John Deere 240DLC & 270DLC Excavator Operation and Test TECHNICAL MANUAL TM2320 PDF

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John Deere 240DLC & 270DLC Excavator Operation and Test TECHNICAL MANUAL TM2320  -PDF DOWNLOAD

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John Deere 240DLC & 270DLC Excavator Operation and Test TECHNICAL MANUAL TM2320  -PDF DOWNLOAD

Language : English
Pages :1218
Downloadable : Yes
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John Deere 240DLC & 270DLC Excavator Operation and Test TECHNICAL MANUAL TM2320  -PDF DOWNLOAD

Foreword

• This manual is written for an experienced technician. Essential tools required in performing certain service work are identified in this manual and are recommended for use. Live with safety: Read the safety messages in the introduction of this manual and the cautions presented throughout the text of the manual.
• This is the safetyalert 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 onthejob 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 240DLC & 270DLC Excavator Operation and Test TECHNICAL MANUAL TM2320  -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 Oils 11
Beware of Exhaust Fumes 12
Prevent Fires 12
Prevent Battery Explosions 12
Handle Chemical Products Safely 13
Dispose of Waste Properly 13
Prepare for Emergencies 13
Use Steps and Handholds Correctly 13
Start Only From Operator’s Seat 14
Use and Maintain Seat Belt 14
Prevent Unintended Machine Movement 14
Avoid Work Site Hazards 15
Keep Riders Off Machine 15
Avoid Backover Accidents 16
Avoid Machine Tip Over 16
Use Special Care When Lifting Objects 17
Add and Operate Attachments Safely 17
Prevent Unintended Detonation of Explosive Devices 17
Park and Prepare for Service Safely 18
Service Cooling System Safely 18
Remove Paint Before Welding or Heating 18
Make Welding Repairs Safely 19
Drive Metal Pins Safely 19
Diagnostics 24
Main Controller (MCF) Diagnostic Trouble Codes 25
Main Controller (MCF) Diagnostic Trouble Codes 25
1100002 — Abnormal EEPROM 25
Controller Hardware Diagnostics 25
1100102 — Abnormal RAM 25
Controller Hardware Diagnostics 25
1100202 — Abnormal A/D Conversion 26
Controller Hardware Diagnostics 26
1100303 — Abnormal Sensor Voltage 27
Harness diagnostics 27
1100402 — Abnormal CAN Communication 27
Controller Area Network (CAN) Diagnostics 27
1110002 — Abnormal Engine Speed 40
Engine Speed Diagnostics 40
1110103 — Engine Control Dial Sensor Voltage High 40
Engine Speed Dial Diagnostics 40
1110104 — Engine Control Dial Sensor Voltage Low 42
Engine Speed Dial Diagnostics 43
1120003 — Pump 1 Delivery Pressure Sensor Voltage High 44
Pump 1 Delivery Pressure Sensor Diagnostics 45
1120004 — Pump 1 Delivery Pressure Sensor Voltage Low 48
Pump 1 Delivery Pressure Sensor Diagnostics 48
1120203 — Pump 2 Delivery Pressure Sensor Voltage High 51
Pump 2 Delivery Pressure Sensor Diagnostics 51
1120204 — Pump 2 Delivery Pressure Sensor Voltage Low 54
Pump 2 Delivery Pressure Sensor Diagnostics 54
1120603 — Pump 1 Control Pressure Sensor Voltage High 57
Pump 1 Control Pressure Sensor Diagnostics 57
1120604 — Pump 1 Control Pressure Sensor Voltage Low 60
Pump 1 Control Pressure Sensor Diagnostics 60
1120803 — Pump 2 Control Pressure Sensor Voltage High 63
Pump 2 Control Pressure Sensor Diagnostics 63
