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John Deere 130G Excavator Operation & Test Technical Manual TM13344X19 – PDF DOWNLOAD
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John Deere 130G Excavator Operation & Test Technical Manual TM13344X19 – PDF DOWNLOAD
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Description
John Deere 130G Excavator Operation & Test Technical Manual TM13344X19 – PDF DOWNLOAD
FILE DETAILS:
John Deere 130G Excavator Operation & Test Technical Manual TM13344X19 – PDF DOWNLOAD
Language : English
Pages : 1170
Downloadable : Yes
File Type : PDF
IMAGES PREVIEW OF THE MANUAL:
DESCRIPTION:
John Deere 130G Excavator Operation & Test Technical Manual TM13344X19 – 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 to quickly identify the majority of routine failures quickly.
- Information is organized in groups for the various components requiring service instruction. At the beginning of each group are summary listings of all applicable essential tools, service equipment and tools, other materials needed to do the job, service parts kits, specifications, wear tolerances, and torque values.
- Technical manuals are concise guides for specific machines. They are on-the-job guides containing only the vital information needed for diagnosis, analysis, testing, and repair.
TABLE OF CONTENTS:
John Deere 130G Excavator Operation & Test Technical Manual TM13344X19 – PDF DOWNLOAD
Contents...................................................................................................................... 5 General Information....................................................................................................... 7 Safety................................................................................................................ 9 Recognize Safety Information...................................................................................... 9 Follow Safety Instructions........................................................................................ 9 Operate Only If Qualified......................................................................................... 9 Wear Protective Equipment......................................................................................... 10 Avoid Unauthorized Machine Modifications.......................................................................... 10 Control Pattern Selector—If Equipped.............................................................................. 10 Add Cab Guarding for Special Uses................................................................................. 10 Inspect Machine................................................................................................... 11 Stay Clear of Moving Parts........................................................................................ 11 Avoid High-Pressure Fluids........................................................................................ 11 Avoid High-Pressure Oils.......................................................................................... 12 Work In Ventilated Area........................................................................................... 12 Avoid Static Electricity Risk When Refueling...................................................................... 13 Prevent Fires..................................................................................................... 13 In Case of Machine Fire........................................................................................... 14 Prevent Battery Explosions........................................................................................ 14 Handle Chemical Products Safely................................................................................... 14 Handle Starting Fluid Safely...................................................................................... 15 Decommissioning — Proper Recycling and Disposal of Fluids and Components.......................................... 15 Exhaust Filter Ash Handling and Disposal.......................................................................... 15 Prepare for Emergencies........................................................................................... 16 Clean Debris from Machine......................................................................................... 16 Use Steps and Handholds Correctly................................................................................. 16 Start Only From Operator's Seat................................................................................... 16 Use and Maintain Seat Belt........................................................................................ 17 Prevent Unintended Machine Movement............................................................................... 17 Avoid Work Site Hazards........................................................................................... 18 Keep Riders Off Machine........................................................................................... 18 Avoid Backover Accidents.......................................................................................... 19 Inspect and Maintain ROPS......................................................................................... 19 Avoid Machine Tip Over............................................................................................ 20 Use Special Care When Lifting Objects............................................................................. 20 Travel Safely..................................................................................................... 21 Prevent Acid Burns................................................................................................ 21 Add and Operate Attachments Safely................................................................................ 21 Park and Prepare for Service Safely............................................................................... 22 Service Cooling System Safely..................................................................................... 22 Remove Paint Before Welding or Heating............................................................................ 23 Make Welding Repairs Safely....................................................................................... 23 Drive Metal Pins Safely........................................................................................... 23 Clean Exhaust Filter Safely....................................................................................... 24 Diagnostics............................................................................................................... 31 Main Controller (MCZ) Diagnostic Trouble Codes........................................................................ 33 Main Controller (MCZ) Diagnostic Trouble Codes.................................................................... 33 Controller Area Network 0 (CAN 0) Circuit Diagnostics............................................................. 33 Controller Area Network 1 (CAN 1) Circuit Diagnostics............................................................. 33 Interface Controller Area Network (N-CAN) Diagnostics............................................................. 33 Engine Controller Area Network (Engine CAN) Diagnostics .......................................................... 33 Aftertreatment Controller Area Network (AT CAN) Diagnostics....................................................... 33 011000.02 — Abnormal EEPROM....................................................................................... 33 Abnormal EEPROM Diagnostic Procedure.......................................................................... 34 011001.02 — Abnormal RAM.......................................................................................... 34 Abnormal RAM Diagnostic Procedure............................................................................. 34 011002.02 — Abnormal A/D Converter................................................................................ 35 Abnormal A/D Converter Diagnostic Procedure................................................................... 35 011003.03 — Abnormal Sensor Voltage............................................................................... 35 Abnormal Sensor Voltage Diagnostic Procedure.................................................................. 35 011006.02 — Engine Controller Communication Error................................................................. 36 011007.02 — (CAN 0) Data Converter Communication Error 1.......................................................... 36 011008.02 — (CAN 1) Data Converter Communication Error 2.......................................................... 36 011009.02 — (CAN 0) Monitor Controller Communication Error 1...................................................... 37 011010.02 — (CAN 1) Monitor Controller Communication Error 2...................................................... 37 011100.02 — Abnormal Engine Speed................................................................................. 37 Abnormal Engine Speed Diagnostic Procedure.................................................................... 37 011101.03 — Engine Speed Dial Sensor Circuit High Input........................................................... 37 Engine Speed Dial Sensor Circuit High Input Diagnostic Procedure.............................................. 38 011101.04 — Engine Speed Dial Sensor Circuit Low Input............................................................ 