John Deere 180CW and 210CW Wheeled Excavator Service Manual (Operation & Test) - TM2286

TM2286 - John Deere 180CW and 210CW Wheeled Excavator Technical Manaul (Operation & Test).PDF

Complete official service manual with Electrical Wiring Diagrams for John Deere 180CW and 210CW Wheeled Excavator, with all the shop information to maintain, diagnose, repair, rebuild like professional mechanics.

John Deere 180CW and 210CW Wheeled Excavator workshop service & repair 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.

Total Pages: 1,000 pages
File Format: PDF (bookmarked, Searchable, Printable, high quality)
Language: English

tm2286 - 180CW and 210CW Wheeled Excavator

Table of Contents

Foreword

Technical Information Feedback Form

Section 9000: General Information

Group 01: Safety

Recognize Safety Information

Follow Safety Instructions

Operate Only If Qualified

Wear Protective Equipment

Avoid Unauthorized Machine Modifications

Add Cab Guarding for Special Uses

Inspect Machine

Stay Clear of Moving Parts

Avoid High-Pressure Oils

Beware of Exhaust Fumes

Prevent Fires

Prevent Battery Explosions

Handle Chemical Products Safely

Dispose of Waste Properly

Prepare for Emergencies

Use Steps and Handholds Correctly

Start Only From Operator's Seat

Use and Maintain Seat Belt

Prevent Unintended Machine Movement

Avoid Work Site Hazards

Keep Riders Off Machine

Avoid Backover Accidents

Avoid Machine Tip Over

Use Special Care When Lifting Objects

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 9005: Operational Checkout Procedure

Group 10: Operational Checkout Procedure

Operational Checkout

Section 9010: Engine

Group 05: Theory of Operation

Engine Component Location

Engine Fuel System Operation

Engine Cooling System Operation

Engine Lubrication System Operation

Engine Intake and Exhaust System Operation

Engine Turbocharger Operation

Engine Speed Control System Operation

Group 15: Diagnostic Information

Diagnose Engine Malfunctions

Group 25: Tests

Engine Speed Test and Adjustment

Engine Learning Procedure

Fuel Injection Nozzle Check and Adjust

Injection Pump Timing Check and Adjust

Fan Belt and A/C Compressor Belt Tension Check and Adjust

Engine Valve Lash (Clearance) Check and Adjust—180CW

Engine Valve Lash (Clearance) Check and Adjust—210CW

Engine Compression Pressure Test

Fuel Line Leakage Test

Air Intake System Leakage Test

Head Gasket Leakage Check

Intake Manifold Pressure Test—Turbocharger Boost

Engine Oil Pressure Test

Radiator Temperature Drop Test

Section 9015: Electrical System

Group 05: System Information

Electrical Diagram Information

Component Identification Table

Fuse (Blade-Type) Color Codes

Group 10: System Diagrams

Fuse Specifications

System Functional Schematic, Wiring Diagrams, and Component Locations Master Legend

System Functional Section Legend

System Functional Schematic (Circuits SE1—SE3)

System Functional Schematic (Circuits SE4—SE6)

System Functional Schematic (Circuits SE7—SE9)

System Functional Schematic (Circuits SE10—SE12)

System Functional Schematic (Circuits SE13—SE15)

System Functional Schematic (Circuits SE16—SE18)

System Functional Schematic (Circuits SE19—SE21)

System Functional Schematic (Circuits SE22—SE24)

System Functional Schematic (Circuits SE25—SE27)

System Functional Schematic (Circuits SE28—SE30)

System Functional Schematic (Circuits SE31—SE33)

System Functional Schematic (Circuits SE34—SE36)

System Functional Schematic (Circuits SE37—SE39)

System Functional Schematic (Circuits SE40—SE42)

System Functional Schematic (Circuits SE43—SE45)

System Functional Schematic (Circuits SE46—SE48)

System Functional Schematic (Circuits SE49—SE51)

System Functional Schematic (Circuits SE52—SE54)

System Functional Schematic (Circuits SE55—SE57)

System Functional Schematic (Circuits SE58—SE60)

System Functional Schematic (Circuits SE61—SE63)