1120804 — Pump 2 Control Pressure Sensor Voltage Low 66
Pump 2 Control Pressure Sensor Diagnostics 66
1130103 — Swing Pilot Pressure Sensor Voltage High 69
Swing Pilot Pressure Sensor Diagnostics 69
1130104 — Swing Pilot Pressure Sensor Voltage Low 71
Swing Pilot Pressure Sensor Diagnostics 71
1130203 — Boom Up Pilot Pressure Sensor Voltage High 74
Boom Up Pilot Pressure Sensor Diagnostics 74
1130204 — Boom Up Pilot Pressure Sensor Voltage Low 77
Boom Up Pilot Pressure Sensor Diagnostics 77
1130303 — Arm In Pilot Pressure Sensor Voltage High 80
Arm In Pilot Pressure Sensor Diagnostics 80
1130304 — Arm In Pilot Pressure Sensor Voltage Low 83
Arm In Pilot Pressure Sensor Diagnostics 83
1130403 — Travel Pilot Pressure Sensor Voltage High 86
Travel Pilot Pressure Sensor Diagnostics 86
1130404 — Travel Pilot Pressure Sensor Voltage Low 89
Travel Pilot Pressure Sensor Diagnostics 89
1130703 — Front Attachment Pilot Pressure Sensor Voltage High 92
Front Attachment Pilot Pressure Sensor Diagnostics 92
1130704 — Front Attachment Pilot Pressure Sensor Voltage Low 95
Front Attachment Pilot Pressure Sensor Diagnostics 95
1140002 — Pump 2 Flow Rate Limit Solenoid Current Feedback Abno 98
Pump 2 Flow Rate Limit Solenoid Diagnostics 98
1140003 — Pump 2 Flow Rate Limit Solenoid Current Feedback Abno 99
Pump 2 Flow Rate Limit Solenoid Diagnostics 99
1140004 — Pump 2 Flow Rate Limit Solenoid Feedback Current Low 100
Pump 2 Flow Rate Limit Solenoid Diagnostics 100
1140102 — Torque Control Solenoid Feedback Current Abnormal 101
Torque Control Solenoid Diagnostics 101
1140103 — Torque Control Solenoid Feedback Current High 102
Torque Control Solenoid Diagnostics 102
1140104 — Torque Control Solenoid Feedback Current Low 103
Torque Control Solenoid Diagnostics 103
1140202 — Dig Regenerative Solenoid Feedback Current Abnormal 103
Dig Regenerative Solenoid Diagnostics 104
1140203 — Dig Regenerative Solenoid Feedback Current High 104
Dig Regenerative Solenoid Diagnostics 104
1140204 — Dig Regenerative Solenoid Feedback Current Low 105
Dig Regenerative Solenoid Diagnostics 105
1140302 — Arm Regenerative Solenoid Feedback Current Abnormal 106
Arm Regenerative Solenoid Diagnostics 106
1140303 — Arm Regenerative Solenoid Feedback Current High 107
Arm Regenerative Solenoid Diagnostics 107
1140304 — Arm Regenerative Solenoid Feedback Current Low 108
Arm Regenerative Solenoid Diagnostics 108
1140402 — Power Dig Solenoid Feedback Current Abnormal 109
Power Dig Solenoid Diagnostics 109
1140403 — Power Dig Solenoid Feedback Current High 110
Power Dig Solenoid Diagnostics 110
1140404 — Power Dig Solenoid Feedback Current Low 111
Power Dig Solenoid Diagnostics 111
1140502 — Travel Speed Solenoid Feedback Current Abnormal 112
Power Dig Solenoid Diagnostics 112
1140503 — Travel Speed Solenoid Feedback Current High 113
Travel Speed Solenoid Diagnostics 113
1140504 — Travel Speed Solenoid Feedback Current Low 114
Travel Speed Solenoid Diagnostics 114
1141002 — Pump 1 Flow Rate Limit Solenoid Feedback Current Abno 115
Pump 1 Flow Rate Limit Solenoid Diagnostics 115
1141003 — Pump 1 Flow Rate Limit Solenoid Feedback Current High 116
Pump 1 Flow Rate Limit Solenoid Diagnostics 116
1141004 — Pump 1 Flow Rate Limit Solenoid Feedback Current Low 117
