John Deere 744J 824J 4WD Loader Operation & Test Service Manual (TM2083) PDF - MJODTM2083.zip

A full diagnostic and repair guide containing complete Electrical Wiring Diagrams for the John Deere 744J and 824J 4WD Loaders, offering every detail shops need to maintain, troubleshoot, and overhaul these machines to the standard of expert technicians.

The John Deere 744J and 824J 4WD Loader Operation and Test Service manual covers the following:

* 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.

TM2083 - John Deere 4WD Loaders 744J, 824J Technical Manual (Operation and Tes).PDF

TM2083 - John Deere 4WD Loaders 744J, 824J Technical Manual (Operation and Tes).EPUB

Total Pages: 1,241 pages

File Format: PDF/EPUB/MOBI/AZW (PC/Mac/Android/Kindle/iPhone/iPad; bookmarked, ToC, Searchable, Printable)

Language: English

MAIN SECTIONS

Foreword

Technical Information Feedback Form

General Information

Safety Information

Operational Checkout Procedure

Operational Checkout Procedure

Engine

Theory of Operation

Diagnostic Information

Tests

Electrical System-744J And 824J (S.N. -590067)

System Information

System Diagrams

Sub-System Diagnostics

References

Electrical System-744J And 824J (S.N. 590068-600915)

System Information

System Diagrams

Sub-System Diagnostics

References

Electrical System-744J And 824J (S.N. 600916- )

System Information

System Diagrams

Sub-System Diagnostics

References

Power Train

Theory of Operation

Diagnostic Information

Adjustments

Tests

Hydraulic System

Theory of Operation

Diagnostic Information

Adjustments

Test

Heating And A/C

Theory Of Operation

Diagnostic Information

Tests

tm2083 - 744J and 824J Loader

Table of Contents

Foreword

Technical Information Feedback Form

Section 9000: General Information

Group 01: Safety Information

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

Use Special Care When Operating Loader

Keep Riders Off Machine

Avoid Backover Accidents

Avoid Machine Tip Over

Operating on Slopes

Operating or Traveling On Public Roads

Inspect and Maintain ROPS

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

Complete Machine Operational Checkout

Section 9010: Engine

Group 05: Theory of Operation

POWERTECH POWERTECH is a trademark of Deere & Company 12.5L (6125) John Deere Engines

Electronic Fuel Systems

Engine Air Heater Circuit Theory of Operation (S.N. —590067)

Engine Air Heater Circuit Theory of Operation (S.N. 590068— )

Group 15: Diagnostic Information

Diagnose Engine Malfunctions

Group 25: Tests

Engine Speed Test

Air Filter Restriction Indicator Switch Test

Engine Power Test Using Engine Pulldown

Air Intake System Leakage Test

Engine Power Test Using Turbocharger Boost Pressure

Fuel Line Leakage Test

Section 9015A: Electrical System—744J And 824J (S.N. —590067)

Group 05: System Information

Electrical Diagram Information (S.N. —590067)

Group 10: System Diagrams

Fuse and Relay Specifications (S.N. —590067)

System Functional Schematic Section Legend (S.N. —590067)

Functional Schematic And Component Location Legend (S.N. —590067)

System Functional Schematic (S.N. —590067)

Loader Frame Harness (W2) Component Location (S.N. —590067)

Load Center Harness (W3) Component Location (S.N. —590067)

Front Console Harness (W4) Component Location (S.N. —590067)

Engine Frame Harness (W5) Component Location (S.N. —590067)

Engine Harness (W6) Component Location (S.N. —590067)

Engine Air Heater Harness (W7) Component Location (S.N. —590067)

Return-to-Dig Harness (W8) Component Location (S.N. —590067)

Ride Control Harness (W9) Component Location (S.N. —590067)

Transmission Harness (W10) Component Location (S.N. —590067)

Rear Frame Harness (W13) Component Location (S.N. —590067)