System Functional Schematic (Circuits SE64—SE66)

System Functional Schematic (Circuits SE67—SE69)

System Functional Schematic (Circuits SE70—SE72)

System Functional Schematic (Circuits SE73—SE75)

System Functional Schematic (Circuits SE76—SE78)

System Functional Schematic (Circuits SE79—SE81)

System Functional Schematic (Circuits SE82—SE84)

System Functional Schematic (Circuits SE85—SE87)

System Functional Schematic (Circuits SE88—SE90)

System Functional Schematic (Circuits SE91—SE93)

System Functional Schematic (Circuits SE94—SE96)

Battery and Power Cables (W1 and W2) Component Location—180CW

Battery and Power Cables (W1 and W2) Component Location—210CW

Engine Harness (W3) and Travel Alarm Harness (W10) Component Location—180CW

Engine Harness (W3) Wiring Diagram—180CW

Engine Harness (W3) and Travel Alarm Harness (W10) Component Location—210CW

Engine Harness (W3) Wiring Diagram—210CW

Pump Harness (W4) Component Location—180CW

Pump Harness (W4) Wiring Diagram—180CW

Pump Harness (W4) Component Location—210CW

Pump Harness (W4) Wiring Diagram—210CW

Chassis Harness (W5), Slip Ring Harness (W11), and Stabilizer Harnesses (W25 and W26) Component Location

Chassis Harness (W5), Slip Ring Harness (W11), and Stabilizer Harnesses (W25 and W26) Wiring Diagram

Cab Harness (W6) Component Location

Cab Harness (W6) Wiring Diagram

Monitor Controller and Display Harness (W7) and Wiper Motor Harness (W12) Component Location