Pump 1 Flow Rate Limit Solenoid Diagnostics 117
1190103 — Hydraulic Oil Temperature Sensor Voltage High 118
Hydraulic Oil Temperature Sensor Diagnostics 118
1190104 — Hydraulic Oil Temperature Sensor Voltage Low 120
Hydraulic Oil Temperature Sensor Diagnostics 120
1191002 — Actual Engine Speed Message Error 123
Controller Area Network (CAN) Diagnostics 123
1191102 — Security Signal Received from ECM 135
Controller Area Network (CAN) Diagnostics 135
1191402 — Radiator Coolant Temperature Message Error 147
Controller Area Network (CAN) Diagnostics 147
1191802 — Work Mode Received Message Error 159
Controller Area Network (CAN) Diagnostics 159
1191902 — ML Crane Received Message Error 171
Controller Area Network (CAN) Diagnostics 171
1192002 — Fuel Flow Rate Message Error 183
Controller Area Network (CAN) Diagnostics 183
Engine Control Unit (ECU) Diagnostic Trouble Codes 197
Engine Control Unit (ECU) Diagnostic Trouble Codes 197
17103 — Intake Air Temperature Sensor Out of Range High 197
Intake Air Temperature Sensor Diagnostics 197
17104 — Intake Air Temperature Sensor Out of Range Low 198
Intake Air Temperature Sensor Diagnostics 198
64705 — Proportional Fan Speed Solenoid Driver Open 199
Proportional Fan Speed Solenoid Diagnostics 199
64731 — Fan Manual Reverse Mode Input Active Too Long 201
Fan Manual Reverse Mode Input Diagnostics 201
89809 — Engine Speed Request Not Received or Timed Out 202
Controller Area Network (CAN) Diagnostics 202
163809 — Hydraulic Oil Temperature Message Not Received or Time 241
Controller Area Network (CAN) Diagnostics 241
Information Controller (ICF) Diagnostic Trouble Codes 281
Information Controller (ICF) Diagnostic Trouble Codes 281
1400002 — Abnormal CAN Communication 281
1400102 — ICF: Flash Memory: Read / Write Error 281
1400202 — ICF: External RAM: Read / Write Error 281
1400302 — ICF: EEPROM: Sum Check Error 281
1400602 — ICF: Satellite Communication Terminal: Communication 281
1400802 — ICF: Abnormal Internal RAM 281
1410002 — Satellite Communication Terminal: Abnormal EEPROM 281
1410102 — Satellite Communication Terminal: Abnormal IB / OB Qu 281
1410202 — Satellite Communication Terminal: Abnormal Local Loop 281
1410302 — Satellite Communication Terminal: The Satellite is no 281
1410402 — Satellite Communication Terminal: Fail 1 of Remote Lo 282
1410502 — Satellite Communication Terminal: Tail 2 of Remote Lo 282
1410602 — Satellite Communication Terminal: Sending and Receivi 282
Air Conditioner Controller (ACF) Diagnostic Trouble Codes 283
Air Conditioner Controller (ACF) Diagnostic Trouble Codes 283
21 — Mix Door Open Circuit 283
Harness Diagnostics 283
-21 — Mix Door Short Circuit 283
Harness Diagnostics 283
22 — Mode Encoder Open Circuit 284
Harness Diagnostics 284
23 — In-Cab Ambient Temperature Sensor Open Circuit 285
Harness Diagnostics 285
-23 — In-Cab Ambient Temperature Sensor Short Circuit 285
Harness Diagnostics 285
24 — Outdoor Ambient Temperature Sensor Open Circuit 286
Harness Diagnostics 286
-24 — Outdoor Ambient Temperature Sensor Short Circuit 286
Harness Diagnostics 286
25 — Coolant Temperature Sensor Open Circuit 287
Harness Diagnostics 287
-25 — Coolant Temperature Sensor Short Circuit 287
Harness Diagnostics 287
26 — Solar Radiation Sensor Open Circuit 288
Harness Diagnostics 288
