John Deere 8100 8400 Tractors Diagnosis Service Manual

John Deere Agriculture

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8100, 8200, 8300 and 8400 Tractors

DIAGNOSIS AND TESTS SERVICE MANUAL Covered models: 8100, 8200, 8300, 8400 (SN: 000000-010000, 010001-024000, 024001-)

tm1576, July 2008

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8100, 8200, 8300 and 8400 Tractors

(g) by Belgreen v2.0

Table of contents

Download Service Manual FOREWORD Section 205 - SAFETY INFORMATION Group 05 - Safety Section 210 - GENERAL INFORMATION Group 05 - Operational Checks Group 10 - General Reference Information Group 15 - Test Equipment Calibration Section 211 - SERVICE CODES Group ACU - ACU Code Diagnostics Group AMS - AMS Code Diagnostics Group CCU - CCU Code Diagnostics Group ECU - ECU Code Diagnostics Group HCU - HCU Code Diagnostics Group ICU - ICU Code Diagnostics Group LHP - LHP Code Diagnostics Group PCU - PCU Code Diagnostics Group SCo - SCo Code Diagnostics Group SCU - SCU Code Diagnostics Group SSU - SSU Code Diagnostics Group SUP - SUP Code Diagnostics Section 212 - OBSERVABLE SYMPTOMS Group 16 - Ag Management Solutions (AMS) Group 20 - Engine Group 40 - Electrical Group 50 - Powershift Transmission Group 60 - Steering and Brakes Group 70 - Hydraulics Section 220 - ENGINE OPERATION AND TESTS Group 10 - Engine Diagnosis, Tractors—Pin (—11,000) Group 15 - Engine Diagnosis, Tractors—PIN (11,001—) Section 230 - FUEL, AIR INTAKE AND ENGINE COOLING SYSTEMS Group 20 - Theory of Operation Section 240 - ELECTRICAL OPERATION AND TESTS Group 04 - Codes and Addresses Group 05 - System Information Group 10 - System Diagrams Group 15 - Sub-System Diagnosis Group 20 - Calibration and References Section 246A - AG MANAGEMENT SOLUTIONS (AMS) — GREENSTAR™ Group GSS - GREENSTAR™ System References Section 246B - AG MANAGEMENT SOLUTIONS (AMS)—JDLINK™ Group 10A - AG MANAGEMENT SOLUTIONS (AMS)—JDLINK™ Section 246C - AG MANAGEMENT SOLUTIONS (AMS) — AUTOTRAC Group 5A - How to Use This Diagnostic Information Group 10A - Accessing Diagnostic Addresses and Codes Group 10B - Diagnostic Trouble Codes Group 15A - AutoTrac Identification Group 15B - AutoTrac Diagnostics - 8000 Series Field Installed <- Go to Global Table of contents

8100, 8200, 8300 and 8400 Tractors

8100, 8200, 8300 and 8400 Tractors

(g) by Belgreen v2.0

Group 15C - GREENSTAR™ Parallel Tracking Identification Group 15D - Parallel Tracking Diagnostics - 8000 Series Field Installed Group 15E - GREENSTAR™ Display Diagnostics Group 15F - GREENSTAR™ Mobile Processor Diagnostics

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8100, 8200, 8300 and 8400 Tractors

