John Deere 700H Crawler Dozer Operation & Test Technical Manual (TM1858)

TM1858 - John Deere 700H Crawler Dozer Operation and Test Manual.pdf.pdf
891 pages, bookmarked, Searchable, Printable, high quality PDF

Complete technical Operation & Test Manual with electrical wiring diagrams for John Deere 700H Crawler Dozer. It's the same service manual used by dealers that guaranteed to be fully functional and intact without any missing page.

John Deere 700H Crawler Dozer Operation & Test Technical Manual (including maintenance, overhaul, disassembling & assembling, adjustment, tune-up, operation, inspecting, diagnostic & troubleshooting…) is divided into different sections. Each section covers a specific component or system with detailed illustrations. A table of contents is placed at the beginning of each section. Pages are easily found by category, and each page is expandable for great detail. The printer-ready PDF documents work like a charm on all kinds of devices.

tm1858 - 700H Crawler Dozer

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

Inspect Machine

Stay Clear of Moving Parts

Avoid High-Pressure Fluids

Beware of Exhaust Fumes

Prevent Fires

Prevent Battery Explosions

Handle Chemical Products Safely

Dispose of Waste Properly

Prepare for Emergencies

Add Cab Guarding For Special Uses

Start Only From Operator's Seat

Prevent Unintended Machine Movement

Avoid Work Site Hazards

Keep Riders Off Machine

Avoid Backover Accidents

Avoid Machine Tip Over

Park And Prepare For Service Safely

Service Cooling System Safely

Remove Paint Before Welding or Heating

Make Welding Repairs Safely

Drive Metal Pins Safely

Group 02: General Specifications

700H Crawler Dozer Dimensions

700H Crawler Dozer Specification

700H Crawler Dozer Weights

700H Other Information

700H Dozer Drain and Refill Capacities

4000S Winch

Group 03: Torque Values

Hardware Torque Specifications

Keeping ROPS Installed Properly

Checking Track Shoe Cap Screw Torque

Unified Inch Bolt and Screw Torque Values

Metric Bolt and Screw Torque Values

Additional Metric Cap Screw Torque Values

Check Oil Lines And Fittings

O-Ring Groove Connections

Service Recommendations For Flat Face O-Ring Seal Fittings

Service Recommendations for O-Ring Boss Fittings

Service Recommendations for Inch Series Four Bolt Flange Fittings

Service Recommendations for Metric Series Four Bolt Flange Fitting

Group 04: Fuels and Lubricants

Diesel Fuel

Low Sulfur Diesel Fuel Conditioner

Diesel Fuel Storage

Fuel Tank

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

Track Rollers, Front Idler, and Carrier Roller Oil

Transmission and Hydraulic Oil

Winch Oil

Inner and Outer Final Drive 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: System Operational Checks

POWERTECH POWERTECH is a trademark of Deere & Company 4.5L (4045) and 6.8L (6068) John Deere Engines

Engine Operational Checks

Hydrostatic Transmission Operational Checks

Operational Electrical Checks

Section 9010: Engine

Group 05: Theory Of Operation

POWERTECH POWERTECH is a trademark of Deere & Company 4.5L (4045) and 6.8L (6068) John Deere Engines

Engine—Sectional View

General Engine Description

Cold Weather Starting Aid Operation

Group 15: System Diagnostic Information

POWERTECH POWERTECH is a trademark of Deere & Company 4.5L (4045) and 6.8L (6068) John Deere Engines

Make Visual Inspection Of Engine And Supporting Systems

Diagnose Engine Malfunctions (S.N. —920838)

Observable Symptom Diagnostics (S.N. 920839— )

Group 20: Adjustments

POWERTECH POWERTECH is a trademark of Deere & Company 4.5L (4045) and 6.8L (6068) John Deere Engines

Accessing RPM

Engine Speed Adjustment (S.N. —920838)

Slow and Fast Idle Check (S.N. 920839— )

Engine Speed Control Linkage Adjustment (S.N. —920838)

Engine Speed Control Linkage Adjustment (S.N. 920839— )

Injection Pump Dynamic Timing Adjustment (S.N. —920838)

Group 25: Tests

POWERTECH POWERTECH is a trademark of Deere & Company 4.5L (4045) and 6.8L (6068) John Deere Engines

