Valve Leakage Test Park Brake Release Pressure Test Transmission System Pressure Test Manual Shift Forward and Reverse Clutch Pressure Test Power Shift Low Range Forward, High Range Forward, Reverse and Speed Clutch Pressure Test Reducing Valve Pressure Test Modulation Valve Pressure Test Differential Lock Pressure Test MFWD Pressure Test—If Equipped Transmission Cooler In and Cooler Out Pressure Test Solenoid Circuit Leakage Test Transmission Pump Flow Test Open-Center Hydraulic System Hydraulic System Component Location (S.N. —872334) Hydraulic System Component Location (S.N. 872335—880907) Hydraulic System Component Location (S.N. 880908–882034) Hydraulic System Component Location (S.N. 882035—882699) Hydraulic System Component Location (S.N. 882700—883904) Hydraulic System Component Location (S.N. 883905— ) Hytdmr1a6u9l1ic System Schematic (S.N. —883904)5

46 6 46 7 47 0 47 3 47 6 47 8 48 0 48 2 48 4 48 5 50 4 50 5 51 2 51 3 51 7 51 9 52 1 52 4 52 6 53 0 53 2 53 5 53 7 53 9 54 2 54 5

Hydraulic System Schematic (S.N. 883905— ) Hydraulic Control Valve Component Locations (S.N.883905— ) Hydraulic Pump Operation Hydraulic Filter Operation Steering Valve Operation Priority Valve Operation (S.N. —883904) Priority Valve Section Operation —Steering Actuated (S.N. 883905— ) Relief Valve Operation With Anticavitation (S.N. 883905— ) Relief Valve Without Anticavitation (S.N. 883905— ) Outlet Plate (S.N. —883904) Control Valve—Bucket Section (S.N. —883904) Control Valve—Boom Section—Raise (S.N. —883904) Control Valve—Boom Section—Lower (S.N. —883904) Control Valve—Boom Section—Float (S.N. —883904) Control Valve—Flow Control Section (S.N. —883904) Control Valve—Hitch Lift Section (S.N. —883904) Control Valve—Hitch Pitch Section (S.N. —883904) Control Valve—Hitch Tilt and Auxiliary Sections (S.N. —883904) Control Valve—Inlet Section with System Relief Valve (S.N. 883905— ) Control Valve—Bucket Section—Dump (S.N. 883905— ) Control Valve—Boom Section—Raise (S.N. 883905— ) Control Valve—Flow Control Section (S.N. 883905— ) Control Valve—Boom Section—Float (S.N. 883905— ) Control Valve—Hitch Pitch Section (S.N. 883905— ) Control Valve—Hitch Lift Section—Raise (S.N. 883905— ) Control Valve—Hitch Tilt and Auxiliary Sections (S.N. 883905— ) Use These Seven Basic Steps to Diagnose and Test the Hydraulic System Make a Pretest Inspection and an Operation Check of the Machine Hydraulic System Pretest Diagnose Hydraulic System Problems Loader Bucket Self-Leveling Linkage Indicator Adjustment (S.N. —870948) Loader Bucket Self-Leveling Linkage Indicator Adjustment (S.N. 870949— ) Return-to-Dig Switch Adjustment JT05800 Digital Thermometer Installation Hydraulic Oil Warm-Up Procedure Hydraulic Pump Flow Test (S.N. —880053) Hydraulic Pump Flow Test (S.N. 880054—883904) Hydraulic Pump Flow Test (S.N. 883905— ) Priority Relief Valve Pressure Test (S.N. —888053) Priority Relief Valve Pressure Test (S.N. 880054—883904 ) Priority Relief Valve Pressure Test (S.N. 883905— ) System Relief Valve Pressure Test (S.N. —883904) System Relief Valve Pressure Test (S.N. 883905— ) Hydraulic Oil Cooler Restriction Test (S.N. —883904) Hydraulic Oil Cooler Restriction Test (S.N. 883905— ) tm1691