Spin Control Harness (W14) Component Location (S.N. —590067)

License Plate Light Harness (W15) Component Location (S.N. —590067)

Pin Disconnect Harness (W16) Component Location (S.N. —590067)

Secondary Steering Switch Harness (W17) Component Location (S.N. —590067)

Cab Work Lights Harness (W19) Component Location (S.N. —590067)

Blower And A/C Harness (W20) Component Location (S.N. —590067)

Converter and Power Plug Harness (W21) Component Location (S.N. —590067)

Secondary Steering Pump Motor Harness (W23) Component Location (S.N. —590067)

Battery (Cables) Harness (W24) Component Location (S.N. —590067)

Engine Valve Cover Harness (W33) Component Location (S.N. —590067)

Radio Harness (W34) Component Location (S.N. —590067)

Electric Air Adjust Seat Harness (W36) Component Location (S.N. —590067)

CAN Terminator Harness (W37) Component Location (S.N. —590067)

Group 15: Sub-System Diagnostics

Start Circuit Theory of Operation (S.N. —590067)

Ride Control Circuit Theory Of Operation (S.N. —590067)

Monitor Display Unit Circuit Theory Of Operation (S.N. —590067)

Monitor Display Unit—Accessing Menus (S.N. —590067)

Monitor Display Unit—Normal Display Menu (S.N. —590067)

Monitor Display Unit—Accessory Menu (S.N. —590067)

Monitor Display Unit—Diagnostics Menu (S.N. —590067)

Monitor Display Unit—Service Menu (S.N. —590067)

Chassis Control Unit Circuit Theory Of Operation (S.N. —590067)

Spin Control Circuit Theory Of Operation (824J) (S.N. —590067)

Transmission Control Unit Circuit Theory Of Operation (S.N. —590067)

Transmission Modes Of Operation—Manual And Automatic (S.N. —590067)

Transmission Functions Set At Monitor Display Unit (S.N. —590067)

Transmission Shift Ranges In Automatic Mode (S.N. —590067)

Transmission Control Unit Response To Malfunctions (S.N. —590067)

Park Brake Circuit Theory Of Operation (S.N. —590067)

Pilot Enable And Boom Down Circuit Theory Of Operation (S.N. —590067)

Return-to-Carry, Boom Height Kickout And Return-to-Dig Circuit Theory Of Operation (S.N. —590067)

Secondary Steering Circuit Theory Of Operation (S.N. —590067)

Engine Control Unit Theory of Operation (S.N. —590067)

Group 20: References

Diagnostic Trouble Codes Quick Reference List (S.N. —590067)

Transmission Diagnostic Trouble Codes (S.N. —590067)

Transmission Diagnostic Trouble Codes (S.N. —590067) (Continued)

Engine Related Diagnostic Trouble Codes (S.N. —590067)

Engine Diagnostic Trouble Codes (S.N. —590067)

Steering and Brake Diagnostic Trouble Codes (S.N. —590067)

Electrical System Diagnostic Trouble Codes (S.N. —590067)

Hydraulic System Diagnostic Trouble Codes (S.N. —590067)

CAN Circuit Testing

Check Battery Electrolyte Level and Terminals (S.N. —590067)

Procedure for Testing Batteries (S.N. —590067)

Electrical Component Specifications (S.N. —590067)

Transmission Control Valve Solenoid Check (S.N. —590067)

Clutch Cut-Off Sensor Adjustment (S.N. —590067)

Throttle Position Sensor Adjustment (S.N. —590067)

Boom Height Kickout Adjustment (S.N. —590067)

Return-to-Carry Kickout Adjustment (S.N. —590067)

Return-to-Dig Adjustment (S.N. —590067)

Sensor Circuitry Check (S.N. —590067)

Diagnostic Trouble Codes—After Machine Repair (S.N. —590067)

Change Back-Up alarm Volume (S.N. —590067)

Remove and Install Pressure Switches (S.N. —590067)

