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John Deere 200D & 200DLC Excavator Operation & Test Manual TM10076 – PDF DOWNLOAD
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Description
John Deere 200D & 200DLC Excavator Operation & Test Manual TM10076 – PDF DOWNLOAD
FILE DETAILS:
John Deere 200D & 200DLC Excavator Operation & Test Manual TM10076 – PDF DOWNLOAD
Language : English
Pages : 988
Downloadable : Yes
File Type : PDF
IMAGES PREVIEW OF THE MANUAL:
DESCRIPTION:
John Deere 200D & 200DLC Excavator Operation & Test Manual TM10076 – 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.
- This is the safety-alert symbol. When you see this symbol on the machine or in this manual, be alert to the potential for personal injury.
- Technical manuals are divided in two parts: repair and operation and tests. Repair sections tell how to repair the components. Operation and tests sections help you identify the majority of routine failures quickly.
- Information is organized in groups for the various components requiring service instruction. At the beginning of each group are summary listings of all applicable essential tools, service equipment and tools, other materials needed to do the job, service parts kits, specifications, wear tolerances, and torque values.
- Technical Manuals are concise guides for specific machines. They are on-the-job guides containing only the vital information needed for diagnosis, analysis, testing, and repair.
- Fundamental service information is available from other sources covering basic theory of operation, fundamentals of troubleshooting, general maintenance, and basic type of failures and their causes
TABLE OF CONTENTS:
John Deere 200D & 200DLC Excavator Operation & Test Manual TM10076 – 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 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 Beware of Exhaust Fumes.......................................................................................... 12 Prevent Fires.................................................................................................... 13 Prevent Battery Explosions....................................................................................... 13 Handle Chemical Products Safely.................................................................................. 13 Dispose of Waste Properly........................................................................................ 14 Prepare for Emergencies.......................................................................................... 14 Use Steps and Handholds Correctly................................................................................ 14 Start Only From Operator's Seat.................................................................................. 14 Use and Maintain Seat Belt....................................................................................... 15 Prevent Unintended Machine Movement.............................................................................. 15 Avoid Worksite Hazards........................................................................................... 16 Keep Riders Off Machine.......................................................................................... 16 Avoid Backover Accidents......................................................................................... 17 Avoid Machine Tip Over........................................................................................... 17 Use Special Care When Lifting Objects............................................................................ 18 Add and Operate Attachments Safely............................................................................... 18 Park and Prepare for Service Safely.............................................................................. 18 Service Cooling System Safely.................................................................................... 19 Remove Paint Before Welding or Heating........................................................................... 19 Make Welding Repairs Safely...................................................................................... 19 Drive Metal Pins Safely.......................................................................................... 20 Diagnostics.............................................................................................................. 24 Main Controller (MCF) Diagnostic Trouble Codes....................................................................... 25 Main Controller (MCF) Diagnostic Trouble Codes................................................................... 25 11000.02 — Abnormal EEPROM....................................................................................... 25 Controller Hardware Diagnostics.............................................................................. 25 11001.02 — Abnormal RAM.......................................................................................... 25 Controller Hardware Diagnostics.............................................................................. 25 11002.02 — Abnormal A/D Conversion............................................................................... 26 Controller Hardware Diagnostics.............................................................................. 26 11003.03 — Abnormal Sensor Voltage............................................................................... 27 Abnormal Sensor Voltage Diagnostic Procedure................................................................. 27 11004.02 — Abnormal CAN Communication............................................................................ 28 Controller Area Network (CAN) Diagnostics ................................................................... 28 11100.02 — Abnormal Engine Speed................................................................................. 40 Engine Speed Diagnostics..................................................................................... 40 11101.03 — Engine Control Dial Voltage High...................................................................... 40 Engine Speed Dial Diagnostics................................................................................ 40 11101.04 — Engine Control Dial Sensor Voltage Low................................................................ 42 Engine Speed Dial Diagnostics................................................................................ 42 11200.03 — Pump 1 Delivery Pressure Sensor Voltage High.......................................................... 44 Pump 1 Delivery Pressure Sensor Diagnostics.................................................................. 44 11200.04 — Pump 1 Delivery Pressure Sensor Voltage Low........................................................... 46 Pump 1 Delivery Pressure Sensor Diagnostics.................................................................. 46 11202.03 — Pump 2 Delivery Pressure Sensor Voltage High.......................................................... 48 Pump 2 Delivery Pressure Sensor Diagnostics.................................................................. 48 11202.04 — Pump 2 Delivery Pressure Sensor Voltage Low........................................................... 50 Pump 2 Delivery Pressure Sensor Diagnostics.................................................................. 50 11206.03 — Pump 1 Control Pressure Sensor Voltage High........................................................... 52 Pump 1 Control Pressure Sensor Diagnostics................................................................... 52 11206.04 — Pump 1 Control Pressure Sensor Voltage Low............................................................ 54 Pump 1 Control Pressure Sensor Diagnostics................................................................... 54 11208.03 — Pump 2 Control Pressure Sensor Voltage High........................................................... 56 Pump 2 Control Pressure Sensor Diagnostics................................................................... 56 11208.04 — Pump 2 Control Pressure Sensor Voltage Low............................................................ 58 Pump 2 Control Pressure Sensor Diagnostics................................................................... 