Complete Operation and Test manual with Electrical Wiring Diagrams for John Deere Crawler Dozer 850JR, with workshop information to maintain, diagnose, and service like professional mechanics.

John Deere Crawler Dozer 850JR workshop Operation and 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.

TM10779 -John Deere 850JR Crawler Dozer Technical Manual - Operation and Test.PDF
TM10779 -John Deere 850JR Crawler Dozer Technical Manual - Operation and Test.EPUB

Total Pages: 590 pages
File Format: PDF/EPUB/MOBI/AZW (PC/Mac/Android/Kindle/iPhone/iPad; bookmarked, ToC, Searchable, Printable)
Language: English

MAIN SECTIONS
 Foreword
   General Information
      Safety
   Diagnostic Trouble Codes (DTCs)
      CAN Monitor Unit (CMU) Diagnostic Trouble Codes
      Engine Control Unit (ECU) Diagnostic Trouble Codes
      Transmission Control Unit (TCU) Diagnostic Trouble Codes
   Operational Checkout Procedure
      Operational Checkout Procedure
   Engine
      Theory of Operation
      Diagnostic Information
      Tests
   Electrical System
      System Information
      System Diagrams
      Sub-System Diagnostics
      References
   Hydraulic System
      Theory
      Diagnostic Information
      Tests
   Hydrostatic System
      Theory of Operation
      Diagnostic Information
      Tests
   Heating and Air Conditioning
      Theory of Operation
      Diagnostic Information
      Tests

tm10779 - 850JR Crawler Dozer

Table of Contents

Foreword

Section 9000: General Information

Group 01: Safety

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

Avoid High-Pressure Oils

Beware of Exhaust Fumes

Prevent Fires

Prevent Battery Explosions

Handle Chemical Products Safely

Dispose of Waste Properly

Prepare for Emergencies

Cab Guarding For Special Uses

Use Steps and Handholds Correctly

Start Only From Operator's Seat

Use and Maintain Seat Belt

Prevent Unintended Machine Movement

Use Ground Guide

Avoid Work Site Hazards

Keep Riders Off Machine

Avoid Backover Accidents

Avoid Machine Tip Over and Machine Damage

Add and Operate Attachments Safely

Park and Prepare for Service Safely

Service Cooling System Safely

Remove Paint Before Welding or Heating

Make Welding Repairs Safely

Drive Metal Pins Safely

Section 9001: Diagnostic Trouble Codes (DTCs)