Monitor Harness (W7) and Wiper Motor Harness (W12) Wiring Diagram

12-Volt Converter Harness (W8) and Option Power Harness (W22) Component Location

12-Volt Converter Harness (W8) and Option Power Harness (W22) Wiring Diagram

Blade / Stabilizer Switch Panel Harness (W9) Component Location

Blade / Stabilizer Switch Panel Harness (W9) Wiring Diagram

Travel Alarm Harness (W10) Wiring Diagram

A/C and Heater Harness (W13 and W14) Component Location—180CW

A/C and Heater Harness (W15) Component Location—210CW

Front Work Lights Harness (W16, W17, and W18) Component Location

Front Work Lights Harness (W16, W17, and W18) Wiring Diagrams

Rear Work Light Harness (W19 and W20) Component Location

Rear Work Light Harness (W19 and W20) Wiring Diagrams

Boom Work Light Harness (W21) Component Location

Boom Work Light Harness (W21) Wiring Diagram

Option Power Harness (W22) Wiring Diagram

ICX Download Harness (W23) Wiring Diagram

Power Boost Harness (W24) Component Location

Power Boost Harness (W24) Wiring Diagram

Group 15: Sub-System Diagnostics

Start Circuit Theory of Operation

Charging and Load Dump Circuits Theory of Operation

QOS Controller (Preheat) Circuit Theory of Operation

Monitor Controller and Display Circuit Theory of Operation

Main Controller (MCX) Circuit Theory of Operation

Main Controller (MCX)—Engine Control Circuit Theory of Operation

Main Controller (MCX)—Pump Control Circuit Theory of Operation

Main Controller (MCX)—Valve Control Circuit Theory of Operation

Main Controller (MCX)—Other Control Circuits Theory of Operation

Information Controller (ICX) Circuit Theory of Operation

Travel Control Circuit Theory of Operation

Travel Motor Alarm Circuit Theory of Operation

Park Brake Circuit Theory of Operation

Park Brake Alarm Circuit Theory of Operation

Service (Work) Brakes Circuit Theory of Operation

Travel Alarm Circuit Theory of Operation

Wiper and Washer Circuit Theory of Operation

Air Conditioner Controller Circuit Theory of Operation—180CW

Air Conditioner Controller Circuit Theory of Operation—210CW

Group 20: References

Electrical Component Specifications

Dr.ZX Diagnostic Application

Information Controller (ICX) Initialization and Download

Information Controller (ICX) Recorded Data

Monitor Data Items Using the Monitor Controller and Display

Monitor Data Items Using Dr.ZX Diagnostic Application

Reading Main Controller Diagnostic Trouble Codes Using Blink Method

Main Controller (MCX) Diagnostic Trouble Codes

Relay Test

Pressure Sensor Test

Speed Sensor Test

Temperature Sensor Test

Engine Control (EC) Sensor Test

Engine Control (EC) Motor Test

Alternator Test

Electrical Component Checks

Rear Cover Remove and Install

QOS Controller (Glow Plug Module) Remove and Install

Information Controller (ICX) and Main Controller (MCX) Remove and Install

Monitor Controller and Display Remove and Install

Wiper and Washer Enable Switch Remove and Install

Servicing Connectors

Section 9020: Power Train

Group 05: Theory of Operation

Travel Hydraulic System Operation—180CW

Travel Hydraulic System Operation—210CW

Travel Pilot Control Valve Operation

Shockless Travel Valve Operation

Travel Motor and Regulator Operation

Counterbalance Valve Operation

Transmission Operation

Shift Interlock Operation

Transmission Disconnect Operation

Transmission Control Valve Operation

Park Brake Operation

Service Brake Circuit Operation

Service Brake Accumulator Charging Valve Operation

Axle Lock Circuit Operation

Group 15: Diagnostic Information

Diagnose Transmission Malfunctions

Diagnose Brake Malfunctions

Travel Hydraulic System Schematic—180CW

Travel Hydraulic System Component Location—180CW

Travel Hydraulic System Line Identification—180CW

Service Brake System Schematic—180CW

Axle Lock System Schematic—180CW

Service Brake and Axle Lock Line Identification—180CW

Travel Hydraulic System Schematic—210CW

Travel Hydraulic System Component Location—210CW

Travel Hydraulic System Line Identification—210CW

Service Brake System Schematic—210CW

Axle Lock System Schematic—210CW

Service Brake and Axle Lock Line Identification—210CW

Group 25: Tests and Adjustments

Transmission Manual Disconnect Procedure

Brake Bleeding Procedure

Transmission Control Valve Pressure Reducing Valve Test and Adjustment

Transmission Control Valve Park Brake Relief Valve Test

Transmission Low Range Brake Bleeding Procedure—180CW

Transmission Low Range Brake Bleeding Procedure—210CW

Transmission Low Range Brake Pressure Test

Transmission High Range Clutch Pressure Test

Transmission Shift Interlock Pressure Test

Rear Service Brakes Pressure Test

Front Service Brakes Pressure Test—180CW

Front Service Brakes Pressure Test—210CW

Brake Accumulate Pressure Test

Measure Swing Bearing Wear

Section 9025: Hydraulic System