39 Engine Speed Dial Sensor Circuit Low Input Diagnostic Procedure............................................... 39 011200.03 — Pump 1 Delivery Pressure Sensor Circuit High Input.................................................... 40 Pump 1 Delivery Pressure Sensor Circuit High Diagnostics...................................................... 40 011200.04 — Pump 1 Delivery Pressure Sensor Circuit Low Input..................................................... 42 Pump 1 Delivery Pressure Sensor Circuit Low Input Diagnostic Procedure........................................ 42 011202.03 — Pump 2 Delivery Pressure Sensor Circuit High Input.................................................... 44 Pump 2 Delivery Pressure Sensor Circuit High Input Diagnostic Procedure....................................... 44 011202.04 — Pump 2 Delivery Pressure Sensor Circuit Low Input..................................................... 46 Pump 2 Delivery Pressure Sensor Circuit Low Input Diagnostic Procedure........................................ 46 011206.03 — Pump 1 Flow Control Pressure Sensor Circuit High Input................................................ 48 Pump 1 Flow Control Pressure Sensor Circuit High Input Diagnostic Procedure................................... 48 011206.04 — Pump 1 Flow Control Pressure Sensor Circuit Low Input................................................. 49 Pump 1 Flow Control Pressure Sensor Circuit Low Input Diagnostic Procedure.................................... 49 011208.03 — Pump 2 Flow Control Pressure Sensor Circuit High Input................................................ 51 Pump 2 Flow Control Pressure Sensor Circuit High Input Diagnostic Procedure................................... 51 011208.04 — Pump 2 Flow Control Pressure Sensor Circuit Low Input................................................. 52 Pump 2 Flow Control Pressure Sensor Circuit Low Input Diagnostic Procedure.................................... 52 011301.03 — Swing Pressure Sensor Circuit High Input.............................................................. 54 Swing Pilot Pressure Sensor Circuit High Input Diagnostic Procedure........................................... 54 011301.04 — Swing Pilot Pressure Sensor Circuit Low Input......................................................... 55 Swing Pilot Pressure Sensor Circuit Low Input Diagnostic Procedure............................................ 55 011302.03 — Boom Up Pilot Pressure Sensor Circuit High Input...................................................... 57 Boom Up Pilot Pressure Sensor Circuit High Input Diagnostic Procedure......................................... 57 011302.04 — Boom Up Pilot Pressure Sensor Circuit Low Input....................................................... 58 Boom Up Pilot Pressure Sensor Circuit Low Input Diagnostic Procedure.......................................... 58 011303.03 — Arm In Pressure Sensor Circuit High Input............................................................. 59 Arm In Pilot Pressure Sensor Circuit High Input Diagnostic Procedure.......................................... 60 011303.04 — Arm In Pressure Sensor Circuit Low Input.............................................................. 61 Arm In Pilot Pressure Sensor Circuit Low Input Diagnostic Procedure........................................... 61 011304.03 — Travel Pilot Pressure Sensor Circuit High Input....................................................... 62 Travel Pilot Pressure Sensor Circuit High Input Diagnostic Procedure.......................................... 62 011304.04 — Travel Pilot Pressure Sensor Circuit Low Input........................................................ 64 Travel Pilot Pressure Sensor Circuit Low Input Diagnostic Procedure........................................... 64 011307.03 — Front Attachment Pilot Pressure Sensor Circuit High Input............................................. 65 Front Attachment Pilot Pressure Sensor Circuit High Input Diagnostic Procedure................................ 65 011307.04 — Front Attachment Pilot Pressure Sensor Circuit Low Input.............................................. 67 Front Attachment Pilot Pressure Sensor Circuit Low Input Diagnostic Procedure................................. 67 011325.03 — Bucket Roll-In Pilot Pressure Sensor Circuit High Input............................................... 68 Bucket Roll-In Pilot Pressure Sensor Circuit High Input Diagnostic Procedure.................................. 68 011325.04 — Bucket Roll-In Pilot Pressure Sensor Circuit Low Input................................................ 69 Bucket Roll-In Pilot Pressure Sensor Circuit Low Input Diagnostic Procedure................................... 69 011400.02 — Pump 2 Flow Rate Limit Solenoid Feedback Abnormal..................................................... 71 Pump 2 Flow Rate Limit Solenoid Feedback Abnormal Diagnostic Procedure........................................ 71 011400.03 — Pump 2 Flow Rate Limit Solenoid Feedback High Current................................................. 73 Pump 2 Flow Rate Limit Solenoid Valve Feedback High Current Diagnostic Procedure.............................. 73 011400.04 — Pump 2 Flow Rate Limit Solenoid Feedback Low Current.................................................. 75 Pump 2 Flow Rate Limit Solenoid Valve Feedback Low Current Diagnostic Procedure............................... 75 011401.02 — Torque Control Solenoid Abnormal Feedback............................................................. 76 Torque Control Solenoid Abnormal Feedback Diagnostic Procedure................................................ 76 011401.03 — Torque Control Solenoid Feedback High Current......................................................... 78 Torque Control Solenoid Feedback High Current Diagnostic Procedure............................................ 78 011401.04 — Torque Control Solenoid Valve Feedback Low Current.................................................... 80 Torque Control Solenoid Valve Feedback Low Current Diagnostic Procedure....................................... 80 011402.02 — Dig Regenerative Solenoid Feedback Current Abnormal................................................... 81 Dig Regenerative Solenoid Feedback Current Abnormal Diagnostic Procedure...................................... 81 011402.03 — Dig Regenerative Solenoid Feedback Current High....................................................... 83 Dig Regenerative Solenoid Feedback Current High Diagnostic Procedure.......................................... 83 011402.04 — Dig Regenerative Solenoid Feedback Current Low........................................................ 85 Dig Regenerative Solenoid Feedback Current Low Diagnostic Procedure........................................... 85 011403.02 — Arm Regenerative Solenoid Feedback Current Abnormal................................................... 86 Arm Regenerative Solenoid Feedback Current Abnormal Diagnostic Procedure...................................... 86 011403.03 — Arm Regenerative Solenoid Feedback Current High....................................................... 88 Arm Regenerative Solenoid Feedback Current High Diagnostic Procedure.......................................... 88 011403.04 — Arm Regenerative Solenoid Feedback Current Low........................................................ 90 Arm Regenerative Solenoid Feedback Current Low Diagnostic Procedure........................................... 90 011407.02 — Power Dig/Travel Speed Solenoid Feedback Current Abnormal............................................. 91 Power Dig/Travel Speed Solenoid Feedback Current Abnormal Diagnostic Procedure................................ 91 011407.03 — Power Dig/Travel Speed Solenoid Feedback Current High................................................. 93 Power Dig/Travel Speed Solenoid Feedback Current High Diagnostic Procedure.................................... 93 011407.04 — Power Dig/Travel Speed Solenoid Feedback Current Low.................................................. 95 Power Dig/Travel Speed Solenoid Feedback Current Low Diagnostic Procedure..................................... 95 011408.02 — Exhaust Aftertreatment Solenoid Valve Feedback Current Abnormal....................................... 96 011408.03 — Exhaust Aftertreatment Solenoid Valve Feedback Current High........................................... 96 011408.04 — Exhaust Aftertreatment Solenoid Valve Feedback Current Low............................................ 97 011409.02 — Exhaust Aftertreatment Solenoid Valve Feedback Current Abnormal....................................... 97 011409.03 — Exhaust Aftertreatment Solenoid Valve Feedback Current High........................................... 97 011409.04 — Exhaust Aftertreatment Solenoid Valve Feedback Current Low............................................ 97 011410.02 — Pump 1 Flow Rate Limit Solenoid Valve Feedback Abnormal............................................... 97 Pump 1 Flow Rate Limit Solenoid Valve Feedback Abnormal Diagnostic Procedure.................................. 97 011410.03 — Pump 1 Flow Rate Limit Solenoid Valve Feedback High Input............................................. 99 Pump 1 Flow Rate Limit Solenoid Valve Feedback High Input Diagnostic Procedure................................ 99 011410.04 — Pump 1 Flow Rate Limit Solenoid Valve Feedback Low Input.............................................. 101 Pump 1 Flow Rate Limit Solenoid Valve Feedback Low Input Diagnostic Procedure................................. 