-26 — Solar Radiation Sensor Short Circuit 288
Harness Diagnostics 289
Monitor Controller (MON) Diagnostic Trouble Codes 291
Monitor Controller (MON) Diagnostic Trouble Codes 291
1330302 — Abnormal Thermister Temperature 291
Monitor Temperature Diagnostics 291
1330402 — Abnormal REG Input H Level 291
Alternator Output Diagnostics 291
1330602 — Abnormal EEPROM 292
Information Controller Diagnostics 292
1330802 — Abnormal CAN Communication 293
Controller Area Network Diagnostics 293
1331002 — Shorted Circuit in Coolant Temperature Sensor 294
1331103 — Fuel Level Sensor Short Circuit 294
Fuel Level Sensor Diagnostics 294
1331104 — Fuel Level Sensor Open Circuit 294
Fuel Level Sensor Diagnostics 295
Operational Checkout Procedure 297
Operational Checkout Procedure 299
Operational Checkout 299
Diagnostic Trouble Code Check 299
Operational Checks—Key Switch Off, Engine Off Checks 299
Operational Checks—Key Switch On, Engine Off Checks 301
Operational Checks—Key Switch On, Engine On Checks 310
Engine 343
Theory of Operation 345
Engine Oil Sampling Port Location 345
Engine Fuel System Component Location 347
Engine Cooling System Component Location 353
Cold Weather Starting Aid 355
Engine Speed Control System Operation 356
Diagnostic Information 359
PowerTech Plus™ 45 L and 68 L (4045 and 6068) John Deere Engin 359
Tests 361
Radiator Temperature Differential Check 361
Electrical System 365
System Information 367
Electrical Diagram Information 367
System Diagrams—240DLC 377
Explanation of Wire Markings 377
Fuse and Relay Specifications 377
System Functional Schematic, Component Location, and Wiring Diag 381
System Functional Schematic 387
Cab Harness (W1) Component Location 423
Cab Harness (W1) Wiring Diagram 427
Machine Harness (W2) Component Location 443
Machine Harness (W2) Wiring Diagram 455
Monitor Harness (W3) Component Location 466
Monitor Harness (W3) Wiring Diagram 467
Engine Harness (W4) Component Location—Tier 3 474
Engine Harness (W4) Component Location—Stage II 478
Engine Harness (W4) Wiring Diagram—Tier 3 481
Engine Harness (W4) Wiring Diagram—Stage II 485
Engine Interface Harness (W6) Component Location—Tier 3 488
Engine interface Harness (W6) Component Location—Stage II 494
Engine Interface Harness (W6) Wiring Diagram—Tier 3 497
Engine Interface Harness (W6) Wiring Diagram—Stage II 513
Pump Harness (W8) Component Location 516
Pump Harness (W8) Wiring Diagram 518
Right Console Harness (W11) Component Location 521
Right Console Harness (W11) Wiring Diagram 525
Auxiliary Fuse Box Harness (W13) Component Location 528
Auxiliary Fuse Box Harness (W13) Wiring Diagram 531
Heated Air Seat Harness (W14) Component Location 534
Heated Air Seat Harness (W14) Wiring Diagram 535
Multi-Function Pilot Control Lever Harness (W15) Component Locat 536
Multi-Function Pilot Control Lever Harness (W15) Wiring Diagram 539
Travel Alarm Cancel Switch Harness (W16) Component Location 541
Travel Alarm Cancel Switch Harness (W16) Wiring Diagram 541
Pilot Shutoff Switch Harness (W17) Component Location 542
Pilot Shutoff Switch Harness (W17) Wiring Diagram 543
Alternator Harness (W18) Component Location 545
Alternator Harness (W18) Wiring Diagram 546
Fan Reversing Switch Harness (W19) Component Location 547
Fan Reversing Switch Harness (W19) Wiring Diagram 548
