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John Deere 160GLC Excavator Operation and Tests Technical Manual PDF DOWNLOAD
John Deere 160GLC Excavator Operation & Test Technical Manual TM13345X19 – PDF DOWNLOAD
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John Deere 160GLC Excavator Operation & Test Technical Manual TM13345X19 – PDF DOWNLOAD
Language : English
Pages : 1219
Downloadable : Yes
File Type : PDF
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DESCRIPTION:
John Deere 160GLC Excavator Operation & Test Technical Manual TM13345X19 – PDF DOWNLOAD
- 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.
- Technical manuals are divided in two parts: repair and operation and tests. Repair sections tell how to repair the components. Operation and test 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, service parts, 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.
TABLE OF CONTENTS:
John Deere 160GLC Excavator Operation & Test Technical Manual TM13345X19 – PDF DOWNLOAD
Contents...................................................................................................................... 7 General Information....................................................................................................... 9 Safety................................................................................................................ 11 Recognize Safety Information...................................................................................... 11 Follow Safety Instructions........................................................................................ 11 Operate Only If Qualified......................................................................................... 11 Wear Protective Equipment......................................................................................... 12 Avoid Unauthorized Machine Modifications.......................................................................... 12 Control Pattern Selector—If Equipped.............................................................................. 12 Add Cab Guarding for Special Uses................................................................................. 12 Inspect Machine................................................................................................... 13 Stay Clear of Moving Parts........................................................................................ 13 Avoid High-Pressure Fluids........................................................................................ 13 Avoid High-Pressure Oils.......................................................................................... 14 Work In Ventilated Area........................................................................................... 14 Avoid Static Electricity Risk When Refueling...................................................................... 15 Prevent Fires..................................................................................................... 15 In Case of Machine Fire........................................................................................... 16 Prevent Battery Explosions........................................................................................ 16 Handle Chemical Products Safely................................................................................... 16 Handle Starting Fluid Safely...................................................................................... 17 Decommissioning — Proper Recycling and Disposal of Fluids and Components.......................................... 17 Exhaust Filter Ash Handling and Disposal.......................................................................... 17 Prepare for Emergencies........................................................................................... 18 Clean Debris from Machine......................................................................................... 18 Use Steps and Handholds Correctly................................................................................. 18 Start Only From Operator's Seat................................................................................... 18 Use and Maintain Seat Belt........................................................................................ 19 Prevent Unintended Machine Movement............................................................................... 19 Avoid Work Site Hazards........................................................................................... 20 Keep Riders Off Machine........................................................................................... 20 Avoid Backover Accidents.......................................................................................... 21 Inspect and Maintain ROPS......................................................................................... 21 Avoid Machine Tip Over............................................................................................ 22 Use Special Care When Lifting Objects............................................................................. 22 Travel Safely..................................................................................................... 23 Prevent Acid Burns................................................................................................ 23 Add and Operate Attachments Safely................................................................................ 23 Park and Prepare for Service Safely............................................................................... 24 Service Cooling System Safely..................................................................................... 24 Remove Paint Before Welding or Heating............................................................................ 25 Make Welding Repairs Safely....................................................................................... 25 Drive Metal Pins Safely........................................................................................... 25 Clean Exhaust Filter Safely....................................................................................... 26 Diagnostics............................................................................................................... 33 Main Controller (MCZ) Diagnostic Trouble Codes........................................................................ 35 Main Controller (MCZ) Diagnostic Trouble Codes.................................................................... 35 Controller Area Network 0 (CAN 0) Circuit Diagnostics............................................................. 35 Controller Area Network 1 (CAN 1) Circuit Diagnostics............................................................. 35 Interface Controller Area Network (N-CAN) Diagnostics............................................................. 35 Engine Controller Area Network (Engine CAN) Diagnostics .......................................................... 35 Aftertreatment Controller Area Network (AT CAN) Diagnostics....................................................... 35 011000.02 — Abnormal EEPROM....................................................................................... 35 Abnormal EEPROM Diagnostic Procedure.......................................................................... 35 011001.02 — Abnormal RAM.......................................................................................... 36 Abnormal RAM Diagnostic Procedure............................................................................. 36 011002.02 — Abnormal A/D Converter................................................................................ 37 Abnormal A/D Converter Diagnostic Procedure................................................................... 37 011003.03 — Abnormal Sensor Voltage............................................................................... 37 Abnormal Sensor Voltage Diagnostic Procedure.................................................................. 37 011006.02 — Engine Controller Communication Error................................................................. 38 011007.02 — (CAN 0) Data Converter Communication Error 1.......................................................... 38 011008.02 — (CAN 1) Data Converter Communication Error 2.......................................................... 38 011009.02 — (CAN 0) Monitor Controller Communication Error 1...................................................... 39 011010.02 — (CAN 1) Monitor Controller Communication Error 2...................................................... 39 011100.02 — Abnormal Engine Speed................................................................................. 39 Abnormal Engine Speed Diagnostic Procedure.................................................................... 39 011101.03 — Engine Speed Dial Sensor Circuit High Input........................................................... 39 Engine Speed Dial Sensor Circuit High Input Diagnostic Procedure.............................................. 40 011101.04 — Engine Speed Dial Sensor Circuit Low Input............................................................ 41 Engine Speed Dial Sensor Circuit Low Input Diagnostic Procedure............................................... 41 011200.03 — Pump 1 Delivery Pressure Sensor Circuit High Input.................................................... 42 Pump 1 Delivery Pressure Sensor Circuit High Diagnostics...................................................... 42 011200.04 — Pump 1 Delivery Pressure Sensor Circuit Low Input..................................................... 44 Pump 1 Delivery Pressure Sensor Circuit Low Input Diagnostic Procedure........................................ 44 011202.03 — Pump 2 Delivery Pressure Sensor Circuit High Input.................................................... 46 Pump 2 Delivery Pressure Sensor Circuit High Input Diagnostic Procedure....................................... 46 011202.04 — Pump 2 Delivery Pressure Sensor Circuit Low Input..................................................... 48 Pump 2 Delivery Pressure Sensor Circuit Low Input Diagnostic Procedure........................................ 48 011206.03 — Pump 1 Flow Control Pressure Sensor Circuit High Input................................................ 50 Pump 1 Flow Control Pressure Sensor Circuit High Input Diagnostic Procedure................................... 50 011206.04 — Pump 1 Flow Control Pressure Sensor Circuit Low Input................................................. 51 Pump 1 Flow Control Pressure Sensor Circuit Low Input Diagnostic Procedure.................................... 51 011208.03 — Pump 2 Flow Control Pressure Sensor Circuit High Input................................................ 53 Pump 2 Flow Control Pressure Sensor Circuit High Input Diagnostic Procedure................................... 53 011208.04 — Pump 2 Flow Control Pressure Sensor Circuit Low Input................................................. 54 Pump 2 Flow Control Pressure Sensor Circuit Low Input Diagnostic Procedure.................................... 54 011301.03 — Swing Pressure Sensor Circuit High Input.............................................................. 56 Swing Pilot Pressure Sensor Circuit High Input Diagnostic Procedure........................................... 