101 011428.02 — Arm 2 Flow Rate Control Solenoid Valve Feedback Abnormal.............................................. 103 Arm 2 Flow Rate Control Solenoid Valve Feedback Abnormal Diagnostic Procedure................................. 103 011428.03 — Arm 2 Flow Rate Control Solenoid Valve Feedback High Input............................................ 105 Arm 2 Flow Rate Control Solenoid Valve Feedback High Input Diagnostic Procedure............................... 105 011428.04 — Arm 2 Flow Rate Control Solenoid Valve Feedback Low Input............................................. 107 Arm 2 Flow Rate Control Solenoid Valve Feedback Low Input Diagnostic Procedure................................ 107 011434.02 — Attachment Relief 1 (Upper) Proportional Solenoid Valve Abnormal Feedback............................. 108 011434.03 — Attachment Relief 1 (Upper) Proportional Solenoid Valve Feedback High Current......................... 108 011434.04 — Attachment Relief 1 (Upper) Proportional Solenoid Valve Feedback Low Current.......................... 109 011435.02 — Attachment Relief 2 (Lower) Proportional Solenoid Valve Abnormal Feedback............................. 109 011435.03 — Attachment Relief 2 (Lower) Proportional Solenoid Valve Feedback High Current......................... 109 011435.04 — Attachment Relief 2 (Lower) Proportional Solenoid Valve Feedback Low Current.......................... 109 011436.02 — Breaker Relief Proportional Solenoid Valve Abnormal Feedback.......................................... 109 011436.03 — Breaker Relief Proportional Solenoid Valve Feedback High Current...................................... 109 011436.04 — Breaker Relief Proportional Solenoid Valve Feedback Low Current....................................... 109 011457.02 — 2-Speed Activation Solenoid Valve Disconnected........................................................ 109 2-Speed Activation Solenoid Valve Disconnected Diagnostic Procedure........................................... 109 011458.02 — Selector Valve Solenoid Valve Disconnected............................................................ 111 Selector Valve Solenoid Valve Disconnected Diagnostic Procedure............................................... 111 011459.02 — Idle Stop Relay Circuit Malfunction................................................................... 113 Idle Stop Relay Circuit Malfunction Diagnostic Procedure...................................................... 113 011810.03 — Electric Lever Operating Pressure Sensor 1 High Voltage............................................... 114 Auxiliary Function Lever (AFL) Solenoid Pressure Sensor (marked PS1) (B85) High Input Diagnostic Procedure.... 114 011810.04 — Electric Lever Operating Pressure Sensor 1 Low Voltage................................................ 115 Auxiliary Function Lever (AFL) Solenoid Pressure Sensor (marked PS1) (B85) Low Input Diagnostic Procedure..... 115 011812.02 — OPT Electric Lever 1 Neutral Abnormal................................................................. 117 OPT Electric Lever 1 Neutral Abnormal Diagnostic Procedure.................................................... 117 011813.02 — OPT Electric Lever 1 Abnormal Operation............................................................... 118 OPT Electric Lever 1 Abnormal Operation Diagnostic Procedure.................................................. 118 011816.02 — OPT Solenoid 1 Feedback Abnormal...................................................................... 119 Auxiliary Function Lever (AFL) Solenoid A (marked 1A) (Y61) Abnormal Feedback Diagnostic Procedure............ 119 011816.03 — OPT Solenoid 1 Feedback Current High.................................................................. 121 Auxiliary Function Lever (AFL) Solenoid A (marked 1A) (Y61) Feedback High Current Diagnostic Procedure........ 121 011816.04 — OPT Solenoid 1 Feedback Current Low................................................................... 123 Auxiliary Function Lever (AFL) Solenoid A (marked 1A) (Y61) Feedback Low Current Diagnostic Procedure......... 123 011817.02 — OPT Solenoid 2 Feedback Abnormal...................................................................... 125 Auxiliary Function Lever (AFL) Solenoid B (marked 1B) (Y62) Abnormal Feedback Diagnostic Procedure............ 125 011817.03 — OPT Solenoid 2 Feedback Current High.................................................................. 126 Auxiliary Function Lever (AFL) Solenoid B (marked 1B) (Y62) Feedback High Current Diagnostic Procedure........ 127 011817.04 — OPT Solenoid 2 Feedback Current Low................................................................... 128 Auxiliary Function Lever (AFL) Solenoid B (marked 1B) (Y62) Feedback Low Current Diagnostic Procedure......... 128 011901.03 — Hydraulic Oil Temperature Sensor Circuit High Input................................................... 130 Hydraulic Oil Temperature Sensor Circuit High Input Diagnostic Procedure...................................... 130 011901.04 — Hydraulic Oil Temperature Sensor Circuit Low Input.................................................... 131 Hydraulic Oil Temperature Sensor Circuit Low Input Diagnostic Procedure....................................... 131 011995.03 — Arm Roll-Out Pilot Pressure Sensor Circuit High Input................................................. 132 Arm Roll-Out Pressure Sensor Circuit High Diagnostic Procedure................................................ 132 011995.04 — Arm Roll-Out Pilot Pressure Sensor Circuit Low Input.................................................. 134 Arm Roll-Out Pilot Pressure Sensor Circuit Low Input Diagnostic Procedure..................................... 134 011997.03 — Bucket Roll-Out Pressure Sensor Circuit High.......................................................... 135 Bucket Roll-Out Pressure Sensor Circuit High Diagnostic Procedure............................................. 135 011997.04 — Bucket Roll-Out Pressure Sensor Circuit Low........................................................... 137 Bucket Roll-Out Pressure Sensor Circuit Low Diagnostic Procedure.............................................. 137 015011.03 — Hydraulic Oil Temperature Sensor Circuit High Input (Pilot).......................................... 138 Secondary Hydraulic Oil Temperature Sensor Circuit High Input Diagnostic Procedure............................ 138 015011.04 — Hydraulic Oil Temperature Sensor Circuit Low Input (Pilot)........................................... 140 Secondary Hydraulic Oil Temperature Sensor Circuit Low Input Diagnostic Procedure............................. 140 015016.03 — Right Analog Stroke Sensor Circuit High Input......................................................... 141 Auxiliary Function Lever (AFL) Proportional Control Switch Sensor Circuit High Input Diagnostic Procedure..... 141 015016.04 — Right Analog Stroke Sensor Circuit Low Input.......................................................... 142 Auxiliary Function Lever (AFL) Proportional Control Switch Sensor Circuit Low Input Diagnostic Procedure...... 142 020010.02 — Abnormal Exhaust Filter............................................................................... 143 Abnormal Exhaust Filter Diagnostic Procedure.................................................................. 143 020011.02 — Electric Lever Alarm.................................................................................. 144 Electric Control Lever Alarm Diagnostic Procedure............................................................. 144 020062.02 — Hydraulic Oil Temperature Alarm....................................................................... 144 020303.02 — Electric Lever Pilot Cut Alarm........................................................................ 144 Electric Control Lever Alarm Diagnostic Procedure............................................................. 144 Engine Control Unit (ECU) Diagnostic Trouble Codes.................................................................... 147 Engine Control Unit (ECU) Diagnostic Trouble Codes................................................................ 147 000111.07 — Coolant Level Low—Moderately Severe Level............................................................. 147 Coolant Level Low—Moderately Severe Level Diagnostic Procedure................................................ 147 000647.05 — Variable Speed Fan Solenoid Open Circuit.............................................................. 148 Variable Speed Fan Solenoid Open Circuit Diagnostic Procedure................................................. 148 000647.06 — Variable Speed Fan Solenoid High Current.............................................................. 149 Variable Speed Fan Solenoid High Current Diagnostic Procedure................................................. 149 001639.01 — Fan Speed Low—Most Severe Level....................................................................... 150 Fan Speed Low—Most Severe Level Diagnostic Procedure.......................................................... 150 001761.01 — Diesel Exhaust Fluid Extremely Low.................................................................... 151 001761.18 — Diesel Exhaust Fluid Very Low......................................................................... 152 001639.18 — Fan Speed Low—Moderately Severe Level................................................................. 152 002030.09 — (CAN 0) Flex Power Controller Communication Error..................................................... 