Replace METRI-PACK® Connectors (S.N. —590067)

Install METRI-PACK® Contact (S.N. —590067)

Replace DEUTSCH® Connectors (S.N. —590067)

Install DEUTSCH® Contact (S.N. —590067)

Replace WEATHER PACK® Connector (S.N. —590067)

Install WEATHER PACK® Contact (S.N. —590067)

Replace CINCH™ Connectors (S.N. —590067)

Install CINCH™ Contact (S.N. —590067)

Remove Connector Body from Blade Terminals

Remove Blade Terminals From Fuse Block (S.N. —590067)

Transmission Controller Remove and Install (S.N. —590067)

Engine Controller Remove and Install (S.N. —590067)

Chassis Control Unit Remove and Install (S.N. —590067)

Monitor Display Unit Remove and Install (S.N. —590067)

Reprogram Monitor Display Unit (S.N. —590067)

Section 9015B: Electrical System—744J And 824J (S.N. 590068—600915)

Group 05: System Information

Electrical Diagram Information (S.N. 590068— )

Group 10: System Diagrams

Fuse and Relay Specifications (S.N. 590068—600915)

System Functional Schematic, Wiring Diagram and Component Location Legend (S.N. 590068—600915)

System Functional Schematic and Section Legend (S.N. 590068—600915)

Loader Frame Harness (W2) Component Location (S.N. 590068—600915)

Loader Frame Harness (W2) Wiring Diagram (S.N. 590068—600915)

Load Center Harness (W3) Component Location (S.N. 590068—600915)

Load Center Harness (W3) Wiring Diagram (S.N. 590068—600915)

Front Console Harness (W4) Component Location (S.N. 590068— )

Front Console Harness (W4) Wiring Diagram (S.N. 590068— )

Engine Frame Harness (W5) Component Location (S.N. 590068— )

Engine Frame Harness (W5) Wiring Diagram (S.N. 590068— )

Engine Harness (W6) Component Location (S.N. 590068— )

Engine Harness (W6) Wiring Diagram (S.N. 590068—600915)

Engine Air Heater Harness (W7) Component Location (S.N. 590068— )

Engine Air Heater Harness (W7) Wiring Diagram (S.N. 590068— )

Ride Control Harness (W9) Component Location (S.N. 590068—600915)

Ride Control Harness (W9) Wiring Diagram (S.N. 590068—600915)

Transmission Harness (W10) Component Location (S.N. 590068— )

Transmission Harness (W10) Wiring Diagram (S.N. 590068— )

Rear Frame Harness (W13) Component Location (S.N. 590068— )

Rear Frame Harness (W13) Wiring Diagram (S.N. 590068—600915)

Cab Roof Harness (W19) Component Location (S.N. 590068—600915)

Cab Roof Harness (W19) Wiring Diagram (S.N. 590068—600915)

Blower and A/C (W20) Component Location (S.N. 590068— )

Blower and A/C (W20) Wiring Diagram (S.N. 590068— )

Radio Harness (W34) Component Location (S.N. 590068— )

Radio Harness (W34) Wiring Diagram (S.N. 590068— )

Group 15: Sub-System Diagnostics

Starting and Charging Circuit Theory of Operation (S.N. 590068— )

Controller Area Network (CAN) Theory of Operation (S.N. 590068— )

Engine Control Unit (ECU) Circuit Theory of Operation (S.N. 590068— )

Flex Load Controller (FLC) Circuit Theory of Operation (S.N. 590068— )

Transmission Control Unit (TCU) Circuit Theory of Operation (S.N. 590068— )

CAN Monitor Unit (CMU) Circuit Theory of Operation (S.N. 590068— )

Group 20: References

Diagnostic Trouble Codes Quick Reference List (S.N. 590068—600915)

CAN Monitor Unit (CMU) Diagnostic Trouble Codes (S.N. 590068—600915)