56 011301.04 — Swing Pilot Pressure Sensor Circuit Low Input......................................................... 57 Swing Pilot Pressure Sensor Circuit Low Input Diagnostic Procedure............................................ 57 011302.03 — Boom Up Pilot Pressure Sensor Circuit High Input...................................................... 59 Boom Up Pilot Pressure Sensor Circuit High Input Diagnostic Procedure......................................... 59 011302.04 — Boom Up Pilot Pressure Sensor Circuit Low Input....................................................... 60 Boom Up Pilot Pressure Sensor Circuit Low Input Diagnostic Procedure.......................................... 60 011303.03 — Arm In Pressure Sensor Circuit High Input............................................................. 61 Arm In Pilot Pressure Sensor Circuit High Input Diagnostic Procedure.......................................... 62 011303.04 — Arm In Pressure Sensor Circuit Low Input.............................................................. 63 Arm In Pilot Pressure Sensor Circuit Low Input Diagnostic Procedure........................................... 63 011304.03 — Travel Pilot Pressure Sensor Circuit High Input....................................................... 64 Travel Pilot Pressure Sensor Circuit High Input Diagnostic Procedure.......................................... 64 011304.04 — Travel Pilot Pressure Sensor Circuit Low Input........................................................ 66 Travel Pilot Pressure Sensor Circuit Low Input Diagnostic Procedure........................................... 66 011307.03 — Front Attachment Pilot Pressure Sensor Circuit High Input............................................. 67 Front Attachment Pilot Pressure Sensor Circuit High Input Diagnostic Procedure................................ 67 011307.04 — Front Attachment Pilot Pressure Sensor Circuit Low Input.............................................. 69 Front Attachment Pilot Pressure Sensor Circuit Low Input Diagnostic Procedure................................. 69 011325.03 — Bucket Roll-In Pilot Pressure Sensor Circuit High Input............................................... 70 Bucket Roll-In Pilot Pressure Sensor Circuit High Input Diagnostic Procedure.................................. 70 011325.04 — Bucket Roll-In Pilot Pressure Sensor Circuit Low Input................................................ 71 Bucket Roll-In Pilot Pressure Sensor Circuit Low Input Diagnostic Procedure................................... 71 011400.02 — Pump 2 Flow Rate Limit Solenoid Valve Feedback Abnormal............................................... 73 Pump 2 Flow Rate Limit Solenoid Valve Feedback Abnormal Diagnostic Procedure.................................. 73 011400.03 — Pump 2 Flow Rate Limit Solenoid Valve Feedback High Current........................................... 75 Pump 2 Flow Rate Limit Solenoid Valve Feedback High Current Diagnostic Procedure.............................. 75 011400.04 — Pump 2 Flow Rate Limit Solenoid Feedback Low Current.................................................. 77 Pump 2 Flow Rate Limit Solenoid Valve Feedback Low Current Diagnostic Procedure............................... 77 011401.02 — Torque Control Solenoid Valve Abnormal Feedback....................................................... 78 Torque Control Solenoid Valve Abnormal Feedback Diagnostic Procedure.......................................... 78 011401.03 — Torque Control Solenoid Valve Feedback High Current................................................... 80 Torque Control Solenoid Valve Feedback High Current Diagnostic Procedure...................................... 80 011401.04 — Torque Control Solenoid Valve Feedback Low Current.................................................... 82 Torque Control Solenoid Valve Feedback Low Current Diagnostic Procedure....................................... 82 011402.02 — Dig Regenerative Solenoid Valve Feedback Current Abnormal............................................. 83 Dig Regenerative Solenoid Valve Feedback Current Abnormal Diagnostic Procedure................................ 83 011402.03 — Dig Regenerative Solenoid Valve Feedback Current High................................................. 85 Dig Regenerative Solenoid Valve Feedback Current High Diagnostic Procedure.................................... 85 011402.04 — Dig Regenerative Solenoid Valve Feedback Current Low.................................................. 87 Dig Regenerative Solenoid Valve Feedback Current Low Diagnostic Procedure..................................... 87 011403.02 — Arm Regenerative Solenoid Valve Feedback Current Abnormal............................................. 88 Arm Regenerative Solenoid Valve Feedback Current Abnormal Diagnostic Procedure................................ 88 011403.03 — Arm Regenerative Solenoid Valve Feedback Current High................................................. 90 Arm Regenerative Solenoid Valve Feedback Current High Diagnostic Procedure.................................... 90 011403.04 — Arm Regenerative Solenoid Valve Feedback Current Low.................................................. 92 Arm Regenerative Solenoid Valve Feedback Current Low Diagnostic Procedure..................................... 92 011407.02 — Power Dig/Travel Speed Solenoid Valve Feedback Current Abnormal....................................... 93 Power Dig/Travel Speed Solenoid Valve Feedback Current Abnormal Diagnostic Procedure.......................... 93 011407.03 — Power Dig/Travel Speed Solenoid Valve Feedback Current High........................................... 95 Power Dig/Travel Speed Solenoid Valve Feedback Current High Diagnostic Procedure.............................. 95 011407.04 — Power Dig/Travel Speed Solenoid Valve Feedback Current Low............................................ 97 Power Dig/Travel Speed Solenoid Valve Feedback Current Low Diagnostic Procedure............................... 97 011408.02 — Exhaust Aftertreatment Solenoid Valve Feedback Current Abnormal....................................... 98 011408.03 — Exhaust Aftertreatment Solenoid Valve Feedback Current High........................................... 98 011408.04 — Exhaust Aftertreatment Solenoid Valve Feedback Current Low............................................ 99 011409.02 — Exhaust Aftertreatment Solenoid Valve Feedback Current Abnormal....................................... 99 011409.03 — Exhaust Aftertreatment Solenoid Valve Feedback Current High........................................... 99 011409.04 — Exhaust Aftertreatment Solenoid Valve Feedback Current Low............................................ 99 011410.02 — Pump 1 Flow Rate Limit Solenoid Valve Abnormal Feedback.............................................. 99 Pump 1 Flow Rate Limit Solenoid Valve Abnormal Feedback Diagnostic Procedure.................................. 99 011410.03 — Pump 1 Flow Rate Limit Solenoid Valve Feedback High Current........................................... 101 Pump 1 Flow Rate Limit Solenoid Valve Feedback High Current Diagnostic Procedure.............................. 101 011410.04 — Pump 1 Flow Rate Limit Solenoid Valve Feedback Low Current............................................ 103 Pump 1 Flow Rate Limit Solenoid Valve Feedback Low Current Diagnostic Procedure............................... 103 011434.02 — Attachment Relief 1 (Upper) Proportional Solenoid Valve Abnormal Feedback............................. 104 011434.03 — Attachment Relief 1 (Upper) Proportional Solenoid Valve Feedback High Current......................... 104 011434.04 — Attachment Relief 1 (Upper) Proportional Solenoid Valve Feedback Low Current.......................... 105 011435.02 — Attachment Relief 2 (Lower) Proportional Solenoid Valve Abnormal Feedback............................. 105 011435.03 — Attachment Relief 2 (Lower) Proportional Solenoid Valve Feedback High Current......................... 105 011435.04 — Attachment Relief 2 (Lower) Proportional Solenoid Valve Feedback Low Current.......................... 105 011436.02 — Breaker Relief Proportional Solenoid Valve Abnormal Feedback.......................................... 105 011436.03 — Breaker Relief Proportional Solenoid Valve Feedback High Current...................................... 105 011436.04 — Breaker Relief Proportional Solenoid Valve Feedback Low Current....................................... 105 011457.02 — 2-Speed Activation Solenoid Valve Disconnected........................................................ 105 2-Speed Activation Solenoid Valve Disconnected Diagnostic Procedure........................................... 105 011458.02 — Selector Valve Solenoid Valve Disconnected............................................................ 107 Selector Valve Solenoid Valve Disconnected Diagnostic Procedure............................................... 107 011459.02 — Idle Stop Relay Circuit Malfunction................................................................... 109 Idle Stop Relay Circuit Malfunction Diagnostic Procedure...................................................... 109 011810.03 — Electric Lever Operating Pressure Sensor 1 High Voltage............................................... 110 Auxiliary Function Lever (AFL) Solenoid Pressure Sensor (marked PS1) (B85) High Input Diagnostic Procedure.... 110 011810.04 — Electric Lever Operating Pressure Sensor 1 Low Voltage................................................ 111 Auxiliary Function Lever (AFL) Solenoid Pressure Sensor (marked PS1) (B85) Low Input Diagnostic Procedure..... 111 011812.02 — OPT Electric Lever 1 Neutral Abnormal................................................................. 113 OPT Electric Lever 1 Neutral Abnormal Diagnostic Procedure.................................................... 113 011813.02 — OPT Electric Lever 1 Abnormal Operation............................................................... 114 OPT Electric Lever 1 Abnormal Operation Diagnostic Procedure.................................................. 114 011816.02 — OPT Solenoid 1 Feedback Abnormal...................................................................... 116 Auxiliary Function Lever (AFL) Solenoid A (marked 1A) (Y61) Abnormal Feedback Diagnostic Procedure............ 116 011816.03 — OPT Solenoid 1 Feedback Current High.................................................................. 117 Auxiliary Function Lever (AFL) Solenoid A (marked 1A) (Y61) Feedback High Current Diagnostic Procedure........ 118 011816.04 — OPT Solenoid 1 Feedback Current Low................................................................... 119 Auxiliary Function Lever (AFL) Solenoid A (marked 1A) (Y61) Feedback Low Current Diagnostic Procedure......... 119 011817.02 — OPT Solenoid 2 Feedback Abnormal...................................................................... 121 Auxiliary Function Lever (AFL) Solenoid B (marked 1B) (Y62) Abnormal Feedback Diagnostic Procedure............ 121 011817.03 — OPT Solenoid 2 Feedback Current High.................................................................. 122 Auxiliary Function Lever (AFL) Solenoid B (marked 1B) (Y62) Feedback High Current Diagnostic Procedure........ 123 011817.04 — OPT Solenoid 2 Feedback Current Low................................................................... 124 Auxiliary Function Lever (AFL) Solenoid B (marked 1B) (Y62) Feedback Low Current Diagnostic Procedure......... 