152 002228.09 — (CAN 0) Main Controller (MCZ) Communication Error..................................................... 152 003031.12 — Diesel Exhaust Fluid Temperature Sensor Fault......................................................... 152 003353.31 — Alternator Excitation Fault........................................................................... 153 Alternator Excitation Fault Diagnostic Procedure.............................................................. 153 003516.01 — Diesel Exhaust Fluid Concentration Extremely Low...................................................... 154 003516.07 — Diesel Exhaust Fluid Concentration Invalid............................................................ 154 003516.09 — Diesel Exhaust Fluid Tank Header Communication Fault.................................................. 155 003516.12 — Diesel Exhaust Fluid Concentration Sensor Fault....................................................... 155 003517.12 — Diesel Exhaust Fluid Tank Level Sensor Fault.......................................................... 155 003719.15 — Calculated Soot Level Slightly High................................................................... 156 004366.05 — DEF Tank Heater Coolant Control Valve Circuit Has High Resistance..................................... 156 Diagnostic Procedure.......................................................................................... 157 004366.06 — DEF Tank Heater Coolant Control Valve Circuit Has Low Resistance...................................... 160 Diagnostic Procedure.......................................................................................... 160 004366.16 — DEF Tank Temperature Moderately High.................................................................. 164 Diagnostic Procedure.......................................................................................... 164 004366.18 — DEF Tank Insufficient Heating Fault................................................................... 167 Diagnostic Procedure.......................................................................................... 168 520956.06 — Battery Disconnect Indicator Light Short to Ground.................................................... 170 Battery Disconnect Indicator Light Short to Ground Diagnostic Procedure....................................... 170 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.................................................................................................................... 267 Theory of Operation................................................................................................... 269 Engine Identification............................................................................................. 269 John Deere Engine................................................................................................. 269 Engine Fuel System Component Location............................................................................. 271 Engine Cooling System Component Location.......................................................................... 275 Diesel Exhaust Fluid (DEF) System Component Location.............................................................. 282 Cold Weather Starting Aid......................................................................................... 285 Engine Speed Control System Operation............................................................................. 286 Diagnostic Information................................................................................................ 291 John Deere Engine................................................................................................. 291 Adjustments........................................................................................................... 293 John Deere Engine................................................................................................. 293 Tests................................................................................................................. 295 John Deere Engine................................................................................................. 295 Electrical System......................................................................................................... 299 System Information.................................................................................................... 301 Electrical Diagram Information.................................................................................... 301 System Diagrams....................................................................................................... 309 Explanation of Wire Markings...................................................................................... 309 Fuse and Relay Specifications..................................................................................... 309 System Functional Schematic, Component Location, and Wiring Diagram Master Legend................................. 313 System Functional Schematic....................................................................................... 321 Cab Harness (W1) Component Location............................................................................... 387 Cab Harness (W1) Wiring Diagram................................................................................... 395 Machine Harness (W2) Component Location........................................................................... 427 Machine Harness (W2) Wiring Diagram............................................................................... 431 Monitor Harness (W3) Component Location........................................................................... 450 Monitor Harness (W3) Wiring Diagram............................................................................... 452 Engine Harness (W4) Component Location............................................................................ 455 Engine Harness (W4) Wiring Diagram................................................................................ 459 Engine Interface Harness (W5) Component Location.................................................................. 467 Engine Interface Harness (W5) Wiring Diagram...................................................................... 475 Pump Harness (W8) Component Location.............................................................................. 495 Pump Harness (W8) Wiring Diagram.................................................................................. 498 Exhaust Filter Parked Cleaning Switch Harness (W9) Component Location............................................. 499 Exhaust Filter Parked Cleaning Switch Harness (W9) Wiring Diagram................................................. 499 Service ADVISOR™ Remote (SAR) Harness (W10) Component Location.................................................... 499 Service ADVISOR™ Remote (SAR) Switch Harness (W10) Wiring Diagram................................................. 500 Pilot Shutoff Switch Harness (W11) Component Location............................................................. 501 Pilot Shutoff Switch Harness (W11) Wiring Diagram................................................................. 503 Heated Air Seat Harness (W14) Component Location.................................................................. 506 Heated Air Seat Harness (W14) Wiring Diagram...................................................................... 507 Multi-Function Pilot Control Lever Harness (W15) Component Location............................................... 508 Multi-Function Pilot Control Lever Harness (W15) Wiring Diagram................................................... 511 Travel Alarm Cancel Switch Harness (W16) Component Location....................................................... 513 Travel Alarm Cancel Switch Harness (W16) Wiring Diagram........................................................... 513 Attachment Harness (W17) Component Location....................................................................... 514 Attachment Harness (W17) Wiring Diagram........................................................................... 515 Rear Camera Harness (W19) Component Location...................................................................... 518 Rear Camera Harness (W19) Wiring Diagram.......................................................................... 519 Pilot Shutoff Valve Harness (W21) Component Location.............................................................. 520 Pilot Shutoff Valve Harness (W21) Wiring Diagram.................................................................. 521 Auxiliary 3-Button Cancel Switch Harness (W22) Component Location................................................. 521 Auxiliary 3-Button Cancel Switch Harness (W22) Wiring Diagram..................................................... 522 Seat Heater Switch Harness (W24) Component Location............................................................... 522 Seat Heater Switch Harness (W24) Wiring Diagram................................................................... 523 Attachment Interface Harness (W25) Component Location—If Equipped................................................. 524 Attachment Interface Harness (W25) Wiring Diagram—If Equipped..................................................... 525 Travel Alarm Harness (W26) Component Location..................................................................... 526 Travel Alarm Harness (W26) Wiring Diagram......................................................................... 