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John Deere 850J Crawler Dozer Operation & Test Technical Manual TM1730 – PDF DOWNLOAD
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Description
John Deere 850J Crawler Dozer Operation & Test Technical Manual TM1730 – PDF DOWNLOAD
FILE DETAILS:
John Deere 850J Crawler Dozer Operation & Test Technical Manual TM1730 – PDF DOWNLOAD
Language : English
Pages : 964
Downloadable : Yes
File Type : PDF
IMAGES PREVIEW OF THE MANUAL:
DESCRIPTION:
John Deere 850J Crawler Dozer Operation & Test Technical Manual TM1730 – PDF DOWNLOAD
- This manual is written for an experienced technician. Essential tools required in performing certain service work are identified in this manual and are recommended for use.
- Live with safety: Read the safety messages in the introduction of this manual and the cautions 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 potential for personal injury.
- Technical manuals are divided in two parts: repair and operation and tests. Repair sections tell how to repair the components. Operation and tests sections help you identify the majority of routine problems quickly.
- Information is organized in groups for the various components requiring service instruction. At the beginning of each group are summary listings of all applicable essential tools, service equipment and tools, other materials needed to do the job, service parts kits, specifications, wear tolerances, and torque values.
- Technical Manuals are concise guides for specific machines. They are on-the-job guides containing only the vital information needed for diagnosis, analysis, testing, and repair.
TABLE OF CONTENTS:
John Deere 850J Crawler Dozer Operation & Test Technical Manual TM1730 – PDF DOWNLOAD
Contents............................................................................................................... 5 General Information................................................................................................ 7 Safety......................................................................................................... 9 Recognize Safety Information............................................................................... 9 Follow Safety Instructions................................................................................. 9 Operate Only If Qualified.................................................................................. 9 Wear Protective Equipment.................................................................................. 10 Avoid Unauthorized Machine Modifications................................................................... 10 Inspect Machine............................................................................................ 10 Stay Clear of Moving Parts................................................................................. 10 Avoid High-Pressure Fluids................................................................................. 11 Beware of Exhaust Fumes.................................................................................... 11 Prevent Fires.............................................................................................. 12 Prevent Battery Explosions................................................................................. 12 Handle Chemical Products Safely............................................................................ 12 Dispose of Waste Properly.................................................................................. 13 Prepare for Emergencies.................................................................................... 13 Add Cab Guarding For Special Uses.......................................................................... 13 Use Steps and Handholds Correctly.......................................................................... 14 Start Only From Operator's Seat............................................................................ 14 Use and Maintain Seat Belt................................................................................. 14 Prevent Unintended Machine Movement........................................................................ 14 Avoid Work Site Hazards.................................................................................... 15 Keep Riders Off Machine.................................................................................... 15 Avoid Backover Accidents................................................................................... 16 Avoid Machine Tip Over and Machine Damage.................................................................. 16 Add and Operate Attachments Safely......................................................................... 16 Park and Prepare for Service Safely........................................................................ 17 Service Cooling System Safely.............................................................................. 17 Remove Paint Before Welding or Heating..................................................................... 17 Make Welding Repairs Safely................................................................................ 18 Drive Metal Pins Safely.................................................................................... 18 Diagnostic Trouble Codes (DTC)..................................................................................... 23 CAN Monitor Unit (CMU) Diagnostic Trouble Codes................................................................ 25 Diagnostic Trouble Code (DTC) Quick Reference List—CAN Monitor Unit (CMU).................................. 25 96.03 — Fuel Level Sensor Open or Short.................................................................... 25 96.04 — Fuel Level Sensor Short to Ground.................................................................. 26 107.03 — Engine Air Filter Restriction Indicator Switch Short to Power..................................... 26 107.04 — Engine Air Filter Restricted...................................................................... 26 177.03 — Transmission Oil Temperature Sensor Short to Power................................................ 27 177.04 — Transmission Oil Temperature Sensor Short to Ground............................................... 27 177.16 — Transmission Oil Temperature High................................................................. 27 Transmission Oil Temperature High...................................................................... 27 609.09 — CAN Communication Error, No TCU Message........................................................... 28 1638.00 — Hydraulic Oil Temperature High................................................................... 28 1638.03 — Hydraulic Oil Temperature Short to Power......................................................... 28 1638.04 — Hydraulic Oil Temperature Short to Ground........................................................ 29 1713.31 — Hydraulic Oil Filter Restricted.................................................................. 29 Hydraulic Oil Filter Restricted Diagnostic Procedure................................................... 29 2000.09 — CAN Communication Error, No ECU Configuration.................................................... 31 3156.09 — CAN Blade Mode Missing From EHC.................................................................. 32 3359.31 — Transmission Oil Filter Restricted............................................................... 32 Transmission Oil Filter Restricted Diagnostic Procedure................................................ 32 524227.31 — Fan Oil Filter Restricted...................................................................... 34 Fan Oil Filter Restricted Diagnostic Procedure......................................................... 34 Engine Control Unit (ECU) Diagnostic Trouble Codes............................................................. 37 Diagnostic Trouble Code (DTC) Quick Reference List—Engine Control Unit (ECU)............................... 