124 011901.03 — Hydraulic Oil Temperature Sensor Circuit High Input................................................... 126 Hydraulic Oil Temperature Sensor Circuit High Input Diagnostic Procedure...................................... 126 011901.04 — Hydraulic Oil Temperature Sensor Circuit Low Input.................................................... 127 Hydraulic Oil Temperature Sensor Circuit Low Input Diagnostic Procedure....................................... 127 015011.03 — Hydraulic Oil Temperature Sensor Circuit High Input (Pilot).......................................... 128 Secondary Hydraulic Oil Temperature Sensor Circuit High Input Diagnostic Procedure............................ 128 015011.04 — Hydraulic Oil Temperature Sensor Circuit Low Input (Pilot)........................................... 130 Secondary Hydraulic Oil Temperature Sensor Circuit Low Input Diagnostic Procedure............................. 130 011995.03 — Arm Roll-Out Pilot Pressure Sensor Circuit High Input................................................. 131 Arm Roll-Out Pressure Sensor Circuit High Diagnostic Procedure................................................ 131 011995.04 — Arm Roll-Out Pilot Pressure Sensor Circuit Low Input.................................................. 132 Arm Roll-Out Pilot Pressure Sensor Circuit Low Input Diagnostic Procedure..................................... 132 011997.03 — Bucket Roll-Out Pressure Sensor Circuit High.......................................................... 134 Bucket Roll-Out Pressure Sensor Circuit High Diagnostic Procedure............................................. 134 011997.04 — Bucket Roll-Out Pressure Sensor Circuit Low........................................................... 135 Bucket Roll-Out Pressure Sensor Circuit Low Diagnostic Procedure.............................................. 135 015016.03 — Right Analog Stroke Sensor Circuit High Input......................................................... 137 Auxiliary Function Lever (AFL) Proportional Control Switch Sensor Circuit High Input Diagnostic Procedure..... 137 015016.04 — Right Analog Stroke Sensor Circuit Low Input.......................................................... 138 Auxiliary Function Lever (AFL) Proportional Control Switch Sensor Circuit Low Input Diagnostic Procedure...... 138 020010.02 — Abnormal Exhaust Filter............................................................................... 139 Abnormal Exhaust Filter Diagnostic Procedure.................................................................. 139 020011.02 — Electric Lever Alarm.................................................................................. 140 Electric Control Lever Alarm Diagnostic Procedure............................................................. 140 020062.02 — Hydraulic Oil Temperature Alarm....................................................................... 140 020303.02 — Electric Lever Pilot Cut Alarm........................................................................ 140 Electric Control Lever Alarm Diagnostic Procedure............................................................. 140 Engine Control Unit (ECU) Diagnostic Trouble Codes.................................................................... 143 Engine Control Unit (ECU) Diagnostic Trouble Codes................................................................ 143 000111.07 — Coolant Level Low—Moderately Severe Level............................................................. 143 Coolant Level Low—Moderately Severe Level Diagnostic Procedure................................................ 143 000647.05 — Variable Speed Fan Solenoid Open Circuit.............................................................. 144 Variable Speed Fan Solenoid Open Circuit Diagnostic Procedure................................................. 144 000647.06 — Variable Speed Fan Solenoid High Current.............................................................. 145 Variable Speed Fan Solenoid High Current Diagnostic Procedure................................................. 145 000647.16 — Reversing Fan Switch Active Too Long.................................................................. 146 Reversing Fan Switch Active Too Long Diagnostic Procedure..................................................... 146 001639.00 — Fan Speed High—Moderately Severe Level................................................................ 147 Fan Speed High—Moderately Severe Level Diagnostic Procedure................................................... 147 001639.01 — Fan Speed Low—Most Severe Level....................................................................... 149 Fan Speed Low—Most Severe Level Diagnostic Procedure.......................................................... 149 001639.18 — Fan Speed Low—Moderately Severe Level................................................................. 150 001761.01 — Diesel Exhaust Fluid Extremely Low.................................................................... 150 001761.18 — Diesel Exhaust Fluid Very Low......................................................................... 151 002030.09 — (CAN 0) Flex Power Controller Communication Error..................................................... 151 002228.09 — (CAN 0) Main Controller (MCZ) Communication Error..................................................... 151 003031.12 — Diesel Exhaust Fluid Temperature Sensor Fault......................................................... 151 003353.31 — Alternator Excitation Fault........................................................................... 151 Alternator Excitation Fault Diagnostic Procedure.............................................................. 152 003516.01 — Diesel Exhaust Fluid Concentration Extremely Low...................................................... 153 003516.07 — Diesel Exhaust Fluid Concentration Invalid............................................................ 153 003516.09 — Diesel Exhaust Fluid Tank Header Communication Fault.................................................. 154 003516.12 — Diesel Exhaust Fluid Concentration Sensor Fault....................................................... 154 003517.12 — Diesel Exhaust Fluid Tank Level Sensor Fault.......................................................... 154 003719.15 — Calculated Soot Level Slightly High................................................................... 155 004366.05 — DEF Tank Heater Coolant Control Valve Circuit Has High Resistance..................................... 155 Diagnostic Procedure.......................................................................................... 156 004366.06 — DEF Tank Heater Coolant Control Valve Circuit Has Low Resistance...................................... 159 Diagnostic Procedure.......................................................................................... 159 004366.16 — DEF Tank Temperature Moderately High.................................................................. 163 Diagnostic Procedure.......................................................................................... 163 004366.18 — DEF Tank Insufficient Heating Fault................................................................... 166 Diagnostic Procedure.......................................................................................... 167 005484.05 — Reversing Fan Solenoid Open Circuit................................................................... 169 Reversing Fan Solenoid Open Circuit Diagnostic Procedure...................................................... 169 005484.06 — Reversing Fan Solenoid Short Circuit.................................................................. 170 Reversing Fan Solenoid Short Circuit Diagnostic Procedure..................................................... 170 520956.06 — Battery Disconnect Indicator Light Short to Ground.................................................... 171 Battery Disconnect Indicator Light Short to Ground Diagnostic Procedure....................................... 171 Monitor Controller (DSZ) Diagnostic Trouble Codes..................................................................... 173 Monitor Controller (DSZ) Diagnostic Trouble Codes................................................................. 173 013000.02 — Flash Memory Failure 1................................................................................ 173 Flash Memory Failure 1 Diagnostic Procedure................................................................... 173 013001.02 — Flash Memory Failure 2................................................................................ 173 Flash Memory Failure 2 Diagnostic Procedure................................................................... 173 013002.02 — ECU Communication Error............................................................................... 173 013003.02 — Main Controller (MCZ) Communication Error 1........................................................... 174 013004.02 — Main Controller (MCZ) Communication Error 2........................................................... 174 013005.02 — Monitor Controller (DSZ) Communication Error 1........................................................ 174 013006.02 — Monitor Controller (DSZ) Communication Error 2........................................................ 174 013007.02 — Machine Controller (BCZ) Communication Error.......................................................... 174 020113.02 — System Error Alarm.................................................................................... 174 Information Controller (ICZ) Diagnostic Trouble Codes................................................................. 175 Information Controller (ICZ) Diagnostic Trouble Codes............................................................. 175 013303.02 — Abnormal Monitor Internal Temperature Sensor.......................................................... 175 Monitor Internal Temperature Sensor Diagnostic Procedure...................................................... 175 013304.02 — Alternator Alarm...................................................................................... 175 Alternator Alarm Diagnostic Procedure......................................................................... 175 013305.02 — Abnormal Manual Glow EXT Output....................................................................... 176 013310.03 — Coolant Temperature Sensor Short Circuit.............................................................. 176 013311.03 — Fuel Level Sensor Open Circuit........................................................................ 176 Fuel Level Sensor Open Circuit Diagnostic Procedure........................................................... 176 013311.04 — Fuel Level Sensor Shorted Circuit..................................................................... 177 Fuel Level Sensor Shorted Circuit Diagnostic Procedure........................................................ 177 013334.02 — Radiator Water Temp Receive Error..................................................................... 178 014000.02 — CAN Communication Error 1............................................................................. 178 014001.02 — Flash Memory Read/Write Error......................................................................... 178 Data Converter Diagnostics.................................................................................... 