527 Starter Switch Harness (W29) Component Location................................................................... 527 Starter Switch Harness (W29) Wiring Diagram....................................................................... 528 Attachment Pressure Sensor Harness (W31) Component Location....................................................... 528 Attachment Pressure Sensor Harness (W31) Wiring Diagram........................................................... 529 2-Speed Harness (W32) Component Location.......................................................................... 530 2-Speed Harness (W32) Wiring Diagram.............................................................................. 532 Fuel Injector Harness (W38) Component Location.................................................................... 534 Fuel Injector Harness (W38) Wiring Diagram........................................................................ 535 Glow Plug Harness (W40) Component Location........................................................................ 539 Glow Plug Harness (W40) Wiring Diagram............................................................................ 542 Heater and Air Conditioner Harness (W41) Component Location....................................................... 543 Heater and Air Conditioner Harness (W41) Wiring Diagram........................................................... 545 Cab Roof Light Harness (W44) Component Location................................................................... 547 Cab Roof Light Harness (W44) Wiring Diagram....................................................................... 548 Cab Roof Light Jumper Harness (W45) Component Location............................................................ 548 Cab Roof Light Jumper Harness (W45) Wiring Diagram................................................................ 549 Cab Roof Light 1 Relay Harness (W46) Component Location........................................................... 549 Cab Roof Light 1 Relay Harness (W46) Wiring Diagram............................................................... 550 Cab Roof Light 2 Relay Harness (W47) Component Location........................................................... 550 Cab Roof Light 2 Relay Harness (W47) Wiring Diagram............................................................... 551 Heater and Air Conditioner Relay Harness (W51) Component Location................................................. 552 Heater and Air Conditioner Relay Harness (W51) Wiring Diagram..................................................... 554 Exhaust Aftertreatment Harness (W53) Component Location........................................................... 556 Exhaust Aftertreatment Harness (W53) Wiring Diagram............................................................... 557 Diesel Exhaust Fluid (DEF) Harness (W54) Component Location....................................................... 561 Diesel Exhaust Fluid (DEF) Harness (W54) Wiring Diagram........................................................... 569 Engine Light Harness (W58) Component Location..................................................................... 576 Engine Light Harness (W58) Wiring Diagram......................................................................... 577 Auxiliary Solenoid Harness (W61) Component Location............................................................... 579 Auxiliary Solenoid Harness (W61) Wiring Diagram................................................................... 580 Diesel Particulate Filter (DPF) Harness (W62) Component Location.................................................. 582 Diesel Particulate Filter (DPF) Harness (W62) Wiring Diagram...................................................... 583 Auxiliary Function Lever (AFL) Harness (W75) Component Location................................................... 588 Auxiliary Function Lever (AFL) Harness (W75) Wiring Diagram....................................................... 591 Auxiliary Function Lever (AFL) Solenoid Harness (W76) Component Location.......................................... 595 Auxiliary Function Lever (AFL) Solenoid Harness (W76) Wiring Diagram.............................................. 598 USB Harness (W82) Component Location.............................................................................. 599 USB Harness (W82) Wiring Diagram.................................................................................. 599 USB Jumper Harness (W83) Component Location....................................................................... 599 USB Jumper Harness (W83) Wiring Diagram........................................................................... 600 Rear Cab Light Switch Harness (W84) Component Location............................................................ 601 Rear Cab Light Switch Harness (W84) Wiring Diagram................................................................ 602 Rear Cab Light Relay Harness (W85) Component Location............................................................. 602 Rear Cab Light Relay Harness (W85) Wiring Diagram................................................................. 603 Rear Cab Light Harness (W86) Component Location................................................................... 603 Rear Cab Light Harness (W86) Wiring Diagram....................................................................... 604 Premium Seat Harness (W87) Component Location..................................................................... 605 Premium Seat Harness (W87) Wiring Diagram......................................................................... 607 Satellite (SAT) Harness (W6003) Component Location................................................................ 609 Satellite (SAT) Harness (W6003) Wiring Diagram.................................................................... 609 Sub-System Diagnostics................................................................................................ 611 Controller Area Network (CAN) Theory of Operation................................................................. 611 Starting and Charging Circuit Theory of Operation................................................................. 619 Monitor Controller (DSZ) Circuit Theory of Operation.............................................................. 629 Engine Control Unit (ECU) Circuit Theory of Operation............................................................. 639 Exhaust Aftertreatment Circuit Theory of Operation................................................................ 670 Main Controller (MCZ) Circuit Theory of Operation................................................................. 685 Travel Alarm Circuit Theory of Operation.......................................................................... 702 Machine Controller (BCZ) Circuit Theory of Operation.............................................................. 703 Windshield Wiper and Washer Circuit Theory of Operation........................................................... 705 Lighting Circuit Theory of Operation.............................................................................. 709 Pilot Shutoff Circuit Theory of Operation......................................................................... 717 Attachment Control Circuit Theory of Operation.................................................................... 720 Monitor Operation..................................................................................................... 729 Service Menu...................................................................................................... 729 Troubleshooting................................................................................................... 729 Monitoring........................................................................................................ 730 Controller Version................................................................................................ 733 Issued Warning Record............................................................................................. 733 Operation......................................................................................................... 734 Machine Setting................................................................................................... 735 Monitor Setting................................................................................................... 739 Alarm Setting..................................................................................................... 741 Exhaust Filter No................................................................................................. 741 References............................................................................................................ 743 Reading Diagnostic Trouble Codes with Monitor Display............................................................. 743 Service ADVISOR™ Diagnostic Application........................................................................... 743 Service ADVISOR™ Connection Procedure............................................................................. 744 Reading Diagnostic Trouble Codes with Service ADVISOR™ Diagnostic Application..................................... 745 MPDr Application.................................................................................................. 747 MPDr Connection Procedure......................................................................................... 