58 11301.03 — Swing Pilot Pressure Sensor Voltage High.............................................................. 60 Swing Pilot Pressure Sensor Diagnostics...................................................................... 60 11301.04 — Swing Pilot Pressure Sensor Voltage Low............................................................... 62 Swing Pilot Pressure Sensor Diagnostics...................................................................... 62 11302.03 — Boom Up Pilot Pressure Sensor Voltage High............................................................ 64 Boom Up Pilot Pressure Sensor Diagnostics.................................................................... 64 11302.04 — Boom Up Pilot Pressure Sensor Voltage Low............................................................. 66 Boom Up Pilot Pressure Sensor Diagnostics.................................................................... 66 11303.03 — Arm In Pilot Pressure Sensor Voltage High............................................................. 68 Arm In Pilot Pressure Sensor Diagnostics..................................................................... 68 11303.04 — Arm In Pilot Pressure Sensor Voltage Low.............................................................. 70 Arm In Pilot Pressure Sensor Diagnostics..................................................................... 70 11304.03 — Travel Pilot Pressure Sensor Voltage High............................................................. 72 Travel Pilot Pressure Sensor Diagnostics..................................................................... 72 11304.04 — Travel Pilot Pressure Sensor Voltage Low.............................................................. 74 Travel Pilot Pressure Sensor Diagnostics..................................................................... 74 11307.03 — Front Attachment Pilot Pressure Sensor Voltage High................................................... 75 Front Attachment Pilot Pressure Sensor Diagnostics........................................................... 75 11307.04 — Front Attachment Pilot Pressure Sensor Voltage Low.................................................... 77 Front Attachment Pilot Pressure Sensor Diagnostics........................................................... 77 11400.02 — Pump 2 Flow Rate Limit Solenoid Current Feedback Abnormal............................................. 79 Pump 2 Flow Rate Limit Solenoid Diagnostics.................................................................. 79 11400.03 — Pump 2 Flow Rate Limit Solenoid Current Feedback Abnormal............................................. 80 Pump 2 Flow Rate Limit Solenoid Diagnostics.................................................................. 80 11400.04 — Pump 2 Flow Rate Limit Solenoid Feedback Current Low.................................................. 81 Pump 2 Flow Rate Limit Solenoid Diagnostics.................................................................. 81 11401.02 — Torque Control Solenoid Feedback Current Abnormal..................................................... 81 Torque Control Solenoid Diagnostics.......................................................................... 81 11401.03 — Torque Control Solenoid Feedback Current High......................................................... 82 Torque Control Solenoid Diagnostics.......................................................................... 82 11401.04 — Torque Control Solenoid Feedback Current Low.......................................................... 83 Torque Control Solenoid Diagnostics.......................................................................... 83 11402.02 — Dig Regenerative Solenoid Feedback Current Abnormal................................................... 84 Dig Regenerative Solenoid Diagnostics........................................................................ 85 11402.03 — Dig Regenerative Solenoid Feedback Current High....................................................... 85 Dig Regenerative Solenoid Diagnostics........................................................................ 85 11402.04 — Dig Regenerative Solenoid Feedback Current Low........................................................ 86 Dig Regenerative Solenoid Diagnostics........................................................................ 86 11403.02 — Arm Regenerative Solenoid Feedback Current Abnormal................................................... 87 Arm Regenerative Solenoid Diagnostics........................................................................ 87 11403.03 — Arm Regenerative Solenoid Feedback Current High....................................................... 88 Arm Regenerative Solenoid Diagnostics........................................................................ 88 11403.04 — Arm Regenerative Solenoid Feedback Current Low........................................................ 88 Arm Regenerative Solenoid Diagnostics........................................................................ 88 11404.02 — Power Dig Solenoid Feedback Current Abnormal.......................................................... 89 Power Dig Solenoid Diagnostics............................................................................... 89 11404.03 — Power Dig Solenoid Feedback Current High.............................................................. 90 Power Dig Solenoid Diagnostics............................................................................... 90 11404.04 — Power Dig Solenoid Feedback Current Low............................................................... 91 Power Dig Solenoid Diagnostics............................................................................... 91 11405.02 — Travel Speed Solenoid Feedback Current Abnormal....................................................... 91 Power Dig Solenoid Diagnostics............................................................................... 91 11405.03 — Travel Speed Solenoid Feedback Current High........................................................... 92 Travel Speed Solenoid Diagnostics............................................................................ 92 11405.04 — Travel Speed Solenoid Feedback Current Low............................................................ 93 Travel Speed Solenoid Diagnostics............................................................................ 93 11901.03 — Hydraulic Oil Temperature Sensor Voltage High......................................................... 94 Hydraulic Oil Temperature Sensor Diagnostics................................................................. 94 11901.04 — Hydraulic Oil Temperature Sensor Voltage Low.......................................................... 95 Hydraulic Oil Temperature Sensor Diagnostics................................................................. 95 11910.02 — Actual Engine Speed Message Error..................................................................... 97 Controller Area Network (CAN) Diagnostics ................................................................... 97 11911.02 — Security Signal Received from Monitor................................................................. 98 Controller Area Network (CAN) Diagnostics ................................................................... 