37 Transmission Control Unit (TCU) Diagnostic Trouble Codes....................................................... 39 Diagnostic Trouble Code (DTC) Quick Reference List—Transmission Control Unit (TCU)......................... 39 70.00 — Park Lock Lever Inputs Both ON..................................................................... 41 70.01 — Park Lock Lever Inputs Both OFF.................................................................... 42 91.00 — Throttle Sensor Input Greater Than Maximum Calibration Value....................................... 43 91.01 — Throttle Sensor Input Less Than Minimum Calibration Value.......................................... 44 91.03 — Throttle Sensor Short to Power..................................................................... 45 91.04 — Throttle Sensor Open or Short...................................................................... 46 91.15 — Throttle Sensor Minimum Calibration Value Too High................................................. 46 91.16 — Throttle Sensor Maximum Calibration Value Too High................................................. 47 91.17 — Throttle Sensor Minimum Calibration Value Too Low.................................................. 47 91.18 — Throttle Sensor Maximum Calibration Value Too Low.................................................. 48 116.00 — Brake Pressure High............................................................................... 48 Brake Pressure Low Diagnostic Procedure................................................................ 48 116.01 — Brake Pressure Low................................................................................ 49 Brake Pressure Low Diagnostic Procedure................................................................ 49 116.03 — Brake Pressure Short to Power..................................................................... 51 116.04 — Brake Pressure Open or Short...................................................................... 52 158.03 — TCU System Volts Too High......................................................................... 52 158.04 — TCU System Volts Too Low.......................................................................... 53 177.00 — Transmission Over Temp............................................................................ 53 190.09 — CAN Communication Error No Engine Speed........................................................... 53 190.19 — CAN Communication Error Invalid Engine Speed...................................................... 54 521.00 — Decel Sensor Input Greater Than Maximum Calibration Value......................................... 54 521.01 — Decel Sensor Input Less Than Minimum Calibration Value............................................ 55 521.03 — Decel Sensor Short to Power....................................................................... 56 521.04 — Decel Sensor Open or Short........................................................................ 57 521.05 — Decel Sensor Brake Calibration Value Too Low...................................................... 58 521.06 — Decel Sensor Brake Calibration Value Too High..................................................... 58 521.15 — Decel Sensor Minimum Calibration Value Too High................................................... 59 521.16 — Decel Sensor Maximum Calibration Value Too Low.................................................... 59 521.17 — Decel Sensor Minimum Calibration Value Too Low.................................................... 60 521.18 — Decel Sensor Maximum Calibration Value Too Low.................................................... 60 581.00 — Speed Buttons Input Greater Than Maximum Calibration Value........................................ 60 Transmission Speed Control Sensor Input Greater Than Maximum Calibration Value Diagnostic Procedure.... 61 581.01 — Speed Buttons Input Less Than Minimum Calibration Value........................................... 62 581.03 — Speed Buttons Short to Power...................................................................... 63 581.04 — Speed Buttons Open or Short....................................................................... 64 581.15 — Speed Buttons Minimum Calibration Value Too High.................................................. 65 581.16 — Speed Buttons Maximum Calibration Value Too High.................................................. 66 581.17 — Speed Buttons Minimum Calibration Value Too Low................................................... 67 581.18 — Speed Buttons Maximum Calibration Value Too Low................................................... 68 604.03 — FNR Neutral Switch Open Circuit................................................................... 69 604.04 — FNR Neutral Switch Short Circuit.................................................................. 70 604.15 — FNR Neutral Switch Minimum Calibration Value Too High............................................. 71 604.16 — FNR Neutral Switch Maximum Calibration Value Too High............................................. 71 604.17 — FNR Neutral Switch Minimum Calibration Value Too Low.............................................. 72 604.18 — FNR Neutral Switch Maximum Calibration Value Too Low.............................................. 72 619.05 — Brake Solenoid No Response........................................................................ 73 620.03 — TCU 5V Supply Short to Power...................................................................... 74 620.04 — TCU 5V Supply Open or Short....................................................................... 76 907.03 — Left Speed Sensor Short to Power.................................................................. 78 907.04 — Left Speed Sensor Short........................................................................... 79 907.07 — Left Speed Sensor No Response..................................................................... 80 907.12 — Left Speed Sensor Open............................................................................ 80 908.03 — Right Speed Sensor Short to Power................................................................. 81 908.04 — Right Speed Sensor Short.......................................................................... 82 908.07 — Right Speed Sensor No Response.................................................................... 83 908.12 — Right Speed Sensor Open........................................................................... 83 977.05 — Fan Reverse Solenoid No Response.................................................................. 84 1071.05 — Fan Drive Solenoid Open Circuit.................................................................. 84 1071.06 — Fan Drive Solenoid Short Circuit................................................................. 85 2660.00 — Steer Sensor Input Greater Than Maximum Calibration Value........................................ 85 2660.01 — Steer Sensor Input Less Than Minimum Calibration Value........................................... 86 2660.03 — Steer Sensor Short to Power...................................................................... 87 2660.04 — Steer Sensor Open or Short....................................................................... 88 2660.15 — Steer Sensor Minimum Calibration Value Too High.................................................. 89 2660.16 — Steer Sensor Maximum Calibration Value Too Low................................................... 89 2660.17 — Steer Sensor Minimum Calibration Value Too Low................................................... 90 2660.18 — Steer Sensor Maximum Calibration Value Too Low................................................... 90 2661.00 — FNR Sensor Input Greater Than Maximum Calibration Value.......................................... 91 2661.01 — FNR Sensor Input Less Than Minimum Calibration Value............................................. 