John Deere 870G, 870GP, 872G, 872GP Motor Grader Operation and Test Service Manual, Engines 6090HDW01 6090HDW04 (TM11208) - MJODTM11208.zip
This is a full Operation and Test service manual featuring electrical wiring schematics for the John Deere Motor Grader lineup—Models 870G, 870GP, 872G, and 872GP, equipped with 6090HDW01 and 6090HDW04 engines. It delivers workshop-level guidance so you can maintain, troubleshoot, service, and overhaul these machines just as trained technicians do.
The John Deere Motor Grader 870G, 870GP, 872G and 872GP Diagnostic and Test shop manual covers:
* 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.
TM11208 - John Deere Motor Graders 870G, 870GP, 872G, 872GP Technical Manual - Operation and Test.PDF
TM11208 - John Deere Motor Graders 870G, 870GP, 872G, 872GP Technical Manual - Operation and Test.EPUB
Total Pages: 2,331 pages
File Format: PDF/EPUB/MOBI/AZW (PC/Mac/Android/Kindle/iPhone/iPad; bookmarked, ToC, Searchable, Printable)
Language: English
MAIN SECTIONS (SN. before 634753)
Foreword
General Information
Safety
Torque Values
Wheels
Powered Wheels and Fasteners
Axles and Suspension Systems
Input Drive Shafts and U-Joints
Non-Powered Wheel Axles
Powered Wheel Axles
Axle Shafts, Bearings, and Reduction Gears
Hydraulic System
Transmission
Removal and Installation
Hydraulic System
Engine
Removal and Installation
Engine Auxiliary System
Cooling System
External Fuel Supply Systems
Torsional Isolator
Elements
Steering System
Power Steering
Hydraulic System
Service Brakes
Active Elements
Hydraulic System
Park Brake
Active Elements
Frame, Chassis or Supporting Structure
Frame Installation
Operator’s Station
Removal and Installation
Operator Enclosure
Pedal Assembly
Steering Tilt Console
Seat and Seat Belt
Heating and Air Conditioning
Sheet Metal and Styling
Grille and Grille Housing
Main Hydraulic System
Hydraulic System
Grading Device
Controls Linkage
Frames
Circle Gearbox
Hydraulic System
Ground Conditioning Tool
Frames
Dealer Fabricated Tools
tm11208 - 870G, 870GP, 872G, and 872GP Motor Grader
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
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
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
Service Tires Safely
Section 9001: Diagnostics
Group 10: Transmission Control Unit (TCU) Diagnostic Trouble Codes
000177.00 - Transmission Oil Temperature High
000177.04 - Transmission Oil Temperature Short To Ground
000525.02 - Program Variable REQ_GEAR Has Taken On An Invalid Value
000525.12 - Request For An Undefined Shift Being Made
000723.02 - Engine Speed Sensor Bias Voltage Out Of Tolerance
002000.02 - ECU CAN Data Invalid
002000.09 - Can Communication Lost For ECU
002033.02 - FLC CAN Data Invalid
002033.09 - CAN Communication Lost For FLC
002225.09 - CAN Communication Lost For Six Wheel Drive
522252.00 - Clutch 1 Hold Pressure Too High
522252.01 - Clutch 1 Hold Pressure Too Low
522253.00 - Clutch 2 Hold Pressure Too High
522253.01 - Clutch 2 Hold Pressure Too Low
522254.00 - Clutch 3 Hold Pressure Too High
522254.01 - Clutch 3 Hold Pressure Too Low
522255.00 - Clutch 4 Hold Pressure Too High
522255.01 - Clutch 4 Hold Pressure Too Low
522256.00 - Clutch A Hold Pressure Too High
522256.01 - Clutch A Hold Pressure Too Low
522257.00 - Clutch B Hold Pressure Too High
522257.01 - Clutch B Hold Pressure Too Low
522258.00 - Clutch C Hold Pressure Too High
522258.01 - Clutch C Hold Pressure Too Low
522259.00 - Clutch D Hold Pressure Too High
522259.01 - Clutch D Hold Pressure Too Low
522397.04 - Not In Forward Or Reverse While In Gear