98 11914.02 — Radiator Coolant Temperature Message Error............................................................110 Controller Area Network (CAN) Diagnostics ...................................................................110 11918.02 — Work Mode Received Message Error......................................................................111 Controller Area Network (CAN) Diagnostics ...................................................................111 11920.02 — Fuel Flow Rate Message Error..........................................................................123 Controller Area Network (CAN) Diagnostics ...................................................................123 20100.02 — Engine Coolant Overheat Message.......................................................................124 Engine Control Unit (ECU) Diagnostic Trouble Codes...................................................................125 Engine Control Unit (ECU) Diagnostic Trouble Codes...............................................................125 171.03 — Intake Air Temperature Sensor Out of Range High.........................................................125 Intake Air Temperature Sensor Diagnostics....................................................................125 171.04 — Intake Air Temperature Sensor Out of Range Low..........................................................125 Intake Air Temperature Sensor Diagnostics....................................................................125 647.05 — Proportional Fan Speed Solenoid Driver Open.............................................................126 Proportional Fan Speed Solenoid Diagnostics..................................................................126 647.31 — Fan Manual Reverse Mode Input Active Too Long...........................................................127 Fan Manual Reverse Mode Input Diagnostics....................................................................127 898.09 — Engine Speed Request Not Received or Timed Out..........................................................127 Controller Area Network (CAN) Diagnostics ...................................................................127 1638.09 — Hydraulic Oil Temperature Message Not Received or Timed Out............................................139 Controller Area Network (CAN) Diagnostics ...................................................................139 Information Controller (ICF) Diagnostic Trouble Codes................................................................151 Information Controller (ICF) Diagnostic Trouble Codes............................................................151 14000.02 — Abnormal CAN Communication............................................................................151 Controller Area Network (CAN) Diagnostics ...................................................................151 14001.02 — ICF: Flash Memory: Read/Write Error...................................................................162 Controller Hardware Diagnostics..............................................................................162 14002.02 — ICF: External RAM: Read/Write Error...................................................................163 Controller Hardware Diagnostics..............................................................................163 14003.02 — ICF: EEPROM: Sum Check Error..........................................................................164 Controller Hardware Diagnostics..............................................................................164 14006.02 — ICF: Satellite Communication Terminal: Communication Error............................................165 14008.02 — ICF: Abnormal Internal RAM............................................................................165 Controller Hardware Diagnostics..............................................................................165 14100.02 — Satellite Communication Terminal: Abnormal EEPROM.....................................................165 14101.02 — Satellite Communication Terminal: Abnormal IB/OB Queue................................................165 14102.02 — Satellite Communication Terminal: Abnormal Local Loop Back............................................166 14103.02 — Satellite Communication Terminal: The Satellite is not found..........................................166 14104.02 — Satellite Communication Terminal: Fail 1 of Remote Loop Back..........................................166 14105.02 — Satellite Communication Terminal: Tail 2 of Remote Loop Back..........................................166 14106.02 — Satellite Communication Terminal: Sending and Receiving Data are Mismatched...........................166 Air Conditioner Controller (ACF) Diagnostic Trouble Codes............................................................167 Air Conditioner Controller (ACF) Diagnostic Trouble Codes........................................................167 21 — Mix Door Open Circuit.......................................................................................167 Harness Diagnostics..........................................................................................167 -21 — Mix Door Short Circuit.....................................................................................167 Harness Diagnostics..........................................................................................167 22 — Mode Encoder Open Circuit...................................................................................168 Harness Diagnostics..........................................................................................168 23 — In-Cab Ambient Temperature Sensor Open Circuit..............................................................169 Harness Diagnostics..........................................................................................169 -23 — In-Cab Ambient Temperature Sensor Short Circuit............................................................169 Harness Diagnostics..........................................................................................169 24 — Outdoor Ambient Temperature Sensor Open Circuit.............................................................169 Harness Diagnostics..........................................................................................170 -24 — Outdoor Ambient Temperature Sensor Short Circuit...........................................................170 Harness Diagnostics..........................................................................................170 25 — Coolant Temperature Sensor Open Circuit.....................................................................170 Harness Diagnostics..........................................................................................170 -25 — Coolant Temperature Sensor Short Circuit...................................................................171 Harness Diagnostics..........................................................................................171 26 — Solar Radiation Sensor Open Circuit.........................................................................171 Harness Diagnostics..........................................................................................171 -26 — Solar Radiation Sensor Short Circuit.......................................................................172 Harness Diagnostics..........................................................................................172 Monitor Controller (MON) Diagnostic Trouble Codes....................................................................173 Monitor Controller (MON) Diagnostic Trouble Codes................................................................173 13303.02 — Abnormal Thermister Temperature.......................................................................173 Monitor Temperature Diagnostics..............................................................................173 13304.02 — Abnormal REG Input H Level............................................................................173 Alternator Output Diagnostics................................................................................173 13306.02 — Abnormal EEPROM.......................................................................................174 Information Controller Diagnostics...........................................................................174 13308.02 — Abnormal CAN Communication............................................................................174 Controller Area Network Diagnostics..........................................................................175 13310.02 — Shorted Circuit in Coolant Temperature Sensor.........................................................175 13311.03 — Fuel Level Sensor Short Circuit.......................................................................175 Fuel Level Sensor Diagnostics................................................................................175 13311.04 — Fuel Level Sensor Open Circuit........................................................................176 