Complete repair service manual for John Deere / BELL B35C and B40C Articulated Dump Truck , with all the technical information to maintain, diagnose, and rebuild like professional mechanics.

John Deere / BELL B35C, B40C workshop service 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.

tm1815 - B35C and B40C Articulated Dump Truck Operation and Tests.pdf

PRODUCT DETAILS:
Total Pages: 1,411 pages
File Format: PDF (Windows & Mac & Linux)
Language: English

MAIN CONTENTS
Foreword
   Technical Information Feedback Form
   Machine Number Identification
   General Information
      Safety
      General Specifications
      Torque Values
      Fuels and Lubricants
   Operational Checkout Procedure
      Operational Checkout Procedure
   Engine
      Theory of Operation
      Diagnose Engine Malfunctions
      Adjustments
      Tests
   Electrical System
      System Information
      System Diagrams
      Sub-System Diagnostics
      References
   Power Train
      Theory of Operation
      Diagnostic Information
      Tests
   Pneumatic System
      Theory of Operation
      Diagnostic Information
      Tests
   Hydraulic System
      Theory of Operation
      Diagnostic Information
      Tests
   Heater and Air Conditioner
      Theory of Operation
      Diagnostic Information
      Adjustments
      Tests

tm1815 - B35C and B40C Articulated Dump Truck Operation and Tests

Table of Contents

Foreword

Technical Information Feedback Form

Machine Number Identification

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

Service Tires Safely

Practice Safe Maintenance

Use Proper Tools

Dispose of Waste Properly

Live With Safety

Group 02: General Specifications

Articulated Dump Truck Left Side View

B35C Articulated Dump Truck Specifications

B40C Articulated Dump Truck Specifications

B35C Engine Specifications

B40C Engine Specifications

B35C Travel Speeds

B40C Travel Speeds

Drain and Refill Capacities

Group 03: Torque Values

Hardware Torque Specifications

Metric Bolt and Cap Screw Torque Values

Additional Metric Cap Screw Torque Values

Unified Inch Bolt and Cap Screw Torque Values

Metric Cap Screw And Nut Torque Values

Imperial and SAE (Inch) Cap Screw And Nut 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 Metric Series Four Bolt Flange Fitting

Service Recommendations For Inch Series Four Bolt Flange Fittings

Group 04: Fuels and Lubricants

Diesel Fuel

Lubricity of Diesel Fuels

Low Sulfur Diesel Fuel Conditioner

Diesel Fuel Storage

Do Not Use Galvanized Containers

Fuel Tank

Diesel Engine Oil

Hydraulic Oil and Transfer Case Oil

Transmission Oil

Multipurpose Lubricant (Axles and Final Drives)

Grease

Oil Filters

Alternative and Synthetic Lubricants

Lubricant Storage

Mixing of Lubricants

Section 9005: Operational Checkout Procedure

Group 10: Operational Checkout Procedure

Operational Checkout

Section 9010: Engine

Group 05: Theory of Operation

B35C (OM 442A) Engine Sectional View

B40C (OM 442TI) Engine Sectional View

Engine Operation

Exhaust Valve Brake Operation

Fuel Circuit

Fuel Injection Pump Operation

Fuel Injection Nozzle Operation

Mechanical Governor Operation

Starting Engine-Mechanical Governor

Engine Running at Slow Idle-Mechanical Governor

Engine Running at Medium Speed-Mechanical Governor

Engine Running at Full Load Rated Speed-Mechanical Governor

Stopping the Engine-Mechanical Governor

Aneroid Operation

Cooling System Operation

Crankcase Ventilation System Operation

Cold Start Operation

Group 15: Diagnose Engine Malfunctions

Diagnose Engine Malfunctions

Group 20: Adjustments

JT05801 Clamp-On Electronic Tachometer Installation

PRO-LINKPRO-LINK is a trademark of Micro Processor Systems. 9000 Microprocessor Installation