Seat Heater Switch Harness (W20) Component Location 549
Seat Heater Switch Harness (W20) Wiring Diagram 549
Attachment Harness (W20) Component Location 551
Attachment Harness (W20) Wiring Diagram 555
2-Speed Harness (W21) Component Location 557
2-Speed Harness (W21) Wiring Diagram 558
Starter Harness (W27) Component Location 560
Starter Harness (W27) Wiring Diagram 563
JDLink™ System Harnesses (W50, W51, W52, W53, and W54) Component 571
Machine Information Gateway (MIG) Harness (W50) Wiring Diagram—I 575
GlobalTRACS® Terminal (GTT) Harness (W51) Wiring Diagram—If Equi 579
JDLink™ CAN Harness (W52) Wiring Diagram—If Equipped 582
JDLink™ Power Harness (W53) Wiring Diagram—If Equipped 585
JDLink™ Jumper Harness (W54) Wiring Diagram—If Equipped 588
System Diagrams—270DLC 589
Explanation of Wire Markings 589
Fuse and Relay Specifications 589
System Functional Schematic, Component Location, and Wiring Diag 593
System Functional Schematic 599
Cab Harness (W1) Component Location 635
Cab Harness (W1) Wiring Diagram 639
Machine Harness (W2) Component Location 655
Machine Harness (W2) Wiring Diagram 667
Monitor Harness (W3) Component Location 678
Monitor Harness (W3) Wiring Diagram 679
Engine Harness (W4) Component Location—Tier 3 686
Engine Harness (W4) Component Location—Stage II 690
Engine Harness (W4) Wiring Diagram—Tier 3 693
Engine Harness (W4) Wiring Diagram—Stage II 697
Engine Interface Harness (W6) Component Location—Tier 3 700
Engine Interface Harness (W6) Component Location—Stage II 706
Engine Interface Harness (W6) Wiring Diagram—Tier 3 709
Engine Interface Harness (W6) Wiring Diagram—Stage II 725
Pump Harness (W8) Component Location 728
Pump Harness (W8) Wiring Diagram 730
Right Console Harness (W11) Component Location 733
Right Console Harness (W11) Wiring Diagram 737
Auxiliary Fuse Box Harness (W13) Component Location 740
Auxiliary Fuse Box Harness (W13) Wiring Diagram 743
Heated Air Seat Harness (W14) Component Location 746
Heated Air Seat Harness (W14) Wiring Diagram 747
Multi-Function Pilot Control Lever Harness (W15) Component Locat 748
Multi-Function Pilot Control Lever Harness (W15) Wiring Diagram 751
Travel Alarm Cancel Switch Harness (W16) Component Location 753
Travel Alarm Cancel Switch Harness (W16) Wiring Diagram 753
Pilot Shutoff Switch Harness (W17) Component Location 754
Pilot Shutoff Switch Harness (W17) Wiring Diagram 755
Alternator Harness (W18) Component Location 757
Alternator Harness (W18) Wiring Diagram 758
Fan Reversing Switch Harness (W19) Component Location 759
Fan Reversing Switch Harness (W19) Wiring Diagram 760
Seat Heater Switch Harness (W20) Component Location 761
Seat Heater Switch Harness (W20) Wiring Diagram 761
Attachment Harness (W20) Component Location 763
Attachment Harness (W20) Wiring Diagram 767
2-Speed Harness (W21) Component Location 769
2-Speed Harness (W21) Wiring Diagram 770
Starter Harness (W27) Component Location 772
Starter Harness (W27) Wiring Diagram 775
JDLink™ System Harnesses (W50, W51, W52, W53, and W54) Component 783
Machine Information Gateway (MIG) Harness (W50) Wiring Diagram—I 787
GlobalTRACS® Terminal (GTT) Harness (W51) Wiring Diagram—If Equi 791
JDLink™ CAN Harness (W52) Wiring Diagram—If Equipped 794
JDLink™ Power Harness (W53) Wiring Diagram—If Equipped 797
JDLink™ Jumper Harness (W54) Wiring Diagram—If Equipped 800
