Complete Diagnostics Operation manual with electrical wiring diagrams for John Deere Crawler Dozers 750C, 850C, with workshop information to maintain, diagnose, and service like professional mechanics.

John Deere Crawler Dozers 750C, 850C workshop Diagnosis Test manual includes:
* Numbered table of contents easy to use so that you can find the information you need fast.
* Detailed sub-steps expand on repair procedure information
* Numbered instructions guide you through every repair procedure step by step.
* Troubleshooting and electrical service procedures are combined with detailed wiring diagrams for ease of use.
* Notes, cautions and warnings throughout each chapter pinpoint critical information.
* Bold figure number help you quickly match illustrations with instructions.
* Detailed illustrations, drawings and photos guide you through every procedure.
* Enlarged inset helps you identify and examine parts in detail.

TM1588 - John Deere 750C, 850C Crawler Dozer Technical Manual - Operation and Test.pdf
TM1588 - John Deere 750C, 850C Crawler Dozer Technical Manual - Operation and Test.epub

Total Pages: 1,191 pages
File Format: PDF/EPUB/MOBI/AZW (PC/Mac/Android/Kindle/iPhone/iPad; bookmarked, ToC, Searchable, Printable)
Language: English

tm1588 - 750C, 750C Series II, 850C, 850C Series II Crawler Dozer

Table of Contents

Foreword

Technical Information Feedback Form

Section 9000: General Information

Group 01: Safety

Handle Fluids Safely—Avoid Fires

Prevent Battery Explosions

Prepare for Emergencies

Prevent Acid Burns

Handle Chemical Products Safely

Avoid High-Pressure Fluids

Park Machine Safely

Support Machine Properly

Wear Protective Clothing

Work in Clean Area

Service Machines Safely

Work In Ventilated Area

Illuminate Work Area Safely

Replace Safety Signs

Use Proper Lifting Equipment

Remove Paint Before Welding or Heating

Avoid Heating Near Pressurized Fluid Lines

Keep ROPS Installed Properly

Practice Safe Maintenance

Decommissioning — Proper Recycling and Disposal of Fluids and Components

Live With Safety

Group 02: General Specifications

750C Specifications

750C Capacity Specifications

750C General Specifications

750C Dimensions

750C WT Dimensions

750C LGP Dimensions

750C LT Series II Dimensions

750C WT Series II Dimensions

750C LGP Series II Dimensions

850C Specifications

850C Capacity Specifications

850C General Specifications

850C Dimensions

850C WT Dimensions

850C LGP Dimensions

850C LT Series II Dimensions

850C WT Series II Dimensions

850C LGP Series II Dimensions

Group 03: Torque Values

Hardware Torque Specifications

Keeping ROPS Installed Properly

Checking Track Shoe Cap Screw Torque

Checking Track Shoe Cap Screw Torque—Master Link

Metric Bolt and Screw Torque Values

Additional Metric Cap Screw Torque Values

Service Recommendations for Metric Series Four Bolt Flange Fitting

Unified Inch Bolt and Screw Torque Values

Check Oil Lines And Fittings

Service Recommendations for O-Ring Boss Fittings

Service Recommendations For Flat Face O-Ring Seal Fittings

Service Recommendations For Inch Series Four Bolt Flange Fittings

Group 04: Fuels and Lubricants

Diesel Fuel

Handling and Storing Diesel Fuel

Fuel Tank

Low Sulfur Diesel Fuel Conditioner

Diesel Fuel Storage

Diesel Engine Oil — Non-Emissions Certified and Certified Tier 1 and Stage I

Transmission, Hydraulic, and Hand Pump Reservoir Oil

Inner and Outer Final Drive Oil

Track Rollers, Front Idler, Carrier Roller and Track Frame Outer Pivot Oil

Grease

Lubricant Storage

Alternative and Synthetic Lubricants

Mixing of Lubricants

Diesel Engine Coolant (engine with wet sleeve cylinder liners)

