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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
FILE DETAILS:
JOHN DEERE 160GLC EXCAVATOR OPERATION & TEST TECHNICAL MANUAL TM13345X19 – PDF DOWNLOAD
Language : English
Pages : 1128
Downloadable : Yes
File Type : PDF
IMAGES PREVIEW OF THE MANUAL:
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 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 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............................................................................................................... 32 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 (CAN 0) Diagnostics................................................................... 33 Controller Area Network 1 (CAN 1) Circuit Diagnostics............................................................. 41 Controller Area Network (CAN 1) Diagnostic Procedure ......................................................... 41 Interface Controller Area Network (N-CAN) Diagnostics............................................................. 52 Interface Controller Area Network (N-CAN) Diagnostics ........................................................ 52 Engine Controller Area Network (Engine CAN) Diagnostics .......................................................... 58 Engine Controller Area Network (Engine CAN) Diagnostics ...................................................... 59 Aftertreatment Controller Area Network (AT CAN) Diagnostics....................................................... 62 Aftertreatment Controller Area Network (AT CAN) Diagnostics................................................... 62 011000.02 — Abnormal EEPROM....................................................................................... 65 Abnormal EEPROM Diagnostic Procedure.......................................................................... 66 011001.02 — Abnormal RAM.......................................................................................... 66 Abnormal RAM Diagnostic Procedure............................................................................. 66 011002.02 — Abnormal A/D Converter................................................................................ 67 Abnormal A/D Converter Diagnostic Procedure................................................................... 67 011003.03 — Abnormal Sensor Voltage............................................................................... 67 Abnormal Sensor Voltage Diagnostic Procedure.................................................................. 67 011006.02 — Engine Controller Communication Error................................................................. 68 011007.02 — (CAN 0) Data Converter Communication Error 1.......................................................... 68 011008.02 — (CAN 1) Data Converter Communication Error 2.......................................................... 68 011009.02 — (CAN 0) Monitor Controller Communication Error 1...................................................... 69 011010.02 — (CAN 1) Monitor Controller Communication Error 2...................................................... 69 011100.02 — Abnormal Engine Speed................................................................................. 69 Abnormal Engine Speed Diagnostic Procedure.................................................................... 69 011101.03 — Engine Speed Dial Sensor Circuit High Input........................................................... 69 Engine Speed Dial Sensor Circuit High Input Diagnostic Procedure.............................................. 70 011101.04 — Engine Speed Dial Sensor Circuit Low Input............................................................ 71 Engine Speed Dial Sensor Circuit Low Input Diagnostic Procedure............................................... 71 011200.03 — Pump 1 Delivery Pressure Sensor Circuit High Input.................................................... 72 Pump 1 Delivery Pressure Sensor Circuit High Diagnostics...................................................... 72 011200.04 — Pump 1 Delivery Pressure Sensor Circuit Low Input..................................................... 74 Pump 1 Delivery Pressure Sensor Circuit Low Input Diagnostic Procedure........................................ 74 011202.03 — Pump 2 Delivery Pressure Sensor Circuit High Input.................................................... 76 Pump 2 Delivery Pressure Sensor Circuit High Input Diagnostic Procedure....................................... 76 011202.04 — Pump 2 Delivery Pressure Sensor Circuit Low Input..................................................... 78 Pump 2 Delivery Pressure Sensor Circuit Low Input Diagnostic Procedure........................................ 78 011206.03 — Pump 1 Flow Control Pressure Sensor Circuit High Input................................................ 80 Pump 1 Flow Control Pressure Sensor Circuit High Input Diagnostic Procedure................................... 80 011206.04 — Pump 1 Flow Control Pressure Sensor Circuit Low Input................................................. 81 Pump 1 Flow Control Pressure Sensor Circuit Low Input Diagnostic Procedure.................................... 81 011208.03 — Pump 2 Flow Control Pressure Sensor Circuit High Input................................................ 83 Pump 2 Flow Control Pressure Sensor Circuit High Input Diagnostic Procedure................................... 83 011208.04 — Pump 2 Flow Control Pressure Sensor Circuit Low Input................................................. 84 Pump 2 Flow Control Pressure Sensor Circuit Low Input Diagnostic Procedure.................................... 84 011301.03 — Swing Pressure Sensor Circuit High Input.............................................................. 86 Swing Pilot Pressure Sensor Circuit High Input Diagnostic Procedure........................................... 86 011301.04 — Swing Pilot Pressure Sensor Circuit Low Input......................................................... 87 Swing Pilot Pressure Sensor Circuit Low Input Diagnostic Procedure............................................ 87 011302.03 — Boom Up Pilot Pressure Sensor Circuit High Input...................................................... 89 Boom Up Pilot Pressure Sensor Circuit High Input Diagnostic Procedure......................................... 89 011302.04 — Boom Up Pilot Pressure Sensor Circuit Low Input....................................................... 90 Boom Up Pilot Pressure Sensor Circuit Low Input Diagnostic Procedure.......................................... 90 011303.03 — Arm In Pressure Sensor Circuit High Input............................................................. 91 Arm In Pilot Pressure Sensor Circuit High Input Diagnostic Procedure.......................................... 92 011303.04 — Arm In Pressure Sensor Circuit Low Input.............................................................. 93 Arm In Pilot Pressure Sensor Circuit Low Input Diagnostic Procedure........................................... 93 011304.03 — Travel Pilot Pressure Sensor Circuit High Input....................................................... 94 Travel Pilot Pressure Sensor Circuit High Input Diagnostic Procedure.......................................... 94 011304.04 — Travel Pilot Pressure Sensor Circuit Low Input........................................................ 96 Travel Pilot Pressure Sensor Circuit Low Input Diagnostic Procedure........................................... 96 011307.03 — Front Attachment Pilot Pressure Sensor Circuit High Input............................................. 97 Front Attachment Pilot Pressure Sensor Circuit High Input Diagnostic Procedure................................ 97 011307.04 — Front Attachment Pilot Pressure Sensor Circuit Low Input.............................................. 99 Front Attachment Pilot Pressure Sensor Circuit Low Input Diagnostic Procedure................................. 99 011400.02 — Pump 2 Flow Rate Limit Solenoid Valve Feedback Abnormal............................................... 100 Pump 2 Flow Rate Limit Solenoid Valve Feedback Abnormal Diagnostic Procedure.................................. 100 011400.03 — Pump 2 Flow Rate Limit Solenoid Valve Feedback High Current........................................... 102 Pump 2 Flow Rate Limit Solenoid Valve Feedback High Current Diagnostic Procedure.............................. 102 011400.04 — Pump 2 Flow Rate Limit Solenoid Feedback Low Current.................................................. 104 Pump 2 Flow Rate Limit Solenoid Valve Feedback Low Current Diagnostic Procedure............................... 104 011401.02 — Torque Control Solenoid Valve Abnormal Feedback....................................................... 105 Torque Control Solenoid Valve Abnormal Feedback Diagnostic Procedure.......................................... 105 011401.03 — Torque Control Solenoid Valve Feedback High Current................................................... 107 Torque Control Solenoid Valve Feedback High Current Diagnostic Procedure...................................... 107 011401.04 — Torque Control Solenoid Valve Feedback Low Current.................................................... 109 Torque Control Solenoid Valve Feedback Low Current Diagnostic Procedure....................................... 109 011402.02 — Dig Regenerative Solenoid Valve Feedback Current Abnormal............................................. 110 Dig Regenerative Solenoid Valve Feedback Current Abnormal Diagnostic Procedure................................ 110 011402.03 — Dig Regenerative Solenoid Valve Feedback Current High................................................. 112 Dig Regenerative Solenoid Valve Feedback Current High Diagnostic Procedure.................................... 