91 2661.03 — FNR Sensor Short to Power........................................................................ 92 2661.04 — FNR Sensor Open or Short......................................................................... 93 2661.15 — FNR Sensor Minimum Calibration Value Too High.................................................... 94 2661.16 — FNR Sensor Maximum Calibration Value Too Low..................................................... 94 2661.17 — FNR Sensor Minimum Calibration Value Too Low..................................................... 95 2661.18 — FNR Sensor Maximum Calibration Value Too Low..................................................... 95 522439.05 — Tank Bypass Solenoid Open Circuit.............................................................. 96 522440.05 — Blade Left Solenoid Open Circuit............................................................... 96 522440.06 — Blade Left Solenoid Short Circuit.............................................................. 97 522441.05 — Blade Right Solenoid Open Circuit.............................................................. 97 522441.06 — Blade Right Solenoid Short Circuit............................................................. 98 522442.00 — Blade Buttons Input Greater Than Maximum Calibration Value..................................... 99 522442.01 — Blade Buttons Input Less Than Minimum Calibration Value........................................100 522442.03 — Blade Buttons Short to Power...................................................................101 522442.04 — Blade Buttons Open or Short....................................................................102 522442.15 — Blade Buttons Minimum Calibration Value Too High...............................................103 522442.16 — Blade Buttons Maximum Calibration Value Too High...............................................104 522442.17 — Blade Buttons Minimum Calibration Value Too Low................................................105 522442.18 — Blade Buttons Maximum Calibration Value Too Low................................................106 522444.00 — Charge Pressure High...........................................................................106 522444.01 — Charge Pressure Low............................................................................107 522444.03 — Charge Pressure Short to Power.................................................................107 522444.04 — Charge Pressure Open or Short..................................................................108 522447.05 — Right Forward Pump Coil Open...................................................................108 Right Forward Pump Coil Open Diagnostic Procedure......................................................108 522447.06 — Right Forward Pump Coil Short..................................................................110 Right Forward Pump Coil Short Diagnostic Procedure.....................................................110 522447.15 — Right Forward Pump Threshold Calibration Value Too High........................................112 Right Forward Pump Threshold Calibration Value Too High Diagnostic Procedure...........................113 522447.16 — Right Forward Pump Max Speed Calibration Value Too High........................................113 522447.17 — Right Forward Pump Threshold Calibration Value Too Low.........................................113 Right Forward Pump Threshold Calibration Value Too High Diagnostic Procedure...........................114 522447.18 — Right Forward Pump Max Speed Calibration Value Too Low.........................................114 522448.05 — Right Reverse Pump Coil Open...................................................................114 Right Reverse Pump Coil Open Diagnostic Procedure......................................................115 522448.06 — Right Reverse Pump Coil Short..................................................................116 Right Reverse Pump Coil Short Diagnostic Procedure.....................................................117 522448.15 — Right Reverse Pump Threshold Calibration Value Too High........................................118 Right Reverse Pump Threshold Calibration Value Too High Diagnostic Procedure...........................119 522448.16 — Right Reverse Pump Max Speed Calibration Value Too High........................................119 522448.17 — Right Reverse Pump Thresh Calibration Value Too Low............................................119 Right Reverse Pump Threshold Calibration Value Too High Diagnostic Procedure...........................120 522448.18 — Right Reverse Pump Max Speed Calibration Value Too Low.........................................120 522449.05 — Left Reverse Pump Coil Open....................................................................120 Left Reverse Pump Coil Open Diagnostic Procedure.......................................................121 522449.06 — Left Reverse Pump Coil Short...................................................................122 Left Reverse Pump Coil Open Diagnostic Procedure.......................................................123 522449.15 — Left Reverse Pump Threshold Calibration Value Too High.........................................124 Left Reverse Pump Threshold Calibration Value Too High Diagnostic Procedure............................125 522449.16 — Left Reverse Pump Max Speed Calibration Value Too Low..........................................125 522449.17 — Left Reverse Pump Threshold Calibration Value Too Low..........................................125 Left Reverse Pump Threshold Calibration Value Too High Diagnostic Procedure............................126 522449.18 — Left Reverse Pump Max Speed Calibration Value Too Low..........................................126 522450.05 — Left Forward Pump Coil Open....................................................................126 Left Forward Pump Coil Open Diagnostic Procedure.......................................................127 522450.06 — Left Forward Pump Coil Short...................................................................128 Left Forward Pump Coil Short Diagnostic Procedure......................................................129 522450.15 — Left Forward Pump Threshold Calibration Value Too High.........................................130 Left Forward Pump Threshold Calibration Value Too High Diagnostic Procedure............................131 522450.16 — Left Forward Pump Max Speed Calibration Value Too High.........................................131 522450.17 — Left Forward Pump Threshold Calibration Value Too Low..........................................131 Left Forward Pump Threshold Calibration Value Too High Diagnostic Procedure............................132 522450.18 — Left Forward Pump Max Speed Calibration Value Too Low..........................................132 522451.05 — Cooler Bypass Solenoid No Response.............................................................133 523108.13 — TCU Not Calibrated High Speed Not Done.........................................................133 523108.14 — TCU Not Calibrated Sensor/Pump/Motor...........................................................133 523436.07 — TCU Watchdog Timer Exceeded....................................................................133 523577.05 — Left Motor Solenoid Open Circuit...............................................................134 523577.06 — Left Motor Solenoid Short Circuit..............................................................134 523577.16 — Left Motor Maximum Calibration Value Too High..................................................134 523577.18 — Left Motor Maximum Calibration Value Too Low...................................................135 523578.05 — Right Motor Solenoid Open Circuit..............................................................135 523578.06 — Right Motor Solenoid Short Circuit.............................................................135 523578.16 — Right Motor Maximum Calibration Value Too High.................................................136 