Section 9005: Operational Checkout Procedure

Group 10: Operational Checkout Procedure

Operational Checkout Procedure

Section 9010: Engine

Group 05: Theory of Operation

6068 John Deere Engine—Use CTM8

6068 John Deere POWERTECH POWERTECH is a trademark of Deere & Company Engine—Use CTM104

6076 John Deere Engine—Use CTM42

6081 John Deere POWERTECH POWERTECH is a trademark of Deere & Company Engine—Use CTM134

Sectional View (6068) Engine—750C

General (6068) Engine Description—750C (S.N. —831315)

General (6068) POWERTECH POWERTECH is a trademark of Deere & Company Engine Description—750C (S.N. 831316— )

Sectional View (6076) Engine—850C (S.N. —822867)

General (6076) Engine Description—850C (S.N. —822867)

Sectional View (6081) POWERTECH POWERTECH is a trademark of Deere & Company Engine—850C (S.N. 822868— )

General (6081) POWERTECH POWERTECH is a trademark of Deere & Company Engine Description—850C (S.N. 822868— )

Group 10: System Operational Checks

6068 John Deere Engine—Use CTM8

6068 John Deere POWERTECH POWERTECH is a trademark of Deere & Company Engine—Use CTM104

6076 John Deere Engine—Use CTM42

6081 John Deere POWERTECH POWERTECH is a trademark of Deere & Company Engine—Use CTM134

Engine Operational Checks

Group 15: Diagnostic Information

Diagnose Engine Malfunctions

Cooling System Inspection

Group 20: Adjustments

6068 John Deere Engine—Use CTM8

6068 John Deere POWERTECH POWERTECH is a trademark of Deere & Company Engine—Use CTM104

6076 John Deere Engine—Use CTM42

6081 John Deere POWERTECH POWERTECH is a trademark of Deere & Company Engine—Use CTM134

JT05801 Clamp-On Electronic Digital Tachometer Installation

Fan Belt Tension Adjustment—750C (S.N. —831315)

Engine Speed Adjustment—750C

Engine Speed Adjustment—850C

Engine Speed Control Cable Adjustment

Engine Speed Control Sensor Adjustment (750C, 850C S.N.—875378)

Decelerator Sensor Adjustment—Single Lever Steer

Throttle Sensor Adjustment—850C (S.N. 822868— )

Fuel Shut-Off Solenoid Adjustment—850C (S.N. —822867)

Primary Fuel Filter, Drain Valve—750C

Primary Fuel Filter, Drain Valve—850C

Bleed the Fuel System—750C

Bleed the Fuel System—850C

Group 25: Tests

JT07158 TIME TRAC TIME TRAC is a registered trademark of the Stanadyne Automotive Corp. Installation

Injection Pump Dynamic Timing—750C

Compression Pressure Test

Radiator Air Flow Test

JT05529 Air Flowmeter Test Record

Fuel Line Leakage Test

Air Intake System Leakage Test

Air Filter Restriction Indicator Switch Test

Check Engine Performance Using Turbocharger Boost Pressure Test

Fuel Supply Pump Pressure Test

Section 9015: Electrical System

Group 05: System Information

Visually Inspect Electrical System

Electrical Circuit Malfunctions

High Resistance Circuit

Open Circuit

Grounded Circuit

Shorted Circuit

Multimeter

Seven Step Electrical Test Procedure

Welding Procedure

Wiring Diagram and Schematic Information

Reading a System Functional Schematic

Reading a Wiring Diagram

Electrical Schematic Symbols

Group 10: System Diagrams

Fuse (Blade-Type) Color Codes

Fuse Specifications

Component Identification Table

Wiring and Schematic Diagrams Legend (S.N. —883331)

System Functional Schematic Section Legend (S.N. —883331)