Group 10: CAN Monitor Unit (CMU) Diagnostic Trouble Codes

CAN Monitor Unit (CMU) Diagnostic Trouble Codes

96.03 - Fuel Level Sensor Open or Short

96.04 - Fuel Level Sensor Short to Ground

107.03 - Engine Air Filter Restriction Indicator Switch Short to Power

107.04 - Engine Air Filter Restricted

177.03 - Transmission Oil Temperature Sensor Short to Power

177.04 - Transmission Oil Temperature Sensor Short to Ground

177.16 - Transmission Oil Temperature High

609.09 - CAN Communication Error, No TCU Message

1638.00 - Hydraulic Oil Temperature High

1638.03 - Hydraulic Oil Temperature Short to Power

1638.04 - Hydraulic Oil Temperature Short to Ground

1713.31 - Hydraulic Oil Filter Restricted

1857.03 - Winch Oil Pressure Sensor Short to Power

1857.04 - Winch Oil Pressure Low

2000.09 - CAN Communication Error, No ECU Configuration

3359.31 - Transmission Oil Filter Restricted

524227.31 - Fan Oil Filter Restricted

Group 20: Engine Control Unit (ECU) Diagnostic Trouble Codes

Engine Control Unit (ECU) Diagnostic Trouble Codes

Group 30: Transmission Control Unit (TCU) Diagnostic Trouble Codes

Transmission Control Unit (TCU) Diagnostic Trouble Codes

70.00 - Park Lock Lever Inputs Both ON

70.01 - Park Lock Lever Inputs Both OFF

91.00 - Throttle Sensor Input Greater Than Maximum Calibration Value

91.01 - Throttle Sensor Input Less Than Minimum Calibration Value

91.03 - Throttle Sensor Short to Power

91.04 - Throttle Sensor Open or Short

91.15 - Throttle Sensor Minimum Calibration Value Too High

91.16 - Throttle Sensor Maximum Calibration Value Too High

91.17 - Throttle Sensor Minimum Calibration Value Too Low

91.18 - Throttle Sensor Maximum Calibration Value Too Low

116.00 - Brake Pressure High

116.01 - Brake Pressure Low

116.03 - Brake Pressure Short to Power

116.04 - Brake Pressure Open or Short

158.03 - TCU System Volts Too High

158.04 - TCU System Volts Too Low

177.00 - Transmission Over Temp

190.09 - CAN Communication Error No Engine Speed

190.19 - CAN Communication Error Invalid Engine Speed

521.00 - Decel Sensor Input Greater Than Maximum Calibration Value

521.01 - Decel Sensor Input Less Than Minimum Calibration Value

521.03 - Decel Sensor Short to Power

521.04 - Decel Sensor Open or Short

521.05 - Decel Sensor Brake Calibration Value Too Low

521.06 - Decel Sensor Brake Calibration Value Too High

521.15 - Decel Sensor Minimum Calibration Value Too High

521.16 - Decel Sensor Maximum Calibration Value Too Low

521.17 - Decel Sensor Minimum Calibration Value Too Low

521.18 - Decel Sensor Maximum Calibration Value Too Low

581.00 - Speed Buttons Input Greater Than Maximum Calibration Value

581.01 - Speed Buttons Input Less Than Minimum Calibration Value

581.03 - Speed Buttons Short to Power

581.04 - Speed Buttons Open or Short

581.15 - Speed Buttons Minimum Calibration Value Too High

581.16 - Speed Buttons Maximum Calibration Value Too High

581.17 - Speed Buttons Minimum Calibration Value Too Low

581.18 - Speed Buttons Maximum Calibration Value Too Low

604.03 - FNR Neutral Switch Open Circuit

604.04 - FNR Neutral Switch Short Circuit

604.15 - FNR Neutral Switch Minimum Calibration Value Too High

604.16 - FNR Neutral Switch Maximum Calibration Value Too High

604.17 - FNR Neutral Switch Minimum Calibration Value Too Low

604.18 - FNR Neutral Switch Maximum Calibration Value Too Low

619.05 - Brake Solenoid No Response

620.03 - TCU 5V Supply Short to Power

620.04 - TCU 5V Supply Open or Short

907.03 - Left Speed Sensor Short to Power

907.04 - Left Speed Sensor Short

907.07 - Left Speed Sensor No Response

907.12 - Left Speed Sensor Open

908.03 - Right Speed Sensor Short to Power

908.04 - Right Speed Sensor Short

908.07 - Right Speed Sensor No Response

908.12 - Right Speed Sensor Open

977.05 - Fan Reverse Solenoid No Response

1071.05 - Fan Drive Solenoid Open Circuit

1071.06 - Fan Drive Solenoid Short Circuit

2660.00 - Steer Sensor Input Greater Than Maximum Calibration Value

2660.01 - Steer Sensor Input Less Than Minimum Calibration Value

2660.03 - Steer Sensor Short to Power

2660.04 - Steer Sensor Open or Short

2660.15 - Steer Sensor Minimum Calibration Value Too High

2660.16 - Steer Sensor Maximum Calibration Value Too Low

2660.17 - Steer Sensor Minimum Calibration Value Too Low

2660.18 - Steer Sensor Maximum Calibration Value Too Low

2661.00 - FNR Sensor Input Greater Than Maximum Calibration Value