523578.18 — Right Motor Maximum Calibration Value Too Low..................................................136 Electro-Hydraulic Controller (EHC) Diagnostic Trouble Codes....................................................137 Diagnostic Trouble Code (DTC) Quick Reference List—Electro-Hydraulic Controller (EHC)......................137 158.03 — EHC System Volts Too High.........................................................................137 158.04 — EHC System Volts Too Low..........................................................................138 620.03 — Sensor Short to Power.............................................................................138 620.04 — Sensor Short to GND...............................................................................138 1903.00 — Aux 1 PVE Open Circuit...........................................................................139 1903.01 — Aux 1 PVE Low or Open Circuit....................................................................139 1903.03 — Aux 1 PVE Short to Power.........................................................................139 1903.04 — Aux 1 PVE Short to GND...........................................................................139 1903.31 — Aux 1 PVE Spool Pos Error........................................................................140 1915.00 — Aux 2 PVE Open Circuit...........................................................................140 1915.01 — Aux 2 PVE Low or Open Circuit....................................................................140 1915.03 — Aux 2 PVE Short to Power.........................................................................141 1915.04 — Aux 2 PVE Short to GND...........................................................................141 1915.31 — Aux 2 PVE Spool Pos Error........................................................................141 2660.09 — CAN Jstk Pos Missing From BCJ....................................................................141 2712.00 — Hyd Enable Sw Inputs Both On.....................................................................142 2712.01 — Hyd Enable Sw Inputs Both Off....................................................................142 3157.03 — Incr / Decr Buttons Short to Power...............................................................142 3157.04 — Incr / Decr Buttons Open or Short................................................................143 3157.31 — Incr / Decr Buttons Invalid Output...............................................................143 522442.03 — Blade Buttons Short to Power...................................................................143 522442.04 — Blade Buttons Open or Short....................................................................144 522422.31 — Blade Buttons Invalid Output...................................................................144 523779.00 — Blade Rotate Current Above Max.................................................................144 523779.01 — Blade Rotate Current Below Min.................................................................144 523780.00 — Tilt PVE Open Circuit..........................................................................145 523780.01 — Tilt PVE Low or Open Circuit...................................................................145 523780.03 — Tilt PVE Short to Power........................................................................145 523780.04 — Tilt PVE Short to GND..........................................................................145 523780.31 — Tilt PVE Spool Pos Error.......................................................................146 523781.00 — Height PVE Open Circuit........................................................................146 523781.01 — Height PVE Low or Open Circuit.................................................................146 523781.03 — Height PVE Short to Power......................................................................147 523781.04 — Height PVE Short to GND........................................................................147 523781.31 — Height PVE Spool Pos Error.....................................................................147 524059.00 — Aux 2 Jstk Sensor 2 Volts High.................................................................148 524059.01 — Aux 2 Jstk Sensor 2 Volts Low..................................................................148 524059.03 — Aux 2 Jstk Sensor 2 Short to Power.............................................................148 524059.04 — Aux 2 Jstk Sensor 2 Short to GND...............................................................148 524059.31 — Aux 2 Jstk Sensor 2 Invalid Output.............................................................148 524062.00 — Aux 1 Jstk Sensor 2 Volts High.................................................................148 Sensor 2 of Auxiliary Joystick 1 Diagnostic Procedure..................................................148 524062.01 — Aux 1 Jstk Sensor 2 Volts Low..................................................................150 Sensor 2 of Auxiliary Joystick 1 Diagnostic Procedure..................................................150 524062.03 — Aux 1 Jstk Sensor 2 Short to Power.............................................................152 524062.04 — Aux 1 Jstk Sensor 2 Short to GND...............................................................152 524062.31 — Aux 1 Jstk Sensor 2 Invalid Output.............................................................153 524085.00 — Aux 2 Jstk Sensor 2 Volts High.................................................................153 524085.01 — Aux 2 Jstk Sensor 2 Volts Low..................................................................153 524085.03 — Aux 2 Jstk Sensor 1 Short to Power.............................................................153 524085.04 — Aux 2 Jstk Sensor 1 Short to GND...............................................................153 524085.14 — Aux 2 Jstk Sensor Mismatch.....................................................................153 524085.31 — Aux 2 Jstk Sensor 1 Invalid Output.............................................................154 524086.00 — Aux 1 Jstk Sensor 1 Volts High.................................................................154 Sensor 1 of Auxiliary Joystick 1 Diagnostic Procedure..................................................154 524086.01 — Aux 1 Jstk Sensor 1 Volts Low..................................................................155 Sensor 1 of Auxiliary Joystick 1 Diagnostic Procedure..................................................155 524086.03 — Aux 1 Jstk Sensor 1 Short to Power.............................................................157 524086.04 — Aux 1 Jstk Sensor 1 Short to GND...............................................................157 524086.14 — Aux 1 Jstk Sensor Mismatch.....................................................................158 524086.31 — Aux 1 Jstk Sensor 1 Invalid Output.............................................................158 Blade Control Joystick (BCJ) Diagnostic Trouble Codes..........................................................159 Diagnostic Trouble Code (DTC) Quick Reference List—Blade Control Joystick (BCJ)............................159 2697.03 — Voltage Too High (X Axis)........................................................................159 2697.04 — Voltage Too Low (X Axis).........................................................................159 2697.13 — Input Not Calibrated (X Axis)....................................................................159 2697.14 — Redundant Input Failure (X Axis).................................................................159 2698.03 — Voltage Too High (Y Axis)........................................................................160 2698.04 — Voltage Too Low (Y Axis).........................................................................160 2698.13 — Input Not Calibrated (Y