Air Intake System Leakage Test

Turbocharger Boost Pressure Test

Section 9015: Electrical System

Group 05: System Information

Electrical Diagram Information

Group 10: System Diagrams

Explanation Of Wire Markings

Fuse (Blade-Type) Color Codes

Electrical Wire Color Code Specifications

Fuse Specifications For Cab

Fuse Specifications For ROPS

Component Identification Table

System Functional Schematic, Wiring Diagram And Component Location Legend (S.N. —910010)

System Functional Schematic Section Legend (S.N. —910010)

System Functional Schematic (S.N. —910010)

System Functional Schematic, Wiring Diagram And Component Location Legend (S.N. 910011—920838)

System Functional Schematic Section Legend (S.N. 910011—920838)

System Functional Schematic (S.N. 910011—920838)

System Functional Schematic, Wiring Diagram And Component Location Legend (S.N. 920839— )

System Functional Schematic Section Legend (S.N. 920839— )

System Functional Schematic (S.N. 920839— )

Cab Harness (W5) Wiring Diagram

Cab Harness (W5) Component Location

Engine Harness (W6) Wiring Diagram (S.N. —920838)

Engine Harness (W6) Wiring Diagram (S.N. 920839— )

Engine Harness (W6) Component Location (S.N. 910011—920838)

Engine Harness (W6) Component Location (S.N. 920839— )

Transmission Harness (W7) Wiring Diagram

Transmission Harness (W7) Component Location (S.N. —910010)

Transmission Harness (W7) Component Location (S.N. 910011— )

Radio Harness (W9) Wiring Diagram

Radio Harness (W9) Component Location

Rear Wiper Harness (W11) Wiring Diagram

Group 15: Sub-System Diagnostics

Power Circuit Operational Information

Power Circuit Theory Of Operation

Power Circuit Schematic

Power Circuit Diagnostic Procedures

Start Circuit Operational Information

Start Circuit Theory Of Operation

Start Circuit Schematic

Start Circuit Diagnostic Procedures

Charging Circuit Operational Information

Charging Circuit Theory Of Operation

Charging Circuit Schematic

Charging Circuit Diagnostic Procedures

Display Monitor, Indicator And Gauge Specifications (S.N. —910010)

Display Monitor, Indicator And Gauge Specifications (S.N. 910011— )

Display Monitor, Indicator And Gauge Circuit Operational Information (S.N. —910010)

Display Monitor, Indicator And Gauge Circuit Theory Of Operation (S.N. —910010)

Display Monitor, Indicator And Gauge Circuit Schematic (S.N. —910010)

Display Monitor/Indicator Circuit Operational Information, Theory Of Operation And Circuit Schematic (S.N. 910011— )

Display Monitor, Indicator And Gauge Circuit Diagnostic Procedures

Transmission Control Circuit Operational Information

Transmission Control Circuit Theory Of Operation

Transmission Control Circuit Schematic

Transmission Control Circuit (Flow Chart)

Calculations For Diagnostic Transmission Calibration Limits For (B1, B2, B8, B9)

Diagnostic Transmission Calibration Limits Table

Transmission Controller Circuit Diagnostic Procedures

Transmission Controller Test

Decelerator Sensor (B1) Circuit Test (S.N. —920838)

Decelerator Sensor (B1) Circuit Test (S.N. 920839— )

Transmission Speed Control Switch (B4) Test With Speed In Grip

Reverse Speed Ratio Switch (B19) Switch Test

(R6) Motor Shift Resistor Module Test (S.N. —920838)

(R4 and R5) Can Termination Resistor Test

Left And Right Steer Sensor (B5) Test

FNR Sensor (B2) And Neutral Start Switch (S3) Test

Hydrostatic Pump Speed Sensor B6 Test

Left Track Motor Speed Sensor B7 Test

Right Track Motor Speed Sensor B3 Test

Rear Pump (LH) Pressure Control Pilot (PCP) B8 Test

Front Pump (RH) Pressure Control Pilot (PCP) B9 Test

Right Motor (RH) Pressure Control Pilot (PCP) B26 Test

Left Motor (LH) Pressure Control Pilot (PCP) B27 Test

Engine Controller Circuit Theory of Operation (S.N. 920839— )