System Functional Schematic (S.N. —883331) 1 Of 6

System Functional Schematic (S.N. —883331) Continued 2 Of 6

System Functional Schematic (S.N. —883331) Continued 3 Of 6

System Functional Schematic (S.N. —883331) Continued 4 of 6

System Functional Schematic (S.N. —883331) Continued 5 Of 6

System Functional Schematic (S.N. —883331) Continued 6 Of 6

Wiring and Schematic Diagrams Legend With Speed In Grip (S.N. 883332— )

System Functional Schematic Section Legend With Speed In Grip (S.N. 883332— )

System Functional Schematic With Speed In Grip (S.N. 883332— ) 1 Of 6

System Functional Schematic With Speed In Grip (S.N. 883332— ) Continued 2 Of 6

System Functional Schematic With Speed In Grip (S.N. 883332— ) Continued 3 Of 6

System Functional Schematic With Speed In Grip (S.N. 883332— ) Continued 4 Of 6

System Functional Schematic With Speed In Grip (S.N. 883332— ) Continued 5 Of 6

System Functional Schematic With Speed In Grip (S.N. 883332— ) Continued 6 Of 6

Cab Harness (W6) Wiring Diagram (S.N. —822867)

Cab Harness (W6) Component Location (S.N. —822867)

Cab Harness (W6) Wiring Diagram (S.N. 822868—883331)

Cab Harness (W6) Component Location (S.N. 822868—883331)

Cab Harness (W6) Wiring Diagram With Speed In Grip (S.N. 883332— )

Cab Harness (W6) Component Location With Speed In Grip (S.N. 883332— )

Chassis Harness (W7) Wiring Diagram

Chassis Harness (W7) Component Location

Engine/Pump Harness (W8) Wiring Diagram 750C (S.N. —831315) and 850C (S.N. —822867)

Engine/Pump Harness (W8) Component Location 750C (S.N. —831315)

Engine/Pump Harness (W8) Component Location 850C (S.N. —822867)

Engine/Pump Harness (W8) Wiring Diagram 750C (S.N. 831316—883331)

Engine/Pump Harness (W8) Component Location 750C (S.N. 831616—883331)

Engine/Pump Harness (W8) Wiring Diagram 750C (S.N. 883332—)

Engine/Pump Harness (W8) Component Location 750C (S.N. 883332—)

Engine/Pump Harness (W8) Wiring Diagram 850C (S.N. 822868—)

Engine/Pump Harness (W8) Component Location 850C (S.N. 822868— )

Grille Harness (W9) Component Location 750C (S.N. —831315) and 850C (S.N. —822867)

Grille Harness (W9) Wiring Diagram 750C (S.N. —831315) and 850C (S.N. —822867)

Grille Harness (W9) Wiring Diagram 750C (S.N. 831316— ) and 850C (S.N. 822868— )

Grille Harness (W9) Component Location 750C (S.N. 831316— ) and 850C (S.N. 822868— )

Motor Harness (W10) Component Location

Motor Harness (W10) Wiring Diagram

Wiper Harness (W11) Wiring Diagram

Wiper Harness (W11) Component Location

A/C Compressor Harness (W12) Wiring Diagram 750C (S.N. —831315) and 850C (S.N. —822867)

A/C Compressor Harness (W12) Component Location 750C (S.N. —831315) and 850C (S.N. —822867)

A/C Condenser Harness (W13) Wiring Diagram

A/C Condenser Harness (W13) Component Location

Group 15: Sub-System Diagnostics

Power Circuit Operational Information

Power Circuit Theory of Operation

Power Circuit Schematic

Start Circuit Operational Information

Start Circuit Theory of Operation

Start Circuit Schematic 750C and 850C (S.N. —822867)

Start Circuit Schematic 850C (S.N. 822868—883331)

Start Circuit Schematic 750C, 850C (S.N. 883332—)