112 011402.04 — Dig Regenerative Solenoid Valve Feedback Current Low.................................................. 114 Dig Regenerative Solenoid Valve Feedback Current Low Diagnostic Procedure..................................... 114 011403.02 — Arm Regenerative Solenoid Valve Feedback Current Abnormal............................................. 115 Arm Regenerative Solenoid Valve Feedback Current Abnormal Diagnostic Procedure................................ 115 011403.03 — Arm Regenerative Solenoid Valve Feedback Current High................................................. 117 Arm Regenerative Solenoid Valve Feedback Current High Diagnostic Procedure.................................... 117 011403.04 — Arm Regenerative Solenoid Valve Feedback Current Low.................................................. 119 Arm Regenerative Solenoid Valve Feedback Current Low Diagnostic Procedure..................................... 119 011407.02 — Power Dig/Travel Speed Solenoid Valve Feedback Current Abnormal....................................... 120 Power Dig/Travel Speed Solenoid Valve Feedback Current Abnormal Diagnostic Procedure.......................... 120 011407.03 — Power Dig/Travel Speed Solenoid Valve Feedback Current High........................................... 122 Power Dig/Travel Speed Solenoid Valve Feedback Current High Diagnostic Procedure.............................. 122 011407.04 — Power Dig/Travel Speed Solenoid Valve Feedback Current Low............................................ 124 Power Dig/Travel Speed Solenoid Valve Feedback Current Low Diagnostic Procedure............................... 124 011410.02 — Pump 1 Flow Rate Limit Solenoid Valve Abnormal Feedback.............................................. 125 Pump 1 Flow Rate Limit Solenoid Valve Abnormal Feedback Diagnostic Procedure.................................. 125 011410.03 — Pump 1 Flow Rate Limit Solenoid Valve Feedback High Current........................................... 127 Pump 1 Flow Rate Limit Solenoid Valve Feedback High Current Diagnostic Procedure.............................. 127 011410.04 — Pump 1 Flow Rate Limit Solenoid Valve Feedback Low Current............................................ 129 Pump 1 Flow Rate Limit Solenoid Valve Feedback Low Current Diagnostic Procedure............................... 129 011434.02 — Attachment Relief 1 (Upper) Proportional Solenoid Valve Abnormal Feedback............................. 131 011434.03 — Attachment Relief 1 (Upper) Proportional Solenoid Valve Feedback High Current......................... 131 011434.04 — Attachment Relief 1 (Upper) Proportional Solenoid Valve Feedback Low Current.......................... 131 011435.02 — Attachment Relief 2 (Lower) Proportional Solenoid Valve Abnormal Feedback............................. 131 011435.03 — Attachment Relief 2 (Lower) Proportional Solenoid Valve Feedback High Current......................... 131 011435.04 — Attachment Relief 2 (Lower) Proportional Solenoid Valve Feedback Low Current.......................... 131 011436.02 — Breaker Relief Proportional Solenoid Valve Abnormal Feedback.......................................... 131 011436.03 — Breaker Relief Proportional Solenoid Valve Feedback High Current...................................... 132 011436.04 — Breaker Relief Proportional Solenoid Valve Feedback Low Current....................................... 132 011457.02 — 2-Speed Activation Solenoid Valve Disconnected........................................................ 132 2-Speed Activation Solenoid Valve Disconnected Diagnostic Procedure........................................... 132 011458.02 — Selector Valve Solenoid Valve Disconnected............................................................ 134 Selector Valve Solenoid Valve Disconnected Diagnostic Procedure............................................... 134 011459.02 — Idle Stop Relay Circuit Malfunction................................................................... 135 Idle Stop Relay Circuit Malfunction Diagnostic Procedure...................................................... 135 015011.03 — Hydraulic Oil Temperature Sensor Circuit High Input (Pilot).......................................... 136 Secondary Hydraulic Oil Temperature Sensor Circuit High Input Diagnostic Procedure............................ 137 015011.04 — Hydraulic Oil Temperature Sensor Circuit Low Input (Pilot)........................................... 138 Secondary Hydraulic Oil Temperature Sensor Circuit Low Input Diagnostic Procedure............................. 138 015016.03 — Right Analog Stroke Sensor Circuit High Input......................................................... 139 Auxiliary Function Lever (AFL) Proportional Control Switch Sensor Circuit High Input Diagnostic Procedure..... 139 015016.04 — Right Analog Stroke Sensor Circuit Low Input.......................................................... 140 Auxiliary Function Lever (AFL) Proportional Control Switch Sensor Circuit Low Input Diagnostic Procedure...... 140 011810.03 — Electric Lever Operating Pressure Sensor 1 High Voltage............................................... 141 Auxiliary Function Lever (AFL) Solenoid Pressure Sensor (marked PS1) (B85) High Input Diagnostic Procedure.... 141 011810.04 — Electric Lever Operating Pressure Sensor 1 Low Voltage................................................ 143 Auxiliary Function Lever (AFL) Solenoid Pressure Sensor (marked PS1) (B85) Low Input Diagnostic Procedure..... 143 011812.02 — OPT Electric Lever 1 Neutral Abnormal................................................................. 144 OPT Electric Lever 1 Neutral Abnormal Diagnostic Procedure.................................................... 144 011813.02 — OPT Electric Lever 1 Abnormal Operation............................................................... 145 OPT Electric Lever 1 Abnormal Operation Diagnostic Procedure.................................................. 145 011816.02 — OPT Solenoid 1 Feedback Abnormal...................................................................... 147 Auxiliary Function Lever (AFL) Solenoid A (marked 1A) (Y61) Abnormal Feedback Diagnostic Procedure............ 147 011816.03 — OPT Solenoid 1 Feedback Current High.................................................................. 149 Auxiliary Function Lever (AFL) Solenoid A (marked 1A) (Y61) Feedback High Current Diagnostic Procedure........ 149 011816.04 — OPT Solenoid 1 Feedback Current Low................................................................... 151 Auxiliary Function Lever (AFL) Solenoid A (marked 1A) (Y61) Feedback Low Current Diagnostic Procedure......... 151 011817.02 — OPT Solenoid 2 Feedback Abnormal...................................................................... 153 Auxiliary Function Lever (AFL) Solenoid B (marked 1B) (Y62) Abnormal Feedback Diagnostic Procedure............ 153 011817.03 — OPT Solenoid 2 Feedback Current High.................................................................. 154 Auxiliary Function Lever (AFL) Solenoid B (marked 1B) (Y62) Feedback High Current Diagnostic Procedure........ 155 011817.04 — OPT Solenoid 2 Feedback Current Low................................................................... 156 Auxiliary Function Lever (AFL) Solenoid B (marked 1B) (Y62) Feedback Low Current Diagnostic Procedure......... 156 011901.03 — Hydraulic Oil Temperature Sensor Circuit High Input................................................... 158 Hydraulic Oil Temperature Sensor Circuit High Input Diagnostic Procedure...................................... 158 011901.04 — Hydraulic Oil Temperature Sensor Circuit Low Input.................................................... 159 Hydraulic Oil Temperature Sensor Circuit Low Input Diagnostic Procedure....................................... 159 020010.02 — Abnormal Exhaust Filter............................................................................... 160 Abnormal Exhaust Filter Diagnostic Procedure.................................................................. 160 020011.02 — Electric Lever Alarm.................................................................................. 161 Electric Control Lever Alarm Diagnostic Procedure............................................................. 161 020062.02 — Hydraulic Oil Temperature Alarm....................................................................... 161 020303.02 — Electric Lever Pilot Cut Alarm........................................................................ 161 Electric Control Lever Alarm Diagnostic Procedure............................................................. 161 Engine Control Unit (ECU) Diagnostic Trouble Codes.................................................................... 163 Engine Control Unit (ECU) Diagnostic Trouble Codes................................................................ 163 000111.07 — Coolant Level Low—Moderately Severe Level............................................................. 163 Coolant Level Low—Moderately Severe Level Diagnostic Procedure................................................ 163 000647.05 — Variable Speed Fan Solenoid Open Circuit.............................................................. 164 Variable Speed Fan Solenoid Open Circuit Diagnostic Procedure................................................. 164 000647.06 — Variable Speed Fan Solenoid High Current.............................................................. 165 Variable Speed Fan Solenoid High Current Diagnostic Procedure................................................. 