Flex Load Controller (FLC) Diagnostic Trouble Codes (S.N. 590068—600915)

Sealed Switch Module (SSM) Diagnostic Trouble Codes (S.N. 590068—600915)

Transmission Control Unit (TCU) Diagnostic Trouble Codes (S.N. 590068—600915)

Engine Control Unit (ECU) Diagnostic Trouble Codes (S.N. 590068—600915)

Flex Load Controller (FLC) Fault Exceptions (S.N. 590068— )

CAN Circuit Testing

Check Battery Electrolyte Level and Terminals (S.N. 590068— )

Procedure For Testing Batteries (S.N. 590068— )

Electrical Component Specifications (S.N. 590068— )

Transmission Control Valve Solenoid Check (S.N. 590068— )

Clutch Cut-Off Sensor Check and Adjustment (S.N. 590068— )

Boom Height Kickout/Return-to-Carry Adjustment (S.N. 590068— )

Return-to-Dig Adjustment (S.N. 590068— )

Sensor Circuitry Check (S.N. 590068— )

Diagnostic Trouble Codes—After Machine Repair (S.N. 590068— )

Change Back-Up Alarm Volume (S.N. 590068— )

Remove and Install Pressure Switches (S.N. 590068— )

Replace METRI-PACK® Connectors (S.N. 590068— )

Install METRI-PACK® Contact (S.N. 590068— )

Replace DEUTSCH® Connectors (S.N. 590068— )

Install DEUTSCH® Contact (S.N. 590068— )

Replace WEATHER PACK® Connector (S.N. 590068— )

Install WEATHER PACK® Contact (S.N. 590068— )

Replace CINCH™ Connectors (S.N. 590068— )

Install CINCH™ Contact (S.N. 590068— )

Repair 32 and 48 Way CINCH™ Connectors (S.N. 590068— )

Remove Connector Body from Blade Terminals (S.N. 590068— )

Engine Control Unit (ECU) Remove and Install (S.N. 590068— )

Flex Load Controller (FLC) Remove and Install (S.N. 590068— )

Transmission Control Unit (TCU) Remove and Install (S.N. 590068— )

Sealed Switch Module (SSM) Remove and Install (S.N. 590068— )

CAN Monitor Unit (CMU) Remove and Install (S.N. 590068— )

Reprogram CAN Monitor Unit (CMU) S.N. 590068—)

Electronic Controller Reconfiguration (S.N. 590068 —)

Section 9015C: Electrical System—744J And 824J (S.N. 600916— )

Group 05: System Information

Electrical Diagram Information (S.N. —165691)

Group 10: System Diagrams

Fuse and Relay Specifications (S.N. 600916— )

System Functional Schematic, Wiring Diagram and Component Location Master Legend (S.N. 600916— )

System Functional Schematic (S.N. 600916— )

JDLink™ System Functional Schematic—MIG/GTT

JDLink™ System Functional Schematic—MTG/SAT

Loader Frame Harness (W2) Component Location (S.N. 600916— )

Loader Frame Harness (W2) Wiring Diagram (S.N. 600916— )

Load Center Harness (W3) Component Location (S.N. 600916— )

Load Center Harness (W3) Wiring Diagram (S.N. 600916— )

Front Console Harness (W4) Component Location (S.N. 590068— )

Front Console Harness (W4) Wiring Diagram (S.N. 590068— )

Engine Frame Harness (W5) Component Location (S.N. 590068— )

Engine Frame Harness (W5) Wiring Diagram (S.N. 590068— )

Engine Harness (W6) Component Location (S.N. 590068— )

Engine Harness (W6) Wiring Diagram (S.N. 600916— )

Engine Air Heater Harness (W7) Component Location (S.N. 590068— )

Engine Air Heater Harness (W7) Wiring Diagram (S.N. 590068— )

Joystick Steering Harness (W8) Component Location

Joystick Steering Harness (W8) Wiring Diagram