Charging Circuit Operational Information

Charging Circuit Theory of Operation

Charging Circuit Schematic

Display Monitor Switch, Sender and Gauge Input Specifications

Display Monitor Circuit Operational Information

Display Monitor Circuit Theory of Operation

Display Monitor Circuit Schematic

Fuel Shut-Off Circuit Operational Information

Fuel Shut-Off Circuit Theory of Operation

Fuel Shut-Off Circuit Schematic 750C and 850C (S.N. —822867)

Fuel Shut-Off Circuit Schematic 850C (S.N. 822868— )

Start Aid Circuit Operational Information

Start Aid Circuit Theory of Operation

Start Aid Circuit Schematic

Front and Rear Light Circuit Operational Information

Front and Rear Light Circuit Theory of Operation

Front and Rear Light Circuit Schematic

Transmission Control Circuit Operational Information

Transmission Control Circuit Schematic (S.N. —883331)

Transmission Control Circuit Schematic With Speed In Grip (S.N. 883332— )

Transmission Control Circuit (Flow Chart) (S.N. —883331)

Transmission Control Circuit With Speed In Grip (Flow Chart) (S.N. 883332— )

Transmission Controller Service Codes Diagnostic Procedures

Calculations For Diagnostic Transmission Calibration Limits For (B11) FNR Sensor With Speed In Grip (S.N. 883332— )

Engine Control Circuit Operational Information 850C (S.N. 822868— )

Engine Control Circuit Theory of Operation 850C (S.N. 822868— )

Engine Control Circuit Schematic 850C (S.N. 822868— )

Engine Control Circuit (Flow Chart) 850C (S.N. 822868— )

Engine Control Circuit Diagnostic Schematic 850C (S.N. 822868— )

Engine Control Circuit Diagnostic Procedures 850C (S.N. 822868— )

Horn Circuit Operational Information

Horn Circuit Theory of Operation

Horn Circuit Schematic (S.N. —883331)

Horn Circuit Schematic (S.N. 883332— )

Dome Light Circuit Operational Information

Dome Light Circuit Theory of Operation

Dome Light Circuit Schematic

Front Wiper and Washer Circuit Operational Information

Front Wiper and Washer Circuit Theory of Operation

Front Wiper and Washer Circuit Schematic

Left and Right Door Wiper Circuit Operational Information

Left and Right Door Wiper Circuit Theory of Operation

Left and Right Door Wiper Circuit Schematic

Heater Blower Circuit Operational Information

Heater Blower Circuit Theory of Operation

Heater Blower Circuit Schematic

Radio Circuit Operational Information

Radio Circuit Theory of Operation

Radio Circuit Schematic

Quick Drop Valve Circuit Operational Information

Quick Drop Valve Circuit Theory of Operation

Quick Drop Valve Circuit Schematic

Group 20: TCU Calibration and Diagnostics

Transmission Calibration Theory of Operation — 700 Or Higher Software

Transmission Control Unit (TCU) Calibration with Transmission Decelerator Only, Single Lever Control, and 556 or 600 Software

Transmission Control Unit (TCU) Calibration with Transmission and Engine Decelerator, Single Lever Control, and 556 or 600 Software

Transmission Control Unit (TCU) Calibration with 700 or Higher Software

Calibration Service Codes (Single Lever Steer)

Maximum Ground Speed Service Codes (Single Lever Steer)

Transmission Control Circuit Theory of Operation (S.N. —883331)

Transmission Control Circuit Theory of Operation With Speed In Grip (S.N. 883332— )

Transmission Control Calibration Code Diagnostic Procedures

Transmission Controller Circuit Diagnostic Procedures

Transmission Control Unit (TCU) Calibration with Pedal Steer and 556 or 600 Software

Calibration Service Codes (Pedal Steer)

Maximum Ground Speed Service Codes (Pedal Steer)

Calibration Limits Work Sheet (S.N. —883331)

Calibration Limits Work Sheet With Speed In Grip (S.N. 883332—)