8100, 8200, 8300 and 8400 Tractors

(g) by Belgreen v2.0

Group 15G - STARFIRE™ Receiver Diagnostics Group 15H - GREENSTAR™ KeyCard Diagnostics Group 15I - AutoTrac CAN Bus Identification Group 15J - AutoTrac CAN Bus Diagnostics - 8000 Series Field Installed Group 15K - AutoTrac CCD Bus Identification Group 15L - AutoTrac CCD Bus Diagnostics - 8000 Series Field Installed Group 15M - AutoTrac Power Identification Group 15N - AutoTrac Power Diagnostics - 8000 Series Field Installed Group 15O - AutoTrac Status Identification Group 15P - AutoTrac Status Diagnostics - 8000 Series Field Installed Group 15Q - AutoTrac Steering Response Identification Group 15R - AutoTrac Steering Response Diag. - 8000 Series Field Installed Group 15S - AutoTrac Steering Control Unit Identification Group 15T - AutoTrac Steering Control Unit Diag - 8000 Series Field Installed Group 15U - STARFIRESTARFIRE is a trademark of Deere & Company Receiver w/TCM Diagnostics Group 15V - STARFIRESTARFIRE is a trademark of Deere & Company Receiver w/TCM & RTK Diagnostics Group 20A - Circuit Code Listing Group 20B - Connector Information Section 246D - AG MANAGEMENT SOLUTIONS (AMS) —FIELD DOC™ Group 15A - GREENSTAR™ FIELD DOC™ Diagnostics Group 15B - GREENSTAR™ GPS Receiver Identification Group 15C - GREENSTAR™ GPS Receiver - L-Band Diagnostics Section 250 - POWER SHIFT TRANSMISSION Group 05 - Operational Checks Group 10 - Transmission Diagnosis Group 15A - System Tests (—019999) Group 15B - System Tests (020000—) Group 20A - Calibration and Adjustments (—019999) Group 20B - Calibration and Adjustments (020000—) Group 25 - Power Shift Theory of Operation Section 256 - DRIVE SYSTEMS Group 25 - Theory of Operation Section 260 - STEERING AND BRAKES Group 05 - Operational Checks Group 10 - Steering and Brake Diagnosis Group 25 - Theory of Operation Group 30 - AutoTrac Section 270 - HYDRAULIC SYSTEM Group 05 - Operational Checks Group 10 - Hydraulic System Diagnosis Group 15 - Hydraulic System Tests Group 20 - Calibration and Adjustments Group 25 - Hydraulic System Theory of Operation Section 290 - OPERATOR STATION OPERATION AND TESTS Group 05 - Operational Checks Group 10 - System Diagnosis Group 25 - Theory of Operation Section 299 - DEALER FABRICATED TOOLS Group 05 - Dealer Fabricated Tools

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8100, 8200, 8300 and 8400 Tractors

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8100, 8200, 8300 and 8400 Tractors

SAFETY INFORMATION

(g) by Belgreen v2.0

Foreword This manual is written for an experienced technician. Essential tools required in performing certain service work are identified in this manual and are recommended for use.

Live with safety: Read the safety messages in the introduction of this manual and the cautions presented throughout the text of the manual.

CAUTION: This is the safety-alert symbol. When you see this symbol on the machine or in this manual, be alert to the potential for personal injury.

Technical manuals are divided in two parts: repair and operation and tests. Repair sections tell how to repair the components.

Operation and tests sections help you identify the majority of routine failures quickly.

Information is organized in groups for the various components requiring service instruction. At the beginning of each group are summary listings of all applicable essential tools, service equipment and tools, other materials needed to do the job, service parts kits, specifications, wear tolerances, and torque values.

Technical Manuals are concise guides for specific machines. They are on-the-job guides containing only the vital information needed for diagnosis, analysis, testing, and repair.

Fundamental service information is available from other sources covering basic theory of operation, fundamentals of troubleshooting, general maintenance, and basic type of failures and their causes.