522398.12 - Park And Not Park Both Active
522405.05 - Park Brake Pressure Low At Power-up
522413.12 - Gear Bits Active In Park
522414.03 - Transmission Clutch D Short To Power
522414.05 - Transmission Clutch D Open/Short To Ground
522507.14 - Inching Pedal During Trans Calibration
522517.31 - Engine Stall Prevention Active
523655.03 - Forward And Reverse Both Active
523699.31 - Transmission Speed Clutch Slipping
523700.00 - Clutch Protection Excessive Inching
523700.16 - Clutch Protection Excessive Inching
523700.31 - Transmission Direction Clutch Slipping
523708.02 - Inching Switch Signal Bad
523712.31 - Transmission CAL Without Park Brake Set
523717.31 - Helper Clutch Pressure High
523718.31 - Clutch Drum Speed Decel Excessive
523720.00 - Clutch D Fill Time Too Long
523720.01 - Clutch D Fill Time Too Short
523721.00 - Clutch C Fill Time Too Long
523721.01 - Clutch C Fill Time Too Short
523722.00 - Clutch B Fill Time Too Long
523722.01 - Clutch B Fill Time Too Short
523723.00 - Clutch A Fill Time Too Long
523723.01 - Clutch A Fill Time Too Short
523724.00 - Clutch 4 Fill Time Too Long
523724.01 - Clutch 4 Fill Time Too Short
523725.00 - Clutch 3 Fill Time Too Long
523725.01 - Clutch 3 Fill Time Too Short
523726.00 - Clutch 2 Fill Time Too Long
523726.01 - Clutch 2 Fill Time Too Short
523727.00 - Clutch 1 Fill Time Too Long
523727.01 - Clutch 1 Fill Time Too Short
523728.31 - Transmission Reverse Cylinder Speed Incorrect At Calibration
523729.31 - Transmission Forward Cylinder Speed Incorrect At Calibration
523730.31 - No Transmission Cylinder Speed During Calibration
523731.31 - Transmission Output Speed Detected At Calibration
523732.31 - Engine Speed Too Low To Calibrate The Transmission
523733.31 - Engine Speed Too High To Calibrate The Transmission
523734.31 - Transmission Too Cold To Calibrate
523735.04 - Valve Driver Supply Voltage Low
523736.14 - Bad Gear Position Switch State
523738.02 - Shifter Handle Problem
523738.31 - Shifter Handle Problem
523739.31 - Not Park And Forward/Reverse Mismatch
523740.31 - Forward/Reverse Switch And Gear Mismatch
523741.31 - Started In Gear
523742.31 - Shifter Vsense Low
523747.14 - Park and Not Park Both Passive
523750.04 - Not Park Passive In Gear Or Neutral
523754.03 - Not Park Active At Startup
523755.05 - Park Start Input Passive At Power Up
523761.03 - Transmission Clutch 4 Short To Power
523761.05 - Transmission Clutch 4 Open/Short To Ground
523762.03 - Transmission Clutch 3 Short To Power
523762.05 - Transmission Clutch 3 Open/Short To Ground
523763.03 - Transmission Clutch 2 Short To Power
523763.05 - Transmission Clutch 2 Open/Short To Ground
523764.03 - Transmission Clutch 1 Short To Power
523764.05 - Transmission Clutch 1 Open/Short To Ground
524029.00 - Inching Pedal Out Of Range High
524029.01 - Inching Pedal Out Of Range Low
524029.12 - Inching Pedal Minimum Voltage Exceeds Maximum Voltage
524194.07 - Direction Sensor Mismatch
524271.03 - Transmission Clutch C Short To Power
524271.05 - Transmission Clutch C Open/Short To Ground
524272.03 - Transmission Clutch B Short To Power
524272.05 - Transmission Clutch B Open/Short To Ground
524273.03 - Transmission Clutch A Short To Power
524273.05 - Transmission Clutch A Open/Short To Ground
524275.31 - Forward/Reverse Without Valid Gear
Group 20: Engine Control Unit (ECU) Diagnostic Trouble Codes
29.03 - Decel Pedal Short to Power
91.03 - Accel Pedal Short to Power
91.04 - Accel Pedal Open or Short
107.00 - Engine Air Filter Restricted
596.31 - Engine Speed Control Enable Switch Fault
600.31 - Engine Speed Accel/ Decel Switch Fault