Sub-System Diagnostics 801
Controller Area Network (CAN) Theory of Operation 801
Starting and Charging Circuit Theory of Operation—240DLC 803
Starting and Charging Circuit Theory of Operation—270DLC 809
Monitor Controller Circuit Theory of Operation—240DLC 815
Monitor Controller Circuit Theory of Operation—270DLC 823
Engine Control Unit (ECU) Circuit Theory of Operation—240DLC 831
Engine Control Unit (ECU) Circuit Theory of Operation—270DLC 839
Main Controller (MCF) Circuit Theory of Operation 847
Information Controller (ICF) Circuit Theory of Operation 857
Travel Alarm Circuit Theory of Operation 860
Windshield Wiper and Washer Circuit Theory of Operation 863
Pilot Shutoff Circuit Theory of Operation—240DLC 867
Pilot Shutoff Circuit Theory of Operation—270DLC 871
Attachment Control Circuit Theory of Operation 874
Monitor Operation 879
Monitor Menu Operation 879
Monitor Service Menu Operation 879
References 881
Monitor Data Items 881
Reading Diagnostic Trouble Codes with Monitor Display 882
JDLink™ Connection Procedure—If Equipped 884
Service ADVISOR™ Diagnostic Application 885
Service ADVISOR™ Connection Procedure 885
Reading Diagnostic Trouble Codes with Service ADVISOR™ Diagnosti 886
Fuse Test 888
Relay Test 892
Pressure Sensor Test 893
Solenoid Test 894
Proportional Solenoid Test 894
Temperature Sensor Test 894
Alternator Test 895
Electrical Component Checks 897
Component Checks 897
Battery Remove and Install 902
Rear Cover Remove and Install 904
Main Controller (MCF) Remove and Install 905
Engine Control Unit (ECU) Remove and Install 906
Information Controller (ICF) Remove and Install 907
Monitor Controller Remove and Install 907
Key Switch Remove and Install 909
Switch Panel Remove and Install 910
Travel Alarm Remove and Install 911
Travel Alarm Cancel Switch Remove and Install 911
Disconnect Tab Retainer Connectors 911
Disconnecting Spring Wire Clip Connectors 912
Replace DEUTSCH DEUTSCH is a trademark of the Deutsch Co™ Conne 912
Replace DEUTSCHDEUTSCH is a trademark of Deutsch Co™ Rectangula 913
Install DEUTSCH DEUTSCH is a trademark of the Deutsch Co™ Conta 914
Replace WEATHER PACK WEATHER PACK is a trademark of Packard Elec 916
Install WEATHER PACK WEATHER PACK is a trademark of Packard Elec 917
Replace (Pull Type) Metri-Pack™ Connectors 918
Replace (Push Type) Metri-Pack™ Connectors 919
Replace CINCHCINCH is a trademark of the Cinch Co™ Connectors 919
Install CINCHCINCH is a trademark of the Cinch Co™ Contact 921
Repair 32 and 48 Way CINCHCINCH is a trademark of the Cinch Co™ 922
Remove Connector Body from Blade Terminals 924
Power Train 925
Theory of Operation 927
Track Adjuster and Recoil Spring Operation 927
Travel Gearbox Operation 928
Diagnostic Information 931
Diagnose Undercarriage Components Malfunctions 931
Noisy or Loose Track Chain 931
Tight Track Chain 931
Frequent Track Chain Sag Adjustment Required 931
Excessive Oil Leakage From Front Idler, Track Rollers, or Carrie 932
Bent Track Shoes 932
“Popping” Of Track 933
Cracked Track Link 933
Chipped Link Rails 934
Individual Undercarriage Component Wear 934
Measure Swing Bearing Wear 935
Hydraulic System 939
Theory of Operation 941
Hydraulic System Diagram and Operation 941
Fan Drive System Operation 944
Pilot System Diagram and Operation 948