Slow and Fast Idle Adjustment Using PRO-LINKPRO-LINK is a trademark of Micro Processor Systems. 9000 Microprocessor

Throttle Position Sensor Adjustment Using PRO-LINKPRO-LINK is a trademark of Micro Processor Systems. 9000 Microprocessor

Reset Throttle Calibration Using PRO-LINKPRO-LINK is a trademark of Micro Processor Systems. 9000 Microprocessor

Slow and Fast Idle Adjustment Using Tachometer

Throttle Position Sensor Adjustment-Manual Method

Mechanical Fuel Shutoff Adjustment(B35C Machine No. -408855.01)(B40C Machine No. -408844.01)

Fuel Shutoff Solenoid Adjustment (B35C Machine No. 409855.00-)(B40C Machine No. 409844.00-)

Exhaust Brake Valve Adjustment

Alternator and Water Pump Belts Adjustment

Bleed Fuel System

Group 25: Tests

JT05801 Clamp-On Electronic Tachometer Installation

JT05800 Digital Thermometer Installation

Injection Pump Timing Adjustment

Inspect Thermostat and Test Operating Temperature

Viscous Drive Fan Check

Fuel Line Leakage Test

Fuel Supply Pump Test

Fuel Injection Nozzles Test

Engine Compression Test

Air Intake System Leakage Test

Radiator Cap and Cooling System Pressure Test

Section 9015: Electrical System

Group 05: System Information

Electrical System Visual Inspection

Electrical Circuit Malfunctions

High Resistance Circuit

Open Circuit

Grounded Circuit

Shorted Circuit

Sensor Circuit Shorted to Power

Sensor Circuit Shorted to Itself

Sensor Circuit Shorted to Ground

Multimeter

Seven Step Electrical Test Procedure

Schematic, Wiring Diagram, and Component Location Information

Reading a System Functional Schematic

Reading a Wiring Diagram

Reading a Component Location Diagram

Reading a Connector End View Diagram

Electrical Schematic Symbols

Group 10: System Diagrams

Explanation of Wire Markings

Component Identification Table

Functional Schematic and Component Location Legend

Functional Schematic Section Legend

Power, Starting and Charging System Functional Schematic

Transmission System Functional Schematic

4-Way Flasher, Turn Signal, Horn, and Light System Functional Schematic

Brake and Reverse Light, Exhaust Vehicle Brake, and Indicator Light System Functional Schematic

Gauge, Overspeed, and Range Hold System Functional Schematic

Cooling Fans, Lighter, and Radio System Functional Schematic

Air Conditioner, Dome Light, Wiper/Washer, and Spare Circuit System Functional Schematic

Cab Harness (W5) Wiring Diagram (1 of 6)

Cab Harness (W5) Wiring Diagram (2 of 6)

Cab Harness (W5) Wiring Diagram (3 of 6)

Cab Harness (W5) Wiring Diagram (4 of 6)

Cab Harness (W5) Wiring Diagram (5 of 6)

Cab Harness (W5) Wiring Diagram (6 of 6)

Cab Harness (W5) Component Location (1 of 4)

Cab Harness (W5) Instrument Panel Component Location (2 of 4)

Cab Harness (W5) Dash Panel Component Location (3 of 4)

Cab Harness (W5) Breaker Panel Component Location (4 of 4)

Transfer Case and Cooling Fan Harness (W6) Wiring Diagram

Transfer Case and Cooling Fan Harness (W6) Component Location

Rear Chassis Harness (W7) Wiring Diagram

Rear Chassis Harness (W7) Component Location

Rear Light Harness (W8) Wiring Diagram

Rear Light Harness (W8) Component Location

Engine Harness (W9) Wiring Diagram

Engine (W9), Cold Start (W11), and Front Brake Overstroke Harness (W17) Component Location