165 000647.16 — Reversing Fan Switch Active Too Long.................................................................. 166 Reversing Fan Switch Active Too Long Diagnostic Procedure..................................................... 166 001639.00 — Fan Speed High—Moderately Severe Level................................................................ 167 Fan Speed High—Moderately Severe Level Diagnostic Procedure................................................... 167 001639.01 — Fan Speed Low—Most Severe Level....................................................................... 169 Fan Speed Low—Most Severe Level Diagnostic Procedure.......................................................... 169 001639.18 — Fan Speed Low—Moderately Severe Level................................................................. 170 001761.01 — Diesel Exhaust Fluid Extremely Low.................................................................... 170 001761.18 — Diesel Exhaust Fluid Very Low......................................................................... 171 002030.09 — (CAN 0) Flex Power Controller Communication Error..................................................... 171 002228.09 — (CAN 0) Main Controller (MCZ) Communication Error..................................................... 171 003031.12 — Diesel Exhaust Fluid Temperature Sensor Fault......................................................... 171 003353.31 — Alternator Excitation Fault........................................................................... 171 Alternator Excitation Fault Diagnostic Procedure.............................................................. 172 003516.01 — Diesel Exhaust Fluid Concentration Extremely Low...................................................... 173 003516.07 — Diesel Exhaust Fluid Concentration Invalid............................................................ 173 003516.09 — Diesel Exhaust Fluid Tank Header Communication Fault.................................................. 174 003516.12 — Diesel Exhaust Fluid Concentration Sensor Fault....................................................... 174 003517.12 — Diesel Exhaust Fluid Tank Level Sensor Fault.......................................................... 174 003719.15 — Calculated Soot Level Slightly High................................................................... 175 005484.05 — Reversing Fan Solenoid Open Circuit................................................................... 175 Reversing Fan Solenoid Open Circuit Diagnostic Procedure...................................................... 175 005484.06 — Reversing Fan Solenoid Short Circuit.................................................................. 176 Reversing Fan Solenoid Short Circuit Diagnostic Procedure..................................................... 176 520956.06 — Battery Disconnect Indicator Light Short to Ground.................................................... 177 Battery Disconnect Indicator Light Short to Ground Diagnostic Procedure....................................... 177 Monitor Controller (DSZ) Diagnostic Trouble Codes..................................................................... 179 Monitor Controller (DSZ) Diagnostic Trouble Codes................................................................. 179 013000.02 — Flash Memory Failure 1................................................................................ 179 Flash Memory Failure 1 Diagnostic Procedure................................................................... 179 013001.02 — Flash Memory Failure 2................................................................................ 179 Flash Memory Failure 2 Diagnostic Procedure................................................................... 179 013002.02 — ECU Communication Error............................................................................... 179 013003.02 — Main Controller (MCZ) Communication Error 1........................................................... 180 013004.02 — Main Controller (MCZ) Communication Error 2........................................................... 180 013005.02 — Monitor Controller (DSZ) Communication Error 1........................................................ 180 013006.02 — Monitor Controller (DSZ) Communication Error 2........................................................ 180 013007.02 — Machine Controller (BCZ) Communication Error.......................................................... 180 020113.02 — System Error Alarm.................................................................................... 180 Information Controller (ICZ) Diagnostic Trouble Codes................................................................. 181 Information Controller (ICZ) Diagnostic Trouble Codes............................................................. 181 013303.02 — Abnormal Monitor Internal Temperature Sensor.......................................................... 181 Monitor Internal Temperature Sensor Diagnostic Procedure...................................................... 181 013304.02 — Alternator Alarm...................................................................................... 181 Alternator Alarm Diagnostic Procedure......................................................................... 181 013305.02 — Abnormal Manual Glow EXT Output....................................................................... 182 013310.03 — Coolant Temperature Sensor Short Circuit.............................................................. 182 013311.03 — Fuel Level Sensor Open Circuit........................................................................ 182 Fuel Level Sensor Open Circuit Diagnostic Procedure........................................................... 182 013311.04 — Fuel Level Sensor Shorted Circuit..................................................................... 183 Fuel Level Sensor Shorted Circuit Diagnostic Procedure........................................................ 183 013334.02 — Radiator Water Temp Receive Error..................................................................... 184 014000.02 — CAN Communication Error 1............................................................................. 184 014001.02 — Flash Memory Read/Write Error......................................................................... 184 Data Converter Diagnostics.................................................................................... 184 014002.02 — External RAM Read/Write Error......................................................................... 185 Data Converter Diagnostics.................................................................................... 185 014003.02 — Abnormal EEPROM....................................................................................... 185 Data Converter Diagnostics.................................................................................... 185 014006.02 — Communication Terminal: Communication Error........................................................... 185 Communication Terminal: Communication Error Diagnostic Procedure.............................................. 185 014008.02 — Abnormal Internal RAM................................................................................. 186 Data Converter Diagnostics.................................................................................... 186 014009.02 — CAN Communication Error 2............................................................................. 186 014021.02 — Communication Terminal Security Error................................................................. 187 014022.02 — SIM Card Error........................................................................................ 187 014023.02 — Security Error........................................................................................ 187 020100.02 — Overheat Alarm........................................................................................ 187 020101.02 — Engine Warning Alarm.................................................................................. 187 020102.02 — Engine Oil Pressure Alarm............................................................................. 187 020103.02 — Alternator Alarm...................................................................................... 187 Alternator Alarm Diagnostic Procedure......................................................................... 187 020105.02 — Hydraulic Oil Filter Restriction Alarm................................................................ 188 Hydraulic Oil Filter Restriction Alarm Diagnostic Procedure................................................... 188 020106.02 — Air Cleaner Restriction Alarm......................................................................... 189 020107.02 — Water Separator Alarm................................................................................. 189 020109.02 — Pilot Control Shut-Off Lever Alarm.................................................................... 189 Pilot Control Shut-Off Lever Alarm Diagnostic Procedure....................................................... 189 020110.02 — Fuel Filter Restriction Alarm......................................................................... 190 020114.02 — Overheat Alarm (Immediately After the Key is Turned ON)............................................... 190 020135.02 — Exhaust Filter Regeneration Unnecessary Warning....................................................... 190 020149.02 — EGR Gas Temperature Alarm............................................................................. 190 020150.02 — Coolant Level Alarm................................................................................... 