Pilot Pump, Pressure Regulating Valve and Filter Operation 950
Pilot Shutoff Solenoid Valve Operation 951
Pilot Control Valve Operation 954
Travel Pilot Control Valve Operation 956
Pilot Operation of Control Valve Operation 959
Pilot Signal Manifold Operation 962
Pump and Drive Gearbox Operation 972
Pump Regulator Operation 975
Engine Speed Sensing Control Circuit Operation 981
Control Valve Operation 983
Control Valve Check Valves Identification and Operation 993
Main Relief and Power Digging Valve Circuit Operation 996
Circuit Relief and Anticavitation Valve Operation1000
Travel Flow Combiner Valve Operation1001
Boom Lower Meter Cut-In Valve Operation1004
Boom Regenerative Valve Circuit Operation1006
Dig Regenerative Valve Circuit Operation1008
Arm Regenerative Valve Circuit Operation1012
Bucket Regenerative Valve Circuit Operation1016
Boom and Arm Reduced Leakage Valves Operation1020
Arm 1 (Swing Priority) Flow Rate Valve Circuit Operation1022
Swing Reduction Gearbox Operation1023
Swing Motor, Crossover Relief Valve, and Make-Up Check Valve Ope1024
Swing Motor, Crossover Relief Valve, and Make-Up Check Valve Ope1027
Swing Motor Park Brake Release Circuit Operation1030
Center Joint Operation1031
Travel Motor and Park Brake Valve Operation1032
Travel Motor Speed Circuit Operation1040
Cylinder Operation1043
Return Filter Operation1044
Diagnostic Information1045
Diagnose Hydraulic System Malfunctions1045
All Hydraulic Functions Slow1045
Hydraulic Oil Overheats1047
No Hydraulic Functions1049
Poor Combined Operation1050
Diagnose Pilot Circuit Malfunctions1051
All Functions Cannot Be Operated1051
Function Does Not Stop When Control Lever Released1052
Some Functions Cannot Be Operated, All Others Are Normal1052
All Functions Slow1053
Function Moves in Opposite Direction1054
Diagnose Dig Circuit Malfunctions1054
All Dig Functions Slow or No Power1055
Some Dig Functions Slow (Not All)1055
Load Drifts Down When Control Valve Is In Neutral Position1057
Load Falls When Control Valve Is Actuated To Raise Load With Eng1059
HP (High Power) Function Does Not Operate, P (Standard) Mode Is 1059
Diagnose Swing Circuit Malfunctions1061
Swing Speed Slow In Both Directions1061
Swing Speed Slow or Does Not Operate In One Direction1062
Upperstructure Drift With Swing Valve In Neutral1063
Swing Function Does Not Operate1064
Diagnose Travel Circuit Malfunctions1065
Travel Park Brakes Do Not Apply1065
Track Will Not Move In One Direction1066
Track Will Not Move In Either Direction1067
Machine Mistracks At All Speeds In Both Directions1068
Slow Travel Speed Or Low Power1070
Combined Travel And Dig Functions Slow Or No Power1072
Travel Is “Jerky”1072
Machine Will Not Hold Back And Park Brakes Engage And Disengage 1073
Machine Will Not Turn Smoothly In One Direction Or Park Brake Gr1073
Pump 1, Pump 2, and Pilot Pump Line Identification1075
Control Valve Line Identification1076
Swing Motor Line Identification—240DLC1079
Swing Motor Line Identification—270DLC1079
Pilot Control Valve-to-Pilot Signal Manifold Component Location—1081
Pilot Control Valve-to-Pilot Signal Manifold Component Location—1085
Pilot Signal Manifold-to-Control Valve Line Connection1088
Travel System Component Location1092
Travel Hydraulic System Line Connection1093
Hydraulic System Schematic1095