Cold Start Harness (W11) Wiring Diagram

Front Brake Overstroke Harness (W17) Wiring Diagram

Front Light Harness (W10) Wiring Diagram

Front Light Harness (W10) Component Location

Transmission Control-To-Vehicle Interface Harness (W12) Wiring Diagram

Transmission Control-To-Vehicle Interface Harness (W12) Component Location

Vehicle Interface Harness (W18) Wiring Diagram

Vehicle Interface Harness (W18) Component Location

Vehicle Interface Module Schematic

Transmission Control Harness (W13) Wiring Diagram

Transmission Control Harness (W13) Component Location

Transmission Control-To-Cab Bulkhead (W14) Wiring Diagram

Transmission Control-To-Cab Bulkhead (W14) Component Location

Cab-To-Transmission Harness (W15) Wiring Diagram

Cab-To-Transmission (W15) And Speed Sensor Harness (W16) Component Location

Transmission Speed Sensor Harness (W16) Wiring Diagram

Group 15: Sub-System Diagnostics

Power Circuit Operational Information

Power Circuit Theory of Operation

Power Circuit Schematic

Starting and Charging Circuit Operational Information

Starting and Charging Circuit Theory of Operation

Starting and Charging Circuit Schematic

Transmission Circuit Operational Information

Transmission Circuit Theory of Operation

Transmission Circuit Schematic

4-Way Flasher, Turn Signal, and Horn Circuit Operational Information

4-Way Flasher, Turn Signal, and Horn Circuit Theory of Operation

4-Way Flasher, Turn Signal, and Horn Circuit Schematic

Light Circuit Operational Information

Light Circuit Theory of Operation

Light Circuit Schematic

Brake Light and Reverse Light Circuit Operational Information

Brake Light and Reverse Light Circuit Theory of Operation

Brake Light and Reverse Light Circuit Schematic

Exhaust Brake Circuit Operational Information

Exhaust Brake Circuit Theory of Operation

Exhaust Brake Circuit Schematic

Indicator Light Circuit Operational Information

Indicator Light Circuit Theory of Operation

Indicator Light Circuit Schematic

Gauge and Overspeed Circuit Operational Information

Gauge and Overspeed Circuit Theory of Operation

Gauge and Overspeed Circuit Schematic

Transmission Range Hold Circuit Operational Information

Transmission Range Hold Circuit Theory of Operation

Transmission Range Hold Circuit Schematic

High/Low Range Circuit Operational Information

High/Low Range Circuit Theory of Operation

High/Low Range Circuit Schematic

Cooling Fan Circuit Operational Information

Cooling Fan Circuit Theory of Operation

Cooling Fan Circuit Schematic

Cigar Lighter Circuit Operational Information

Cigar Lighter Circuit Theory of Operation

Cigar Lighter Circuit Schematic

Radio and 12V Circuit Operational Information (B35C Machine No. -408855.00) (B40C Machine No. -408844.00)

Radio and 12V Circuit Theory of Operation (B35C Machine No. -408855.00) (B40C Machine No. -408844.00)

Radio and 12V Circuit Schematic (B35C Machine No. -408855.00) (B40C Machine No. -408844.00)

Radio and 12V Circuit Operational Information (B35C Machine No. 408855.01- ) (B40C Machine No. 408844.01- )

Radio and 12V Circuit Theory of Operation (B35C Machine No. 408855.01- ) (B40C Machine No. 408844.01- )

Radio and 12V Circuit Functional Schematic (B35C Machine No. 408855.01- ) (B40C Machine No. 408844.01- )