178 014002.02 — External RAM Read/Write Error......................................................................... 179 Data Converter Diagnostics.................................................................................... 179 014003.02 — Abnormal EEPROM....................................................................................... 179 Data Converter Diagnostics.................................................................................... 179 014006.02 — Communication Terminal: Communication Error........................................................... 179 Communication Terminal: Communication Error Diagnostic Procedure.............................................. 179 014008.02 — Abnormal Internal RAM................................................................................. 180 Data Converter Diagnostics.................................................................................... 180 014009.02 — CAN Communication Error 2............................................................................. 180 014021.02 — Communication Terminal Security Error................................................................. 181 014022.02 — SIM Card Error........................................................................................ 181 014023.02 — Security Error........................................................................................ 181 020100.02 — Overheat Alarm........................................................................................ 181 020101.02 — Engine Warning Alarm.................................................................................. 181 020102.02 — Engine Oil Pressure Alarm............................................................................. 181 020103.02 — Alternator Alarm...................................................................................... 181 Alternator Alarm Diagnostic Procedure......................................................................... 181 020105.02 — Hydraulic Oil Filter Restriction Alarm................................................................ 182 Hydraulic Oil Filter Restriction Alarm Diagnostic Procedure................................................... 182 020106.02 — Air Cleaner Restriction Alarm......................................................................... 183 020107.02 — Water Separator Alarm................................................................................. 183 020109.02 — Pilot Control Shut-Off Lever Alarm.................................................................... 183 Pilot Control Shut-Off Lever Alarm Diagnostic Procedure....................................................... 183 020110.02 — Fuel Filter Restriction Alarm......................................................................... 184 020114.02 — Overheat Alarm (Immediately After the Key is Turned ON)............................................... 184 020135.02 — Exhaust Filter Regeneration Unnecessary Warning....................................................... 184 020149.02 — EGR Gas Temperature Alarm............................................................................. 184 020150.02 — Coolant Level Alarm................................................................................... 184 020151.02 — Engine Warning Alarm.................................................................................. 184 020152.02 — Engine Oil Pressure Alarm............................................................................. 185 020153.02 — Air Cleaner Restriction Alarm......................................................................... 185 020154.02 — Fuel Filter Restriction Alarm......................................................................... 185 020155.02 — Engine Output Reduction Alarm......................................................................... 185 020156.02 — Cooling Performance Decrease Alarm.................................................................... 185 020157.02 — Cooling Performance Decrease Alarm.................................................................... 185 032000.02 — Coolant Temperature Pre Alarm......................................................................... 185 032001.02 — Hydraulic Oil Temperature Pre Alarm................................................................... 185 032002.02 — Hydraulic and Ambient Temperature Difference Pre Alarm................................................ 185 Air Conditioner Controller (ACF) Diagnostic Trouble Codes............................................................. 187 Air Conditioner Controller (ACF) Diagnostic Trouble Codes......................................................... 187 11 — Open Circuit in Air Recirculation Sensor..................................................................... 187 Open Circuit in Air Recirculation Sensor Diagnostic Procedure................................................. 187 12 — Short-Circuited Air Recirculation Sensor..................................................................... 188 Short-Circuited Air Recirculation Sensor Diagnostic Procedure................................................. 188 13 — Open Circuit in Ambient Air Temperature Sensor............................................................... 190 Open Circuit in Ambient Air Temperature Sensor Diagnostics Procedure.......................................... 190 14 — Short-Circuited Ambient Air Temperature Sensor............................................................... 191 Short-Circuited Ambient Air Temperature Sensor Diagnostic Procedure........................................... 191 18 — Short-Circuited Solar Radiation Sensor....................................................................... 193 Short-Circuited Solar Radiation Sensor Diagnostic Procedure................................................... 193 21 — Open Circuit in Air Conditioner Freeze Control Switch........................................................ 194 Open Circuit in Air Conditioner Freeze Control Switch Diagnostic Procedure.................................... 194 22 — Short-Circuited Air Conditioner Freeze Control Switch........................................................ 196 Short-Circuited Air Conditioner Freeze Control Switch Diagnostic Procedure.................................... 196 43 — Abnormal Air Conditioner and Heater Blower Port Change Servomotor............................................ 197 Abnormal Air Conditioner and Heater Blower Port Change Servomotor Diagnostic Procedure........................ 197 44 — Abnormal Air Conditioner and Heater Mixer Servomotor......................................................... 198 Abnormal Air Conditioner and Heater Mixer Servomotor Diagnostic Procedure..................................... 198 51 — Abnormal High/Low Refrigerant Pressure....................................................................... 200 Abnormal High/Low Refrigerant Pressure Diagnostic Procedure................................................... 200 91 — Communication Error.......................................................................................... 201 92 — CAN Bus Off Error............................................................................................ 201 Premium Seat Controller (PSC) Diagnostic Trouble Codes................................................................ 203 Premium Seat Controller (PSC) Diagnostic Trouble Codes............................................................ 203 0 — Cushion Blower Minimum Voltage................................................................................ 204 1 — Back Blower Minimum Voltage................................................................................... 204 2 — Cushion Blower Short to Power................................................................................. 205 3 — Back Blower Short to Power.................................................................................... 205 4 — Cushion Fan Power Transistor Short to Ground.................................................................. 206 5 — Back Fan Power Transistor Short to Ground..................................................................... 206 6 — Cushion Fan Power Transistor Open Circuit..................................................................... 207 7 — Back Fan Power Transistor Open Circuit........................................................................ 207 8 — Lower Thermal Duct Module Temperature Sensor Short to Ground.................................................. 208 9 — Upper Thermal Duct Module Temperature Sensor Short to Ground.................................................. 209 10 — Lower Thermal Duct Module Temperature Sensor Open Circuit.................................................... 210 11 — Upper Thermal Duct Module Temperature Sensor Open Circuit.................................................... 211 12 — Lower Thermal Duct Module Short to Ground.................................................................... 212 13 — Upper Thermal Duct Module Short to Ground.................................................................... 213 14 — Lower Thermal Duct Module Open Circuit....................................................................... 214 15 — Upper Thermal Duct Module Open Circuit....................................................................... 215 16 — Lower Thermal Duct Module Over Temperature................................................................... 216 17 — Upper Thermal Duct Module Over Temperature................................................................... 217 21 — Thermal Duct Module Short to Power........................................................................... 218 Operational Checkout Procedure............................................................................................ 219 Operational Checkout Procedure........................................................................................ 221 Operational Checkout.............................................................................................. 221 Diagnostic Trouble Code Check................................................................................. 221 Operational Checks—Key Switch Off, Engine Off Checks.......................................................... 221 Operational Checks—Key Switch On, Engine Off Checks........................................................... 224 Operational Checks—Key Switch On, Engine On Checks............................................................ 237 Engine.................................................................................................................... 269 Theory of Operation................................................................................................... 271 Engine Identification............................................................................................. 271 John Deere Engine................................................................................................. 271 Engine Fuel System Component Location............................................................................. 273 Engine Cooling System Component Location.......................................................................... 277 Diesel Exhaust Fluid (DEF) System Component Location.............................................................. 