190 020151.02 — Engine Warning Alarm.................................................................................. 190 020152.02 — Engine Oil Pressure Alarm............................................................................. 191 020153.02 — Air Cleaner Restriction Alarm......................................................................... 191 020154.02 — Fuel Filter Restriction Alarm......................................................................... 191 020155.02 — Engine Output Reduction Alarm......................................................................... 191 020156.02 — Cooling Performance Decrease Alarm.................................................................... 191 020157.02 — Cooling Performance Decrease Alarm.................................................................... 191 Air Conditioner Controller (ACF) Diagnostic Trouble Codes............................................................. 193 Air Conditioner Controller (ACF) Diagnostic Trouble Codes......................................................... 193 11 — Open Circuit in Air Recirculation Sensor..................................................................... 193 Open Circuit in Air Recirculation Sensor Diagnostic Procedure................................................. 193 12 — Short-Circuited Air Recirculation Sensor..................................................................... 194 Short-Circuited Air Recirculation Sensor Diagnostic Procedure................................................. 194 13 — Open Circuit in Ambient Air Temperature Sensor............................................................... 196 Open Circuit in Ambient Air Temperature Sensor Diagnostics Procedure.......................................... 196 14 — Short-Circuited Ambient Air Temperature Sensor............................................................... 197 Short-Circuited Ambient Air Temperature Sensor Diagnostic Procedure........................................... 197 18 — Short-Circuited Solar Radiation Sensor....................................................................... 199 Short-Circuited Solar Radiation Sensor Diagnostic Procedure................................................... 199 21 — Open Circuit in Air Conditioner Freeze Control Switch........................................................ 200 Open Circuit in Air Conditioner Freeze Control Switch Diagnostic Procedure.................................... 200 22 — Short-Circuited Air Conditioner Freeze Control Switch........................................................ 202 Short-Circuited Air Conditioner Freeze Control Switch Diagnostic Procedure.................................... 202 43 — Abnormal Air Conditioner and Heater Blower Port Change Servomotor............................................ 203 Abnormal Air Conditioner and Heater Blower Port Change Servomotor Diagnostic Procedure........................ 203 44 — Abnormal Air Conditioner and Heater Mixer Servomotor......................................................... 204 Abnormal Air Conditioner and Heater Mixer Servomotor Diagnostic Procedure..................................... 204 51 — Abnormal High/Low Refrigerant Pressure....................................................................... 206 Abnormal High/Low Refrigerant Pressure Diagnostic Procedure................................................... 206 91 — Communication Error.......................................................................................... 207 92 — CAN Bus Off Error............................................................................................ 207 Operational Checkout Procedure............................................................................................ 209 Operational Checkout Procedure........................................................................................ 211 Operational Checkout.............................................................................................. 211 Diagnostic Trouble Code Check................................................................................. 211 Operational Checks—Key Switch Off, Engine Off Checks.......................................................... 211 Operational Checks—Key Switch On, Engine Off Checks........................................................... 214 Operational Checks—Key Switch On, Engine On Checks............................................................ 226 Engine.................................................................................................................... 261 Theory of Operation................................................................................................... 263 Engine Identification............................................................................................. 263 John Deere Engine................................................................................................. 263 Engine Fuel System Component Location............................................................................. 265 Engine Cooling System Component Location.......................................................................... 269 Diesel Exhaust Fluid (DEF) System Component Location.............................................................. 276 Cold Weather Starting Aid......................................................................................... 279 Engine Speed Control System Operation............................................................................. 280 Diagnostic Information................................................................................................ 283 John Deere Engine................................................................................................. 283 Adjustments........................................................................................................... 285 John Deere Engine................................................................................................. 285 Tests................................................................................................................. 287 John Deere Engine................................................................................................. 287 Electrical System......................................................................................................... 291 System Information.................................................................................................... 293 Electrical Diagram Information.................................................................................... 293 System Diagrams....................................................................................................... 301 Explanation of Wire Markings...................................................................................... 301 Fuse and Relay Specifications..................................................................................... 301 System Functional Schematic, Component Location, and Wiring Diagram Master Legend................................. 305 System Functional Schematic....................................................................................... 313 Cab Harness (W1) Component Location............................................................................... 367 Cab Harness (W1) Wiring Diagram................................................................................... 371 Machine Harness (W2) Component Location........................................................................... 387 Machine Harness (W2) Wiring Diagram............................................................................... 391 Monitor Harness (W3) Component Location........................................................................... 400 Monitor Harness (W3) Wiring Diagram............................................................................... 402 Engine Harness (W4) Component Location............................................................................ 405 Engine Harness (W4) Wiring Diagram................................................................................ 408 Engine Interface Harness (W5) Component Location.................................................................. 413 Engine Interface Harness (W5) Wiring Diagram...................................................................... 421 Front Engine Harness (W7) Component Location...................................................................... 441 Front Engine Harness (W7) Wiring Diagram.......................................................................... 445 Pump Harness (W8) Component Location.............................................................................. 449 Pump Harness (W8) Wiring Diagram.................................................................................. 453 Exhaust Filter Parked Cleaning Switch Harness (W9) Component Location............................................. 455 Exhaust Filter Parked Cleaning Switch Harness (W9) Wiring Diagram................................................. 455 Service ADVISOR™ Remote (SAR) Switch Harness (W10) Component Location............................................. 455 Service ADVISOR™ Remote (SAR) Switch Harness (W10) Wiring Diagram................................................. 456 Pilot Shutoff Switch Harness (W11) Component Location............................................................. 457 Pilot Shutoff Switch Harness (W11) Wiring Diagram................................................................. 459 Heated Air Seat Harness (W14) Component Location.................................................................. 462 Heated Air Seat Harness (W14) Wiring Diagram...................................................................... 