2661.01 - FNR Sensor Input Less Than Minimum Calibration Value

2661.03 - FNR Sensor Short to Power

2661.04 - FNR Sensor Open or Short

2661.15 - FNR Sensor Minimum Calibration Value Too High

2661.16 - FNR Sensor Maximum Calibration Value Too Low

2661.17 - FNR Sensor Minimum Calibration Value Too Low

2661.18 - FNR Sensor Maximum Calibration Value Too Low

522439.05 - Tank Bypass Solenoid Open Circuit

522444.00 - Charge Pressure High

522444.01 - Charge Pressure Low

522444.03 - Charge Pressure Short to Power

522444.04 - Charge Pressure Open or Short

522447.05 - Right Forward Pump Coil Open

522447.06 - Right Forward Pump Coil Short

522447.15 - Right Forward Pump Threshold Calibration Value Too High

522447.16 - Right Forward Pump Max Speed Calibration Value Too High

522447.17 - Right Forward Pump Threshold Calibration Value Too Low

522447.18 - Right Forward Pump Max Speed Calibration Value Too Low

522448.05 - Right Reverse Pump Coil Open

522448.06 - Right Reverse Pump Coil Short

522448.15 - Right Reverse Pump Threshold Calibration Value Too High

522448.16 - Right Reverse Pump Max Speed Calibration Value Too High

522448.17 - Right Reverse Pump Thresh Calibration Value Too Low

522448.18 - Right Reverse Pump Max Speed Calibration Value Too Low

522449.05 - Left Reverse Pump Coil Open

522449.06 - Left Reverse Pump Coil Short

522449.15 - Left Reverse Pump Threshold Calibration Value Too High

522449.16 - Left Reverse Pump Max Speed Calibration Value Too Low

522449.17 - Left Reverse Pump Threshold Calibration Value Too Low

522449.18 - Left Reverse Pump Max Speed Calibration Value Too Low

522450.05 - Left Forward Pump Coil Open

522450.06 - Left Forward Pump Coil Short

522450.15 - Left Forward Pump Threshold Calibration Value Too High

522450.16 - Left Forward Pump Max Speed Calibration Value Too High

522450.17 - Left Forward Pump Threshold Calibration Value Too Low

522450.18 - Left Forward Pump Max Speed Calibration Value Too Low

522451.05 - Cooler Bypass Solenoid No Response

523108.13 - TCU Not Calibrated High Speed Not Done

523108.14 - TCU Not Calibrated Sensor/Pump/Motor

523436.07 - TCU Watchdog Timer Exceeded

523577.05 - Left Motor Solenoid Open Circuit

523577.06 - Left Motor Solenoid Short Circuit

523577.16 - Left Motor Maximum Calibration Value Too High

523577.18 - Left Motor Maximum Calibration Value Too Low

523578.05 - Right Motor Solenoid Open Circuit

523578.06 - Right Motor Solenoid Short Circuit

523578.16 - Right Motor Maximum Calibration Value Too High

523578.18 - Right Motor Maximum Calibration Value Too Low

Section 9005: Operational Checkout Procedure

Group 10: Operational Checkout Procedure

Operational Checkout

Section 9010: Engine

Group 05: Theory of Operation

POWERTECH™ 9.0L (6090) John Deere Engines

Group 15: Diagnostic Information

Diagnose Engine Malfunctions

Engine Cooling System Component Location

Engine Fuel System Component Location

Engine Intake and Exhaust Component Location

Group 25: Tests

POWERTECH™ 9.0L (6090) John Deere Engines

Fuel Supply Pump Pressure Test

Section 9015: Electrical System

Group 05: System Information

Electrical Diagram Information

Electrical Schematic Symbols

Group 10: System Diagrams

Fuse and Relay Specifications

System Functional Schematic, Wiring Diagram, and Component Location Legend

Standard Cab System Functional Schematic and Section Legend

Armored Cab System Functional Schematic and Section Legend

Standard Cab Operator's Station Harness (W7) Component Location

Standard Cab Operator's Station Harness (W7) Wiring Diagram

Standard Cab Roof Harness (W9) Component Location

Standard Cab Roof Harness (W9) Wiring Diagram

Engine Harness (W10) Component Location

Engine Harness (W10) Wiring Diagram

Transmission Harness (W11) Component Location

Transmission Harness (W11) Wiring Diagram

Air Conditioning Harness (W14) and Condenser Harness (W17) Component Location

Air Conditioning Harness (W14) and Condenser Harness (W17) Wiring Diagram

Fuel Tank Harness (W18) Component Location

Fuel Tank Harness (W18) Wiring Diagram

Wiper Harness (W23 and W24) Component Location

Wiper Harness (W23 and W24) Wiring Diagram

Armored Cab Operator's Station Harness (W25) Component Location

Armored Cab Operator's Station Harness (W25) Wiring Diagram

Armored Cab Roof Harness (W26) Component Location

Armored Cab Roof Harness (W26) Wiring Diagram

Pressure Sensor Harness (W27) Wiring Diagram

Dome Light Harness (W28) Wiring Diagram (S.N. 180505— )