Wiper And Washer Circuit Operational Information

Wiper And Washer Circuit Theory Of Operation

Wiper And Washer Circuit Schematic

Wiper And Washer Circuit Diagnostic Procedures

Heater Blower Circuit Operational Information

Heater Blower Circuit Theory Of Operation

Heater Blower Circuit Schematic

Heater Blower Circuit Diagnostic Procedures

Under Seat Heater Circuit Operational Information

Under Seat Heater Circuit Theory Of Operation

Under Seat Heater Circuit Schematic

Under Seat Heater Circuit Diagnostic Procedures

Front And Rear Light Circuit Operational Information

Front And Rear Light Circuit Theory Of Operation

Front And Rear Light Circuit Schematic

Front And Rear Light Circuit Diagnostic Procedures

Radio Circuit Operational Information

Radio Circuit Theory Of Operation

Radio Circuit Schematic

Radio Circuit Diagnostic Procedures

Group 20: References

Alternators And Starting Motors—Use CTM77

Service Equipment And Tools

Battery Specifications

Battery Operation

Diagnose Battery Malfunctions

Check Battery Electrolyte Level And Terminals

Procedure For Testing Batteries

Using Booster Batteries—24 Volt System

Alternator Operation—24V—55 Amp Bosch Alternator

Alternator Operation—24V—55 Amp Bosch Alternator

Starter Operation

Display Monitor Diagnostic Trouble Codes (S.N. 910011—920838)

Display Monitor Diagnostic Trouble Codes (S.N. 920839— )

Access Display Monitor Diagnostic Trouble Codes (S.N. 910011— )

Program Display Monitor (S.N. 910011— )

Engine Diagnostic Trouble Codes (S.N. 920839— )

Access Engine Diagnostic Trouble Codes (S.N. 920839— )

Transmission Controller Diagnostic Trouble Codes And Calibration Codes

Transmission Controller Display Window Structure

Transmission Controller Display Window Structure

Accessing And Clearing Stored Transmission Controller Service Codes

Accessing RPM

Calibration Theory

Calibrate Transmission Controller

Accessing Transmission Controller Rate Of Speed

Accessing Transmission Controller Diagnostics

Calculations For Diagnostic Transmission Calibration Limits For (B1, B2, B8, B9)

Diagnostic Transmission Calibration Limits Table

Test Harness Kit (JT07329)

Test Harness Kit-Continued

Transmission Controller Connectors

Test Box (JT07349) For Transmission Controller And Transmission Harness

Test Box (JT07349)-Continued

Rotary Sensor Component Location

Section 9025: Hydraulic System

Group 05: Theory of Operation

Dozer Hydraulic System Operation

Component Location—Dozer

Hydraulic System Schematic

Lift Cylinders Circuit—Blade Raise Position

Hydraulic Cooler Circuit

Blade Angle Cylinder Circuit

Blade Tilt Cylinder Circuit—Tilt Left Position

Hydraulic Pump

Hydraulic Pump and Reservoir Operation

Hydraulic Filter Operation—Normal

Hydraulic Filter Operation Continued—Restricted

Hydraulic Control Valve Operation

Hydraulic System Relief Valve Operation

Control Valve Inlet Section Operation

Dozer Blade Auxiliary Valve Operation—Neutral Position

Dozer Blade Lift Valve Operation—Lift Position

Dozer Blade Angle Valve Operation-Right Angle Position

Dozer Blade Tilt Valve Operation—Tilt Right Position

Auxiliary Valve with Float—Float Activated (No Other Function Activated)

Control Valve Outlet Cover

Hydraulic Cylinder Operation

Group 15: Diagnostic Information

Use These Seven Basic Steps to Diagnose and Test the Hydraulic System

Make a Pretest Inspection and an Operation Check of the Machine

Hydraulic System Pretest

Diagnose Hydraulic System

Group 20: Adjustments

Blade Pitch Linkage Adjustment

T—Bar Lever Linkage Adjustment

Auxiliary Fourth Function Lever Linkage Adjustment

Auxiliary Fifth Function Lever Linkage Adjustment

Group 25: Tests

JT05801 Clamp—On Electronic Tachometer Installation

JT05800 Digital Thermometer Installation

Hydraulic Oil Warm-Up Procedure

Hydraulic Pump Flow Test

Hydraulic System Relief Valve Test

Pump General Performance Test Using Cycle Times

Cycle Time Test

Hydraulic Cylinder Drift Test Procedure

Lift Cylinder Drift Test

Cylinder Leakage 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

Neutral Charge Relief Valve

Park Brake Valve

Hydrostatic Pump

Pressure Control Pilot (PCP)

Pump Displacement Control Valve (PDCV)

Multi-Function Valve

Flushing Valve and Operating Charge Relief Valve

Oil Cooler Bypass Valve

Hydrostatic Motor Operation

Hydrostatic System Component Location

Hydrostatic System Diagram—Park Brake On (Neutral) (S.N. —908629)