284 Cold Weather Starting Aid......................................................................................... 287 Engine Speed Control System Operation............................................................................. 288 Diagnostic Information................................................................................................ 293 John Deere Engine................................................................................................. 293 Adjustments........................................................................................................... 295 John Deere Engine................................................................................................. 295 Tests................................................................................................................. 297 John Deere Engine................................................................................................. 297 Electrical System......................................................................................................... 301 System Information.................................................................................................... 303 Electrical Diagram Information.................................................................................... 303 System Diagrams....................................................................................................... 311 Explanation of Wire Markings...................................................................................... 311 Fuse and Relay Specifications..................................................................................... 311 System Functional Schematic, Component Location, and Wiring Diagram Master Legend................................. 315 System Functional Schematic....................................................................................... 323 Cab Harness (W1) Component Location............................................................................... 389 Cab Harness (W1) Wiring Diagram................................................................................... 397 Machine Harness (W2) Component Location........................................................................... 429 Machine Harness (W2) Wiring Diagram............................................................................... 433 Monitor Harness (W3) Component Location........................................................................... 450 Monitor Harness (W3) Wiring Diagram............................................................................... 452 Engine Harness (W4) Component Location............................................................................ 455 Engine Harness (W4) Wiring Diagram................................................................................ 458 Engine Interface Harness (W5) Component Location.................................................................. 463 Engine Interface Harness (W5) Wiring Diagram...................................................................... 471 Front Engine Harness (W7) Component Location...................................................................... 491 Front Engine Harness (W7) Wiring Diagram.......................................................................... 495 Pump Harness (W8) Component Location.............................................................................. 499 Pump Harness (W8) Wiring Diagram.................................................................................. 503 Exhaust Filter Parked Cleaning Switch Harness (W9) Component Location............................................. 505 Exhaust Filter Parked Cleaning Switch Harness (W9) Wiring Diagram................................................. 505 Service ADVISOR™ Remote (SAR) Switch Harness (W10) Component Location............................................. 505 Service ADVISOR™ Remote (SAR) Switch Harness (W10) Wiring Diagram................................................. 506 Pilot Shutoff Switch Harness (W11) Component Location............................................................. 507 Pilot Shutoff Switch Harness (W11) Wiring Diagram................................................................. 509 Heated Air Seat Harness (W14) Component Location.................................................................. 512 Heated Air Seat Harness (W14) Wiring Diagram...................................................................... 513 Multi-Function Pilot Control Lever Harness (W15) Component Location............................................... 514 Multi-Function Pilot Control Lever Harness (W15) Wiring Diagram................................................... 517 Travel Alarm Cancel Switch Harness (W16) Component Location....................................................... 519 Travel Alarm Cancel Switch Harness (W16) Wiring Diagram........................................................... 519 Attachment Harness (W17) Component Location....................................................................... 520 Attachment Harness (W17) Wiring Diagram........................................................................... 523 Rear Camera Harness (W19) Component Location...................................................................... 525 Rear Camera Harness (W19) Wiring Diagram.......................................................................... 526 Pilot Shutoff Valve Harness (W21) Component Location.............................................................. 527 Pilot Shutoff Valve Harness (W21) Wiring Diagram.................................................................. 528 Auxiliary 3-Button Cancel Switch Harness (W22) Component Location................................................. 528 Auxiliary 3-Button Cancel Switch Harness (W22) Wiring Diagram..................................................... 529 Reversing Fan Switch Harness (W23) Component Location............................................................. 529 Reversing Fan Switch Harness (W23) Wiring Diagram................................................................. 530 Seat Heater Switch Harness (W24) Component Location............................................................... 530 Seat Heater Switch Harness (W24) Wiring Diagram................................................................... 531 Attachment Interface Harness (W25) Component Location—If Equipped................................................. 532 Attachment Interface Harness (W25) Wiring Diagram—If Equipped..................................................... 533 Travel Alarm Harness (W26) Component Location..................................................................... 534 Travel Alarm Harness (W26) Wiring Diagram......................................................................... 535 Starter Switch Harness (W29) Component Location................................................................... 535 Starter Switch Harness (W29) Wiring Diagram....................................................................... 536 2-Speed Harness (W32) Component Location.......................................................................... 536 2-Speed Harness (W32) Wiring Diagram.............................................................................. 538 Fuel Injector Harness (W38) Component Location.................................................................... 539 Fuel Injector Harness (W38) Wiring Diagram........................................................................ 541 Glow Plug Harness (W40) Component Location........................................................................ 545 Glow Plug Harness (W40) Wiring Diagram............................................................................ 548 Heater and Air Conditioner Harness (W41) Component Location....................................................... 549 Heater and Air Conditioner Harness (W41) Wiring Diagram........................................................... 551 Cab Roof Light Harness (W44) Component Location................................................................... 553 Cab Roof Light Harness (W44) Wiring Diagram....................................................................... 554 Cab Roof Light Jumper Harness (W45) Component Location............................................................ 554 Cab Roof Light Jumper Harness (W45) Wiring Diagram................................................................ 555 Cab Roof Light 1 Relay Harness (W46) Component Location........................................................... 555 Cab Roof Light 1 Relay Harness (W46) Wiring Diagram............................................................... 556 Cab Roof Light 2 Relay Harness (W47) Component Location........................................................... 556 Cab Roof Light 2 Relay Harness (W47) Wiring Diagram............................................................... 557 Heater and Air Conditioner Relay Harness (W51) Component Location................................................. 558 Heater and Air Conditioner Relay Harness (W51) Wiring Diagram..................................................... 560 Exhaust Aftertreatment Harness (W53) Component Location........................................................... 563 Exhaust Aftertreatment Harness (W53) Wiring Diagram............................................................... 566 Diesel Exhaust Fluid (DEF) Harness (W54) Component Location....................................................... 571 Diesel Exhaust Fluid (DEF) Harness (W54) Wiring Diagram........................................................... 579 Fan Harness (W57) Component Location.............................................................................. 587 Fan Harness (W57) Wiring Diagram.................................................................................. 590 Engine Light Harness (W58) Component Location..................................................................... 593 Engine Light Harness (W58) Wiring Diagram......................................................................... 593 Auxiliary Solenoid Harness (W61) Component Location............................................................... 595 Auxiliary Solenoid Harness (W61) Wiring Diagram................................................................... 596 Diesel Particulate Filter (DPF) Harness (W62) Component Location.................................................. 598 Diesel Particulate Filter (DPF) Harness (W62) Wiring Diagram...................................................... 600 Auxiliary Function Lever (AFL) Harness (W75) Component Location................................................... 604 Auxiliary Function Lever (AFL) Harness (W75) Wiring Diagram....................................................... 607 Auxiliary Function Lever (AFL) Solenoid Harness (W76) Component Location.......................................... 611 Auxiliary Function Lever (AFL) Solenoid Harness (W76) Wiring Diagram.............................................. 614 USB Harness (W82) Component Location.............................................................................. 615 USB Harness (W82) Wiring Diagram.................................................................................. 615 USB Jumper Harness (W83) Component Location....................................................................... 