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Circuit Relief Valve Test—With Remote Pump (S.N. —883904) Circuit Relief Valve Test—With Remote Pump (S.N. 883905— ) Steering System Leakage Test Steering Cylinder Leakage Test Hydraulic Cylinder Drift Test Procedure Function Drift Test Cylinder Leakage Test Cycle Time Specifications (S.N. —883904) Cycle Time Specifications (S.N. 883905— ) Hydrostatic PTO System Component Location (S.N. —882699) Hydrostatic PTO System Component Location (S.N. 882700—) Hydrostatic PTO System Schematic—If Equipped Hydrostatic PTO Pump Operation—If Equipped Hydrostatic PTO Pump Control Circuit Operation—Actuated Hydrostatic PTO High Pressure Relief Valve Operation Hydrostatic PTO Motor Operation—If Equipped Diagnose Hydrostatic PTO System Problems Before Performing Hydrostatic PTO Tests and Adjustments Hydrostatic PTO Pump Servo Piston Neutral Adjustment—If Equipped Before Performing Hydrostatic PTO Tests and Adjustments (1) Hydrostatic PTO Pump Neutral Charge Relief Valve Pressure Test and Adjustment—If Equipped Hydrostatic PTO Pump High Pressure Relief Valve and Pressure Override Valve Tests and Adjustments—If Equipped PTO Oil Cooler Restriction Test (S.N. —882699) PTO Oil Cooler Restriction Test (S.N. 882700—)

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Foreword This manual is wri en for an experienced technician. Essen al tools required in performing certain service work are iden fied in this manual and are recommended for use.

Live with safety: Read the safety messages in the introduc on of this manual and the cau ons presented throughout the text of the manual.

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

Technical manuals are divided in two parts: repair and opera on and tests. Repair sec ons tell how to repair the components. Opera on and tests sec ons help you iden fy the majority of rou ne failures quickly.

Informa on is organized in groups for the various components requiring service instruc on. At the beginning of each group are summary lis ngs of all applicable essen al tools, service equipment and tools, other materials needed to do the job, service parts kits, specifica ons, wear tolerances, and torque values.

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

Fundamental service informa on is available from other sources covering basic theory of opera on, fundamentals of troubleshoo ng, general maintenance, and basic type of failures and their causes.

To order a technical manual, see DB1990 Service Publica ons Catalog. A complete Opera on and Test manual includes the following sec ons: Sec on 9000 General Informa on Sec on 9005 Opera onal Checkout Procedure Sec on 9010 Engine Sec on 9015 Electrical System Sec on 9020 Power Train Sec on 9025 Hydraulic System Sec on 9026 Hydrosta c PTO System

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For the full PDF version of this manual, Please click on the above download PDF button.

Technical Informa on Feedback Form We need your help to con nually improve our technical publica ons. Please copy this page and FAX or mail your comments, ideas and improvements.

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Safety Features

T136893-19: Safety Features

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Recognize Safety Informa on

T133555-UN: Safety alert Symbols

T133588-19: Safety Alert Symbols This is the safety alert symbol. When you see this symbol on your machine or in this manual, be alert for the poten al of personal injury.

Follow the precau ons and safe opera ng prac ces highlighted by this symbol.

A signal word — DANGER, WARNING, or CAUTION — is used with the safety alert symbol. DANGER iden fies the most serious hazards.

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

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Follow Safety Instruc ons

T133556-UN: Follow Safety Instruc ons Read the safety messages in this manual and on the machine. Follow these warnings and instruc ons carefully. Review them frequently. Keep safety signs in good condi on. Replace missing or damaged safety signs. Be sure new equipment components and repair parts include the current safety signs.

Replacement safety signs are available from your authorized John Deere dealer.

Be sure all operators of this machine understand every safety message. Replace operator's manual and safety labels immediately if missing or damaged.

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Operate Only If Qualified Do not operate this machine unless the operator's manual has been read carefully, and you have been qualified by supervised training and instruc on.

Operator should be familiar with the job site and surroundings before opera ng. Try all controls and machine func ons with the machine in an open area before star ng to work.

Know and observe all safety rules that may apply to every work situa on and work site.

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Wear Protec ve Equipment

TS206-UN: Protec ve Equipment Guard against injury from flying pieces of metal or debris; wear goggles or safety glasses.

Wear close fi ng clothing and safety equipment appropriate to the job.

Prolonged exposure to loud noise can cause impairment or loss of hearing. Wear suitable hearing protec on such as earmuffs or earplugs to protect against objec onable or uncomfortable loud noises.