Air Conditioner Circuit Operational Information

Air Conditioner Circuit Theory of Operation

Air Conditioner Circuit Schematic

Dome Light Circuit Operational Information

Dome Light Circuit Theory of Operation

Dome Light Circuit Schematic

Wiper/Washer Circuit Operational Information

Wiper/Washer Circuit Theory of Operation

Wiper/Washer Circuit Schematic

Rotating Beacon Circuit Operational Information

Rotating Beacon Circuit Theory of Operation

Rotating Beacon Circuit Schematic

Spare Circuit Operational Information

Spare Circuit Theory of Operation

Spare Circuit Schematic

Park Brake Circuit Operational Information

Park Brake Circuit Theory of Operation

Park Brake Circuit Schematic

Group 20: References

Battery Operation

Battery Specifications

Diagnose Battery Malfunctions

Check Battery Electrolyte Level and Terminals

Procedure for Testing Batteries

Using Booster Batteries-24 Volt System

Replacing Batteries

Adding 12 or 24 Volt Accessories

Adjusting Headlights

Section 9020: Power Train

Group 05: Theory of Operation

Transmission External Components

Transmission Control System

Transmission Cross Sectional Diagram

Torque Converter Operation

Transmission Planetary Operation

Transmission Clutch Engagement

Group 15: Diagnostic Information

Diagnostic Procedure

Diagnose Power Train System Malfunctions

Power Train Component Location Diagram

Group 25: Tests

Transmission Warm Up Procedure

Transmission Pressure Test

Transmission Clutch Drag Test

Torque Converter Stall Test-B35C

Torque Converter Stall Test-B40C

Torque Converter Stator Tests

Torque Converter Lockup Test

Front Suspension Strut Leakage Check

Front Suspension Strut Recharging Procedure

Park Brake Test (B35C Machine No. -408855.01) (B40C Machine No. -408844.01)

Park Brake Test (B35C Machine No. 409855.00- ) (B40C Machine No. 409844.00- )

Park Brake Pad Thickness Check

Park Brake Automatic Slack Adjustment (B35C Machine No. -408855.01) (B40C Machine No. -408844.01)

Park Brake Caliper Adjustment (B35C Machine No. -408855.01) (B40C Machine No. -408844.01)

Park Brake Adjustment (B35C Machine No. 409855.00- ) (B40C Machine No. 409844.00- )

Clutch Enable Test With PRO-LINK PRO-LINK is a trademark of Micro Processor Systems. 9000 Microprocessor

Diagnostic Codes

Diagnostic Code Display Procedure

Transmission Diagnostic Codes

Section 9022: Pneumatic System

Group 05: Theory of Operation

Pneumatic System Schematic Diagram Section Legend

Pneumatic System Diagram

Pneumatic System Schematic (B35C Machine No. -408855.01) (B40C Machine No. -408844.01)

Pneumatic System Schematic (B35C Machine No. 409855.00-) (B40C Machine No. 409844.00-)

Pneumatic System Operation

Air Drier And Unloader Valve

Pressure Protection Valve

Brake Valve-Applying Front Brakes

Brake Valve-Applying Front and Rear Brakes

Brake Valve-Releasing Brakes

Relay Valve

Brake Actuator

Brake Valve Adapter

Accelerator Valve

Park Brake Valve(B35C Machine No. -408855.01)(B40C Machine No. -408844.01)

Park Brake Valve(B35C Machine No. 409855.00-)(B40C Machine No. 409844.00-)

Air Pressure Supply Circuit Operation

Brake Circuit

Auxiliary Circuit

Group 15: Diagnostic Information

Diagnostic Procedure

Diagnose Pneumatic System Malfunctions

Pneumatic System Component Location Diagram

Group 25: Tests

Pneumatic System Main Pressure Test and Adjustment

Park Brake Pressure Test

Brake Actuator Piston Seal Leakage Test

Hydraulic Reservoir Pressure Test and Regulator Adjustment

Hydraulic Reservoir Relief Check Valve Pressure Test and Regulator Adjustment

Brake Light Pressure Switch Test

Park Brake Pressure Switch and Low Air Pressure Switch Test

High Range Hold Pressure Switch and Low Range Hold Pressure Switch Test

Section 9025: Hydraulic System

Group 05: Theory of Operation

Articulated Dump Truck Hydraulic System Operation

Hydraulic System Schematic Diagram (B35C Machine No. -408855.01) (B40C Machine No. -408844.01)