Fuel Level Sensor Diagnostics................................................................................176 13334.2 — Radiator Coolant Error.................................................................................177 20105.2 — Hydraulic Oil Filter Restriction Alarm.................................................................177 Hydraulic Oil Filter Restriction Alarm Diagnostic Procedure..................................................177 20106.2 — Air Cleaner Restriction Alarm..........................................................................178 Air Cleaner Restriction Alarm Diagnostics....................................................................178 Operational Checkout Procedure...........................................................................................181 Operational Checkout Procedure.......................................................................................183 Operational Checkout.............................................................................................183 Diagnostic Trouble Codes Check...............................................................................183 Operational Checks—Key Switch Off, Engine Off Checks.........................................................183 Operational Checks—Key Switch On, Engine Off Checks..........................................................185 Operational Checks—Key Switch On, Engine On Checks...........................................................191 Engine...................................................................................................................221 Theory of Operation..................................................................................................223 Engine Fuel System Component Location............................................................................223 Engine Cooling System Component Location.........................................................................225 Cold Weather Starting Aid........................................................................................226 Engine Speed Control System Operation............................................................................227 Diagnostic Information...............................................................................................229 PowerTech Plus™ 4.5 L and 6.8 L (4045 and 6068) John Deere Engines...............................................229 Tests................................................................................................................231 Radiator Temperature Differential Check..........................................................................231 Engine Power Test Using Turbocharger Boost Pressure..............................................................233 Electrical System........................................................................................................236 System Information...................................................................................................237 Electrical Diagram Information...................................................................................237 System Diagrams......................................................................................................245 Explanation of Wire Markings.....................................................................................245 Fuse and Relay Specifications....................................................................................245 System Functional Schematic, Component Location, and Wiring Diagram Master Legend................................249 System Functional Schematic......................................................................................255 Cab Harness (W1) Component Location..............................................................................291 Cab Harness (W1) Wiring Diagram..................................................................................295 Machine Harness (W2) Component Location..........................................................................311 Machine Harness (W2) Wiring Diagram..............................................................................323 Monitor Harness (W3) Component Location..........................................................................346 Monitor Harness (W3) Wiring Diagram..............................................................................347 Engine Harness (W4) Component Location...........................................................................354 Engine Harness (W4) Wiring Diagram...............................................................................363 Engine Interface Harness (W5) Component Location.................................................................379 Engine Interface Harness (W5) Wiring Diagram.....................................................................386 Right Console Harness (W7) Component Location....................................................................390 Right Console Harness (W7) Wiring Diagram........................................................................395 Pump Harness (W8) Component Location.............................................................................402 Pump Harness (W8) Wiring Diagram.................................................................................403 Auxiliary Fuse Box Harness (W9) Component Location...............................................................406 Auxiliary Fuse Box Harness (W9) Wiring Diagram...................................................................409 Pilot Shutoff Switch Harness (W11) Component Location............................................................412 Pilot Shutoff Switch Harness (W11) Wiring Diagram................................................................413 Air Suspension Seat Harness (W12) Component Location.............................................................416 Air Suspension Seat Harness (W12) Wiring Diagram.................................................................418 Seat Heater Switch Harness (W13) Component Location..............................................................419 Seat Heater Switch Harness (W13) Wiring Diagram..................................................................420 Multi-Function Pilot Control Lever Harness (W14) Component Location..............................................422 Multi-Function Pilot Control Lever Harness (W14) Wiring Diagram..................................................423 Travel Alarm Cancel Switch Harness (W15) Component Location......................................................425 Travel Alarm Cancel Switch Harness (W15) Wiring Diagram..........................................................425 Fan Reversing Switch Harness (W16) Component Location............................................................425 Fan Reversing Switch Harness (W16) Wiring Diagram................................................................426 Pilot Shutoff Valve Harness (W17) Component Location.............................................................427 Pilot Shutoff Valve Harness (W17) Wiring Diagram.................................................................427 Attachment Harness (W20) Component Location......................................................................429 Attachment Harness (W20) Wiring Diagram..........................................................................433 2-Speed Harness (W21) Component Location.........................................................................435 2-Speed Harness (W21) Wiring Diagram.............................................................................436 Alternator Harness (W22) Component Location......................................................................437 Alternator Harness (W22) Wiring Diagram..........................................................................438 Start Aid Switch Harness (W23) Component Location................................................................439 Start Aid Switch Harness (W23) Wiring Diagram....................................................................439 Starter Harness (W27) Component