748 Controller Area Network (CAN) Circuit Test........................................................................ 749 Controller Area Network (CAN) Diagnostics .................................................................... 756 Electrical Component Specifications............................................................................... 759 Alternator Test................................................................................................... 762 Electrical Component Checks....................................................................................... 763 Component Checks.............................................................................................. 763 Battery Remove and Install........................................................................................ 772 Rear Cover Remove and Install..................................................................................... 774 Main Controller (MCZ) Remove and Install.......................................................................... 776 Monitor Controller (DSZ) Remove and Install....................................................................... 777 Heater Control Disable and Enable................................................................................. 777 Power Train............................................................................................................... 779 Theory of Operation................................................................................................... 781 Track Adjuster and Recoil Spring Operation........................................................................ 781 Travel Gear Case Operation........................................................................................ 782 Diagnostic Information................................................................................................ 783 Noisy or Loose Track Chain........................................................................................ 783 Noisy or Loose Track Chain Diagnostic Procedure............................................................... 783 Tight Track Chain................................................................................................. 783 Tight Track Chain Diagnostic Procedure........................................................................ 783 Frequent Track Chain Sag Adjustment Required...................................................................... 784 Frequent Track Chain Sag Adjustment Required Diagnostic Procedure............................................. 784 Excessive Oil Leakage From Front Idler, Track Rollers, or Carrier Rollers......................................... 784 Excessive Oil Leakage From Front Idler, Track Rollers, or Carrier Rollers Diagnostic Procedure................ 784 Bent Track Shoes.................................................................................................. 784 Bent Track Shoes Diagnostic Procedure......................................................................... 784 “Popping” of Track................................................................................................ 785 “Popping” of Track Diagnostic Procedure....................................................................... 785 Cracked Track Link................................................................................................ 785 Cracked Track Link Diagnostic Procedure....................................................................... 785 Chipped Link Rails................................................................................................ 786 Chipped Link Rails Diagnostic Procedure....................................................................... 786 Individual Undercarriage Component Wear........................................................................... 787 Individual Undercarriage Component Wear Diagnostic Procedure.................................................. 787 Measure Swing Bearing Wear........................................................................................ 788 Hydraulic System.......................................................................................................... 791 Theory of Operation................................................................................................... 793 Hydraulic System Operation........................................................................................ 793 Pilot System Operation............................................................................................ 793 Pilot Pump, Pressure Regulating Valve, and Filter Operation....................................................... 794 Pilot Shutoff Solenoid Valve Operation............................................................................ 795 Pilot Control Valve Operation..................................................................................... 798 Travel Pilot Control Valve Operation.............................................................................. 800 Single Pedal Travel Operation—If Equipped......................................................................... 802 Pilot Operation of Control Valve Operation........................................................................ 804 Pilot Signal Manifold Operation................................................................................... 805 Pump 1, Pump 2, and Drive Gear Case Operation..................................................................... 816 Pump 1 and Pump 2 Regulator Operation............................................................................. 820 Engine Speed Sensing Control Circuit Operation.................................................................... 828 Control Valve Operation........................................................................................... 830 Control Valve Check Valves Identification and Operation........................................................... 843 Main Relief Valve Circuit Operation............................................................................... 847 Circuit Relief and Anticavitation Valve Operation................................................................. 850 Travel Flow Combiner Valve Operation.............................................................................. 853 Auxiliary Flow Combiner Valve and Bypass Shutoff Valve Operation.................................................. 857 Boom Lower Meter-In Cut Valve Operation........................................................................... 861 Boom Regenerative Valve Circuit Operation......................................................................... 864 Dig Regenerative Valve Circuit Operation.......................................................................... 865 Arm Regenerative Valve Circuit Operation.......................................................................... 871 Bucket Regenerative Valve Circuit Operation....................................................................... 877 Boom and Arm Reduced Leakage Valves Operation..................................................................... 878 Arm 1 Flow Rate Control Valve Circuit Operation................................................................... 881 Arm 2 Flow Rate Control Valve Circuit Operation................................................................... 887 Bucket Flow Rate Control Valve Circuit Operation.................................................................. 893 Boom Flow Rate Control Valve Circuit Operation.................................................................... 899 Auxiliary Flow Rate Control Valve Circuit Operation............................................................... 905 Blade Circuit Operation—If Equipped............................................................................... 911 Swing Reduction Gear Case Operation............................................................................... 914 Swing Motor, Crossover Relief Valve, and Make-Up Check Valve Operation............................................ 915 Swing Motor Park Brake Release Circuit Operation.................................................................. 918 Center Joint Operation............................................................................................ 920 Travel Motor and Park Brake Valve Operation....................................................................... 922 Travel Motor Speed Circuit Operation.............................................................................. 929 Cylinder Operation................................................................................................ 933 Return Filter Operation........................................................................................... 934 Auxiliary System Operation........................................................................................ 934 Auxiliary Pilot Control Valve Operation........................................................................... 935 Flow Rate Select Solenoid Valve Operation......................................................................... 946 Flow Rate Pressure Reducing Valve Operation....................................................................... 947 Selector Valve Solenoid Valve Operation........................................................................... 947 Selector Valve Operation.......................................................................................... 