Axis)....................................................................160 2698.14 — Redundant Input Failure (Y Axis).................................................................160 Operational Checkout Procedure.....................................................................................161 Operational Checkout Procedure.................................................................................163 Operational Checkout.......................................................................................163 Diagnostic Trouble Code (DTC) Check....................................................................163 Operational Checks—Key Switch OFF, Engine OFF..........................................................163 Operational Checks—Key Switch ON, Engine OFF...........................................................164 Operational Checks—Key Switch ON, Engine ON............................................................169 Engine.............................................................................................................179 Theory of Operation............................................................................................181 POWERTECH 8.1L Diesel Engines..............................................................................181 POWERTECH PLUS 9.0L Diesel Engines.........................................................................181 Diagnostic Information.........................................................................................183 Engine Identification......................................................................................183 Diagnose Engine Malfunctions—8.1L..........................................................................185 Diagnose Engine Malfunctions—9.0L..........................................................................186 Engine Cooling System Component Location—8.1L..............................................................190 Engine Cooling System Component Location—9.0L..............................................................192 Engine Fuel System Component Location—8.1L.................................................................193 Engine Fuel System Component Location—9.0L.................................................................195 Engine Intake and Exhaust Component Location—8.1L..........................................................196 Engine Intake and Exhaust Component Location—9.0L..........................................................198 Tests..........................................................................................................201 POWERTECH 8.1L Diesel Engines..............................................................................201 POWERTECH PLUS 9.0L Diesel Engines.........................................................................201 Intake Manifold Pressure Test—Turbocharger Boost (8.1L Only)...............................................201 Fuel Supply Pump Pressure Test.............................................................................202 Electrical System..................................................................................................204 System Information.............................................................................................205 Electrical Diagram Information.............................................................................205 System Diagrams................................................................................................211 Fuse and Relay Specifications..............................................................................211 System Functional Schematic, Wiring Diagram, and Component Location Legend—9.0L............................217 System Functional Schematic and Section Legend—9.0L........................................................222 System Functional Schematic, Wiring Diagram, and Component Location Legend—8.1L............................278 System Functional Schematic and Section Legend—8.1L........................................................282 JDLink™ System Functional Schematic—MIG/GTT................................................................337 JDLink™ System Functional Schematic—MTG/SAT................................................................341 Operator's Station Harness (W7) Component Location.........................................................345 Operator's Station Harness (W7) Wiring Diagram.............................................................355 Canopy Roof Harness (W8) Component Location................................................................388 Canopy Roof Harness (W8) Wiring Diagram....................................................................391 Cab Roof Harness (W9) Component Location...................................................................394 Cab Roof Harness (W9) Wiring Diagram.......................................................................399 Engine Harness (W10) Component Location....................................................................417 Engine Harness (W10) Wiring Diagram........................................................................428 Transmission Harness (W11) Component Location..............................................................443 Transmission Harness (W11) Wiring Diagram..................................................................458 Air Conditioning Harness (W14) Component Location..........................................................482 Air Conditioning Harness (W14) Wiring Diagram..............................................................485 Radio Harness (W15) Component Location.....................................................................488 Radio Harness (W15) Wiring Diagram.........................................................................490 IGC Machine Harness (W21) and IGC Cab Harness (W22) Component Location.....................................493 Integrated Grade Control (IGC) Machine Harness (W21) Wiring Diagram........................................497 Integrated Grade Control (IGC) Cab Harness (W22) Wiring Diagram............................................507 Pressure Sensor Harness (W27) Wiring Diagram...............................................................510 JDLink™ System Harnesses Component Location—MIG/GTT........................................................510 JDLink™ System Harnesses Component Location—MTG/SAT........................................................514 JDLink™ System Wiring Diagrams—MIG/GTT.....................................................................516 JDLink™ System Wiring Diagrams—MTG/SAT.....................................................................524 Sub-System Diagnostics.........................................................................................529 Starting and Charging Circuit Theory of Operation..........................................................529 Controller Area Network (CAN) Theory of Operation..........................................................537 Engine Control Unit (ECU) Circuit Theory of Operation—9.0L.................................................541 Engine Control Unit (ECU) Circuit Theory of Operation—8.1L.................................................553 Transmission Control Unit (TCU) Circuit Theory of Operation................................................557 CAN Monitor Unit (CMU) Circuit Theory of Operation.........................................................573 Integrated Grade Control (IGC) Theory of Operation—If Equipped.............................................577 JDLink™ Circuit Theory of Operation—If Equipped............................................................583 References.....................................................................................................587 Electrical Component Specifications........................................................................587 Service ADVISOR™ Diagnostic Application....................................................................593 