615 USB Jumper Harness (W83) Wiring Diagram........................................................................... 616 Rear Cab Light Switch Harness (W84) Component Location............................................................ 617 Rear Cab Light Switch Harness (W84) Wiring Diagram................................................................ 618 Rear Cab Light Relay Harness (W85) Component Location............................................................. 618 Rear Cab Light Relay Harness (W85) Wiring Diagram................................................................. 619 Rear Cab Light Harness (W86) Component Location................................................................... 619 Rear Cab Light Harness (W86) Wiring Diagram....................................................................... 620 Premium Seat Harness (W87) Component Location..................................................................... 621 Premium Seat Harness (W87) Wiring Diagram......................................................................... 623 Satellite (SAT) Harness (W6003) Component Location................................................................ 625 Satellite (SAT) Harness (W6003) Wiring Diagram.................................................................... 625 Sub-System Diagnostics................................................................................................ 627 Controller Area Network (CAN) Theory of Operation................................................................. 627 Starting and Charging Circuit Theory of Operation................................................................. 635 Monitor Controller (DSZ) Circuit Theory of Operation.............................................................. 645 Engine Control Unit (ECU) Circuit Theory of Operation............................................................. 655 Exhaust Aftertreatment Circuit Theory of Operation................................................................ 690 Main Controller (MCZ) Circuit Theory of Operation................................................................. 705 Machine Controller (BCZ) Circuit Theory of Operation.............................................................. 721 Windshield Wiper and Washer Circuit Theory of Operation........................................................... 723 Lighting Circuit Theory of Operation.............................................................................. 727 Travel Alarm Circuit Theory of Operation.......................................................................... 736 Pilot Shutoff Circuit Theory of Operation......................................................................... 739 Attachment Control Circuit Theory of Operation.................................................................... 742 Monitor Operation..................................................................................................... 751 Service Menu...................................................................................................... 751 Troubleshooting................................................................................................... 751 Monitoring........................................................................................................ 752 Controller Version................................................................................................ 755 Issued Warning Record............................................................................................. 755 Operation......................................................................................................... 756 Machine Setting................................................................................................... 757 Monitor Setting................................................................................................... 761 Alarm Setting..................................................................................................... 763 Exhaust Filter No................................................................................................. 763 References............................................................................................................ 765 Reading Diagnostic Trouble Codes with Monitor Display............................................................. 765 Service ADVISOR™ Diagnostic Application........................................................................... 765 Service ADVISOR™ Connection Procedure............................................................................. 766 Reading Diagnostic Trouble Codes with Service ADVISOR™ Diagnostic Application..................................... 767 MPDr Application.................................................................................................. 769 MPDr Connection Procedure......................................................................................... 770 Controller Area Network (CAN) Circuit Test........................................................................ 771 Controller Area Network (CAN) Diagnostics .................................................................... 778 Electrical Component Specifications............................................................................... 781 Alternator Test................................................................................................... 784 Electrical Component Checks....................................................................................... 785 Component Checks.............................................................................................. 785 Battery Remove and Install........................................................................................ 794 Rear Cover Remove and Install..................................................................................... 796 Main Controller (MCZ) Remove and Install.......................................................................... 798 Monitor Controller (DSZ) Remove and Install....................................................................... 799 Heater Control Disable and Enable................................................................................. 799 Power Train............................................................................................................... 801 Theory of Operation................................................................................................... 803 Track Adjuster and Recoil Spring Operation........................................................................ 803 Travel Gear Case Operation........................................................................................ 804 Diagnostic Information................................................................................................ 807 Noisy or Loose Track Chain........................................................................................ 807 Noisy or Loose Track Chain Diagnostic Procedure............................................................... 807 Tight Track Chain................................................................................................. 807 Tight Track Chain Diagnostic Procedure........................................................................ 807 Frequent Track Chain Sag Adjustment Required...................................................................... 808 Frequent Track Chain Sag Adjustment Required Diagnostic Procedure............................................. 808 Excessive Oil Leakage From Front Idler, Track Rollers, or Carrier Rollers......................................... 808 Excessive Oil Leakage From Front Idler, Track Rollers, or Carrier Rollers Diagnostic Procedure................ 808 Bent Track Shoes.................................................................................................. 808 Bent Track Shoes Diagnostic Procedure......................................................................... 808 “Popping” of Track................................................................................................ 809 “Popping” of Track Diagnostic Procedure....................................................................... 809 Cracked Track Link................................................................................................ 809 Cracked Track Link Diagnostic Procedure....................................................................... 809 Chipped Link Rails................................................................................................ 810 Chipped Link Rails Diagnostic Procedure....................................................................... 810 Individual Undercarriage Component Wear........................................................................... 811 Individual Undercarriage Component Wear Diagnostic Procedure.................................................. 811 Measure Swing Bearing Wear........................................................................................ 812 Hydraulic System.......................................................................................................... 815 Theory of Operation................................................................................................... 817 Hydraulic System Operation........................................................................................ 817 Fan Drive Hydraulic System Operation.............................................................................. 818 Pilot System Operation............................................................................................ 820 Pilot Pump, Pressure Regulating Valve and Filter Operation........................................................ 821 Pilot Shutoff Solenoid Valve Operation............................................................................ 822 Pilot Control Valve Operation..................................................................................... 825 Travel Pilot Control Valve Operation.............................................................................. 828 Single Pedal Travel Operation—If Equipped......................................................................... 830 Pilot Operation of Control Valve Operation........................................................................ 833 Pilot Signal Manifold Operation................................................................................... 836 Pump 1, Pump 2, and Drive Gear Case Operation..................................................................... 846 Pump 1 and Pump 2 Regulator Operation............................................................................. 849 Engine Speed Sensing Control Circuit Operation.................................................................... 854 Control Valve Operation........................................................................................... 856 Control Valve Check Valves Identification and Operation........................................................... 874 Main Relief Valve Circuit Operation............................................................................... 877 Circuit Relief and Anticavitation Valve Operation................................................................. 881 Travel Flow Combiner Valve Operation.............................................................................. 