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Avoid Unauthorized Machine Modifica ons Modifica ons of this machine, or addi on of unapproved products or a achments, may affect machine stability or reliability, and may create a hazard for the operator or others near the machine. The installer of any modifica on which may affect the electronic controls of this machine is responsible for establishing that the modifica on does not adversely affect the machine or its performance.

Always contact an authorized dealer before making machine modifica ons that change the intended use, weight or balance of the machine, or that alter machine controls, performance or reliability.

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Inspect Machine

T6607AQ-UN: Inspect Machine Inspect machine carefully each day by walking around it before star ng.

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

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Stay Clear of Moving Parts

T133592-UN: Stay Clear of Moving Parts Entanglements in moving parts can cause serious injury.

Stop engine before examining, adjus ng or maintaining any part of machine with moving parts.

Keep guards and shields in place. Replace any guard or shield that has been removed for access as soon as service or repair is complete.

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Avoid High-Pressure Fluids

T133509-UN: Avoid High Pressure Fluids

T133840-UN: Avoid High-Pressure Fluids This machine uses a high-pressure hydraulic system. Escaping fluid under pressure can penetrate the skin causing serious injury.

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

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

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Beware of Exhaust Fumes

T133546-UN: Beware of Exhaust Fumes Prevent asphyxia on. Engine exhaust fumes can cause sickness or death.

If you must operate in an enclosed space, provide adequate ven la on. Use an exhaust pipe extension to remove the exhaust fumes or open doors and windows to bring outside air into the area.

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Prevent Fires

T133552-UN: Handle Fuel Safely

T133553-UN: Clean Machine Regularly

T133554-UN: Carry A Fire Ex nguisher Handle Fuel Safely: Store flammable fluids away from fire hazards. Never refuel machine while smoking or when near sparks or flame.

Clean Machine Regularly: Keep trash, debris, grease and oil from accumula ng in engine compartment, around fuel lines, hydraulic lines, exhaust components and electrical wiring. Never store oily rags or flammable materials inside a machine compartment.

Maintain Hoses and Wiring: Replace hydraulic hoses immediately if they begin to leak, and clean up any oil spills. Examine electrical wiring and connectors frequently for damage.

Keep A Fire Ex nguisher Available: Always keep a mul -purpose fire ex nguisher on or near the tm1691

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Prevent Ba ery Explosions

TS204-UN: Ba ery Explosions Ba ery gas can explode. Keep sparks, lighted matches, and open flame away from the top of ba ery.

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

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

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Handle Chemical Products Safely

T133580-UN: Handle Chemical Products Safely Exposure to hazardous chemicals can cause serious injury. Under certain condi ons, lubricants, coolants, paints and adhesives used with this machine may be hazardous.

If uncertain about safe handling or use of these chemical products, contact your authorized dealer for a Material Safety Data Sheet (MSDS) or go to internet website h p://www.jdmsds.com. The MSDS describes physical and health hazards, safe use procedures, and emergency response techniques for chemical substances. Follow MSDS recommenda ons to handle chemical products safely.

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Dispose of Waste Properly

T133567-UN: Dispose of Waste Properly Improper disposal of waste can threaten the environment. Fuel, oils, coolants, filters and ba eries used with this machine may be harmful if not disposed of properly.

Never pour waste onto the ground, down a drain, or into any water source.

Air condi oning refrigerants can damage the atmosphere. Government regula ons may require using a cer fied service center to recover and recycle used refrigerants.

If uncertain about the safe disposal of waste, contact your local environmental or recycling center or your authorized dealer for more informa on.

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Prepare for Emergencies

TS291-UN: First Aid Kit Be prepared if an emergency occurs or a fire starts.

Keep a first aid kit and fire ex nguisher handy.

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

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Use Steps and Handholds Correctly

T133468-UN: Use Handholds And Steps Prevent falls by facing the machine when you get on and off. Maintain 3-point contact with steps and handrails. Never use machine controls as handholds.

Use extra care when mud, snow, or moisture present slippery condi ons. Keep steps clean and free of grease or oil. Never jump when exi ng machine. Never mount or dismount a moving machine.

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For the full PDF version of this manual, Please click on the above download PDF button.