Grade Control System Harnesses (W32, W33, W34, W35, W36, and W37) Component Location

Group 15: Sub-System Diagnostics

Starting and Charging Circuit Theory of Operation

Controller Area Network (CAN) Theory of Operation

Engine Control Unit (ECU) Circuit Theory of Operation

Transmission Control Unit (TCU) Circuit Theory of Operation

CAN Monitor Unit (CMU) Circuit Theory of Operation

Group 20: References

Electrical Component Specifications

Battery Charging Procedure

Service ADVISOR™ Diagnostic Application

Service ADVISOR™ Connection Procedure

Reading Diagnostic Trouble Codes with Service ADVISOR™ Diagnostic Application

CAN Monitor Unit (CMU) Menu Structure—Service Mode

Alternator Test Procedure

CAN Circuit Test

Transmission Control Unit (TCU) Remove and Install

Transmission Control Unit (TCU) Calibration

Wire Harness Test

Decelerator/Brake Pedal Adjustment

Engine Speed Control Remove and Install

Rotary Sensor Remove and Install

Transmission Control Lever (TCL) Adjustment

Bussed Sensor Connectors (X6 and X7) Diagnostics

Engine Control Unit (ECU) Remove and Install

Replace Weather Pack™ Connector

Install Weather Pack™ Contact

Replace DEUTSCH® Connectors

Replace DEUTSCH DEUTSCH is a trademark of Deutsch Co. Rectangular or Triangular Connectors

Install DEUTSCH® Contact

Replace CINCH CINCH is a trademark of the Cinch Co. Connectors

Install CINCH CINCH is a trademark of the Cinch Co. Contact

Replace (Pull Type) Metri-Pack™ Connectors

Replace (Push Type) Metri-Pack™ Connectors

Section 9025: Hydraulic System

Group 05: Theory

Hydraulic System Operation

Hydraulic Pump Operation

Hydraulic Control Valve Operation

Load Sense Circuit Operation

Load Sense Isolator Operation

Circuit Relief Valve with Anticavitation Operation

Hydraulic System Relief Valve Operation

Hydraulic Oil Filter Manifold Operation

Ripper Operation

Winch Operation

Hydraulic Cylinder Operation

Quick-Drop Valve Operation

Group 15: Diagnostic Information

Hydraulic System Schematic

Hydraulic System Component Location

Ripper Hydraulic Component Location

Winch Hydraulic Component Location

Diagnose Hydraulic System Malfunctions

No Hydraulic Functions

Hydraulic Functions Slow

Hydraulic Pump Noisy

Blade Float Does Not Work

One Hydraulic Function Does Not Work

Function Drifts Down

Hydraulic Oil Overheats

Diagnose Winch System Malfunctions

Group 25: Tests

JT02156A Digital Pressure/Temperature Analyzer Installation

Ultra Clean® Hand Launcher

Hydraulic Oil Cleanup Procedure

Hydraulic System Relief Valve Test

Circuit Relief Valve Test

Pump Load Sense Differential and System Pressure (Pump Cutoff) Test and Adjustment

Lift and Tilt Cylinder Function Drift Test

Hydraulic Cylinder Drift Test

Cylinder Leakage Test

Pressure Reducing Valve Pressure Test and Adjustment

Blade Down Accumulator Hydraulic Discharge

Blade Down Accumulator Precharge Test

Hydraulic Pump Flow Test

Hydraulic Pump Case Drain Test

Section 9026: Hydrostatic System

Group 05: Theory of Operation

Hydrostatic System

Transmission Control Circuit Operation (Flow Chart)