Fan Drive Hydraulic System Schematic1110
Hydraulic System Component Location1112
Hydraulic System Line Connections1113
Fan Drive System Component Location1115
Tests—240DLC and 270DLC1121
JT05800 Digital Thermometer Installation1121
JT02156A Digital Pressure/Temperature Analyzer Installation1121
Hydraulic Oil Cleanup Procedure Using Portable Filter Caddy1122
Hydraulic Oil Warm-Up Procedure1123
Pilot Pressure Regulating Valve Test and Adjustment1124
Control Valve Spool Actuating Pilot Pressure Test1126
Dig Regenerative Solenoid Valve Test and Adjustment1127
Arm Regenerative Solenoid Valve Test and Adjustment1129
Power Digging Solenoid Valve Test and Adjustment1131
Travel Speed Solenoid Valve Test and Adjustment1133
Pump Control Pilot Pressure Signal Test1135
Torque Control Solenoid Valve Test and Adjustment1136
Main Relief and Power Digging Valve Test and Adjustment1138
Circuit Relief Valve Test and Adjustment1140
Travel Motor Leakage Test1142
Fan Speed Test1143
Tests—240DLC1145
Cylinder Drift Test—Boom, Arm, and Bucket—240DLC1145
Swing Motor Crossover Relief Valve Test and Adjustment—240DLC1146
Travel Motor Crossover Relief Valve Test and Adjustment—240DLC1148
Pump Regulator Test and Adjustment—Minimum Flow—240DLC1151
Pump Regulator Test and Adjustment—Maximum Flow—240DLC1153
Pump Flow Test—240DLC1154
Swing Motor Leakage Test—240DLC1157
Fan Drive Pump Flow Test—240DLC1158
Tests—270DLC1161
Cylinder Drift Test—Boom, Arm, and Bucket—270DLC1161
Swing Motor Crossover Relief Valve Test and Adjustment—270DLC1162
Travel Motor Crossover Relief Valve Test and Adjustment—270DLC1164
Pump Regulator Test and Adjustment—Minimum Flow—270DLC1166
Pump Regulator Test and Adjustment—Maximum Flow—270DLC1168
Pump Flow Test—270DLC1169
Swing Motor Leakage Test—270DLC1172
Fan Drive Pump Flow Test—270DLC1173
Heating and Air Conditioning1175
Theory of Operation1177
Air Conditioning System Cycle of Operation1177
Diagnostic Information1179
Diagnose Air Conditioning System Malfunctions1179
Diagnose Heating System Malfunctions1183
Heater and Air Conditioner Diagnostic Trouble Code Check1186
Heater and Air Conditioner Component Location1189
Tests1193
Refrigerant Cautions and Proper Handling1193
Heater and Air Conditioner Operational Checks1193
Visual Inspection of Components1193
R134a Air Conditioning System Test1196
Air Conditioner Compressor Clutch Test1197
Refrigerant Leak Test1197
Refrigerant Hoses and Tubing Inspection1198
Air Conditioner Belt Check and Adjustment1198
Operating Pressure Diagnostic Chart1198
Reference Material1199
Terminology Cross Reference Chart1201
Terminology Cross Reference Chart1201
Dealer Fabricated Tools1203
Dealer Fabricated Tools1205
DFT1218 Split Flange Hose Cap1205
Page Number 5
Section 9000 7
Group 01 9
Section 9001 24
Group 10 25
Group 20 197
Group 30 281
Group 40 283
Group 50 291
Section 9005 297
Group 10 299
Section 9010 343
Group 05 345
Group 15 359
Group 25 361
Section 9015 365
Group 05 367
Group 10A 377
Group 10B 589
Group 15 801
Group 16 879
Group 20 881
Section 9020 925
Group 05 927
Group 15 931
Section 9025 939
Group 05 941
Group 151045
Group 251121
Group 25A1145
Group 25B1161
Section 90311175
Group 051177
Group 151179
Group 251193
Section 90501199
Group 051201
Section 99001203
Group 991205

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