Service ADVISOR™ Connection Procedure......................................................................593 Reading Diagnostic Trouble Codes with Service ADVISOR™ Diagnostic Application..............................594 JDLink™ System Identification..............................................................................596 JDLink™ Connection Procedure—If Equipped...................................................................599 CAN Monitor Unit (CMU) Menu Structure—Service Mode.........................................................600 Integrated Grade Control (IGC) Checks—If Equipped..........................................................604 IGC System Checks......................................................................................604 Integrated Grade Control (IGC) Diagnose Malfunctions—If Equipped...........................................609 All Blade Functions Do Not Operate in Manual or Auto Modes.............................................609 All Blade Functions Operate Normally in Manual Mode, But Not in Auto Mode..............................614 All Blade Functions Operate Normally in Auto Mode, But Not in Manual Mode..............................617 Blade Lift and Tilt Operate Normally in Auto Mode, But Not in Manual Mode..............................619 Blade Lift and Tilt Operate Normally, But Blade Angle Does Not.........................................621 Blade Lift and Angle Operate Normally, But Blade Incr/Decr Does Not....................................624 Blade Response Is Not Smooth...........................................................................625 All Blade Functions Are Slow or Sluggish...............................................................627 Blade Response Is Too Fast.............................................................................628 Blade Moves Quickly (Jumps) to One Side, Then Slowly Comes Back on Grade...............................629 Waves in Graded Surface................................................................................630 Alternator Test Procedure..................................................................................631 CAN Circuit Test...........................................................................................632 Controller Area Network (CAN) Diagnostics .............................................................632 Transmission Control Unit (TCU) Calibration................................................................637 Wire Harness Test..........................................................................................638 Decelerator/Brake Pedal Adjustment.........................................................................638 Engine Speed Control Remove and Install....................................................................639 Rotary Sensor Remove and Install...........................................................................640 Transmission Control Lever (TCL) Adjustment................................................................641 Bussed Sensor Connectors (X6 and X7) Diagnostics...........................................................643 Engine Control Unit (ECU) Remove and Install...............................................................645 Replace Weather Pack™ Connector............................................................................646 Install Weather Pack™ Contact..............................................................................647 Replace DEUTSCH® Connectors................................................................................648 Replace DEUTSCH® Rectangular or Triangular Connectors......................................................649 Install DEUTSCH® Contact...................................................................................650 Replace CINCH® Connectors..................................................................................651 Install CINCH® Contact.....................................................................................653 Repair 32 and 48 Way CINCH® Connectors.....................................................................654 Replace (Pull Type) Metri-Pack™ Connectors.................................................................657 Replace (Push Type) Metri-Pack™ Connectors.................................................................658 Hydraulics.........................................................................................................659 Theory.........................................................................................................661 Hydraulic System Operation.................................................................................661 Hydraulic Pump Operation...................................................................................662 Pressure Reducing Valve Operation..........................................................................671 Pilot Control Valve Operation..............................................................................673 Hydraulic Control Valve Operation..........................................................................675 Hydraulic Control Valve Operation—IGC......................................................................677 Load Sense Circuit Operation...............................................................................683 Load Sense Isolator Operation..............................................................................683 Circuit Relief Valve with Anticavitation Operation.........................................................684 Hydraulic System Relief Valve Operation....................................................................685 Hydraulic Oil Filter Manifold Operation....................................................................686 Blade Angle Operation......................................................................................689 Ripper Operation...........................................................................................693 Ripper Operation with IGC Controlled Auxiliary Valve.......................................................699 Hydraulic Cylinder Operation...............................................................................703 Quick-Drop Valve Operation.................................................................................705 Mechanical Angle Blade Operation...........................................................................708 Diagnostic Information.........................................................................................711 Hydraulic System Schematic.................................................................................711 Hydraulic System Schematic—IGC.............................................................................755 Hydraulic System Schematic—IGC with Auxiliary Valve........................................................759 Main Hydraulic Component Location..........................................................................763 Ripper Ready Hydraulic Component Location..................................................................767 Winch Ready Hydraulic Component Location...................................................................771 Main Hydraulic Component Location—IGC......................................................................775 Hydraulic System Diagnose Malfunctions.....................................................................777 No Hydraulic Functions Diagnostic Procedure............................................................777 Hydraulic Functions Slow Diagnostic Procedure..........................................................778 Hydraulic Pump Noisy Diagnostic Procedure..............................................................780 Blade Float Does Not Work Diagnostic Procedure.........................................................781 One Hydraulic Function Does Not Work Diagnostic Procedure..............................................781 Function Drifts