Location.........................................................................440 Starter Harness (W27) Wiring Diagram.............................................................................443 Auxiliary Solenoid Harness (W61) Component Location..............................................................450 Auxiliary Solenoid Harness (W61) Wiring Diagram..................................................................452 JDLink™ System Harnesses Component Location—MIG/GTT..............................................................453 JDLink™ System Harnesses Component Location—MTG/SAT..............................................................458 JDLink™ System Wiring Diagrams—MIG/GTT...........................................................................459 JDLink™ System Wiring Diagrams—MTG/SAT...........................................................................475 Sub-System Diagnostics...............................................................................................480 Controller Area Network (CAN) Theory of Operation................................................................480 Starting and Charging Circuit Theory of Operation................................................................483 Monitor Controller Circuit Theory of Operation...................................................................489 Engine Control Unit (ECU) Circuit Theory of Operation............................................................497 Main Controller (MCF) Circuit Theory of Operation................................................................505 Information Controller (ICF) Circuit Theory of Operation.........................................................515 Travel Alarm Circuit Theory of Operation.........................................................................518 Windshield Wiper and Washer Circuit Theory of Operation..........................................................521 Pilot Shutoff Circuit Theory of Operation........................................................................525 Attachment Control Circuit Theory of Operation...................................................................528 JDLink™ Circuit Theory of Operation—If Equipped..................................................................532 Monitor Operation....................................................................................................537 Monitor Menu Operation...........................................................................................537 Monitor Service Menu Operation...................................................................................537 References...........................................................................................................541 Monitor Data Items...............................................................................................541 Reading Diagnostic Trouble Codes With Monitor Display............................................................542 JDLink™ System Identification....................................................................................544 JDLink™ Connection Procedure—If Equipped.........................................................................547 Service ADVISOR™ Diagnostic Application..........................................................................547 Service ADVISOR™ Connection Procedure............................................................................548 Reading Diagnostic Trouble Codes With Service ADVISOR™ Diagnostic Application....................................549 Fuse Test........................................................................................................551 Relay Test.......................................................................................................554 Pressure Sensor Test.............................................................................................555 Solenoid Test....................................................................................................555 Proportional Solenoid Test.......................................................................................556 Temperature Sensor Test..........................................................................................556 Alternator Test..................................................................................................557 Electrical Component Checks......................................................................................559 Component Checks.............................................................................................559 Battery Remove and Install.......................................................................................564 Rear Cover Remove and Install....................................................................................565 Main Controller (MCF) Remove and Install.........................................................................565 Engine Control Unit (ECU) Remove and Install.....................................................................566 Information Controller (ICF) Remove and Install..................................................................566 Monitor Controller Remove and Install............................................................................567 Key Switch Remove and Install....................................................................................568 Switch Panel Remove and Install..................................................................................569 Travel Alarm Remove and Install..................................................................................570 Left Console Switch Remove and Install...........................................................................570 Disconnect Tab Retainer Connectors...............................................................................570 Disconnecting Spring Wire Clip Connectors........................................................................571 Replace DEUTSCH DEUTSCH is a trademark of the Deutsch Co.™ Connectors............................................571 Replace DEUTSCHDEUTSCH is a trademark of Deutsch Co.™ Rectangular or Triangular Connectors.......................572 Install DEUTSCH DEUTSCH is a trademark of the Deutsch Co.™ Contact...............................................573 Replace WEATHER PACK WEATHER PACK is a trademark of Packard Electric.™Connector..................................575 Install WEATHER PACK WEATHER PACK is a trademark of Packard Electric.™Contact....................................576 Replace (Pull Type) Metri-Pack™ Connectors.......................................................................577 Replace (Push Type) Metri-Pack™ Connectors.......................................................................578 Replace CINCHCINCH is a trademark of the Cinch Co.™ Connectors...................................................578 Install CINCHCINCH is a trademark of the Cinch Co.™ Contact......................................................580 Repair 32 and 48 Way CINCHCINCH is a trademark of the Cinch Co.