463 Multi-Function Pilot Control Lever Harness (W15) Component Location............................................... 464 Multi-Function Pilot Control Lever Harness (W15) Wiring Diagram................................................... 467 Travel Alarm Cancel Switch Harness (W16) Component Location....................................................... 469 Travel Alarm Cancel Switch Harness (W16) Wiring Diagram........................................................... 469 Attachment Harness (W17) Component Location....................................................................... 470 Attachment Harness (W17) Wiring Diagram........................................................................... 473 Rear Camera Harness (W19) Component Location...................................................................... 476 Rear Camera Harness (W19) Wiring Diagram.......................................................................... 477 Pilot Shutoff Valve Harness (W21) Component Location.............................................................. 478 Pilot Shutoff Valve Harness (W21) Wiring Diagram.................................................................. 479 Auxiliary 3-Button Cancel Switch Harness (W22) Component Location................................................. 479 Auxiliary 3-Button Cancel Switch Harness (W22) Wiring Diagram..................................................... 480 Reversing Fan Switch Harness (W23) Component Location............................................................. 480 Reversing Fan Switch Harness (W23) Wiring Diagram................................................................. 481 Seat Heater Switch Harness (W24) Component Location............................................................... 481 Seat Heater Switch Harness (W24) Wiring Diagram................................................................... 482 Travel Alarm Harness (W26) Component Location..................................................................... 483 Travel Alarm Harness (W26) Wiring Diagram......................................................................... 484 Starter Switch Harness (W29) Component Location................................................................... 484 Starter Switch Harness (W29) Wiring Diagram....................................................................... 485 2-Speed Harness (W32) Component Location.......................................................................... 485 2-Speed Harness (W32) Wiring Diagram.............................................................................. 486 Fuel Injector Harness (W38) Component Location.................................................................... 487 Fuel Injector Harness (W38) Wiring Diagram........................................................................ 489 Glow Plug Harness (W40) Component Location........................................................................ 493 Glow Plug Harness (W40) Wiring Diagram............................................................................ 496 Heater and Air Conditioner Harness (W41) Component Location....................................................... 497 Heater and Air Conditioner Harness (W41) Wiring Diagram........................................................... 499 Cab Roof Light Harness (W44) Component Location................................................................... 501 Cab Roof Light Harness (W44) Wiring Diagram....................................................................... 502 Cab Roof Light Jumper Harness (W45) Component Location............................................................ 502 Cab Roof Light Jumper Harness (W45) Wiring Diagram................................................................ 503 Cab Roof Light 1 Relay Harness (W46) Component Location........................................................... 503 Cab Roof Light 1 Relay Harness (W46) Wiring Diagram............................................................... 504 Cab Roof Light 2 Relay Harness (W47) Component Location........................................................... 504 Cab Roof Light 2 Relay Harness (W47) Wiring Diagram............................................................... 505 Heater and Air Conditioner Relay Harness (W51) Component Location................................................. 506 Heater and Air Conditioner Relay Harness (W51) Wiring Diagram..................................................... 508 Exhaust Aftertreatment Harness (W53) Component Location........................................................... 511 Exhaust Aftertreatment Harness (W53) Wiring Diagram............................................................... 514 Diesel Exhaust Fluid (DEF) Harness (W54) Component Location....................................................... 519 Diesel Exhaust Fluid (DEF) Harness (W54) Wiring Diagram........................................................... 527 Fan Harness (W57) Component Location.............................................................................. 535 Fan Harness (W57) Wiring Diagram.................................................................................. 538 Engine Light Harness (W58) Component Location..................................................................... 541 Engine Light Harness (W58) Wiring Diagram......................................................................... 541 Auxiliary Solenoid Harness (W61) Component Location............................................................... 543 Auxiliary Solenoid Harness (W61) Wiring Diagram................................................................... 544 Diesel Particulate Filter (DPF) Harness (W62) Component Location.................................................. 546 Diesel Particulate Filter (DPF) Harness (W62) Wiring Diagram...................................................... 548 Auxiliary Function Lever (AFL) Harness (W75) Component Location................................................... 552 Auxiliary Function Lever (AFL) Harness (W75) Wiring Diagram....................................................... 555 Auxiliary Function Lever (AFL) Solenoid Harness (W76) Component Location.......................................... 559 Auxiliary Function Lever (AFL) Solenoid Harness (W76) Wiring Diagram.............................................. 562 Satellite (SAT) Harness (W6003) Component Location................................................................ 563 Satellite (SAT) Harness (W6003) Wiring Diagram.................................................................... 563 Sub-System Diagnostics................................................................................................ 565 Controller Area Network (CAN) Theory of Operation................................................................. 565 Starting and Charging Circuit Theory of Operation................................................................. 573 Monitor Controller (DSZ) Circuit Theory of Operation.............................................................. 583 Engine Control Unit (ECU) Circuit Theory of Operation............................................................. 593 Exhaust Aftertreatment Circuit Theory of Operation................................................................ 628 Main Controller (MCZ) Circuit Theory of Operation................................................................. 643 Machine Controller (BCZ) Circuit Theory of Operation.............................................................. 655 Windshield Wiper and Washer Circuit Theory of Operation........................................................... 657 Lighting Circuit Theory of Operation.............................................................................. 661 Travel Alarm Circuit Theory of Operation.......................................................................... 670 Pilot Shutoff Circuit Theory of Operation......................................................................... 673 Attachment Control Circuit Theory of Operation.................................................................... 676 Monitor Operation..................................................................................................... 685 Service Menu...................................................................................................... 685 Troubleshooting................................................................................................... 685 Monitoring........................................................................................................ 686 Controller Version................................................................................................ 689 Issued Warning Record............................................................................................. 689 Operation......................................................................................................... 689 Machine Setting................................................................................................... 690 Monitor Setting................................................................................................... 694 Exhaust Filter No................................................................................................. 695 References............................................................................................................ 697 Reading Diagnostic Trouble Codes with Monitor Display............................................................. 697 Service ADVISOR™ Diagnostic Application........................................................................... 