Down Diagnostic Procedure..............................................................782 Oil Overheats Diagnostic Procedure.....................................................................783 Hydraulic System Diagnose Malfunctions—IGC.................................................................784 No Hydraulic Functions Diagnostic Procedure—IGC........................................................784 Hydraulic Functions Slow Diagnostic Procedure—IGC......................................................785 Blade Float Does Not Work Diagnostic Procedure—IGC.....................................................787 One Hydraulic Function Does Not Work Diagnostic Procedure—IGC..........................................788 Hydraulic Power Low Diagnostic Procedure—IGC...........................................................789 Function Drifts Down Diagnostic Procedure—IGC..........................................................790 Oil Overheats Diagnostic Procedure—IGC.................................................................791 Blade Response Not Smooth Diagnostic Procedure—IGC.....................................................792 Tests..........................................................................................................795 JT02156A Digital Pressure/Temperature Analyzer Installation................................................795 Ultra Clean® Hand Launcher.................................................................................795 Hydraulic Oil Cleanup Procedure............................................................................795 Hydraulic System Relief Valve Test.........................................................................796 Hydraulic System Relief Valve Test—IGC.....................................................................797 Circuit Relief Valve Test..................................................................................799 Circuit Relief Valve Test—IGC..............................................................................800 Pump Load Sense Differential and System Pressure (Pump Cutoff) Test and Adjustment.........................801 Pump Load Sense Differential and System Pressure Test and Adjustment—IGC...................................804 Lift and Tilt Cylinder Function Drift Test.................................................................806 Hydraulic Cylinder Drift Test..............................................................................807 Cylinder Leakage Test......................................................................................808 Pressure Reducing Valve Pressure Test and Adjustment.......................................................809 Blade Down Accumulator Hydraulic Discharge.................................................................809 Blade Down Accumulator Precharge Test......................................................................810 Hydraulic Pump Flow Test...................................................................................811 Hydraulic Pump Case Drain Test.............................................................................812 Hydrostatic System.................................................................................................814 Theory of Operation............................................................................................815 Hydrostatic System.........................................................................................815 Transmission Control Circuit Operation (Flow Chart)........................................................816 Charge Pump Operation......................................................................................817 Hydrostatic Charge Oil Filter Operation....................................................................818 Neutral Charge Relief Valve Operation......................................................................819 Multi-Function Valve Operation.............................................................................820 Hydraulic Integrated Circuit (HIC) Valve Operation.........................................................822 Park Brake Valve Operation.................................................................................823 Oil Cooler and Reservoir Bypass Operation..................................................................824 Pump Pressure Control Pilot (PCP) Operation................................................................825 Pump Displacement Control Valve (PDCV) Operation...........................................................826 Hydrostatic Pump Operation.................................................................................827 Flushing Valve and Operating Charge Relief Valve Operation.................................................828 Hydrostatic Motor Operation................................................................................829 Hydraulic Reversing Fan Drive Operation....................................................................831 Hydraulic Non-Reversing Fan Drive Operation................................................................835 Hydraulic Fan Return Filter Operation......................................................................837 Diagnostic Information.........................................................................................839 Overheating—Flowchart......................................................................................839 Low Charge Pressure—Flowchart..............................................................................840 Mistrack/Indexes—Flowchart.................................................................................841 Machine Will Not Reach Full Speed—Flowchart................................................................842 Low Power—Flowchart........................................................................................843 Engine Starts But One Or Both Tracks Will Not Move—Flowchart...............................................845 TCU Calibration Malfunctions...............................................................................846 TCU Calibration Malfunctions Diagnostic Procedure......................................................846 Hydrostatic System Component Location......................................................................855 Park Brake System Component Location.......................................................................858 Hydrostatic System Schematic—Neutral (Park Brake On).......................................................861 Hydrostatic System Diagram—Neutral (Park Brake On).........................................................873 Hydrostatic System Diagram—Reverse (Slow Speed)............................................................877 Hydrostatic System Diagram—Forward (Fast Speed)............................................................881 Tests..........................................................................................................885 JT02156A Digital Pressure/Temperature Analyzer Installation................................................885 Ultra Clean® Hand Launcher.................................................................................885 Machine Supporting Procedure...............................................................................886 Transmission Oil Warm-Up Procedure.........................................................................887 Releasing Park Brake to Tow the Machine....................................................................889 Hydrostatic Pump and Motor Initial Start-Up Procedure......................................................891 Hydrostatic Pump Flushing Procedure........................................................................892 Hydraulic Oil Cleanup Procedure............................................................................893 Pressure Control Pilot (PCP) Manual Override Test..........................................................893 Pressure