™ Connectors......................................581 Remove Connector Body from Blade Terminals.......................................................................583 Power Train..............................................................................................................585 Theory of Operation..................................................................................................587 Track Adjuster and Recoil Spring Operation.......................................................................587 Travel Gearbox Operation.........................................................................................588 Diagnostic Information...............................................................................................591 Diagnose Undercarriage Components Malfunctions...................................................................591 Noisy or Loose Track Chain...................................................................................591 Tight Track Chain............................................................................................591 Frequent Track Chain Sag Adjustment Required.................................................................591 Excessive Oil Leakage From Front Idler, Track Rollers, or Carrier Rollers....................................592 Bent Track Shoes.............................................................................................592 “Popping” Of Track...........................................................................................593 Cracked Track Link...........................................................................................593 Chipped Link Rails...........................................................................................594 Individual Undercarriage Component Wear......................................................................594 Measure Swing Bearing Wear.......................................................................................595 Hydraulic System.........................................................................................................599 Theory of Operation..................................................................................................601 Hydraulic System Diagram and Operation...........................................................................601 Fan Drive Hydraulic System Operation—If Equipped (Serial No. —511303)............................................603 Fan Drive Hydraulic System Operation—If Equipped (Serial No. 511304— )...........................................606 Pilot System Diagram and Operation...............................................................................610 Pilot Pump, Pressure Regulating Valve and Filter Operation.......................................................612 Pilot Shutoff Solenoid Valve Operation...........................................................................613 Pilot Control Valve Operation....................................................................................616 Travel Pilot Control Valve Operation.............................................................................618 Pilot Operation of Control Valve Operation.......................................................................621 Pilot Signal Manifold Operation..................................................................................624 Pump 1, Pump 2 and Drive Gearbox Operation.......................................................................634 Pump 1 and Pump 2 Regulator Operation............................................................................637 Engine Speed Sensing Control Circuit Operation...................................................................645 Control Valve Operation..........................................................................................647 Control Valve Check Valves Identification and Operation..........................................................660 Main Relief and Power Digging Valve Circuit Operation............................................................663 Circuit Relief and Anticavitation Valve Operation................................................................667 Travel Flow Combiner Valve Operation.............................................................................668 Boom Lower Meter-In Cut Valve Operation..........................................................................671 Boom Regenerative Valve Circuit Operation........................................................................674 Dig Regenerative Valve Circuit Operation.........................................................................677 Arm Regenerative Valve Circuit Operation.........................................................................682 Bucket Regenerative Valve Circuit Operation......................................................................686 Boom and Arm Reduced Leakage Valves Operation....................................................................690 Arm 1 Flow Rate Control Valve Circuit Operation..................................................................693 Arm 2 Flow Rate Control Valve Circuit Operation..................................................................697 Bucket Flow Rate Control Valve Circuit Operation.................................................................701 Boom Flow Rate Control Valve Circuit Operation...................................................................705 Auxiliary Flow Rate Control Valve Circuit Operation..............................................................708 Swing Reduction Gearbox Operation................................................................................711 Swing Motor, Crossover Relief Valve, and Make-Up Check Valve Operation...........................................712 Swing Motor Dampener Valve Operation.............................................................................715 Swing Motor Park Brake Release Circuit Operation.................................................................723 Center Joint Operation...........................................................................................724 Travel Motor and Park Brake Valve Operation......................................................................726 Travel Motor Speed Circuit Operation.............................................................................733 Cylinder Operation...............................................................................................735 Return Filter Operation..........................................................................................736 Auxiliary System Operation.......................................................................................737 Auxiliary Pilot Control Valve Operation..........................................................................737 Flow Rate Select Solenoid Valve Operation........................................................................748 Flow Rate Pressure Reducing Valve Operation......................................................................749 Secondary Auxiliary Relief Valve Solenoid Valve Operation........................................................749 Secondary Auxiliary Relief Control Valve Operation...............................................................750 Secondary Auxiliary Relief Valve Operation.......................................................................750 Selector Valve Solenoid Valve Operation..........................................................................751 Selector Valve Operation.........................................................................................751 Auxiliary Flow Combiner Valve Operation..........................................................................752 Auxiliary Shuttle Valve Operation................................................................................754 Auxiliary High Flow Line Kit Operation...........................................................................755 Two Way Solenoid Kit Operation...................................................................................759 Two Pump Combined Flow Kit Operation.............................................................................763 Secondary Auxiliary Relief Kit Operation.........................................................................768 Low Flow Kit Operation...........................................................................................771 Diagnostic Information...............................................................................................779 All Hydraulic Functions Slow.....................................................................................779 All Hydraulic Functions Slow Diagnostic Procedure............................................................779 Hydraulic Oil Overheats..........................................................................................780 Hydraulic Oil Overheats Diagnostic Procedure.................................................................780 No Hydraulic Functions...........................................................................................782 No Hydraulic Functions Diagnostic Procedure..................................................................782 