Hydrostatic System Diagram—Park Brake On (Neutral) (S.N. 908630— )

Hydrostatic System Diagram—Forward (High Speed) (S.N. —908629)

Hydrostatic System Diagram—Forward (High Speed) (S.N. 908630— )

Hydrostatic System Diagram—Reverse (Low Speed) (S.N. —908629)

Hydrostatic System Diagram—Reverse (Low Speed) (S.N. 908630— )

Hydrostatic Schematic—Neutral (Park Brake On)

Group 15: Diagnostic Information

Overheating—Flow Chart

Low Charge Pressure—Flow Chart

Mistrack/Indexes—Flow Chart

Machine Will Not Reach Full Speed—Flow Chart

Low Power—Flow Chart

Engine Starts But Both Tracks Do Not Move or Stop Moving—Flow Chart

Moves Only One Direction or One Track Won't Move—Flow Chart

Controller Won't Calibrate And One Of The Following Codes Are Displayed During Calibration—Flow Chart

Group 20: Adjustments

Brake Pedal to Brake Valve Linkage Adjustment

Park Lock Linkage Adjustment

Hydrostatic Motor Speed Sensor Adjustment

Hydrostatic Pump Speed Sensor Adjustment (S.N. —920838)

Single Lever Control (SLC) Adjustment

Group 25: Test

JT05800 Digital Thermometer Installation

Transmission Oil Warm-Up Procedure

Park Brake Release/Towing Procedure

Disconnect Park Brake for Diagnostic Test

Hydrostatic Pump and Motor Initial Start-Up Procedure

Hydrostatic System Flushing 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 Pressure Test

Operating Charge Relief Pressure Test

Pump Displacement Control Valve Neutral (Null) Adjustment

Pump Servo Pressure Test

Motor Displacement Control Valve Adjustment

Charge Pump Flow Test

Cooler Bypass Valve 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 Specifications

Air Conditioning Circuit Operational Information

Air Conditioning Circuit Theory Of Operation

Air Conditioning Circuit Schematic

Air Conditioning (W8) Wiring Diagram

Heater Blower Circuit Operational Information

Heater Blower Circuit Theory Of Operation

Heater Blower Circuit Schematic

Receiver/Dryer—Theory Of Operation

Expansion Valve —Theory Of Operation

Relief Valve Compressor—Theory Of Operation

Temperature Control—Theory Of Operation

Freeze Control Switch Operation

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

R134a System Cleaning Procedure

R134a System—Purge

R134a System—Flush

Group 25: Test

Special or Essential Tools

Service Equipment and Tools

Specifications

Proper Refrigerant Handling

R12 And R134a Refrigerant Cautions

Diagnostic Chart Pressure

Expansion Valve—Test Operation

Blower Switch Test

Blower Resistor Test

Heater Blower Motor Test (Upper Cab)

Freeze Control Switch Test

Air Conditioning Switch Test

Air Conditioner Low Pressure Switch Check

Air Conditioner Low Pressure Switch Test

Air Conditioner High Pressure Switch Check

Air Conditioner High Pressure Switch Test

Air Conditioning Compressor Clutch Coil Test

Freeze Control Switch Test

Air Conditioning System—Test Leak

Refrigerant Hoses And Tubing Inspection

CONTENTS
2. Disconnect decelerator pedal voltage sensor.
3. Connect JT07329-3 harness inline between decelerator pedal sensor and machine harness.
NOTE: Test harnesses used in this procedure can be found in JT07237 and JT07329 test harness kits.
4. Connect black wire connector from JT07329-3 harness to black wire connector from JTO7237-1 harness.
5. Connect white wire connector from JT07329-3 harness to red wire connector from JTO7237-1 harness.
NOTE: Red wire connector on JT07329-3 will not be used.
6. Connect JT07237-1 test harness to a multimeter.
7. Move engine speed control lever (2) to fast idle. Decelerator pedal must be up against roll pin (3).
8. Voltage with decelerator pedal up should be within specification. Record voltage.
9. Item Measurement Specification
Decelerator Pedal Sensor—Fast
Idle Voltage 1.36—2.36
Depress decelerator pedal fully to bottom stop. Record voltage. Voltage must increase within specification.
Item Measurement Specification
Decelerator Pedal Voltage Increase
From Fast To Slow Idle Voltage 1.8—2.2
If voltage increase is not to specification, adjust decelerator pedal slow idle stop as necessary.
...