Control Pilot (PCP) Test..........................................................................895 Pressure Control Pilot (PCP) Internal Adjustment...........................................................897 Multi-Function Relief Valve Test...........................................................................899 Transmission Efficiency Test...............................................................................902 Neutral Charge Relief and Operating Charge Relief Pressure Test............................................905 Pump Displacement Control Valve (PDCV) Neutral (Null) Adjustment...........................................907 Pump Servo Pressure Test...................................................................................910 Motor Displacement Control Valve (MDCV) Adjustment.........................................................912 Hydrostatic Motor Min./Max. Angle Servo Piston Pressure Test...............................................915 Charge Pump Flow Test......................................................................................917 Charge Pressure Sensor Test (S.N. 133015—).................................................................918 Hydrostatic Oil Cooler Bypass Test.........................................................................920 Hydrostatic Oil Reservoir Bypass Test......................................................................922 Park Brake Test............................................................................................924 Park Brake Relief Valve Test...............................................................................928 Cab Tilt Relief Valve Test.................................................................................928 Hand Pump Bleed Procedure..................................................................................929 Fan Pump Pressure Test.....................................................................................930 Fan Pump Flow Test.........................................................................................931 Fan Motor Speed Test.......................................................................................933 Fan Motor Case Drain Test..................................................................................934 Heating and Air Conditioning.......................................................................................935 Theory of Operation............................................................................................937 Air Conditioning System Cycle Of Operation.................................................................937 Diagnostic Information.........................................................................................939 Diagnose Air Conditioning System Malfunctions..............................................................939 Diagnose Heater System Malfunctions........................................................................942 Tests..........................................................................................................945 Proper Refrigerant Handling................................................................................945 R134a Refrigerant Cautions.................................................................................945 R134a Oil Charge Capacity..................................................................................945 R134a Refrigerant Charge Capacity..........................................................................945 Refrigerant Hoses And Tubing Inspection....................................................................946 R134a Air Conditioning System Test.........................................................................947 Operating Pressure Diagnostic Chart........................................................................949 Air Conditioner Low Pressure Switch Test...................................................................951 Air Conditioner High Pressure Switch Test..................................................................952 Freeze Control Switch Test.................................................................................953 Leak Testing...............................................................................................953 Page Number............................................................................................................ 5 Section 9000....................................................................................................... 7 Group 01....................................................................................................... 9 Section 9001....................................................................................................... 23 Group 10....................................................................................................... 25 Group 20....................................................................................................... 37 Group 30....................................................................................................... 39 Group 40.......................................................................................................137 Group 50.......................................................................................................159 Section 9005.......................................................................................................161 Group 10.......................................................................................................163 Section 9010.......................................................................................................179 Group 05.......................................................................................................181 Group 15.......................................................................................................183 Group 25.......................................................................................................201 Section 9015.......................................................................................................204 Group 05.......................................................................................................205 Group 10.......................................................................................................211 Group 15.......................................................................................................529 Group 20.......................................................................................................587 Section 9025.......................................................................................................659 Group 05.......................................................................................................661 Group 15.......................................................................................................711 Group 25.......................................................................................................795 Section 9026.......................................................................................................814 Group 05.......................................................................................................815 Group 15.......................................................................................................839 Group 25.......................................................................................................885 Section 9031.......................................................................................................935 Group 05.......................................................................................................937 Group 15.......................................................................................................939 Group 25.......................................................................................................945
S.S 23/02/2025