No Hydraulic Functions—Electrical Checks.........................................................................783 No Hydraulic Functions—Electrical Checks Diagnostic Procedure................................................783 Function Does Not Stop When Control Lever Released...............................................................785 Function Does Not Stop When Control Lever Released Diagnostic Procedure......................................785 Load Drifts Down When Control Lever is in Neutral Position.......................................................786 Load Drifts Down When Control Lever is in Neutral Position Diagnostic Procedure..............................786 Load Falls When Control Valve is Actuated To Raise Load..........................................................788 Load Falls When Control Valve is Actuated to Raise Load Diagnostic Procedure.................................788 H/P (High Power) Function Does Not Operate, PWR (Power) Mode is Normal...........................................788 H/P (High Power) Function Does Not Operate, PWR (Power) Mode is Normal Diagnostic Procedure..................788 Boom Down Does Not Function, Moves Slowly, or is Erratic, All Other Functions Normal.............................790 Boom Down Does Not Function, Moves Slowly, or is Erratic, All Other Functions Normal Diagnostic Procedure....790 Arm In Does Not Function, Moves Slowly, or is Erratic, All Other Functions Normal................................791 Arm In Does Not Function, Moves Slowly, or is Erratic, All Other Functions Normal Diagnostic Procedure.......791 Swing Speed Slow During Arm In Function..........................................................................792 Swing Speed Slow During Arm In Function Diagnostic Procedure.................................................792 Boom Cannot Raise Track Off Ground...............................................................................792 Boom Cannot Raise Track Off Ground Diagnostic Procedure......................................................792 Swing Function Does Not Operate in Both Directions...............................................................794 Swing Function Does Not Operate in Both Directions Diagnostic Procedure......................................794 Swing Speed Slow in Both Directions..............................................................................796 Swing Speed Slow in Both Directions Diagnostic Procedure.....................................................796 Swing Speed Slow or Does Not Operate in One Direction............................................................797 Swing Speed Slow or Does Not Operate in One Direction Diagnostic Procedure...................................797 Upperstructure Drift With Swing Valve in Neutral.................................................................798 Upperstructure Drift With Swing Valve in Neutral Diagnostic Procedure........................................798 Machine Freewheels Down an Incline...............................................................................800 Machine Freewheels Down an Incline Diagnostic Procedure......................................................800 Track Will Not Move in Either Direction..........................................................................800 Track Will Not Move in Either Direction Diagnostic Procedure.................................................801 Machine Mistracks................................................................................................802 Machine Mistracks Diagnostic Procedure.......................................................................802 Machine Mistracks Left During Combined Travel and Dig Functions..................................................804 Machine Mistracks Left During Combined Travel and Dig Functions Diagnostic Procedure.........................804 Machine Will Not Shift Into Fast (Rabbit) Speed..................................................................804 Machine Will Not Shift Into Fast (rabbit) Speed Diagnostic Procedure.........................................804 Pump 1, Pump 2, and Pilot Pump Line Identification...............................................................808 Control Valve Line Identification................................................................................809 Swing Motor Line Identification..................................................................................812 Pilot Control Valve-to-Pilot Signal Manifold Component Location—Excavator Pattern................................813 Pilot Control Valve-to-Pilot Signal Manifold Component Location—Backhoe Pattern..................................817 Pilot Signal Manifold-to-Control Valve Line Connection...........................................................820 Travel System Component Location.................................................................................824 Travel Hydraulic System Line Connection..........................................................................825 Auxiliary Attachment Schematic...................................................................................829 Auxiliary System Line Connections................................................................................855 Hydraulic System Schematic.......................................................................................863 Hydraulic System Component Location..............................................................................880 Hydraulic System Line Connections................................................................................881 Fan Drive Hydraulic System Component Location....................................................................885 Fan Drive Hydraulic System Schematic (S.N. 511304— ).............................................................888 Fan Drive Hydraulic System Schematic (S.N. —511303)..............................................................890 Tests................................................................................................................893 JT05800 Digital Thermometer Installation.........................................................................893 JT02156A Digital Pressure/Temperature Analyzer Installation......................................................893 Hydraulic Oil Cleanup Procedure With Portable Filter Caddy.......................................................893 Hydraulic Oil Warm-Up Procedure..................................................................................894 Pilot Pressure Regulating Valve Test and Adjustment..............................................................896 Control Valve Spool Actuating Pilot Pressure Test................................................................898 Dig Regenerative Solenoid Valve Test and Adjustment..............................................................900 Arm Regenerative Solenoid Valve Test and Adjustment..............................................................902 Power Digging Solenoid Valve Test and Adjustment.................................................................904 Travel Speed Solenoid Valve Test and Adjustment..................................................................906 Pump Control Pilot Pressure Signal Test..........................................................................908 Torque Control Solenoid Valve Test and Adjustment................................................................909 Main Relief and Power Digging Valve Test and Adjustment..........................................................911 Circuit Relief Valve Test and Adjustment.........................................................................914 Swing Motor Crossover Relief Valve Test and Adjustment...........................................................917 Travel Motor Crossover Relief Valve Test and Adjustment..........................................................919 Pump Regulator Test and Adjustment—Minimum Flow..................................................................922 Pump Regulator Test and Adjustment—Maximum Flow..................................................................924 Pump Flow