1196.31 - ECU Anti Theft Locked
1321.05 - Starter Relay Open Circuit
1321.06 - Starter Relay High Current
1321.30 - Starter Engaged for 30 Seconds
1321.31 - Starter Solenoid Open Circuit
2003.09 - CAN Communication Lost For TCU
2033.09 - CAN Communication Lost For FLC
Group 30: Advance Display Unit (ADU) Diagnostic Trouble Codes
158.03 - Switched Power Voltage High
158.04 - Switched Power Voltage Low
168.03 - Battery Voltage High
168.04 - Battery Voltage Low
442.00 - Display Temperature High
442.01 - Display Temperature Low
1491.11 - LCD Backlight Failure
2033.09 - CAN Communication Lost For FLC
3597.02 - 5.0 Volt Power Supply Invalid
3598.02 - 1.5 Volt Power Supply Invalid
3599.02 - 3.3 Volt Power Supply Invalid
523436.14 - ADU Watchdog Time Out
523438.31 - Memory Error
523651.02 - Memory Stack Overflow
523773.03 - CAN High Voltage High
523773.04 - CAN High Voltage Low
523774.03 - CAN Low Voltage High
523774.04 - CAN Low Voltage Low
524076.10 - Information Button Stuck
524077.10 - Back Key Button Stuck
524078.10 - Menu Select Button Stuck
524080.10 - Down Arrow Button Stuck
524082.10 - Up Arrow Button Stuck
Group 40: Flex Load Controller (FLC) Diagnostic Trouble Codes
96.03 - Fuel Level Sender Open or Short
96.04 - Fuel Level Sender Short To Ground
117.01 - Service Brake Pressure Low
117.04 - Service Brake Accumulator Switch Short to Ground
167.03 - System Voltage Above Normal
167.04 - System Voltage Below Normal
168.03 - High Battery Voltage
168.04 - Low Battery Voltage
628.12 - Updating Software
746.05 - Differential Lock Solenoid Open or Short
746.06 - Differential Lock Solenoid High Current
880.05 - Brake Lights Open or Short
880.06 - Brake Lights High Current
977.05 - Reverse Fan Solenoid Open or Short
977.06 - Reverse Fan Solenoid Short to Ground
977.07 - Fan Pressure Too High to Reverse
1045.04 - Brake Light Switch Short to Ground
1071.03 - Fan Speed Solenoid Open or Short
1071.04 - Fan Speed Solenoid High Current
1550.05 - AC Clutch Open Circuit
1550.06 - AC Clutch Short to Ground
1638.00 - Hydraulic Oil High Temperature
1638.04 - Hydraulic Oil Temp Short To Ground
1713.01 - Hydraulic Oil Filter Restricted
1713.03 - Hydraulic Oil Filter Switch Short to Power
001762.01 - Hydraulic Pressure Low
001762.03 - Hydraulic Pressure Short to Power
001762.04 - Hydraulic Pressure Short to Ground
2000.09 - CAN Communication Lost For ECU
2003.09 - CAN Communication Lost For TCU
2034.09 - CAN Communication Lost For AVC
2040.09 - CAN Communication Lost For ADU
2141.09 - CAN Communication Lost For SSM
2160.09 - CAN Communication Lost For RJ1
2161.09 - CAN Communication Lost For RJ2
2162.09 - CAN Communication Lost For RJ3
2163.09 - CAN Communication Lost For RJ4
2165.09 - CAN Communication Lost For LJ1
2166.09 - CAN Communication Lost For LJ2
2167.09 - CAN Communication Lost For LJ3
2168.09 - CAN Communication Lost For LJ4
2213.09 - CAN Communication Lost For HVC
2225.09 - CAN Communication Lost For 6WD
2348.05 - Hi Beam Lamps Open Circuit
2348.06 - High Beam Lamps High Current
2350.05 - Low Beam Lamps Open Circuit
2350.06 - Low Beam Lamps High Current
2352.05 - Cab Front Work Lights Open Circuit
2352.06 - Cab Front Work Lights High Current
2353.05 - Front Work Lights Open Circuit
2353.06 - Front Work Lights High Current
2356.05 - Front Cab Corner Lights Open Circuit
2356.06 - Front Cab Corner Lights High Current
2360.05 - Rear Work Lights Open Circuit
2360.06 - Rear Work Lights High Current
2362.05 - Rear Cab Corner Lights Open Circuit
2362.06 - Rear Cab Corner Lights High Current
2366.05 - Side Work Lights Open Circuit