Group 05: Theory of Operation

Hydraulic System Diagram and Operation

Pilot System Diagram and Operation

Pilot Relief Valve Operation

Pilot Control Shut-Off Valve Operation

Control Lever Pilot Valve Operation

Positioning / Auxiliary and Blade / Stabilizer Pilot Valve Operation

Pilot Operation of Control Valve Operation

Pilot Signal Control Valve Operation

Hydraulic Pump and Drive Gearbox Operation

Hydraulic Pump Regulator Component Identification

Hydraulic Pump Regulator Operation

Engine Speed Sensing Control Circuit Operation

Control Valve Operation

Control Valve Check Valves Identification and Operation

Main Relief Valve Operation—180CW

Main Relief and Power Boost Valve Circuit Operation—210CW

Circuit Relief Valve Operation—180CW

Circuit Relief Valve Operation—210CW

Arm Regenerative Valve Circuit Operation

Bucket and Boom Regenerative Valve Circuit Operation

Boom and Arm Anti-Drift Valves Operation

Bucket, Arm, and Auxiliary Flow Rate Valve Circuit Operation

Auxiliary Flow Combiner Valve Operation

Swing Reduction Gearbox Operation

Swing Motor, Crossover Relief Valve, and Make-Up Check Valve Operation

Swing Motor Park Brake Release Circuit Operation

Center Joint Operation

Steering Circuit Operation

Steering Valve Operation

Blade / Stabilizer Circuit Operation

Blade / Stabilizer Cylinder Check Valve Operation

Lowering Valve Operation

Return Filter Operation

Group 15: Diagnostic Information

Diagnose Hydraulic Component Malfunctions

Diagnose Hydraulic System Malfunctions

Diagnose Pilot Circuit Malfunctions

Diagnose Dig Circuit Malfunctions

Diagnose Swing Circuit Malfunctions

Diagnose Steering System Malfunctions

Control Valve Line Identification—180CW

Control Valve Line Identification—210CW

Hydraulic Pump 1, Hydraulic Pump 2, Pilot, and Steering Pump Line Identification

Swing Motor Line Identification

Pilot Signal Control Valve-to-Control Valve Line Connections—180CW

Pilot Signal Control Valve-to-Control Valve Line Connections—210CW

Pilot Valves-to-Pilot Signal Control Valve Line Connections—Excavator Pattern

Pilot Valves-to-Pilot Signal Control Valve Line Connections—Backhoe Pattern

Steering Valve Line Connections

Hydraulic System Circuit Symbols

Pilot Valves and Pilot Signal Control Valve Schematic—180CW

Pilot Valves and Pilot Signal Control Valve Schematic—210CW

Control Valve Schematic—180CW

Control Valve Schematic—210CW

Swing Motor Schematic

Hydraulic Pump 1 and Hydraulic Pump 2 Regulators Schematic

Steering Circuit Schematic—180CW

Steering Circuit Schematic—210CW

Main Hydraulic System Component Location—180CW

Main Hydraulic System Component Location—210CW

Group 25: Tests and Adjustments

JT05801 Clamp-On Electronic Tachometer 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

Pilot Pressure Relief Valve Test and Adjustment

Main Relief Valve Test and Adjustment—180CW

Main Relief and Power Boost Valve Test and Adjustment—210CW

Circuit Relief Valve Test and Adjustment—180CW

Circuit Relief Valve Test and Adjustment—210CW

Swing Motor Crossover Relief Valve Test and Adjustment—180CW

Swing Motor Crossover Relief Valve Test and Adjustment—210CW

Stabilizer and Blade Relief Valve Test and Adjustment—180CW

Stabilizer and Blade Relief Valve Test and Adjustment—210CW

Control Valve Spool Actuating Pilot Pressure Test—180CW

Control Valve Spool Actuating Pilot Pressure Test—210CW

Arm Regenerative, Axle Lock, Brake, and Travel Motor Swash Plate Angle Solenoid Valve Test and Adjustment—180CW

Arm Regenerative, Brake, Power Boost, and Travel Motor Swash Plate Angle Solenoid Valve Test and Adjustment—210CW

Axle Lock and Pump 1 Flow Rate Limit Solenoid Valve Test and Adjustment—210CW

Steering Relief Valve Pressure Test

Steering System Leakage Test

Steering Cylinder Leakage Test

Swing Motor Leakage Test

Hydraulic Pump Regulator Test and Adjustment—Engine Pulldown

Hydraulic Pump Flow Test and Regulator Test and Adjustment

Pilot and Steering Pump Specifications

Section 9031: Heating and Air Conditioning

Group 05: Theory of Operation

Air Conditioning System Cycle of Operation

Group 15: Diagnostic Information

Diagnose Air Conditioning System Malfunctions

Diagnose Heating System Malfunctions

Diagnose Air Conditioner Diagnostic Trouble Codes—180CW

Diagnose Air Conditioner Diagnostic Trouble Codes—210CW

Air Conditioner and Heater Component Location—180CW

Air Conditioner and Heater Component Location—210CW

Group 25: Tests

Refrigerant Cautions and Proper Handling

Refrigerant Hoses and Tubing Inspection

Air Conditioner and Heater System Checks

Refrigerant Leak Test

Air Conditioner Compressor Clutch Test

R134a Air Conditioning System Test

Operating Pressure Diagnostic Chart

Section 9050: Reference Material

Group 05: Terminology Cross Reference Chart

Terminology Cross Reference Chart