Test...................................................................................................926 Swing Motor Leakage Test.........................................................................................933 Travel Motor Leakage Test........................................................................................934 Cylinder Drift Test—Boom, Arm, and Bucket........................................................................936 Fan Drive Pump Flow Test.........................................................................................937 Fan Speed Test...................................................................................................939 Heating and Air Conditioning.............................................................................................941 Theory of Operation..................................................................................................943 Air Conditioning System Cycle of Operation.......................................................................943 Diagnostic Information...............................................................................................945 Diagnose Air Conditioning System Malfunctions....................................................................945 Diagnose Heating System Malfunctions.............................................................................948 Heater and Air Conditioner Diagnostic Trouble Code Check.........................................................950 Heater and Air Conditioner Component Location....................................................................953 Tests................................................................................................................957 R134a Refrigerant Cautions and Proper Handling...................................................................957 Heater and Air Conditioner Operational Checks....................................................................957 Visual Inspection of Components..............................................................................957 R134a Air Conditioning System Test...............................................................................960 Air Conditioner Compressor Clutch Test...........................................................................961 Refrigerant Leak Test............................................................................................961 Refrigerant Hoses and Tubing Inspection..........................................................................962 Air Conditioner High/Low-Pressure Switch Test....................................................................963 Air Conditioner Freeze Control Switch Test.......................................................................964 Air Conditioning System Test.....................................................................................965 Air Conditioner Compressor Belt Check and Adjustment.............................................................966 Operating Pressure Diagnostic Chart..............................................................................967 Reference Material.......................................................................................................969 Terminology Cross Reference Chart....................................................................................971 Terminology Cross Reference Chart................................................................................971 Dealer Fabricated Tools..................................................................................................973 Dealer Fabricated Tools..............................................................................................975 DFT1218 Split Flange Hose Cap....................................................................................975 Page Number.................................................................................................................. 5 Section 9000............................................................................................................. 7 Group 01............................................................................................................. 9 Section 9001............................................................................................................. 24 Group 10............................................................................................................. 25 Group 20.............................................................................................................125 Group 30.............................................................................................................151 Group 40.............................................................................................................167 Group 50.............................................................................................................173 Section 9005.............................................................................................................181 Group 10.............................................................................................................183 Section 9010.............................................................................................................221 Group 05.............................................................................................................223 Group 15.............................................................................................................229 Group 25.............................................................................................................231 Section 9015.............................................................................................................236 Group 05.............................................................................................................237 Group 10.............................................................................................................245 Group 15.............................................................................................................480 Group 16.............................................................................................................537 Group 20.............................................................................................................541 Section 9020.............................................................................................................585 Group 05.............................................................................................................587 Group 15.............................................................................................................591 Section 9025.............................................................................................................599 Group 05.............................................................................................................601 Group 15.............................................................................................................779 Group 25.............................................................................................................893 Section 9031.............................................................................................................941 Group 05.............................................................................................................943 Group 15.............................................................................................................945 Group 25.............................................................................................................957 Section 9050.............................................................................................................969 Group 05.............................................................................................................971 Section 9900.............................................................................................................973 Group 99.............................................................................................................975
S.S 16/02/2025