948 Auxiliary Shuttle Valve Operation................................................................................. 948 Auxiliary High Flow Line Kit Operation............................................................................ 949 Two Way Solenoid Kit Operation.................................................................................... 953 Two Pump Combined Flow Kit Operation.............................................................................. 957 Diagnostic Information................................................................................................ 963 All Hydraulic Functions Slow...................................................................................... 963 All Hydraulic Functions Slow Diagnostic Procedure............................................................. 963 Hydraulic Oil Overheats........................................................................................... 964 Hydraulic Oil Overheats Diagnostic Procedure.................................................................. 964 No Hydraulic Functions............................................................................................ 965 No Hydraulic Functions Diagnostic Procedure................................................................... 966 No Hydraulic Functions—Electrical Checks.......................................................................... 967 No Hydraulic Functions—Electrical Checks Diagnostic Procedure................................................. 967 Function Does Not Stop When Control Lever Released................................................................ 969 Function Does Not Stop When Control Lever Released Diagnostic Procedure....................................... 969 Load Drifts Down When Control Lever is in Neutral Position........................................................ 970 Load Drifts Down When Control Lever is in Neutral Position Diagnostic Procedure............................... 970 Load Falls When Control Valve is Actuated to Raise Load........................................................... 972 Load Falls When Control Valve is Actuated to Raise Load Diagnostic Procedure.................................. 972 H/P (High Power) Function Does Not Operate, PWR (Power) Mode is Normal............................................ 972 H/P (High Power) Function Does Not Operate, PWR (Power) Mode is Normal Diagnostic Procedure................... 972 Boom Down Does Not Function, Moves Slowly, or is Erratic, All Other Functions Normal.............................. 974 Boom Down Does Not Function, Moves Slowly, or is Erratic, All Other Functions Normal Diagnostic Procedure..... 974 Arm In Does Not Function, Moves Slowly, or is Erratic, All Other Functions Normal................................. 975 Arm In Does Not Function, Moves Slowly, or is Erratic, All Other Functions Normal Diagnostic Procedure........ 975 Swing Speed Slow During Arm In Function........................................................................... 976 Swing Speed Slow During Arm In Function Diagnostic Procedure.................................................. 976 Boom Cannot Raise Track Off Ground................................................................................ 976 Boom Cannot Raise Track Off Ground Diagnostic Procedure....................................................... 976 Swing Function Does Not Operate in Both Directions................................................................ 978 Swing Function Does Not Operate in Both Directions Diagnostic Procedure....................................... 978 Swing Speed Slow in Both Directions............................................................................... 980 Swing Speed Slow in Both Directions Diagnostic Procedure...................................................... 980 Swing Speed Slow or Does Not Operate in One Direction............................................................. 981 Swing Speed Slow or Does Not Operate in One Direction Diagnostic Procedure.................................... 981 Upperstructure Drift with Swing Valve in Neutral.................................................................. 982 Upperstructure Drift with Swing Valve in Neutral Diagnostic Procedure......................................... 982 Machine Freewheels Down an Incline................................................................................ 984 Machine Freewheels Down an Incline Diagnostic Procedure....................................................... 984 Track Will Not Move in Either Direction........................................................................... 984 Track Will Not Move in Either Direction Diagnostic Procedure.................................................. 984 Machine Mistracks................................................................................................. 986 Machine Mistracks Diagnostic Procedure........................................................................ 986 Machine Mistracks Left During Combined Travel and Dig Functions................................................... 988 Machine Mistracks Left During Combined Travel and Dig Functions Diagnostic Procedure.......................... 988 Machine Will Not Shift Into Fast (rabbit) Speed................................................................... 988 Machine Will Not Shift Into Fast (rabbit) Speed Diagnostic Procedure.......................................... 989 Pump 1, Pump 2, and Pilot Pump Line Identification................................................................ 992 Control Valve Line Identification................................................................................. 993 Swing Motor Line Identification................................................................................... 995 Pilot Control Valve-to-Pilot Signal Manifold Component Location—Excavator Pattern................................. 997 Pilot Control Valve-to-Pilot Signal Manifold Component Location—Backhoe Pattern...................................1001 Pilot Signal Manifold-to-Control Valve Line Connection............................................................1004 Pilot Control Lever Pattern Selector Valve Line Connection—If Equipped............................................1008 Travel System Component Location..................................................................................1008 Travel Hydraulic System Line Connections..........................................................................1009 Blade Hydraulic System Component Location.........................................................................1017 Auxiliary Attachment Schematic....................................................................................1021 Auxiliary System Line Connections.................................................................................1037 Hydraulic System Schematic........................................................................................1045 Hydraulic System Component Location...............................................................................1064 Hydraulic System Line Connections.................................................................................1065 Tests.................................................................................................................1069 JT05800 Digital Thermometer Installation..........................................................................1069 JT02156A Digital Pressure and Temperature Analyzer Kit Installation...............................................1069 General Hydraulic Oil Cleanup Procedure...........................................................................1070 Hydraulic Component Failure Cleanup Procedure.....................................................................1072 Hydraulic Oil Tank Pressure Release Procedure.....................................................................1073 Hydraulic Oil Warm-Up Procedure...................................................................................1074 Pilot Pressure Regulating Valve Test and Adjustment...............................................................1076 Control Valve Spool Actuating Pilot Pressure Test.................................................................1078 Dig Regenerative Solenoid Valve Test and Adjustment...............................................................1080 Arm Regenerative Solenoid Valve Test and Adjustment...............................................................1082 Power Dig/Travel Speed Solenoid Valve Test and Adjustment.........................................................1084 Arm 2 Flow Control Solenoid Valve Test and Adjustment.............................................................1086 Torque Control Solenoid Valve Test and Adjustment.................................................................1088 Pump Control Pilot Pressure Signal Test...........................................................................1090 Main Relief and Power Dig Valve Test and Adjustment...............................................................1091 Circuit Relief Valve Test and Adjustment..........................................................................1095 Blade Main Relief Valve Test and Adjustment.......................................................................1098 Blade Circuit Relief Valve Test and Adjustment....................................................................1100 Swing Motor Crossover Relief Valve Test and