Hydraulic System Schematic Diagram (B35C Machine No. 409855.00- ) (B40C Machine No. 409844.00- )

Main Hydraulic Pump Operation

Main Hydraulic Pump Load Sense Operation

Flow Amplifier Valve Operation

Steering Valve Operation

Secondary Steering System Operation (B35C Machine No. 409855.00-)(B40C Machine No. 409844.00-)

Secondary Steering Hydraulic Pump (B35C Machine No. 409855.00-)(B40C Machine No. 409844.00-)

Group 15: Diagnostic Information

Diagnostic Procedure

Diagnose Hydraulic System Malfunctions

Diagnose Steering System Malfunctions

Hydraulic System Circuit Symbols

Transmission Oil Cooler Circuit and Hydraulic System Component Location(B35C Machine No. -408855.01) (B40C Machine No. -408844.01)

Hydraulic System Schematic(B35C Machine No. -408855.01) (B40C Machine No. -408844.01)

Transmission Oil Cooler Circuit and Hydraulic System Component Location(B35C Machine No. 409855.00-) (B40C Machine No. 409844.00-)

Hydraulic System Schematic(B35C Machine No. 409855.00-) (B40C Machine No. 409844.00-)

Group 25: Tests

JT05801 Clamp-On Electronic Tachometer Installation

JT05800 Digital Thermometer Installation

JT02156A Digital Pressure And Temperature Analyzer Installation

Hydraulic Oil Filter Inspection Procedure

Hydraulic Oil Cleanup Procedure Using Portable Filter Caddy

Hydraulic System Warm-Up Procedure

Tilt Cab Procedure

Cycle Time Test

Main Hydraulic Pump Residual and Compensator Valves Test and Adjustment

System Relief Valve Test and Adjustment

Body Lower Circuit Relief Valve Test and Adjustment

Secondary Steering Pump Residual and Compensator Valves Test and Adjustment(B35C Machine No. 409855.00-)(B40C Machine No. 409844.00-)

Steering Pressure Relief Valve Test and Adjustment

Steering Cylinder Leakage Test

Section 9031: Heater and Air Conditioner

Group 05: Theory of Operation

Proper R134a Refrigerant Handling

R134a Refrigerant Cautions

R134a Refrigerant Operation

Air Conditioner Compressor Operation

Condenser Operation

Receiver-Dryer Operation

Expansion Valve Operation

Freeze Control Switch Operation

Temperature Control Operation

Evaporator Operation

Heater Core Operation

High/Low Pressure Switch Operation

Heater and Air Conditioner Electrical Circuit Operation

Heater and Air Conditioner Circuit Schematic

Group 15: Diagnostic Information

Diagnose Air Conditioner Malfunctions

Diagnose Heater System Malfunctions

Heater and Air Conditioner Component Location

Group 20: Adjustments

Proper R134a Refrigerant Handling

R134a Refrigerant Cautions

R134a Refrigerant Oil Charge Check

Compressor R134a Refrigerant Oil Removal

R134a Refrigerant Oil Component Charge

R134a Refrigerant Recovery, Recycling, and Charging Station Installation

Recover R134a Refrigerant

Evacuate R134a Air Conditioner System

Charge R134a Air Conditioner System

Air Conditioner Compressor Belt Tension Check and Adjustment

R134a Air Conditioner System Cleaning Procedures

Purge R134a Air Conditioner System

Flush Air Conditioner System

Group 25: Tests

Proper R134a Refrigerant Handling

R134a Refrigerant Cautions

Refrigerant Hoses and Tubing Inspection

R134a Air Conditioner System Test

Operating Pressure Diagnostic Chart

Pressure Diagnostic Chart

Freeze Control Switch Test

Leak Testing R134a Air Conditioner System

John Deere / BELL B35C and B40C Articulated Dump Truck Operation & Test Service Manual (TM1815)