882 Auxiliary Flow Combiner Valve and Bypass Shutoff Valve Operation.................................................. 885 Boom Lower Meter-In Cut Valve Operation........................................................................... 889 Boom Regenerative Valve Circuit Operation......................................................................... 891 Dig Regenerative Valve Circuit Operation.......................................................................... 893 Arm Regenerative Valve Circuit Operation.......................................................................... 899 Bucket Regenerative Valve Circuit Operation....................................................................... 905 Boom and Arm Reduced Leakage Valves Operation..................................................................... 908 Arm 1 Flow Rate Control Valve Circuit Operation................................................................... 911 Arm 2 Flow Rate Control Valve Circuit Operation................................................................... 915 Bucket Flow Rate Control Valve Circuit Operation.................................................................. 919 Boom Flow Rate Control Valve Circuit Operation.................................................................... 923 Auxiliary Flow Rate Control Valve Circuit Operation............................................................... 928 Swing Reduction Gear Case Operation............................................................................... 931 Swing Motor, Crossover Relief Valve, and Make-Up Check Valve Operation............................................ 932 Swing Motor Damper Valve.......................................................................................... 935 Swing Motor Park Brake Release Circuit Operation.................................................................. 943 Center Joint Operation............................................................................................ 944 Travel Motor and Park Brake Valve Operation....................................................................... 946 Travel Motor Speed Circuit Operation.............................................................................. 955 Cylinder Operation................................................................................................ 959 Return Filter Operation........................................................................................... 960 Auxiliary System Operation........................................................................................ 961 Auxiliary Pilot Control Valve Operation........................................................................... 961 Flow Rate Select Solenoid Valve Operation......................................................................... 972 Flow Rate Pressure Reducing Valve Operation....................................................................... 973 Secondary Auxiliary Relief Valve Solenoid Valve Operation......................................................... 973 Secondary Auxiliary Relief Control Valve Operation................................................................ 974 Secondary Auxiliary Relief Valve Operation........................................................................ 974 Selector Valve Solenoid Valve Operation........................................................................... 975 Selector Valve Operation.......................................................................................... 975 Auxiliary Shuttle Valve Operation................................................................................. 976 Auxiliary High Flow Line Kit Operation............................................................................ 977 Two Way Solenoid Kit Operation.................................................................................... 981 Two Pump Combined Flow Kit Operation.............................................................................. 985 Secondary Auxiliary Relief Kit Operation.......................................................................... 990 Low Flow Kit Operation............................................................................................ 993 Diagnostic Information................................................................................................1001 All Hydraulic Functions Slow......................................................................................1001 All Hydraulic Functions Slow Diagnostic Procedure.............................................................1001 Hydraulic Oil Overheats...........................................................................................1002 Hydraulic Oil Overheats Diagnostic Procedure..................................................................1002 No Hydraulic Functions............................................................................................1004 No Hydraulic Functions Diagnostic Procedure...................................................................1004 No Hydraulic Functions—Electrical Checks..........................................................................1005 No Hydraulic Functions—Electrical Checks Diagnostic Procedure.................................................1005 Function Does Not Stop When Control Lever Released................................................................1007 Function Does Not Stop When Control Lever Released Diagnostic Procedure.......................................1007 Load Drifts Down When Control Lever is in Neutral Position........................................................1008 Load Drifts Down When Control Lever is in Neutral Position Diagnostic Procedure...............................1008 Load Falls When Control Valve is Actuated To Raise Load...........................................................1010 Load Falls When Control Valve is Actuated To Raise Load Diagnostic Procedure..................................1010 H/P (High Power) Function Does Not Operate, PWR (Power) Mode is Normal............................................1010 H/P (High Power) Function Does Not Operate, PWR (Power) Mode is Normal Diagnostic Procedure...................1010 Boom Down Does Not Function, Moves Slowly, or Is Erratic, All Other Functions Normal..............................1012 Boom Down Does Not Function, Moves Slowly, or Is Erratic, All Other Functions Normal Diagnostic Procedure.....1012 Arm In Does Not Function, Moves Slowly, or Is Erratic, All Other Functions Normal.................................1013 Arm In Does Not Function, Moves Slowly, or Is Erratic, All Other Functions Normal Diagnostic Procedure........1013 Swing Speed Slow During Arm In Function...........................................................................1014 Swing Speed Slow During Arm In Function Diagnostic Procedure..................................................1014 Boom Cannot Raise Track Off Ground................................................................................1014 Boom Cannot Raise Track Off Ground Diagnostic Procedure.......................................................1014 Swing Function Does Not Operate in Both Directions................................................................1016 Swing Function Does Not Operate in Both Directions Diagnostic Procedure.......................................1016 Swing Speed Slow in Both Directions...............................................................................1018 Swing Speed Slow in Both Directions Diagnostic Procedure......................................................1018 Swing Speed Slow or Does Not Operate in One Direction.............................................................1019 Swing Speed Slow or Does Not Operate in One Direction Diagnostic Procedure....................................1019 Upperstructure Drift With Swing Valve in Neutral..................................................................1020 Upperstructure Drift With Swing Valve in Neutral Diagnostic Procedure.........................................1020 Machine Freewheels Down an Incline................................................................................1022 Machine Freewheels Down an Incline Diagnostic Procedure.......................................................1022 Track Will Not Move in Either Direction...........................................................................1022 Track Will Not Move in Either Direction Diagnostic Procedure..................................................1023 Machine Mistracks.................................................................................................1024 Machine Mistracks Diagnostic Procedure........................................................................1024 Machine Mistracks Left During Combined Travel and Dig Functions...................................................1026 Machine Mistracks Left During Combined Travel and Dig Functions Diagnostic Procedure..........................1026 Machine Will Not Shift Into Fast (rabbit) Speed...................................................................1026 Machine Will Not Shift Into Fast (rabbit) Speed Diagnostic Procedure..........................................1027 Pump 1, Pump 2, and Pilot Pump Line Identification................................................................1029 Control Valve Line Identification.................................................................................1030 Swing Motor Line Identification...................................................................................1033 Pilot Control Valve-to-Pilot Signal Manifold Component Location—Excavator Pattern.................................1035 Pilot Control Valve-to-Pilot Signal Manifold Component Location—Backhoe Pattern...................................1039 Pilot Signal Manifold-to-Control Valve Line Connection............................................................1042 Pilot Control Lever Pattern Selector Valve Line Connection—If Equipped............................................1046 Travel System Component Location..................................................................................1046 Travel Hydraulic System Line Connections..........................................................................1047 Auxiliary Attachment Schematic....................................................................................1055 Auxiliary System Line Connections.................................................................................1081 Hydraulic System Schematic........................................................................................1089 Hydraulic System Component Location...............................................................................1108 Hydraulic System Line Connections.................................................................................1109 Fan Drive Hydraulic System Component Location.....................................................................1113 Fan Drive Hydraulic System Schematic..............................................................................1116 Tests.................................................................................................................1119 JT05800 Digital Thermometer Installation..........................................................................1119 JT02156A Digital Pressure and Temperature Analyzer Kit Installation...............................................1119 General