Adjustment............................................................1102 Travel Motor Crossover Relief Valve Test and Adjustment...........................................................1104 Pump Regulator Test and Adjustment—Minimum Flow...................................................................1107 Pump Regulator Test and Adjustment—Maximum Flow...................................................................1109 Pump Flow Test....................................................................................................1111 Comprehensive Pump Flow Test......................................................................................1114 Control Pressure Pump Flow Test...................................................................................1117 Swing Motor Leakage Test..........................................................................................1120 Travel Motor Leakage Test.........................................................................................1121 Cylinder Drift Test—Boom, Arm, and Bucket.........................................................................1123 Upperstructure Drift Test.........................................................................................1125 Heating and Air Conditioning..............................................................................................1127 Theory of Operation...................................................................................................1129 Air Conditioning System Cycle of Operation........................................................................1129 Diagnostic Information................................................................................................1131 Air Conditioning System Does Not Operate..........................................................................1131 Air Conditioning System Does Not Operate Diagnostic Procedure.................................................1131 Air Conditioning System Does Not Cool Interior of Cab.............................................................1132 Air Conditioning System Does Not Cool Interior of Cab Diagnostic Procedure....................................1132 Air Conditioning System Runs Constantly, Too Cold.................................................................1134 Air Conditioning System Runs Constantly, Too Cold Diagnostic Procedure........................................1134 Heating System Does Not Operate...................................................................................1135 Heating System Does Not Operate Diagnostic Procedure..........................................................1135 Heating System Does Not Warm Interior of Cab......................................................................1136 Heating System Does Not Warm Interior of Cab Diagnostic Procedure.............................................1136 Interior Windows Continue to Fog..................................................................................1138 Interior Windows Continue to Fog Using Heater Diagnostic Procedure............................................1138 Heater and Air Conditioner Component Location.....................................................................1140 Tests.................................................................................................................1143 R134a Refrigerant Cautions and Proper Handling....................................................................1143 R134a Oil Charge Capacity.........................................................................................1143 R134a Refrigerant Charge Capacity.................................................................................1143 Heater and Air Conditioner Operational Checks.....................................................................1144 Visual Inspection of Components...............................................................................1144 Air Conditioner Compressor Clutch Test............................................................................1145 R134a Refrigerant Leak Test.......................................................................................1145 R134a Refrigerant Hoses and Tubing Inspection.....................................................................1146 Air Conditioner High/Low-Pressure Switch Test.....................................................................1147 Air Conditioner Freeze Control Switch Test........................................................................1148 Air Conditioning System Test......................................................................................1149 Operating Pressure Diagnostic Chart...............................................................................1151 Dealer Fabricated Tools...................................................................................................1153 Dealer Fabricated Tools...............................................................................................1155 DFT1218 Split Flange Hose Cap.....................................................................................1155 Page Number................................................................................................................... 5 Section 9000.............................................................................................................. 7 Group 01.............................................................................................................. 9 Section 9001.............................................................................................................. 31 Group 10.............................................................................................................. 33 Group 20.............................................................................................................. 147 Group 30.............................................................................................................. 173 Group 40.............................................................................................................. 175 Group 50.............................................................................................................. 187 Group 60.............................................................................................................. 203 Section 9005.............................................................................................................. 219 Group 10.............................................................................................................. 221 Section 9010.............................................................................................................. 267 Group 05.............................................................................................................. 269 Group 15.............................................................................................................. 291 Group 20.............................................................................................................. 293 Group 25.............................................................................................................. 295 Section 9015.............................................................................................................. 299 Group 05.............................................................................................................. 301 Group 10.............................................................................................................. 309 Group 15.............................................................................................................. 611 Group 16.............................................................................................................. 729 Group 20.............................................................................................................. 743 Section 9020.............................................................................................................. 779 Group 05.............................................................................................................. 781 Group 15.............................................................................................................. 783 Section 9025.............................................................................................................. 791 Group 05.............................................................................................................. 793 Group 15.............................................................................................................. 963 Group 25..............................................................................................................1069 Section 9031..............................................................................................................1127 Group 05..............................................................................................................1129 Group 15..............................................................................................................1131 Group 25..............................................................................................................1143 Section 9900..............................................................................................................1153 Group 99..............................................................................................................1155
S.S 23/02/2025