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Section 205 page 1

8100, 8200, 8300 and 8400 Tractors

8100, 8200, 8300 and 8400 Tractors

(g) by Belgreen v2.0

Section 205 - SAFETY INFORMATION Table of contents Group 05 - Safety..................................................................................................................................................... 1 Recognize Safety Information ....................................................................................................................................................... 1 Prevent Machine Runaway ............................................................................................................................................................. 1 Handle Fluids Safely—Avoid Fires .............................................................................................................................................. 1 Prevent Battery Explosions ........................................................................................................................................................... 2 Prepare for Emergencies ................................................................................................................................................................. 2 Handle Starting Fluid Safely .......................................................................................................................................................... 3 Prevent Acid Burns ........................................................................................................................................................................... 4 Service Cooling System Safely ..................................................................................................................................................... 4 Handle Chemical Products Safely ................................................................................................................................................ 5 Avoid High-Pressure Fluids............................................................................................................................................................. 5 Stay Clear of Rotating Drivelines ................................................................................................................................................ 6 Park Machine Safely .......................................................................................................................................................................... 6 Support Machine Properly ............................................................................................................................................................. 7 Remove Paint Before Welding or Heating ............................................................................................................................... 7 Avoid Heating Near Pressurized Fluid Lines .......................................................................................................................... 9 Illuminate Work Area Safely ........................................................................................................................................................... 9 Replace Safety Signs........................................................................................................................................................................ 9 Use Proper Lifting Equipment ................................................................................................................................................ 10 Keep ROPS Installed Properly ................................................................................................................................................ 10 Service Tires Safely ........................................................................................................................................................................ 12 Avoid Harmful Asbestos Dust .................................................................................................................................................... 12 Protect Against High Pressure Spray ...................................................................................................................................... 13 Practice Safe Maintenance ......................................................................................................................................................... 14 Use Proper Tools ............................................................................................................................................................................. 14 Dispose of Waste Properly.......................................................................................................................................................... 15 Live With Safety ............................................................................................................................................................................... 15

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8100, 8200, 8300 and 8400 Tractors

Section 205 - SAFETY INFORMATION

Group 05: Safety

Group 05 - Safety Recognize Safety Information

Safety-alert symbol This is a safety-alert symbol. When you see this symbol on your machine or in this manual, be alert to the potential for personal injury.

Follow recommended precautions and safe operating practices.

Prevent Machine Runaway

Machinery Runaway Avoid possible injury or death from machinery runaway.

Do not start engine by shorting across starter terminals. Machine will start in gear if normal circuitry is bypassed.

NEVER start engine while standing on ground. Start engine only from operator’s seat, with transmission in neutral or park.

Handle Fluids Safely—Avoid Fires

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Section 205 page 1

8100, 8200, 8300 and 8400 Tractors

Section 205 - SAFETY INFORMATION

Group 05: Safety

Avoid Fires When you work around fuel, do not smoke or work near heaters or other fire hazards.

Store flammable fluids away from fire hazards. Do not incinerate or puncture pressurized containers.

Make sure machine is clean of trash, grease, and debris.

Do not store oily rags; they can ignite and burn spontaneously.

Prevent Battery Explosions

Battery Explosions Keep sparks, lighted matches, and open flame away from the top of battery. Battery gas can explode.

Never check battery charge by placing a metal object across the posts. Use a volt-meter or hydrometer.

Do not charge a frozen battery; it may explode. Warm battery to 16°C (60°F).

Prepare for Emergencies

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Section 205 page 2

8100, 8200, 8300 and 8400 Tractors

Section 205 - SAFETY INFORMATION

Group 05: Safety

First Aid Kit Be prepared if a fire starts.

Keep a first aid kit and fire extinguisher handy.

Keep emergency numbers for doctors, ambulance service, hospital, and fire department near your telephone.

Handle Starting Fluid Safely

Store Safely Starting fluid is highly flammable.

Keep all sparks and flame away when using it. Keep starting fluid away from batteries and cables.

To prevent accidental discharge when storing the pressurized can, keep the cap on the container, and store in a cool, protected location.

Do not incinerate or puncture a starting fluid container.

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Section 205 page 3

8100, 8200, 8300 and 8400 Tractors

Section 205 - SAFETY INFORMATION

Group 05: Safety

Prevent Acid Burns

Acid Burns Sulfuric acid in battery electrolyte is poisonous. It is strong enough to burn skin, eat holes in clothing, and cause blindness if splashed into eyes.

Avoid the hazard by: 1. Filling batteries in a well-ventilated area.

2. Wearing eye protection and rubber gloves.

3. Avoiding breathing fumes when electrolyte is added.

4. Avoiding spilling or dripping electrolyte.

5. Use proper jump start procedure.

If you spill acid on yourself: 1. Flush your skin with water.

2. Apply baking soda or lime to help neutralize the acid.

3. Flush your eyes with water for 15—30 minutes. Get medical attention immediately.

If acid is swallowed: 1. Do not induce vomiting.

2. Drink large amounts of water or milk, but do not exceed 2 L (2 quarts).

3. Get medical attention immediately.

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Section 205 page 4

8100, 8200, 8300 and 8400 Tractors