Group 35: References

Alternators and Starting Motors—Use CTM77

JT05801 Clamp-On Electronic Tachometer Installation

Battery Operation

Battery Specifications

Diagnose Battery Malfunctions

Check Battery Electrolyte Level and Terminals

Using Booster Batteries—24 Volt System

Alternator Operation—45 Amp Bosch

Program Display Monitor

Calibrate Tachometer

Access Display Monitor Service Codes

Setting Transmission Controller Rate Of Shift (With 600 or Higher Software Number S.N. 875379— )

Check Setting of Transmission Controller Rate Of Shift (With 600 or Higher Software Number S.N. 875379— )

Monitor Service Codes

Engine Controller Service Codes 850C (S.N. 822868— )

Calibrate Engine Controller 850C (S.N. 822868— )

Engine Calibration Service Codes 850C (S.N. 822868— )

Machine Identity Plugs

Rotary Sensor Component Location (Single Lever Steer) (S.N. —883331)

Rotary Sensor Component Location (Pedal Steer) (S.N. —883331)

Rotary Sensor Component Location With (SIG) Speed In Grip (S.N. 883332— )

Transmission Controller Abbreviations

Test Harness Kit

ServiceEXPERT Computer Connections (750C and 850C Crawler)

Preparing PDM to Take Readings

Section 9020: Power Train

Group 05: Theory of Operation

Final Drive and Park Brake Operation

Group 10: System Operational Checks

Undercarriage System Operational Checks

Group 15: Diagnostic Information

Diagnose Undercarriage Malfunctions

Measure Carrier Roller Wear

Measure Track Roller Wear

Measure Track Shoe Grouser Wear

Measure Front Idler Wear

Measure Track Pitch for Lubricated Track Chain

Measure Bushing Outside Diameter for Lubricated Track Chain

Measure Link Height

Group 20: Adjustments

Adjust Track Sag

Adjust Front Idler Horizontal Movement

Adjust Front Idler Vertical Movement

Adjust Brake Pedal

Adjust Decelerator Pedal

Section 9025: Hydraulics

Group 05: Theory

Dozer Hydraulic System Operation

Hydraulic Component Location

Hydraulic Oil Cooler Component Location 850C (S.N. 883332— )

Hydraulic Pump Operation

Hydraulic Control Valve, Cross Section

Hydraulic Control Valve Component Location/Schematic

Unloading Valve Operation

Blade Lift Valve Section Operation

Blade Tilt Valve Section Operation

Auxiliary Valve with Power Beyond Section Operation

Circuit Relief Valve with Anti-Cavitation Operation

System Relief Valve Operation

Hydraulic Filter Operation

Blade Lift Cylinder Bypass Valve Operation

Angledozer Tilt Cylinder Bypass Valve Operation

Quick-Drop Valve Operation

Group 15: Diagnostic Information

Diagnose Malfunctions of Hydraulic System

Group 25: Tests

JT05801 Clamp-On Electronic Tachometer Installation

JT05800 Digital Thermometer Installation

System Relief Valve Test

Circuit Relief Valve Test—with Remote Pump

Circuit Relief Valve Test

Hydraulic Cylinder Drift Test Procedure

Lift Cylinder Function Drift Test

Lift Cylinder Head End and Rod End Poppet and Piston Seal Leakage Test

Tilt Cylinder Function Drift Test

Tilt Cylinder Piston Seal Leakage Test

Pump General Performance Test Using Cycle Times

Cycle Time Test

Hydraulic Pump Flow Test

Hydraulic Oil Clean-Up Procedure Using Portable Filter Caddy

Section 9026: Hydrostatic System

Group 05: Theory of Operation

Hydrostatic System

Transmission Control Circuit (Flow Chart)

Charge Pump

Hydrostatic Filter and Neutral Charge Relief Valve

Multi-Function Valve

Park Brake Valve

Oil Cooler Bypass Valve

Pump and Motor Pressure Control Pilot (PCP)

Pump Displacement Control Valve (PDCV)