697 Service ADVISOR™ Connection Procedure............................................................................. 698 Reading Diagnostic Trouble Codes with Service ADVISOR™ Diagnostic Application..................................... 699 MPDr Application.................................................................................................. 701 MPDr Connection Procedure......................................................................................... 702 Electrical Component Specifications............................................................................... 703 Alternator Test................................................................................................... 705 Electrical Component Checks....................................................................................... 706 Component Checks.............................................................................................. 706 Battery Remove and Install........................................................................................ 715 Rear Cover Remove and Install..................................................................................... 717 Main Controller (MCZ) Remove and Install.......................................................................... 719 Monitor Controller (DSZ) Remove and Install....................................................................... 720 Heater Control Disable and Enable................................................................................. 720 Power Train............................................................................................................... 721 Theory of Operation................................................................................................... 723 Track Adjuster and Recoil Spring Operation........................................................................ 723 Travel Gear Case Operation........................................................................................ 724 Diagnostic Information................................................................................................ 727 Noisy or Loose Track Chain........................................................................................ 727 Noisy or Loose Track Chain Diagnostic Procedure............................................................... 727 Tight Track Chain................................................................................................. 727 Tight Track Chain Diagnostic Procedure........................................................................ 727 Frequent Track Chain Sag Adjustment Required...................................................................... 728 Frequent Track Chain Sag Adjustment Required Diagnostic Procedure............................................. 728 Excessive Oil Leakage From Front Idler, Track Rollers, or Carrier Rollers......................................... 728 Excessive Oil Leakage From Front Idler, Track Rollers, or Carrier Rollers Diagnostic Procedure................ 728 Bent Track Shoes.................................................................................................. 728 Bent Track Shoes Diagnostic Procedure......................................................................... 728 “Popping” of Track................................................................................................ 729 “Popping” of Track Diagnostic Procedure....................................................................... 729 Cracked Track Link................................................................................................ 729 Cracked Track Link Diagnostic Procedure....................................................................... 729 Chipped Link Rails................................................................................................ 730 Chipped Link Rails Diagnostic Procedure....................................................................... 730 Individual Undercarriage Component Wear........................................................................... 731 Individual Undercarriage Component Wear Diagnostic Procedure.................................................. 731 Measure Swing Bearing Wear........................................................................................ 732 Hydraulic System.......................................................................................................... 735 Theory of Operation................................................................................................... 737 Hydraulic System Operation........................................................................................ 737 Fan Drive Hydraulic System Operation.............................................................................. 738 Pilot System Operation............................................................................................ 740 Pilot Pump, Pressure Regulating Valve and Filter Operation........................................................ 741 Pilot Shutoff Solenoid Valve Operation............................................................................ 742 Pilot Control Valve Operation..................................................................................... 745 Travel Pilot Control Valve Operation.............................................................................. 748 Pilot Operation of Control Valve Operation........................................................................ 751 Pilot Signal Manifold Operation................................................................................... 754 Pump 1, Pump 2, and Drive Gear Case Operation..................................................................... 764 Pump 1 and Pump 2 Regulator Operation............................................................................. 767 Engine Speed Sensing Control Circuit Operation.................................................................... 772 Control Valve Operation........................................................................................... 774 Control Valve Check Valves Identification and Operation........................................................... 792 Main Relief Valve Circuit Operation............................................................................... 795 Circuit Relief and Anticavitation Valve Operation................................................................. 799 Travel Flow Combiner Valve Operation.............................................................................. 800 Auxiliary Flow Combiner Valve and Bypass Shutoff Valve Operation.................................................. 803 Boom Lower Meter-In Cut Valve Operation........................................................................... 807 Boom Regenerative Valve Circuit Operation......................................................................... 809 Dig Regenerative Valve Circuit Operation.......................................................................... 811 Arm Regenerative Valve Circuit Operation.......................................................................... 817 Bucket Regenerative Valve Circuit Operation....................................................................... 823 Boom and Arm Reduced Leakage Valves Operation..................................................................... 826 Arm 1 Flow Rate Control Valve Circuit Operation................................................................... 829 Arm 2 Flow Rate Control Valve Circuit Operation................................................................... 833 Bucket Flow Rate Control Valve Circuit Operation.................................................................. 837 Boom Flow Rate Control Valve Circuit Operation.................................................................... 841 Auxiliary Flow Rate Control Valve Circuit Operation............................................................... 846 Swing Reduction Gear Case Operation............................................................................... 849 Swing Motor, Crossover Relief Valve, and Make-Up Check Valve Operation............................................ 850 Swing Motor Damper Valve.......................................................................................... 853 Swing Motor Park Brake Release Circuit Operation.................................................................. 861 Center Joint Operation............................................................................................ 862 Travel Motor and Park Brake Valve Operation....................................................................... 864 Travel Motor Speed Circuit Operation.............................................................................. 873 Cylinder Operation................................................................................................ 877 Return Filter Operation........................................................................................... 878 Auxiliary System Operation........................................................................................ 879 Auxiliary Pilot Control Valve Operation........................................................................... 879 Flow Rate Select Solenoid Valve Operation......................................................................... 890 Flow Rate Pressure Reducing Valve Operation....................................................................... 891 Secondary Auxiliary Relief Valve Solenoid Valve Operation......................................................... 