Hydraulic Oil Cleanup Procedure...........................................................................1120 Hydraulic Component Failure Cleanup Procedure.....................................................................1122 Hydraulic Oil Tank Pressure Release Procedure.....................................................................1123 Hydraulic Oil Warm-Up Procedure...................................................................................1124 Pilot Pressure Regulating Valve Test and Adjustment...............................................................1126 Control Valve Spool Actuating Pilot Pressure Test.................................................................1128 Dig Regenerative Solenoid Valve Test and Adjustment...............................................................1130 Arm Regenerative Solenoid Valve Test and Adjustment...............................................................1132 Power Dig/Travel Speed Solenoid Valve Test and Adjustment.........................................................1134 Torque Control Solenoid Valve Test and Adjustment.................................................................1136 Pump Control Pilot Pressure Signal Test...........................................................................1138 Main Relief and Power Dig Valve Test and Adjustment...............................................................1140 Circuit Relief Valve Test and Adjustment..........................................................................1143 Swing Motor Crossover Relief Valve Test and Adjustment............................................................1146 Travel Motor Crossover Relief Valve Test and Adjustment...........................................................1148 Pump Regulator Test and Adjustment—Minimum Flow...................................................................1151 Pump Regulator Test and Adjustment—Maximum Flow...................................................................1153 Pump Flow Test....................................................................................................1155 Comprehensive Pump Flow Test......................................................................................1158 Control Pressure Pump Flow Test...................................................................................1161 Swing Motor Leakage Test..........................................................................................1164 Travel Motor Leakage Test.........................................................................................1165 Cylinder Drift Test—Boom, Arm, and Bucket.........................................................................1167 Upperstructure Drift Test.........................................................................................1169 Fan Drive Pump Flow Test..........................................................................................1171 Fan Speed Test....................................................................................................1173 Heating and Air Conditioning..............................................................................................1175 Theory of Operation...................................................................................................1177 Air Conditioning System Cycle of Operation........................................................................1177 Diagnostic Information................................................................................................1179 Air Conditioning System Does Not Operate..........................................................................1179 Air Conditioning System Does Not Operate Diagnostic Procedure.................................................1179 Air Conditioning System Does Not Cool Interior of Cab.............................................................1181 Air Conditioning System Does Not Cool Interior of Cab Diagnostic Procedure....................................1181 Air Conditioning System Runs Constantly, Too Cold.................................................................1182 Air Conditioning System Runs Constantly, Too Cold Diagnostic Procedure........................................1182 Heating System Does Not Operate...................................................................................1183 Heating System Does Not Operate Diagnostic Procedure..........................................................1183 Heating System Does Not Warm Interior of Cab......................................................................1184 Heating System Does Not Warm Interior of Cab Diagnostic Procedure.............................................1184 Interior Windows Continue to Fog..................................................................................1186 Interior Windows Continue to Fog Using Heater Diagnostic Procedure............................................1186 Heater and Air Conditioner Component Location.....................................................................1188 Tests.................................................................................................................1191 R134a Refrigerant Cautions and Proper Handling....................................................................1191 R134a Oil Charge Capacity.........................................................................................1191 R134a Refrigerant Charge Capacity.................................................................................1191 Heater and Air Conditioner Operational Checks.....................................................................1192 Visual Inspection of Components...............................................................................1192 Air Conditioner Compressor Clutch Test............................................................................1193 R134a Refrigerant Leak Test.......................................................................................1193 R134a Refrigerant Hoses and Tubing Inspection.....................................................................1194 Air Conditioner High/Low-Pressure Switch Test.....................................................................1195 Air Conditioner Freeze Control Switch Test........................................................................1196 Air Conditioning System Test......................................................................................1197 Operating Pressure Diagnostic Chart...............................................................................1199 Dealer Fabricated Tools...................................................................................................1201 Dealer Fabricated Tools...............................................................................................1203 DFT1218 Split Flange Hose Cap.....................................................................................1203 Page Number................................................................................................................... 7 Section 9000.............................................................................................................. 9 Group 01.............................................................................................................. 11 Section 9001.............................................................................................................. 33 Group 10.............................................................................................................. 35 Group 20.............................................................................................................. 143 Group 30.............................................................................................................. 173 Group 40.............................................................................................................. 175 Group 50.............................................................................................................. 187 Group 60.............................................................................................................. 203 Section 9005.............................................................................................................. 219 Group 10.............................................................................................................. 221 Section 9010.............................................................................................................. 269 Group 05.............................................................................................................. 271 Group 15.............................................................................................................. 293 Group 20.............................................................................................................. 295 Group 25.............................................................................................................. 297 Section 9015.............................................................................................................. 301 Group 05.............................................................................................................. 303 Group 10.............................................................................................................. 311 Group 15.............................................................................................................. 627 Group 16.............................................................................................................. 751 Group 20.............................................................................................................. 765 Section 9020.............................................................................................................. 801 Group 05.............................................................................................................. 803 Group 15.............................................................................................................. 807 Section 9025.............................................................................................................. 815 Group 05.............................................................................................................. 817 Group 15..............................................................................................................1001 Group 25..............................................................................................................1119 Section 9031..............................................................................................................1175 Group 05..............................................................................................................1177 Group 15..............................................................................................................1179 Group 25..............................................................................................................1191 Section 9900..............................................................................................................1201 Group 99..............................................................................................................1203
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