Charge Pump Operation

Hydrostatic Charge Oil Filter Operation

Neutral Charge Relief Valve Operation

Multi-Function Valve Operation

Hydraulic Integrated Circuit (HIC) Valve Operation

Park Brake Valve Operation

Oil Cooler and Reservoir Bypass Operation

Pump Pressure Control Pilot (PCP) Operation

Pump Displacement Control Valve (PDCV) Operation

Hydrostatic Pump Operation

Flushing Valve and Operating Charge Relief Valve Operation

Hydrostatic Motor Operation

Hydraulic Reversing Fan Drive Operation

Hydraulic Fan Return Filter Operation

Group 15: Diagnostic Information

Hydrostatic System Schematic—Neutral (Park Brake On)

Hydrostatic System Diagram—Neutral (Park Brake On)

Hydrostatic System Diagram—Reverse (Slow Speed)

Hydrostatic System Diagram—Forward (Fast Speed)

Hydrostatic System Component Location

Park Brake System Component Location

Overheating—Flowchart

Low Charge Pressure—Flowchart

Mistrack/Indexes—Flowchart

Machine Will Not Reach Full Speed—Flowchart

Low Power—Flowchart

Engine Starts But One Or Both Tracks Will Not Move—Flowchart

TCU Calibration Malfunctions

Group 25: Tests

JT02156A Digital Pressure/Temperature Analyzer Installation

Ultra Clean Hand Launcher

Machine Supporting Procedure

Transmission Oil Warm-Up Procedure

Releasing Park Brake to Tow the Machine

Hydrostatic Pump and Motor Initial Start-Up Procedure

Hydrostatic Pump Flushing Procedure

Hydraulic Oil Cleanup Procedure

Pressure Control Pilot (PCP) Manual Override Test

Pressure Control Pilot (PCP) Test

Pressure Control Pilot (PCP) Internal Adjustment

Multi-Function Relief Valve Test

Transmission Efficiency Test

Neutral Charge Relief and Operating Charge Relief Pressure Test

Pump Displacement Control Valve (PDCV) Neutral (Null) Adjustment

Pump Servo Pressure Test

Motor Displacement Control Valve (MDCV) Adjustment

Hydrostatic Motor Min./Max. Angle Servo Piston Pressure Test

Charge Pump Flow Test

Charge Pressure Sensor Test

Hydrostatic Oil Cooler Bypass Test

Hydrostatic Oil Reservoir Bypass Test

Park Brake Test

Park Brake Relief Valve Test

Cab Tilt Relief Valve Test

Fan Pump Pressure Test

Fan Pump Flow Test

Fan Motor Speed Test

Fan Motor Case Drain Test

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 Operational Information

Air Conditioning Circuit Theory of Operation

Binary Pressure Switch Operation

Air Conditioning Freeze Switch Operation

Receiver-Dryer Operation

Expansion Valve Operation

Compressor Relief Valve Operation

Heater Blower Circuit Operational Information

Heater Blower Circuit Theory of Operation

Temperature Control Operation

Group 15: Diagnostic Information

Air Conditioning and Heater System Component Location

Air Conditioning Circuit Specifications

Air Conditioning System Does Not Operate

Air Conditioning Does Not Cool Interior of Cab

Air Conditioning Runs Constantly, Too Cold

Interior Windows Continue To Fog

Heater System Does Not Operate

Heater Does Not Warm Interior Of Cab

Group 25: Tests

Proper Refrigerant Handling

R134a Refrigerant Cautions

R134a Air Conditioning System Test

Operating Pressure Diagnostic Chart

R134a Oil Charge Capacity

R134a Refrigerant Charge Capacity

Expansion Valve Operation Test

Blower Switch Test

Blower Motor Resistor Test

Heater Blower Motor Test

Air Conditioner Freeze Switch Test

Air Conditioner Switch Test

Binary Pressure Switch Test

Compressor Clutch Coil Test

Air Conditioning System Leak Test

Refrigerant Hoses and Tubing Inspection

John Deere Crawler Dozer 850JR Operation and Test Service Manual (TM10779)