891 Secondary Auxiliary Relief Control Valve Operation................................................................ 892 Secondary Auxiliary Relief Valve Operation........................................................................ 892 Selector Valve Solenoid Valve Operation........................................................................... 893 Selector Valve Operation.......................................................................................... 893 Auxiliary Shuttle Valve Operation................................................................................. 894 Auxiliary High Flow Line Kit Operation............................................................................ 895 Two Way Solenoid Kit Operation.................................................................................... 899 Two Pump Combined Flow Kit Operation.............................................................................. 903 Secondary Auxiliary Relief Kit Operation.......................................................................... 908 Low Flow Kit Operation............................................................................................ 911 Diagnostic Information................................................................................................ 919 All Hydraulic Functions Slow...................................................................................... 919 All Hydraulic Functions Slow Diagnostic Procedure............................................................. 919 Hydraulic Oil Overheats........................................................................................... 920 Hydraulic Oil Overheats Diagnostic Procedure.................................................................. 920 No Hydraulic Functions............................................................................................ 922 No Hydraulic Functions Diagnostic Procedure................................................................... 922 No Hydraulic Functions—Electrical Checks.......................................................................... 923 No Hydraulic Functions—Electrical Checks Diagnostic Procedure................................................. 923 Function Does Not Stop When Control Lever Released................................................................ 925 Function Does Not Stop When Control Lever Released Diagnostic Procedure....................................... 925 Load Drifts Down When Control Lever is in Neutral Position........................................................ 926 Load Drifts Down When Control Lever is in Neutral Position Diagnostic Procedure............................... 926 Load Falls When Control Valve is Actuated To Raise Load........................................................... 928 Load Falls When Control Valve is Actuated To Raise Load Diagnostic Procedure.................................. 928 H/P (High Power) Function Does Not Operate, PWR (Power) Mode is Normal............................................ 928 H/P (High Power) Function Does Not Operate, PWR (Power) Mode is Normal Diagnostic Procedure................... 928 Boom Down Does Not Function, Moves Slowly, or Is Erratic, All Other Functions Normal.............................. 930 Boom Down Does Not Function, Moves Slowly, or Is Erratic, All Other Functions Normal Diagnostic Procedure..... 930 Arm In Does Not Function, Moves Slowly, or Is Erratic, All Other Functions Normal................................. 931 Arm In Does Not Function, Moves Slowly, or Is Erratic, All Other Functions Normal Diagnostic Procedure........ 931 Swing Speed Slow During Arm In Function........................................................................... 932 Swing Speed Slow During Arm In Function Diagnostic Procedure.................................................. 932 Boom Cannot Raise Track Off Ground................................................................................ 932 Boom Cannot Raise Track Off Ground Diagnostic Procedure....................................................... 932 Swing Function Does Not Operate in Both Directions................................................................ 934 Swing Function Does Not Operate in Both Directions Diagnostic Procedure....................................... 934 Swing Speed Slow in Both Directions............................................................................... 936 Swing Speed Slow in Both Directions Diagnostic Procedure...................................................... 936 Swing Speed Slow or Does Not Operate in One Direction............................................................. 937 Swing Speed Slow or Does Not Operate in One Direction Diagnostic Procedure.................................... 937 Upperstructure Drift With Swing Valve in Neutral.................................................................. 938 Upperstructure Drift With Swing Valve in Neutral Diagnostic Procedure......................................... 938 Machine Freewheels Down an Incline................................................................................ 940 Machine Freewheels Down an Incline Diagnostic Procedure....................................................... 940 Track Will Not Move in Either Direction........................................................................... 940 Track Will Not Move in Either Direction Diagnostic Procedure.................................................. 941 Machine Mistracks................................................................................................. 942 Machine Mistracks Diagnostic Procedure........................................................................ 942 Machine Mistracks Left During Combined Travel and Dig Functions................................................... 944 Machine Mistracks Left During Combined Travel and Dig Functions Diagnostic Procedure.......................... 944 Machine Will Not Shift Into Fast (rabbit) Speed................................................................... 944 Machine Will Not Shift Into Fast (rabbit) Speed Diagnostic Procedure.......................................... 944 Pump 1, Pump 2, and Pilot Pump Line Identification................................................................ 947 Control Valve Line Identification................................................................................. 948 Swing Motor Line Identification................................................................................... 951 Pilot Control Valve-to-Pilot Signal Manifold Component Location—Excavator Pattern................................. 953 Pilot Control Valve-to-Pilot Signal Manifold Component Location—Backhoe Pattern................................... 957 Pilot Signal Manifold-to-Control Valve Line Connection............................................................ 960 Pilot Control Lever Pattern Selector Valve Line Connection........................................................ 964 Travel System Component Location.................................................................................. 966 Travel Hydraulic System Line Connection........................................................................... 967 Auxiliary Attachment Schematic.................................................................................... 971 Auxiliary System Line Connections................................................................................. 997 Hydraulic System Schematic........................................................................................1005 Hydraulic System Component Location...............................................................................1021 Hydraulic System Line Connections.................................................................................1023 Fan Drive Hydraulic System Component Location.....................................................................1027 Fan Drive Hydraulic System Schematic..............................................................................1030 Tests.................................................................................................................1033 JT05800 Digital Thermometer Installation..........................................................................1033 JT02156A Digital Pressure and Temperature Analyzer Kit Installation...............................................1033 General Hydraulic Oil Cleanup Procedure...........................................................................1034 Hydraulic Component Failure Cleanup Procedure.....................................................................1036 Hydraulic Oil Tank Pressure Release Procedure.....................................................................1037 Hydraulic Oil Warm-Up Procedure...................................................................................1038 Pilot Pressure Regulating Valve Test and Adjustment...............................................................1040 Control Valve Spool Actuating Pilot Pressure Test.................................................................1042 Dig Regenerative Solenoid Valve Test and Adjustment...............................................................1044 Arm Regenerative Solenoid Valve Test and Adjustment...............................................................1046 Power Dig/Travel Speed Solenoid Valve Test and Adjustment.........................................................1048 Torque Control Solenoid Valve Test and Adjustment.................................................................1050 Pump Control Pilot Pressure Signal Test...........................................................................1052 Main Relief and Power Dig Valve Test and