Hydrostatic Pump

Flushing Valve and Operating Charge Relief Valve

Hydrostatic Motor Operation

Hydrostatic System Component Location—Forward

Hydrostatic System Diagram—Park Brake On

Hydrostatic System Diagram—Reverse (Low Speed)

Hydrostatic System Diagram—Forward (High Speed)

Hydrostatic Schematic—Neutral (Park Brake On)

Group 10: System Operational Checks

Hydrostatic Transmission Operational Checks

Group 15: Diagnostic Information

Hydrostatic Transmission

Diagnostic Flow Charts

Group 20: Adjustments

JT05801 Clamp-On Electronic Tachometer Installation

JT05800 Digital Thermometer Installation

Park Lock Linkage Adjustment

Motor Displacement Control Valve Adjustment

Engine Speed Control Cable Adjustment

Engine Speed Control Sensor Adjustment (750C, 850C S.N.—875378)

Decelerator Sensor Adjustment—Single Lever Steer

Throttle Sensor Adjustment—850C (S.N. 822868— )

Group 25: Tests

Transmission Oil Warm-Up Procedure

Disconnect Park Brake or Multi-Function Valve for Diagnostic Test

Hand Pump Bleed Procedure

Tilt Cab or ROPS

Hydrostatic Pump and Motor Initial Start-Up Procedure

Hydrostatic Pump Flushing Procedure

Pressure Control Pilot (PCP) Test

Pressure Control Pilot (PCP) Internal Adjustment

Pressure Control Pilot (PCP) Manual Override Test

Tow Disconnect Relief Valve Test

Multi-Function Relief Valve Test

Neutral Charge Relief Pressure Test

Operating Charge Relief Pressure Test

Pump Displacement Control Valve Neutral Adjustment

Cooler Bypass Valve Test

Transmission Efficiency Test

Hydrostatic Motor Speed Sensor Adjustment

Hydrostatic Pump Speed Sensor Adjustment

Charge Pump Flow Test

FNR and Neutral Start Switch Adjustment—Pedal Steer

FNR and Neutral Start Switch Adjustment—Single Lever Steer

Single Lever Control (SLC) Adjustment (with Speed in Grip)

Section 9031: Heating and Air Conditioning

Group 05: Theory of Operation

Proper Refrigerant Handling

R134a Refrigerant Cautions

R134a Refrigerant Theory of Operation

Air Conditioning Circuit Specifications

Air Conditioning Circuit Operational Information

Air Conditioning Circuit Theory of Operation

Air Conditioning Circuit Schematic

Heater Blower Circuit Operational Information

Heater Blower Circuit Theory of Operation

Heater Blower Circuit Schematic

Receiver/Dryer Operation

Expansion Valve Operation

Compressor Relief Valve Operation

Temperature Control

Group 10: System Operational Checks

Air Conditioning Operational Checks

Group 15: Diagnostic Information

Diagnose Air Conditioning Electrical Malfunctions

Air Conditioning Component Location

Group 20: Adjustments

Special or Essential Tools

Service Equipment and Tools

Other Materials

Specifications

Proper Refrigerant Handling

R134a Refrigerant Cautions

R134a Compressor Oil Charge Check

R134a Compressor Oil Removal

R134a Component Oil Charge

R134a Refrigerant Recovery/Recycling and Charging Station Installation Procedure

Recover R134a System

Evacuate R134a System

Charge R134a System

Check and Adjust Compressor Belt Tension (750C)

Group 25: Tests

Special or Essential Tools

Service Equipment and Tools

Specifications

Proper Refrigerant Handling

R12 and R134a Refrigerant Cautions

Pressure Diagnostic Chart

Expansion Valve Operating Test

Low Pressure Switch Test

High Pressure Switch Test

Freeze Control Switch Test

Leak Testing

Refrigerant Hoses and Tubing Inspection

John Deere Crawler Dozers 750C, 850C Operation & Test Service Manual (TM1588)