Adjustment...............................................................1054 Circuit Relief Valve Test and Adjustment..........................................................................1057 Swing Motor Crossover Relief Valve Test and Adjustment............................................................1060 Travel Motor Crossover Relief Valve Test and Adjustment...........................................................1062 Pump Regulator Test and Adjustment—Minimum Flow...................................................................1065 Pump Regulator Test and Adjustment—Maximum Flow...................................................................1067 Pump Flow Test....................................................................................................1069 Swing Motor Leakage Test..........................................................................................1075 Travel Motor Leakage Test.........................................................................................1076 Cylinder Drift Test—Boom, Arm, and Bucket.........................................................................1078 Upperstructure Drift Test.........................................................................................1080 Fan Drive Pump Flow Test..........................................................................................1082 Fan Speed Test....................................................................................................1084 Heating and Air Conditioning..............................................................................................1085 Theory of Operation...................................................................................................1087 Air Conditioning System Cycle of Operation........................................................................1087 Diagnostic Information................................................................................................1089 Air Conditioning System Does Not Operate..........................................................................1089 Air Conditioning System Does Not Operate Diagnostic Procedure.................................................1089 Air Conditioning System Does Not Cool Interior of Cab.............................................................1091 Air Conditioning System Does Not Cool Interior of Cab Diagnostic Procedure....................................1091 Air Conditioning System Runs Constantly, Too Cold.................................................................1092 Air Conditioning System Runs Constantly, Too Cold Diagnostic Procedure........................................1092 Heating System Does Not Operate...................................................................................1093 Heating System Does Not Operate Diagnostic Procedure..........................................................1093 Heating System Does Not Warm Interior of Cab......................................................................1094 Heating System Does Not Warm Interior of Cab Diagnostic Procedure.............................................1094 Interior Windows Continue to Fog..................................................................................1096 Interior Windows Continue to Fog Using Heater Diagnostic Procedure............................................1096 Heater and Air Conditioner Component Location.....................................................................1098 Tests.................................................................................................................1101 R134a Refrigerant Cautions and Proper Handling....................................................................1101 R134a Oil Charge Capacity.........................................................................................1101 R134a Refrigerant Charge Capacity.................................................................................1101 Heater and Air Conditioner Operational Checks.....................................................................1102 Visual Inspection of Components...............................................................................1102 Air Conditioner Compressor Clutch Test............................................................................1103 R134a Refrigerant Leak Test.......................................................................................1103 R134a Refrigerant Hoses and Tubing Inspection.....................................................................1104 Air Conditioner High/Low-Pressure Switch Test.....................................................................1105 Air Conditioner Freeze Control Switch Test........................................................................1106 Air Conditioning System Test......................................................................................1107 Operating Pressure Diagnostic Chart...............................................................................1109 Dealer Fabricated Tools...................................................................................................1111 Dealer Fabricated Tools...............................................................................................1113 DFT1218 Split Flange Hose Cap.....................................................................................1113 Page Number................................................................................................................... 7 Section 9000.............................................................................................................. 9 Group 01.............................................................................................................. 11 Section 9001.............................................................................................................. 32 Group 10.............................................................................................................. 33 Group 20.............................................................................................................. 163 Group 30.............................................................................................................. 179 Group 40.............................................................................................................. 181 Group 50.............................................................................................................. 193 Section 9005.............................................................................................................. 209 Group 10.............................................................................................................. 211 Section 9010.............................................................................................................. 261 Group 05.............................................................................................................. 263 Group 15.............................................................................................................. 283 Group 20.............................................................................................................. 285 Group 25.............................................................................................................. 287 Section 9015.............................................................................................................. 291 Group 05.............................................................................................................. 293 Group 10.............................................................................................................. 301 Group 15.............................................................................................................. 565 Group 16.............................................................................................................. 685 Group 20.............................................................................................................. 697 Section 9020.............................................................................................................. 721 Group 05.............................................................................................................. 723 Group 15.............................................................................................................. 727 Section 9025.............................................................................................................. 735 Group 05.............................................................................................................. 737 Group 15.............................................................................................................. 919 Group 25..............................................................................................................1033 Section 9031..............................................................................................................1085 Group 05..............................................................................................................1087 Group 15..............................................................................................................1089 Group 25..............................................................................................................1101 Section 9900..............................................................................................................1111 Group 99..............................................................................................................1113
S.S 16/02/2025
